Honda HR-V Owners & Service Manuals

Honda HR-V: Manual Transaxle - Service Information

Honda HR-V (2015-2021) Service Manual / Transmission / Manual Transaxle - Service Information

Back-Up Light Switch Removal and Installation (M/T)

Removal

1. Air Cleaner - Remove

2. Back-Up Light Switch - Removal

Manual Transaxle - Service Information

  1. Disconnect the connector (A)
  2. Remove the back-up light switch (B).

Installation

1. Back-Up Light Switch - Install

Manual Transaxle - Service Information
Fig. 1: Back-Up Light Switch With Torque Specifications

  1. Clean any dirt and oil from the sealing surface of the back-up light switch and the transmission housing
  2. Apply liquid gasket (P/N 08C70- K0334M) to the threads of the back-up light switch (A). Install the back-up light switch within 5 minutes of applying the liquid gasket.

    NOTE: If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket

  3. Connect the connector (B).

2. Air Cleaner - Install

Clutch Hose Removal and Installation (M/T)

Removal and Installation

NOTE:

  • Replace the clutch hose it is twisted, cracked, or if it leaks.
  • Use fender covers to avoid damaging painted surfaces.
  • Do not spill brake fluid on the vehicle; it may damage the paint or plastic. If brake fluid gets on the paint or plastic, wash it off immediately with water.

1. Air Cleaner - Remove

2. Clutch Hose - Remove

Manual Transaxle - Service Information
Fig. 2: Clutch Hose With Torque Specifications

  1. Remove and discard the brake fluid from the reservoir with a syringe or other suitable device.
  2. Disconnect the clutch hose (A) from the clutch lines (B).

Manual Transaxle - Service Information

  1. Remove and discard the clutch hose clips (A) from the clutch hose (B)
  2. Remove the clutch hose from the clutch line brackets.

3. All Removed Parts - Install

  1. Install the parts in the reverse order of removal.

    NOTE: This special tool increases the torque applied by the torque wrench. Refer to Torque Specifications for details on how to recalculate the torque wrench setting.

4. Clutch Hydraulic System - Bleed

  1. Bleed the clutch hydraulic system.
  2. Do the following checks:
    • Check the clutch hose and line joint for leaks, and tighten if necessary.
    • Check the clutch hose for interference and twisting.
    • Check the clutch operation.

5. Test Drive - Check

Clutch Master Cylinder Removal and Installation (M/T)

Removal

NOTE:

  • Use fender covers to avoid damaging painted surfaces.
  • Do not spill brake fluid on the vehicle; it may damage the paint or plastic. If brake fluid gets on the paint or plastic, wash it off immediately with water.
  • Plug the ends of the reservoir hose and flare nut to prevent spilling brake fluid.

1. Brake Booster - Remove

2. Clutch Master Cylinder - Remove

Manual Transaxle - Service Information

  1. Remove and discard the brake fluid from the reservoir with a syringe or other suitable device.
  2. Pry out the lock pin (A), and pull the pedal pin (B) out of the yoke.
  3. Remove the master cylinder mounting nuts (C).

Manual Transaxle - Service Information

  1. Remove the retaining clip (A) for disconnecting the clutch line connector (B) from the clutch master cylinder (C)
  2. Remove the O-ring (D)
  3. Remove the clutch master cylinder and the clutch master cylinder seal (E).

Manual Transaxle - Service Information

  1. Remove the reservoir hose (A).

    NOTE: Inspect the hose. If the hose has damage, leaks, interference, or twisting, replace it.

Installation

NOTE:

  • Use fender covers to avoid damaging painted surfaces.
  • Do not spill brake fluid on the vehicle; it may damage the paint or plastic. If brake fluid gets on the paint or plastic, wash it off immediately with water.
  • Plug the ends of the reservoir hose and flare nut to prevent spilling brake fluid.

1. Clutch Master Cylinder - Install

Manual Transaxle - Service Information

  1. Install the reservoir hose (A), and adjust the hose clamp (B) positions and its direction.

    NOTE: Make sure the hose clamp is positioned as shown.

Manual Transaxle - Service Information

Manual Transaxle - Service Information

  1. Install a new O-ring (A) on the clutch line connector (B).

    NOTE: Apply the rubber grease to the O-ring and the end (C) of the clutch line

  2. Connect the clutch line to the clutch master cylinder (D) with a new retaining clip (E)
  3. To prevent the retaining clip (F) from coming off, pry apart the tip (G) of the clip with a flat-tipped screwdriver
  4. Install a new master cylinder seal (H) and the clutch master cylinder.

Manual Transaxle - Service Information
Fig. 3: Clutch Master Cylinder With Torque Specifications

  1. Connect the yoke (A) to the clutch pedal (B)
  2. Apply multipurpose grease between the clutch pedal and the yoke.

    NOTE: Wipe off any excess grease

  3. Install the master cylinder mounting nuts (C)
  4. Apply multipurpose grease to the pedal pin (D)
  5. Slide the pedal pin into the yoke, then install the lock pin (E).

2. Clutch Pedal and Clutch Pedal Position Switch - Adjust

3. Brake Booster - Install

4. Clutch Hydraulic System - Bleed

  1. Bleed the brake hydraulic system.
  2. Bleed the clutch hydraulic system.
  3. Check the clutch operation and check for leaking fluid.

5. Test Drive - Check

Clutch Pedal Assembly Removal and Installation (M/T)

Removal

1. Clutch Pedal Assembly - Remove

Manual Transaxle - Service Information

  1. Disconnect the connectors (A)
  2. Pry out the lock pin (B), and pull the pedal pin (C) out of the yoke
  3. Remove the clutch pedal assembly (D).

2. Clutch Pedal Position Switch - Remove

Installation

1. Clutch Pedal Assembly - Install

Manual Transaxle - Service Information

  1. Loosely install clutch pedal position switch A.

    NOTE:

    • Do not contact clutch pedal position switch A to the clutch pedal.
    • Make sure the installation position of clutch pedal position switch A.
  2. Apply multipurpose grease to the pedal return spring (B).

Manual Transaxle - Service Information
Fig. 4: Clutch Pedal Assembly With Torque Specifications

  1. Install the clutch pedal assembly (A)
  2. Connect the yoke (B) to the clutch pedal
  3. Apply multipurpose grease between the clutch pedal and the yoke.

    NOTE: Wipe off any excess grease

  4. Install the clutch pedal mounting nut and the master cylinder mounting nuts
  5. Apply multipurpose grease to the pedal pin (C)
  6. Slide the pedal pin into the yoke, then install the lock pin (D)
  7. Connect the connectors (E).

    NOTE: Make sure the wire harness is not pinched.

2. Clutch Pedal and Clutch Pedal Position Switch - Adjust

CLUTCH PEDAL POSITION SWITCH REMOVAL AND INSTALLATION (M/T)

Removal

1. Clutch Pedal Position Switch - Remove.

Manual Transaxle - Service Information

  1. Disconnect the connector (B)
  2. Loosen the clutch pedal position switch locknuts
  3. Remove clutch pedal position switch A.

Installation

1. Clutch Pedal Position Switch - Install

Manual Transaxle - Service Information

  1. Loosely install clutch pedal position switch A.

    NOTE:

    • Do not contact clutch pedal position switch A to the clutch pedal.
    • Make sure the installation position of clutch position switch A.
  2. Connect the connector (B).

2. Clutch Pedal and Clutch Pedal Position Switch - Adjust

Clutch Removal and Installation (M/T)

Special Tools Required

Attachment, 22 x 24 mm 07746-001A800

Manual Transaxle - Service Information

Driver Handle, 15 x 135L 07749-0010000

Manual Transaxle - Service Information

Ring Gear Holder 07LAB-PV00100

Manual Transaxle - Service Information

Clutch Alignment Shaft 07ZAFPR8A100

Manual Transaxle - Service Information

Slide Hammer 07936-371020A

Manual Transaxle - Service Information

Bearing Remover Shaft Set, 20 mm 07936-3710600

Manual Transaxle - Service Information

Remover Handle 07936-3710100

Manual Transaxle - Service Information

Clutch Alignment Disc 07JAF-PM7011A

Manual Transaxle - Service Information

Removal

Engine Side

1. Transmission - Remove

2. Height of Diaphragm Spring Finger - Check

Manual Transaxle - Service Information

  1. Check the evenness of the height of the diaphragm spring fingers using the clutch alignment disc, the clutch alignment shaft, the remover handle, and a feeler gauge (A). If the height difference is more than the standard, replace the pressure plate.

Standard: 0.6 mm (0.024 in) max.

3. Pressure Plate - Remove

Manual Transaxle - Service Information

  1. Install the ring gear holder, the clutch alignment tool set, and the remover handle, and the clutch alignment shaft
  2. To prevent warping, loosen the pressure plate mounting bolts (A) in a crisscross pattern in several steps, then remove the pressure plate (B).

4. Pressure Plate - Inspect

Manual Transaxle - Service Information

  1. Inspect the fingers of the diaphragm spring (A) for wear at the release bearing contact area.

Manual Transaxle - Service Information

  1. Inspect the pressure plate surface (A) for wear, cracks, and burning.

5. Clutch Disc - Remove

Manual Transaxle - Service Information

  1. Remove the clutch disc (A), the clutch alignment shaft, and the remover handle.

6. Clutch Disc - Inspect

Manual Transaxle - Service Information

  1. Inspect the lining of the clutch disc for signs of slippage or oil. If the clutch disc looks burnt or is oil soaked, replace the clutch disc. If the clutch disc is oil soaked, find and repair the source of the oil leak
  2. Measure the clutch disc thickness. If the measurement is less than the service limit, replace the clutch disc.

Standard: 8.25-8.95 mm (0.3248-0.3524 in)

Service Limit: 6.95 mm (0.2736 in)

Manual Transaxle - Service Information

  1. Measure the rivet depths from the clutch disc lining surface (A) to the rivets (B) on both sides. If the measurement of the rivet that is closer to the clutch disc lining surface is less than service limit, replace the clutch disc and pressure plate as a set.

Standard: 1.2-1.7 mm (0.047-0.067 in)

Service Limit: 0.7 mm (0.028 in)

7. Flywheel - Inspect

Manual Transaxle - Service Information

  1. Remove the ring gear holder
  2. Inspect the ring gear teeth for wear and damage
  3. Inspect the clutch disc mating surface on the flywheel for wear, cracks, and burning
  4. Measure the flywheel (A) runout using a dial indicator (B). Through at least two full turns with pushing against the flywheel each time you turn it to take up the crankshaft thrust washer clearance. If the measurement is not within the standard, replace the flywheel, and recheck the runout.

Standard (New): 0.05 mm (0.0020 in) max.

8. Crankshaft Pilot Bushing - Check

Manual Transaxle - Service Information

  1. Install the ring gear holder
  2. Check the crankshaft pilot bushing for wear and damage
  3. Check the inside surface of the crankshaft pilot bushing with your finger. If the crankshaft pilot bushing is not smooth, replace it.

9. Crankshaft Pilot Bushing - Remove

Manual Transaxle - Service Information

  1. Remove the crankshaft pilot bushing (A) using the slide hammer, the remover handle, and the 20 mm bearing remover shaft set.

10. Flywheel - Remove

Manual Transaxle - Service Information

  1. Loosen the flywheel mounting bolts in a crisscross pattern in several steps.

    Remove the bolts, then remove the flywheel and the ring gear holder.

Transmission Side

11. Transmission - Remove

12. Release Bearing - Remove

Manual Transaxle - Service Information

  1. Remove the release fork boot (A)
  2. Remove the release fork (B) from the clutch housing (C) by squeezing the release fork set spring (D). Remove the release bearing (E).

13. Release Bearing - Check

Manual Transaxle - Service Information

  1. Check the play of the release bearing by spinning it by hand. If there is excessive play or noise, replace the release bearing.

    NOTE: The release bearing is packed with grease. Do not wash it in solvent.

Installation

Engine Side

1. Flywheel - Install

Manual Transaxle - Service Information
Fig. 5: Flywheel With Torque Specifications

  1. Install the flywheel (A) on the crankshaft, and install the mounting bolts (B) finger-tight
  2. Install the ring gear holder
  3. Torque the flywheel mounting bolts in a crisscross pattern in several steps.

2. Crankshaft Pilot Bushing - Install

Manual Transaxle - Service Information

  1. Install the crankshaft pilot bushing (A) into the crankshaft using the 15 x 135L driver handle and the 22 x 24 mm attachment.

3. Clutch Disc - Install

Manual Transaxle - Service Information

  1. Apply molybdenum grease to the splines (A) of the clutch disc (B).

    NOTE: Wipe off any excess grease

  2. Temporarily install the clutch disc onto the splines of the transmission mainshaft. Make sure the clutch disc slides freely on the mainshaft
  3. Install the clutch disc using the clutch alignment shaft and the remover handle.

4. Pressure Plate - Install

Manual Transaxle - Service Information

  1. Install the pressure plate (A) and the mounting bolts (B), finger-tight.

Manual Transaxle - Service Information

  1. Torque the pressure plate mounting bolts (A) in a crisscross pattern. Tighten the bolts in several steps to prevent warping the diaphragm spring. Make sure that there is not clearance between the pressure plate and the flywheel.

Specified Torque: 26 N.m (2.7 kgf.m, 19 lbf.ft)

  1. Remove the ring gear holder, the clutch alignment shaft, and the remover handle
  2. Make sure the diaphragm spring fingers are all the same height
  3. Do the release bearing inspection, and replace it if necessary.

5. Transmission - Install

Transmission Side

6. Release Bearing - Install

Manual Transaxle - Service Information

  1. Apply molybdenum grease to the release fork (A), the release fork bolt (B), the release bearing (C), and the release bearing guide (D) in the shaded areas.

    NOTE:

    • Do not use silicone grease.
    • Replace the release fork bolt if necessary.
  2. Set the release fork set spring (E).

Manual Transaxle - Service Information

  1. With the release fork (A) slide between the release bearing pawls (B), install the release bearing on the mainshaft while inserting the release fork through the hole (C) in the clutch housing
  2. Align the detent (D) of the release fork with the release fork bolt (E), then press the detent of the release fork over the release fork bolt squarely
  3. Install the release fork boot (F). Make sure the boot seals around the release fork and clutch housing.

Manual Transaxle - Service Information

  1. Move the release fork (A) right and left to make sure that it fits properly against the release bearing (B) and that the release bearing slides smoothly. Wipe off any excess grease.

7. Transmission - Install

CLUTCH SLAVE CYLINDER REMOVAL AND INSTALLATION (M/T)

Removal and Installation

NOTE:

  • Use fender covers to avoid damaging painted surfaces.
  • Do not spill brake fluid on the vehicle; it may damage the paint or plastic. If brake fluid gets on the paint or plastic, wash it off immediately with water.

1. Slave Cylinder - Remove

Manual Transaxle - Service Information
Fig. 6: Slave Cylinder With Torque Specifications

  1. Remove and discard the brake fluid from the reservoir with a syringe or other suitable device.
  2. Disconnect the clutch line (A). To prevent spills, cover the line joint with rags or clean shop towels.

    NOTE: Loosen the flare nut (B) while holding the clutch line connector (C) using a wrench.

  3. Remove the slave cylinder (D).

2. All Removed Parts - Install

  1. Install the parts in the reverse order of removal, and note these items.
    • Apply a light coat of molybdenum grease to the push rod of the slave cylinder.
    • Tighten the flare nut while holding the clutch line connector using a wrench.

NOTE: This special tool increases the torque applied by the torque wrench. Refer to Torque Specifications for details on how to recalculate the torque wrench setting.

3. Clutch Hydraulic System - Bleed

  1. Bleed the clutch hydraulic system.
  2. Check the clutch operation and check for leaking fluid.

4. Test Drive - Check

Countershaft Bearing Replacement (M/T)

Special Tools Required

Bearing Driver Attachment, 62 x 68 mm 07746-0010500

Manual Transaxle - Service Information

Driver Handle, 15 x 135L 07749-0010000

Manual Transaxle - Service Information

Adjustable Bearing Puller, 45-75 mm 07YAC-0010100

Manual Transaxle - Service Information

Slide Hammer 3/8"-16 UNF, commercially available

Manual Transaxle - Service Information

Replacement

1. Bearing - Remove

Manual Transaxle - Service Information

  1. Remove the bearing set plate (A).

Manual Transaxle - Service Information

  1. Remove the bearing (A) using the 45-75 mm adjustable bearing puller, and a commercially available 3/8"-16 UNF slide hammer (B).

2. Bearing - Install

Manual Transaxle - Service Information

  1. Install the bearing using the 15 x 135L driver handle and the 62 x 68 mm bearing driver attachment.

Manual Transaxle - Service Information
Fig. 7: Bearing Set Plate With Torque Specifications

  1. Install the bearing set plate (A).

Gearshift Mechanism Removal and Installation (M/T)

Exploded View

SRS components are located in this area. Review the SRS component locations - Refer to: SRS Component Location Index (KA/KC), or SRS Component Location Index (KA/KC) and the precautions and procedures before doing repair or service.

NOTE: Make sure not to get any silicone grease on the terminal part of the connectors and switches, especially if you have silicone grease on your hands or gloves.

1. Gearshift Mechanism - Exploded View

Manual Transaxle - Service Information
Fig. 8: Gearshift Mechanism - Exploded View With Torque Specifications

M/T DIFFERENTIAL CARRIER BEARING REPLACEMENT (M/T)

Special Tools Required

Remover Installer, 22 x 37/46 x 52 mm 07PAF-0030100

Manual Transaxle - Service Information

Replacement

1. Differential Carrier Bearing - Remove

Clutch housing side

Manual Transaxle - Service Information

Transmission housing side

Manual Transaxle - Service Information

  1. Check the carrier bearings for wear and rough rotation. If they rotate smoothly and their rollers show no signs of wear, the bearings are OK
  2. Remove the carrier bearings (A) with a commercially available bearing puller (B).

2. Differential Carrier Bearing - Install

Clutch housing side

Manual Transaxle - Service Information

Transmission housing side

Manual Transaxle - Service Information

  1. Install the carrier bearings (A) using the 22 x 37/46 x 52 mm remover installer, an attachment and, a press. Press on each bearing until it bottoms. There should be no clearance between the bearings and the differential carrier.

    NOTE: Place the seal part (B) of the bearing towards the outside of the differential, then install it.

M/T Differential Carrier and Final Driven Gear Removal and Installation (M/T)

Removal

1. Differential Carrier Bearing - Remove

2. Final Driven Gear - Remove

Manual Transaxle - Service Information

  1. Loosen the bolts in a crisscross pattern in several steps, then remove the bolts and the final driven gear (A).

Installation

1. Final Driven Gear - Install

Manual Transaxle - Service Information
Fig. 9: Final Driven Gear With Torque Specifications

  1. Install the final driven gear (A). Tighten the bolts in a crisscross pattern in several steps.

2. Differential Carrier Bearing - Install

M/T DIFFERENTIAL OIL SEAL REPLACEMENT (M/T)

Special Tools Required

Driver Handle, 15 x 135L 07749-0010000

Manual Transaxle - Service Information

Oil Seal Driver Attachment 07NADP200100

Manual Transaxle - Service Information

Replacement

Clutch Housing Side

1. Oil Seal - Remove

Manual Transaxle - Service Information

NOTE: Be careful not to damage the clutch housing (A) while removing the oil seal.

2. Oil Seal - Install

Manual Transaxle - Service Information

  1. Install the oil seal flush with the clutch housing using the 15 x 135L driver handle and the oil seal driver attachment.

Transmission Housing Side

3. Oil Seal - Remove

Manual Transaxle - Service Information

NOTE: Be careful not to damage the transmission housing (A) while removing the oil seal.

4. Oil Seal - Install

Manual Transaxle - Service Information

  1. Install the oil seal flush with the transmission housing using the 15 x 135L driver handle and the oil seal driver attachment.

MAINSHAFT OIL SEAL REPLACEMENT (M/T)

Special Tools Required

Bearing Driver Attachment, 42 x 47 mm 07746-0010300

Manual Transaxle - Service Information

Driver Handle, 15 x 135L 07749-0010000

Manual Transaxle - Service Information

Replacement

1. Oil Seal - Remove

Manual Transaxle - Service Information

  1. Remove the oil seal (A).

    NOTE: Be careful not to damage the clutch housing while removing the oil seal.

2. Oil Seal - Install

Manual Transaxle - Service Information

  1. Drive in the oil seal flush with the clutch housing using the 15 x 135L driver handle and the 42 x 47 mm bearing driver attachment.

Manual Transmission Removal and Installation (M/T)

*: Available through the Honda Tool and Equipment Program 888-424-6857.

Special Tools Required

Universal Lifting Eyelet 07AAKSNAA120

Manual Transaxle - Service Information

Engine Support Hanger, A and Reds AAR-T1256*

Manual Transaxle - Service Information

*: Available through the Honda Tool and Equipment Program 888-424-6857.

Removal

NOTE: Special tool engine support hanger AAR-T1256 must be used with the side engine mount installed.

1. Vehicle - Lift

2. Hood - Wide Open

Manual Transaxle - Service Information

  1. Open the hood, and remove the plug cap (A)
  2. Change the hood support rod mounting position
  3. Secure it with the hood support rod in the wide-open position.

3. Cowl Cover - Remove

4. Front Grille Cover - Remove

5. Air Cleaner - Remove

6. 12V Battery - Remove

7. Change Wire Bracket - Remove

Manual Transaxle - Service Information

  1. Remove the lock pins (A)
  2. Remove the change wire bracket bolts (B)
  3. Disconnect the change wire from the change lever assembly (C)
  4. Carefully remove the change wire and the change wire bracket (D) together to avoid bending the change wire.

8. Connector (Neutral Position Sensor) - Disconnect

Manual Transaxle - Service Information

  1. Disconnect the connector (A).

9. Slave Cylinder - Remove

Manual Transaxle - Service Information

  1. Remove the clutch line bracket (A)
  2. Remove the slave cylinder (B)
  3. Carefully move the slave cylinder out of the way to avoid bending the clutch line.

    NOTE:

    • Do not press the clutch pedal after the slave cylinder has been moved.
    • Do not disconnect the clutch line joints.

10. Connectors (Reverse Lockout Solenoid, Output Shaft (Countershaft) Speed Sensor, Back-Up Light Switch) - Disconnect

Front side

Manual Transaxle - Service Information

Rear side

Manual Transaxle - Service Information

  1. Remove the harness clamp brackets (A).

Manual Transaxle - Service Information

  1. Disconnect these connectors (A)
  2. Remove the harness clamp bracket (B).

11. Sub Hanger Stay - Install

Manual Transaxle - Service Information

  1. Disconnect these connectors (A)
  2. Remove the harness holders (B).

Manual Transaxle - Service Information

  1. Remove the bolts (A), clamps (B) and move the harness holder (C)
  2. Remove the bracket (D).

Manual Transaxle - Service Information

  1. Install the universal lifting eyelet.

12. Engine Support Hanger - Install

Manual Transaxle - Service Information

  1. Install the engine support hanger as shown.

    NOTE: Be careful when working around the windshield

  2. Attach the hook (A) to the slotted hole in the universal lifting eyelet
  3. Tighten the wing nut (B) by hand, and lift and support the engine/transmission.

13. Upper Transmission Mounting Bolt - Remove

Manual Transaxle - Service Information

  1. Remove the upper transmission mounting bolts (A).

Manual Transaxle - Service Information

14. Transmission Mount - Remove

15. Steering Joint - Disconnect

NOTE: Hold the steering wheel in the steering wheel holder tool.

16. Vehicle - Lift

  1. Raise the vehicle on the lift.

17. Front Wheel - Remove

18. Engine Undercover - Remove

19. MTF - Drain

20. Front Stabilizer Link Ball Joint - Disconnect

21. Lower Arm Ball Joint - Disconnect

22. Tie-Rod End Ball Joint - Disconnect

23. Front Driveshaft - Remove

24. Intermediate Shaft - Remove

25. Clutch Cover - Remove

Manual Transaxle - Service Information

  1. Remove the clutch cover (A).

26. Torque Rod - Disconnect

27. Subframe - Remove

28. Transmission - Support

  1. Support the transmission with the transmission jack and the wood block.

29. Transmission - Remove

Front side

Manual Transaxle - Service Information

Rear side

Manual Transaxle - Service Information

  1. Remove the lower transmission mounting bolts (A)
  2. Pull the transmission away from the engine until the transmission mainshaft clears the clutch pressure plate
  3. Slowly lower the transmission about 150 mm (5.91 in)
  4. Check once again that all hoses and harness are disconnected and free from the transmission
  5. Lower the transmission.

Installation

1. Release Bearing - Check

  1. Check the release bearing, then install the release bearing and the release fork with specified grease.

2. Transmission - Install

Manual Transaxle - Service Information

  1. Make sure the two dowel pins (A) are undamaged and installed in prescribed holes on the engine block as shown. Replace the dowel pins if they are damaged
  2. Place the transmission on the transmission jack, and raise it to the engine level
  3. Align the transmission mainshaft and the clutch pressure plate
  4. Move the transmission inward until there is no clearance between the transmission housing and the engine block.

Manual Transaxle - Service Information
Fig. 10: Transmission Front side With Torque Specifications

Manual Transaxle - Service Information
Fig. 11: Transmission Rear side With Torque Specifications

  1. Install the lower transmission mounting bolts (A).

3. Subframe - Install

4. Torque Rod - Loosely Install

5. Clutch Cover - Install

Manual Transaxle - Service Information
Fig. 12: Clutch Cover With Torque Specifications

  1. Install the clutch cover (A).

6. Intermediate Shaft - Install

7. Front Driveshaft - Install

8. Tie-Rod End Ball Joint - Connect

9. Front Stabilizer Link - Connect

10. Lower Arm Ball Joint - Connect

11. Vehicle - Lift

  1. Lower the vehicle.

12. Steering Joint - Connect

13. Transmission Mount - Install

14. Upper Transmission Mounting Bolt - Install

Manual Transaxle - Service Information
Fig. 13: Upper Transmission Mounting Bolt (1 Of 2)

Manual Transaxle - Service Information
Fig. 14: Upper Transmission Mounting Bolt (2 Of 2)

  1. Install the upper transmission mounting bolts (A).

15. Engine Support Hanger - Remove

16. Sub Hanger Stay - Remove

Manual Transaxle - Service Information

  1. Remove the sub universal lifting eyelet.

Manual Transaxle - Service Information

  1. Install the bracket (A)
  2. Install the harness holder (B).

Manual Transaxle - Service Information

  1. Install the harness holders (A)
  2. Connect these connectors (B).

17. Connectors (Reverse Lockout Solenoid, Output Shaft (Countershaft) Speed Sensor, Back-Up Light Switch) - Connect

Manual Transaxle - Service Information

  1. Connect these connectors (A)
  2. Install the harness clamp bracket (B).

Front side

Manual Transaxle - Service Information

Rear side

Manual Transaxle - Service Information

  1. Install the harness clamp brackets (A).

18. Slave Cylinder - Install

Manual Transaxle - Service Information
Fig. 15: Slave Cylinder With Torque Specifications

  1. Install the clutch line bracket (A).

    NOTE: Be careful not to bend the clutch line

  2. Apply a light coat of molybdenum grease to the push rod (B) of the slave cylinder (C)
  3. Install the slave cylinder.

19. Connector (Neutral Position Sensor) - Connect

Manual Transaxle - Service Information

  1. Connect the connector (A).

20. Change Wire Bracket - Install

Manual Transaxle - Service Information
Fig. 16: Change Wire Bracket With Torque Specifications

  1. Apply a light coat of silicone grease to the change wire ends (A).

    NOTE: Make sure not to get any silicone grease on the terminal part of the connectors and switches, especially if you have silicone grease on your hands or gloves.

  2. Connect the change wire ends to the change lever assembly (B)
  3. Install the change wire bracket (C)
  4. Install the lock pins (D)
  5. Check that the transmission shifts into all gears smoothly.

21. MTF - Refill

22. 12V Battery - Install

23. Air Cleaner - Install

24. Front Grille Cover - Install

25. Cowl Cover - Install

26. Torque Rod - Tighten

27. Engine Undercover - Install

28. Front Wheel - Install

29. Wheel Alignment - Check

  1. Check the wheel alignment, and adjust it if necessary.

30. Test Drive - Check

  1. Test-drive the vehicle.

NEUTRAL POSITION SENSOR REMOVAL AND INSTALLATION (M/T)

Removal and Installation

1. Air Cleaner - Remove

2. Neutral Position Sensor - Remove

Manual Transaxle - Service Information
Fig. 17: Neutral Position Sensor With Torque Specifications

  1. Disconnect the connector (A)
  2. Remove the neutral position sensor (B) and the O-ring (C).

3. All Removed Parts - Install

  1. Install the parts in the reverse order of removal.

    NOTE: Apply MTF to a new O-ring.

Shift Lever Housing Removal and Installation (M/T)

Removal

Location Index (KA/KC), or SRS Component Location Index (KA/KC) and the precautions and procedures before doing repair or service.

1. Shift Lever Knob - Remove

Manual Transaxle - Service Information

  1. Lower the shift lever boot (A) to release the hooks (B) from the boot
  2. Remove the shift lever knob (C).

2. Center Console - Remove

3. Shift Lever Housing - Remove

Manual Transaxle - Service Information

NOTE: Do not bend the change wire excessively.

  1. Remove the cotter pin (A) and the washer (B)
  2. Remove shift lever housing bolts.

Manual Transaxle - Service Information

  1. Unlock the retainer lock (A)
  2. Rotate the socket holder retainer (B) counterclockwise (C) until it stops, and push the retainer lock (D) into the socket holder retainer to lock the retainer
  3. Slide the socket holder (E) and the change wire (F) out of the shift lever housing (G).

    NOTE: Do not remove the change wire by pulling the change wire guide (H).

Manual Transaxle - Service Information

  1. Remove the clip (A)
  2. Disconnect the shift cable (B) from the shift lever (C).

Installation

SRS components are located in this area. Review the SRS component locations - Refer to: SRS Component Location Index (KA/KC), or SRS Component Location Index (KA/KC) and the precautions and procedures before doing repair or service.

1. Shift Lever Housing - Install

Manual Transaxle - Service Information

Manual Transaxle - Service Information

NOTE: Do not bend the change wire excessively.

  1. Install the clip (A)
  2. Align the socket holder (B) on the shift cables (C) with the slot in the bracket base (D), then slide the holder into the base
  3. Install the shift cable ends (E) to the shift lever assembly.

    NOTE: When installing the shift cable, position the serrated side (F) facing up.

Manual Transaxle - Service Information

  1. Install the shift lever housing bolts

2. Center Console - Install

3. Shift Lever Knob - Install

Manual Transaxle - Service Information

  1. Install the shift lever knob (A).

    NOTE: Tighten the shift lever knob until the shift pattern is properly aligned

  2. Install the shift lever boot (B).

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