How to replace Manual Transaxle Assembly on Acura Car models?

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The procedure is as follows :----

Transaxle Assembly

REMOVAL & INSTALLATION

The radio may have a coded theft protection circuit. Make sure you have the code before disconnecting the battery, removing the radio fuse, or removing the radio.

Integra

1. Disconnect the negative battery cable, then the positive battery cable.
2. Drain the transaxle oil into a suitable container. Install the drain plug with a new washer.
3. Remove the air cleaner case and the air intake tube.

See Figure 1

Fig. Fig. 1: Remove the air cleaner case assembly

4. Detach the backup light switch connector and the transaxle ground wire.
5. Remove the lower radiator hose clamp from the transaxle hanger.

See Figure 2

Fig. Fig. 2: Remove of the transaxle hanger bolt(s)

6. Remove the wiring harness clips.
7. Disconnect the starter motor cables and the Vehicle Speed Sensor (VSS) connector.
8. Remove the clutch pipe bracket and slave cylinder. Do not operate the clutch pedal once the slave cylinder has been removed.

See Figure 3

Fig. Fig. 3: Unfasten the retaining bolts, then remove the slave cylinder

9. Remove the three upper transaxle mounting bolts and the lower starter mounting bolt.
10. Safely raise and support the vehicle.
11. Unfasten the retainers, then remove the engine splash shield.

See Figure 4

Fig. Fig. 4: The splash shield is secured with quite a few retainers

12. Disconnect the heated Oxygen (O ₂ S) sensor connector.
13. Remove and discard the two nuts attaching exhaust pipe "A" to the hanger bracket.
14. Remove and discard the nuts attaching exhaust pipe "A" to the exhaust manifold, then discard the exhaust gaskets.
15. Remove and discard the three nuts attaching the exhaust system to the catalytic converter, then discard the exhaust gasket. Remove exhaust pipe "A" from the vehicle.
16. Remove the cotter pins and castle nuts from the front lower ball joints. Separate the ball joints from the lower control arms. Discard the cotter pins.
17. Remove the right strut fork pinch bolt and lower nut and bolt, then remove the strut fork from the vehicle.

See Figure 5

Fig. Fig. 5: View of the front suspension components

18. Pry the right halfshaft out of the differential, then discard the set ring on the inner joint.
19. Pry the left halfshaft out of the intermediate shaft, discard the set ring on the inner joint.
20. Tie plastic bags over the halfshaft joints to keep the splines of the joints clean.
21. Remove the intermediate shaft mounting bolts, and remove the intermediate shaft.

See Figure 6

Fig. Fig. 6: Unfasten the mounting bolts, then remove the intermediate shaft

22. Remove the set ring from the intermediate shaft and install a new set ring.
23. Disconnect the extension rod and the shift rod:

See Figure 7

Fig. Fig. 7: Once the retainers are removed, you can remove the extension rod

24. If equipped with a Variable Valve Timing and Electronic Lift Control (VTEC) engine, perform the following:
    1. Remove the heat shield.
    2. Disconnect the shift extension rod from the transaxle case.
    3. Slide the boot on the shift rod back to expose the clip and spring pin. Remove the clip from the shift rod.
    4. Drive out the spring pin with a punch and disconnect the shift control rod. Note that on reassembly, install the clip back into place after driving the spring pin in.
25. Remove the rear engine stiffener, and, if equipped with a VTEC engine, remove the front engine stiffener.
26. Remove the clutch cover.

See Figure 8

Fig. Fig. 8: Removing the clutch cover

27. Remove the engine stiffener.

See Figure 9

Fig. Fig. 9: Engine stiffener location and mounting

28. Remove the right front mount/bracket. Discard the long self-locking bolt.

See Figure 10

Fig. Fig. 10: The transaxle mount is secured with a large bolt

29. Place a transaxle jack under the transaxle and a jackstand under the engine.
30. Remove the transaxle mount.

See Figure 11

Fig. Fig. 11: Transaxle mounting bolt locations

31. Remove the transaxle mounting bolts and the bolts from the rear mounting bracket. Discard the self-locking bolts from the rear mounting bracket.
32. Pull the transaxle assembly away from the engine until it clears the main shaft, then lower it on the transaxle jack.

See Figure 12

Fig. Fig. 12: Carefully pull the transaxle away from the engine assembly

To install:

33. Install the dowel pins to the clutch housing.
34. Apply a suitable super high temperature grease to the following components:
    1. The release fork bolt.
    2. The spline of the transaxle input shaft.
    3. The inside of the release bearing and the sleeve on the transaxle input shaft where the release bearing rides.
    4. The tips of the release fork and where the slave cylinder pin rides on the release fork.
35. Install the release fork boot.
36. Place the transaxle assembly on the transaxle jack and raise it to engine level.
37. Install the transaxle mounting bolts and new rear mount bracket bolts. Tighten the transaxle mounting bolts to 47 ft. lbs. (64 Nm) and the rear mount bolts to 87 ft. lbs. (118 Nm).
38. Raise the transaxle and install the transaxle mount. First tighten the mounting nuts and bolt to the transaxle to 47 ft. lbs. (64 Nm), then tighten the mounting bolt to 54 ft. lbs. (74 Nm).
39. Install the three upper transaxle mounting bolts and the lower starter bolt. Tighten the upper transaxle mounting bolts to 47 ft. lbs. (54 Nm), then tighten the lower starter bolt to 33 ft. lbs. (44 Nm).
40. Install the right front mount/bracket. Tighten the new self locking bolt to 61 ft. lbs. (83 Nm), and tighten the other mounting bolts to 33 ft. lbs. (44 Nm).
41. Install the clutch cover. Tighten the 6x1mm bolts to 9 ft. lbs. (12 Nm), tighten the 8x1.25mm bolts to 17 ft. lbs. (24 Nm). If equipped with a B18B1 engine, tighten the 12x1.25mm bolt to 42 ft. lbs. (57 Nm).
42. Install the rear engine stiffener and the front engine stiffener, if equipped. Tighten the bolts attaching the stiffener(s) to the transaxle to 42 ft. lbs. (57 Nm). Tighten the bolts attaching the stiffener(s) to the engine to 17 ft. lbs. (24 Nm).
43. Remove the transaxle jack and the jackstand from the engine.
44. Install the shift rod to the transaxle, then install the spring pin and clip. Install the shift rod boot to the shift rod, making sure the drain hole is facing down.
45. Install the extension rod and tighten the attaching bolt to 16 ft. lbs. (22 Nm).
46. If removed, install the heat shield. Tighten the mounting bolts to 56 inch lbs. (9.8 Nm).
47. Install new set ring to the intermediate shaft and the halfshafts.
48. Install the intermediate shaft and tighten the mounting bolts to 29 ft. lbs. (39 Nm).
49. Turn the right steering knuckle fully outward and slide the halfshaft into the differential unit until you feel the spring clip engage. Turn the left steering knuckle fully outward and slide the halfshaft onto the intermediate shaft until you feel the spring clip engage.
50. Install the right strut fork. Tighten the pinch bolt to 32 ft. lbs. (43 Nm) and tighten the fork lower nut and bolt to 47 ft. lbs. (64 Nm).
51. Connect the lower ball joints to the lower control arms, tighten the castle nuts to 36-43 ft. lbs. (49-59 Nm). Install new cotter pins.
52. Install exhaust pipe "A" using new gaskets and locknuts. Tighten the nuts attaching the exhaust pipe to the exhaust manifold to 40 ft. lbs. (54 Nm). Tighten the nuts attaching the exhaust system to the catalytic converter to 25 ft. lbs. (33 Nm). Tighten the exhaust pipe hanger nuts to 12 ft. lbs. (16 Nm).
53. Install the engine splash shield.
54. Apply a suitable super high temperature grease to the tip of the slave cylinder and install the slave cylinder to the transaxle. Tighten the mounting bolts to 16 ft. lbs. (22 Nm). Install the clutch bracket pipe and tighten the mounting bolts to 56 inch lbs. (9.8 Nm).
55. Install the front wheels and lower the vehicle.
56. Attach the VSS sensor and the starter motor connectors.
57. Connect the lower radiator hose clamp to the transaxle hanger.
58. Connect the transaxle ground cable and the backup light switch connector.
59. Install the air cleaner housing assembly with the air intake tube.
60. Refill the transaxle with the proper type and amount of lubricant.
61. Connect the positive, then the negative battery cables.
62. Check the operation of the clutch and smooth operation of the shifter.
63. Check the front wheel alignment and road test the vehicle.
64. Enter the radio security code.

2.2CL and 2.3CL

1. Disconnect the negative battery cable, then the positive cable. Remove the battery.
2. Drain the transaxle fluid into a suitable container.
3. Remove the air cleaner, air duct and resonator assembly.
4. Remove the starter. For more information, please refer to Engine Performance and Tune-Up of this guide.
5. Tag and remove all wiring from the transaxle.
6. Shift the transaxle into reverse.
7. Remove the cable bracket and the cables from the transaxle.

See Figure 13

Fig. Fig. 13: Exploded view of the cables and brackets

8. Unfasten the bolts and remove the clutch damper bracket.

See Figure 14

Fig. Fig. 14: After removing the bolts, remove the clutch damper bracket

9. Unfasten the retaining bolts, disconnect and plug the fluid line, then remove the slave cylinder.

See Figure 15

Fig. Fig. 15: Clutch slave cylinder location and mounting

10. Remove the two upper transaxle mounting bolts.

See Figure 16

Fig. Fig. 16: Unfasten the two upper transaxle mounting bolts

11. Remove the engine splash shield.

See Figure 17

Fig. Fig. 17: Unfasten the retaining bolts and clips, then remove the splash shield

12. Disconnect the shock absorber from the lower arm.
13. Separate the lower ball joint from the knuckle assembly.

See Figure 18

Fig. Fig. 18: Exploded view of damper fork and lower control arm

14. Remove the radius rod.

See Figure 19

Fig. Fig. 19: Right radius rod and flange bolt location & mounting

15. Swing the hub assemblies outward and remove the halfshafts and intermediate shaft from the transaxle..

See Figures 20 and 21

Fig. Fig. 20: Removing the halfshafts from the transaxle

Fig. Fig. 21: Place a plastic bag over the driveshaft to keep dirt out of the joint and splines

16. Remove the center beam from the sub-frame.

See Figure 22

Fig. Fig. 22: The center beam is secured with five bolts

17. Remove the clutch cover.

See Figure 23

Fig. Fig. 23: Clutch cover mounting and bolt tightening specifications

18. Remove the intake manifold bracket.

See Figure 24

Fig. Fig. 24: The intake manifold bracket must be removed

19. Remove the three bolts from the rear bracket.

See Figure 25

Fig. Fig. 25: Rear mount bracket and bolt location

20. Use a suitable jack to raise the transaxle slightly, then remove the mounting bracket.
21. Remove the three lower transaxle-to-engine mounting bolts.

See Figures 26 and 27

Fig. Fig. 26: Remove the 3 the transaxle mounting bolts

Fig. Fig. 27: Exploded view of the transaxle mount and bolt tightening specifications

22. Pull the transaxle away from the engine. Do not damage the clutch hydraulic lines.

To install:

23. Be sure the two dowels are installed in the clutch housing.
24. Grease the release fork and bearing.
25. Install the transaxle in the reverse order of the removal procedure.
26. Tighten the following components as specified:
    
    
    Transaxle-to-engine bolts to 47 ft. lbs. (64 Nm)

    Rear mount bracket bolts to 40 ft. lbs. (54 Nm)

    Intake manifold bracket bolts to 16 ft. lbs. (22 Nm)

    Center beam bolts to 37 ft. lbs. (50 Nm)
27. Refill the transaxle with the recommended amount and type of lubricant.
28. Properly position the breather cap.

See Figure 28

Fig. Fig. 28: Install the breather cap in the proper position as shown

29. Enter the radio security code.

Legend

1. Disconnect the positive, then the negative battery cables.
2. Unbolt the strut bar from the bulkhead and shock towers.
3. Drain the transaxle fluid and replace the plug with a new washer.
4. Remove the control box, but do not disconnect the vacuum lines.
5. Detach the wiring from the neutral switch, back-up light switch, and the reverse lockout solenoid connector.
6. Unfasten the transaxle housing bolts and the clutch hose bracket from the rear engine hanger.
7. Remove the front exhaust pipe and catalytic converter. On Legends with 6-speed transaxle, remove the twin three-way catalytic converters and their brackets.
8. Remove the converter heat shield and bracket.

A suitable extension shaft puller, should be used to remove the extension shaft before removing the transaxle.

9. Lock the transaxle by shifting it into first gear.
10. Remove the extension shaft secondary cover and the 36mm sealing bolt. Use an extension shaft puller to remove the extension shaft from the rear of the transaxle case. The differential is not removed with the transaxle.
11. Disconnect the transaxle linkage extension and the shift rod.
12. Disconnect the oil cooler lines from the oil pump pipes.
13. Remove the release fork cover and the clutch slave cylinder.
14. Support the steering rack with a suitable jack, and remove the rack cover plate. Reinstall the steering rack bolts to hold the rack in the vehicle.
15. Remove the exhaust pipe bracket.
16. Remove the transaxle rear mount and bracket assembly.
17. Pull out on the clutch fork to release it from the throw-out bearing. Don't remove it from the clutch housing.
18. Use a jack to take up the transaxle's weight. Remove the transaxle mid mounts.
19. Remove the transaxle housing mounting bolts.
20. Remove the engine stiffener and the clutch housing cover.
21. Remove the transaxle mounting bolts and the 26mm shim under the transaxle.
22. Verify that all linkages, vacuum lines, and wiring harnesses have been disconnected.
23. Slide the transaxle back and off the input shaft, and lower it from the vehicle.

To install:

24. Make sure that the transaxle mounting dowel pins are seated in the clutch housing.
25. Clean and lightly lubricate the input shaft and release fork contact points with molybdenum grease and install the fork.
26. Install the extension shaft in place. Use a new set ring on the shaft and lightly lubricate the splines with molybdenum grease. Install the sealing bolt and secondary cover.
27. Install the transaxle and start all of the bolts. Install the 26mm transaxle shim. Tighten the 12mm bolts to 55 ft. lbs. (75 Nm).
28. Install the clutch cover and engine stiffener bolts. Tighten the stiffener bolts to 16 ft. lbs. (22 Nm), and the clutch cover bolts to 9 ft. lbs. (12 Nm).
29. Install the mid mounts and the exhaust bracket. Tighten the 10mm bolts to 29 ft. lbs. (39 Nm), 10mm nuts to 36 ft. lbs. (49 Nm).
30. Install the transaxle rear mount and bracket assembly. Tighten the mount bolts to 29 ft. lbs. (39 Nm).
31. Install the shift linkage and extension rod. Make sure the hole in the shift rod boot is facing down.
32. Install the release fork and the slave cylinder.
33. Install the release fork cover and connect the oil cooler hoses.
34. With the transaxle in gear, install the extension shaft using the special tool. Coat the extension shaft with molybdenum grease and use a new set ring. Make sure the shaft snaps into place on the set ring.
35. Pack the shaft area with molybdenum grease, but keep the thread area clean. Apply liquid gasket to the sealing bolt threads and install the bolt and cover.
36. Support the steering rack with a jack and remove the bolts. Install the rack cover plate and tighten the bolts to 28 ft. lbs. (39 Nm). These bolts thread into aluminum and must have the special Dacro®coating to avoid corrosion.
37. On six-speed Legends, install the twin three-way catalytic converters and brackets.
38. Install the heat shield and the exhaust pipe and catalytic converter. Use new locking nuts and gaskets. Torque the exhaust flange nuts to 40 ft. lbs. (55 Nm) and the catalyst flange nuts to 26 ft. lbs. (34 Nm).
39. Install the clutch hose bracket.
40. Install the upper transaxle mounting bolts and torque to 55 ft. lbs. (75 Nm).
41. Reconnect the neutral position switch, backup light switch, and the reverse lockout solenoid connectors.
42. Install the control box.
43. Install the strut bar.
44. Check that all linkages, vacuum lines, and wiring harnesses have been reconnected.
45. Refill the transaxle with the proper type and amount of fluid
46. Connect the positive, then the negative battery cables.
47. Check the clutch operation and adjust if necessary. Shift the transaxle through the gear range and check for smooth operation.

Vigor

1. Disconnect the positive, then the negative battery cables. Remove the battery and the battery tray.
2. Remove the ABS relay box, but do not disconnect the harness.
3. Remove the heat shield, distributor and the control box. Do not disconnect the vacuum lines from the control box.
4. Detach the transaxle ground wire and the back-up light switch connector.
5. Remove the clutch slave cylinder and the transaxle housing mounting bolts with the 26mm shim. Do not operate the clutch pedal once the slave cylinder has been removed.
6. Remove the mount beam and bracket.
7. Remove the secondary cover and the 33mm sealing bolt. Pull the extension shaft out using a puller that threads into the shaft bore.
8. Remove the exhaust and disconnect the shift and extension rods.
9. Remove the transaxle mount nuts and support the housing with a jack. Remove the mounts and the housing bolt.
10. Remove the clutch cover and the housing bolt.
11. Remove the transaxle from the vehicle.

To install:

12. Lubricate the release bearing, fork and guide with molybdenum grease and make sure the dowel pins are properly placed in the clutch housing.
13. While fitting the transaxle to the engine, turn the release lever up and make sure the fork engages the release bearing on the clutch.
14. Make sure the transaxle is properly fitted and install the lower transaxle bolts. Tighten the bolts to 47 ft. lbs. (65 Nm).
15. If the transaxle or differential is being replaced, measure the gap between them with a feeler gauge and select the correct 26mm shim.
16. Install the front transaxle mounts.
17. Install a new set ring onto the extension shaft and lubricate the shaft with a high temperature molybdenum grease. Install the extension shaft.
18. Pack the shaft area with grease but keep the threads clean. Apply a liquid gasket compound to the threads and install the 33mm sealing bolt. Tighten the bolt to 58 ft. lbs. (80 Nm) and install the secondary cover.
19. Connect the shift linkage and the extension rod.
20. Use new gaskets and install the exhaust pipe.
21. Install the rear transaxle mount and bracket.
22. Install the 26mm shim and the remaining transaxle bolts. Tighten the shim bolt to 55 ft. lbs. (75 Nm) and the rest to 47 ft. lbs. (65 Nm).
23. Install the slave cylinder.
24. Attach the backup light switch connector and the transaxle ground wire.
25. Install the distributor.
26. Install the heat shield and the ABS relay box.
27. Install the battery and connect the positive, then the negative battery cables.
28. Refill the transaxle with the proper type and amount of fluid and check the clutch operation.
29. Check the ignition timing and test drive to check the transaxle smoothness.

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This will help.

Thanks.

For more car related problem troubleshooting:---

This are the sections, you can go through and click the link to read its troubleshooting.

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http://schematicsdiagram.blogspot.com/2011/06/car-will-not-start.html

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http://schematicsdiagram.blogspot.com/2011/06/car-will-not-crank.html

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http://schematicsdiagram.blogspot.com/2011/06/car-has-no-spark.html

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How to troubleshoot car battery?

http://schematicsdiagram.blogspot.com/2011/06/how-to-troubleshoot-car-battery.html

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http://schematicsdiagram.blogspot.com/2011/06/how-to-test-starter-solenoid.html

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How to test cars starter?

http://schematicsdiagram.blogspot.com/2011/06/how-to-test-cars-starter.html

How to replace starter in car?

http://schematicsdiagram.blogspot.com/2011/06/how-to-replace-starter-in-car.html

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car will turn over but will not start?

http://technoanswers.blogspot.com/2011/05/car-will-turn-over-but-will-not-start.html

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http://howtobyme.blogspot.com/2011/10/car-wont-start.html

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