Service Manual2005 MAINTENANCE AND REPAIR To the top of the document
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MAINTENANCE AND REPAIR

ON-VEHICLE SERVICE


T3B15B01
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Checking Fluid Level

  1. With the vehicle on a level surface and the fluid in the transaxle cold, remove the filler plug and check the fluid level. The fluid should come to the bottom edge of the plug hole.

    2. T3B15B02
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  2. If the level is low, add SAE 80 manual transaxle fluid through the filler plug hole until the fluid begins to run out.
  3. Reinstall the filler plug and tighten it securely.
  4. If the fluid is contaminated, drain the oil after removing the differential gear cover.

T3B15B03
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Shift Linkage Adjustment

(Left-Hand Drive shown, Right-Hand Drive Similar)
  1. Disconnect the negative battery cable.
  2. Position the gearshift lever into NEUTRAL.

    3. Important : All the gears must be easy to engage when the vehicle is stationary, the engine is running, and the clutch is disengaged.

  3. Loosen the rod clamp bolt.

    4. J5B15B02
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  4. Turn the gearshift rod to push the adjusting pin.

    5. T3B15B05
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  5. Remove the boot from the console.
  6. Pull the boot upward to expose the shift control lever mechanism.
  7. Position the gearshift lever close to left side of the NEUTRAL position.
  8. Insert a 5 mm (0.2 inch) gauge pin into the holes to align the gearshift lever with the gearshift lever housing.

    9. T3B15B03
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  9. Tighten the rod clamp bolt.

    10. Tighten
    Tighten the rod clamp bolt to 14 N•m (124 lb-in).


    J5B15B03
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  10. Turn the gearshift rod to release the adjusting pin.
  11. Remove the 5 mm (0.2 inch) gauge pin from the gearshift lever.
  12. Install the boot to the console.
  13. Connect the negative battery cable.

T3B15B08
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Gearshift Lever

(Left-Hand Drive shown, Right-Hand Drive Similar)

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Position the gearshift lever into NEUTRAL.
  3. Disconnect the boot from the console cover.
  4. Lift the console cover upward to expose the shift control lever mechanism.

    5. T3B15B09
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  5. Rotate the gearshift lever stop clamp and remove it.
  6. Remove the gearshift lever from the gearshift lever shaft.

T3B15B09
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Installation Procedure

  1. Install the gearshift lever into the gearshift lever shaft.
  2. Install the gearshift lever stop clamp.
  3. Rotate the gearshift lever stop clamp to secure it.

    4. T3B15B08
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  4. Lower the boot and connect it to the console cover.
  5. Connect the negative battery cable.

T3B15B10
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Gearshift Lever Housing

(Left-Hand Drive shown, Right-Hand Drive Similar)

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Remove the rod clamp. Refer to "Shift Linkage Adjustment" in this section.
  3. Remove the console.
  4. Remove the gearshift lever housing bolts and the gearshift lever housing.

T3B15B11
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Installation Procedure

  1. Install the gearshift lever housing and the gearshift lever housing bolts.

    2. Tighten
    Tighten the gearshift housing bolts to 7 N•m ( 62 lb-in).

  2. Adjust the shift linkage.
  3. Install the console.
  4. Connect the negative battery cable.

T3B15B12
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Speedometer Driven Gear

Removal Procedure

  1. Disconnect the speedometer speed sensor electrical connector.

    2. T3B15B13
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  2. Remove the speedometer housing retaining bolt.
  3. Remove the speedometer-driven gear and the speedometer housing.

T3B15B14
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Installation Procedure

  1. Coat the O-ring with petroleum jelly.
  2. Install the speedometer-driven gear and the speedometer housing.
  3. Install the speedometer housing retaining bolt.

    4. Tighten
    Tighten the speedometer housing retaining bolt to 4 N•m (35 lb-in).


    T3B15B12
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  4. Connect the speedometer speed sensor electrical connector.

T3B15B15
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Shift Linkage Assembly

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Remove the rod clamp. Refer to "Shift Linkage Adjustment" in this section.
  3. Remove the clip and the bolt from universal joint.
  4. Separate the universal joint from the transaxle.

    5. T3B15B16
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  5. Remove the fixing shaft pin and separate the linkage connection part from the transaxle rear mounting bracket.
  6. Remove the shift linkage assembly.

T3B15B16
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Installation Procedure

  1. Install the shift linkage assembly.
  2. Install the fixing shaft pin and connect the linkage connection part to the transaxle rear mounting bracket.

    3. T3B15B15
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  3. Install the universal joint to the transaxle.
  4. Install the clip and the bolt from universal joint.
  5. Install the rod clamp. Refer to "Shift Linkage Adjustment" in this section.
  6. Adjust the shift linkage. Refer to "Shift Linkage Adjustment" in this section.
  7. Connect the negative battery cable.

T3B15B17
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Drive Axle Seal

Tools Required

KM-519 Ring Installer

Removal Procedure

    Notice : Do not damage the bearing adjusting ring with the pry bar.

  1. Remove the drive axle from the transaxle. Refer to Section 3B, Manual Transaxle Drive Axle.
  2. Remove the drive axle seal by lifting the outer lip of the seal with a pry bar.

T3B15B18
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Installation Procedure

  1. Install the new drive axle seal using the ring installer KM-519 and a hammer.
  2. Coat the seal lip with the transaxle fluid.
  3. Install the drive. Refer to Section 3B, Manual Transaxle Drive Axle.

T3B15B16
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Transaxle Assembly

Tools Required

J-28467-B Engine Support Fixture

Removal Procedure

  1. Install the engine support fixture J-28467-B.
  2. Remove the battery and battery tray. Refer to Section 1E, ENGINE ELETRICAL.
  3. Remove the shift linkage assembly. Refer to "Shift Linkage Assembly" in this section.
  4. Remove the drive axle shaft. Refer to Section 3B, Manual Transaxle Drive Axle.

    5. T3B15B19
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  5. Disconnect the backup lamp switch electrical connector.
  6. Disconnect the speedometer speed sensor electrical connector.

    7. J3B15B01
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  7. Remove the pin and the clutch release cylinder pipe.

    8. T3B15B21
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  8. Remove the damping block connection nut and bolt.
  9. Remove the three rear mounting bracket bolts.
  10. Remove the rear mounting bracket from the transaxle.

    11. J3B15B02
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  11. Remove the two rear damping block retaining bolts.
  12. Remove the rear damping block from the front cross member.

    13. T3B15B23
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  13. Remove the two cage retaining bolts.
  14. Remove the three transaxle upper mounting bracket bolts.
  15. Remove the upper mounting bracket and cage.

    16. T3B15B24
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  16. Remove the three transaxle upper retaining bolts.

    17. T3B15B25
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  17. Support the transaxle with a transaxle support jack.

    18. T3B15B26
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  18. Remove the seven transaxle lower retaining bolts.

    19. T3B15B27
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  19. Remove the transaxle.

    20. Notice : Rest the transaxle only in an upright position.

  20. Slide the transaxle sideways away from the engine block.
  21. Lower the transaxle.

T3B15B27
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Installation Procedure

  1. Support the transaxle with a transaxle support jack.
  2. Install the transaxle by inserting the transaxle input shaft into the clutch disc and sliding the transaxle sideways into the engine block.

    3. T3B15B28
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  3. Install the seven transaxle lower retaining bolts.

    4. Tighten
    Tighten the transaxle lower retaining bolts(a) to 73 N•m ( 54 lb-ft ).
    Tighten the transaxle lower retaining bolt(b) to 31 N•m ( 23 lb-ft ).
    Tighten the transaxle lower retaining bolts(c) to 21 N•m ( 15 lb-ft ).


    T3B15B29
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  4. Install the three transaxle upper retaining bolts.

    5. Tighten
    Tighten the transaxle upper retaining bolts to 73 N•m (54 lb-ft ).


    T3B15B30
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  5. Install the cage retaining bolt and cage.
  6. Install the three transaxle upper mounting bracket bolts and bracket.

    7. Tighten
    Tighten the transaxle upper mounting bracket bolts to 48 N•m (35 lb-ft ).


    J3B15B03
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  7. Install the two rear damping block retaining bolts.

    8. Tighten
    Tighten the rear damping block retaining bolts to 68 N•m (50 lb-ft ).

  8. Install the rear damping block from the front cross member.

    9. T3B15B32
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  9. Install the three rear mounting bracket bolts and the bracket.

    10. Tighten
    Tighten the rear mounting bracket bolts to 90 N•m (66 lb-ft ).

  10. Install the damping block connection nut and bolt.

    11. Tighten
    Tighten the damping block connection nut and bolt to 68 N•m (50 lb-ft ).


    J3B15B04
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  11. Connect the clutch release cylinder pipe.

    12. T3B15B19
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  12. Connect the speedometer speed sensor electrical connector.
  13. Connect the backup lamp switch electrical connector.

    14. T3B15B16
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  14. Remove the engine support fixture J-28467-B.
  15. Install the drive axle shaft. Refer to Section 3B, Manual Transaxle Drive Axle.
  16. Install the shift linkage assembly. Refer to "Shift Linkage Assembly" in this section.
  17. Install the battery and battery tray. Refer to Section 1E, ENGINE ELETRICAL.
  18. Inspect the fluid level. Refer to "Checking Fluid Level" in this section.


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