Attention! If it becomes necessary to roll the car with the drive shafts removed, then outer CV joints must be inserted into the wheel hubs to avoid damage to the bearings!
Mirage Models
Removing
1. Remove the battery and its installation tray (see chapters Settings and ongoing maintenance and Engine electrical equipment).
2. Remove the air cleaner assembly and vacuum hoses (see chapters Engine and Power and exhaust systems).
3. Having previously marked, disconnect the cables of the gearshift drive.
4. On 1.6L models, remove the tension rod.
5. Disconnect the electrical wiring from the sensor-switch of the reversing lights and starter. Remove starter assembly (see chapter Engine electrical equipment).
6. Jack up the car and put it on stands.
7. Remove the front wheels and lockers protecting their arches.
8. Remove the crankcase protection and lower mudguard.
9. Prepare a suitable container and drain the transmission oil from the manual transmission case.
10. Support the engine with a jack and remove the cross beam.
11. Turn out the top fixing bolt and remove an arm of a support of a transmission.
12. Disconnect the anti-roll bar, tie rod ends and lower ball joints.
13. Remove the clutch slave cylinder and the support bracket for the hydraulic path line of the clutch drive, - do not disconnect the hydraulic path lines, take the cylinder aside and tie it up with wire.
14. With the appropriate vehicle configuration, remove the clutch cable.
15. Using a pry bar, release the drive shafts from the transmission case (try not to damage the seal), - do not pull on the shaft to avoid damage to the inner joint.
Note. There is no need to release the outer ends of the drive shafts from the hub assemblies - they can be removed as an assembly with the steering knuckles. Alternatively, the shafts can be wired to the suspension elements.
16. Remove the transmission dome lower cover.
17. Turn out fixing bolts, disconnect a transmission from the engine and take it from under the car.
Installation
Attention! The final tightening of the fasteners of the suspension elements should be done after lowering the vehicle to the ground!
Note. Retaining rings installed on the internal pins of the drive shafts during assembly must be replaced without fail.
1. Get a transmission on the regular place, press it to the engine and screw in fixing bolts. Tighten fasteners to the required torque (31÷40 Nm: for models up to 1992 vol. and 48 Nm: for models since 1993 vol.).
2. Install the transmission dome cover.
3. Fill the drive shafts into the transmission, - try not to damage the sealing lips of the glands.
4. Install the clutch slave cylinder.
5. Connect ball joints, tie rod ends and anti-roll bar.
6. Install the upper support bracket and screw in the fixing bolt.
7. Install the cross beam.
8. Install the crankcase protection.
9. Screw in the upper bolts of the transmission to the engine and tighten them with the required force (43÷55 Nm: for models up to 1992 vol. and 48 Nm: for models since 1993 vol.).
10. Reinstall the starter (see chapter Engine electrical equipment).
11. Connect electroconducting to a speedometer and the gauge switch of fires of a backing.
12. Connect and adjust shift cables (see Section Adjustment of a drive of a gear change).
13. Install air cleaner assembly and restore original vacuum hose connections (see chapters Engine and Power and exhaust systems).
14. Lokery protection arches and front wheels.
15. Align the car relative to the horizontal plane and fill the gearbox with gear oil type GL-4 (see chapter Settings and ongoing maintenance).
16. Connect the negative wire to the battery.
17. Check up serviceability of functioning of coupling and uniqueness of operation of fires of a backing.
Galant models through 1993 no.
Removing
1. Remove the battery and air duct sleeves.
2. On models equipped with Active-ECS, disconnect the wiring from the compressor.
3. Remove the speed control actuator and the bracket located on the right wing mudguard in the vehicle's engine compartment.
4. Drain the gear oil from the manual transmission housings and transfer case.
5. Turn out a fixing bolt and disconnect from a transmission a cable of a drive of a speedometer.
6. Remove the fixing cotter pin and disconnect the tips of the select and shift cables from the manual transmission assembly.
7. Release the fasteners, remove the clutch slave cylinder, without disconnecting the hydraulic hoses, move the assembly to the side and secure it with wire.
8. Disconnect electroconducting from the gauge switch of stoplights. Move the wires to the side.
9. Disconnect the electrical wiring from the starter. Loosen the fasteners and move the starter to the side.
10. Remove the transmission suspension support bracket.
11. Turn out the top bolts of fastening of a transmission.
12. Jack up the car and put it on stands.
13. Remove the crankcase protection and front wheels.
14. Remove cotter pins and disconnect tie rods from steering knuckles.
15. Give self-locking nuts of power shafts.
16. Release the lower control arm ball joints from the steering knuckle assemblies.
17. Release the drive shafts from the transmission housing.
18. On all-wheel drive (AWD) models, disconnect the exhaust pipe from the exhaust manifold, then loosen the mounting bolts and remove the transfer case by moving it to the left and lowering the front part down. Trying not to damage the oil seal, remove the transfer case from the rear driveshaft, the end of which is immediately tied to the bottom of the car. Seal the openings in the transfer case housing to prevent dirt from entering the assembly.
19. Remove the cover from the transmission dome.
20. On AWD models, remove the cross beam and triangular bracket.
21. Turn out the bottom coupling bolt, - on front-wheel drive (FWD) models, it is located directly above the hole for installing the drive shaft, on AWD models - above the hole for connecting the transfer case.
22. Hang the engine on top of the winch, support the gearbox with a cart jack and give the remaining lower mounting bolts.
23. On turbocharged models, take care not to damage the lower radiator hose when removing the gearbox. Slide the manual transmission assembly to the right, carefully lower it down and remove it from under the car.
Installation
1. Get the gearbox assembly to its regular place, screw in the fixing bolts and tighten them with a force of 48 Nm. Screw in the bottom pinch bolt and tighten it to the required torque (30÷34 Nm).
2. Install the pallet guard, crossbeam and triangular bracket.
3. On AWD models, install the transfer case and connect the exhaust pipe to the exhaust manifold.
4. Install the drive shafts - do not forget to replace the circlips on the trunnions and try to keep the inner pivot assemblies perpendicular to the surface of the manual transmission case. Be careful not to damage the sealing lips of the glands with the splines of the shafts.
5. Fix in rotary fists spherical support and tips of steering draughts.
6. Install the manual transmission suspension support bracket.
7. Install the front wheels, lower the vehicle to the ground and tighten the driveshaft hub nuts to the required torque (200÷260 Nm).
8. Install the starter assembly.
9. Connect electrical wiring to starter and reversing lights switch.
10. Install the clutch slave cylinder.
11. Connect cables of a choice and a gear change and fix their tips with new cotter pins.
12. Install the duct sleeves.
13. Install the tempostat actuator with the support bracket.
14. Install the battery.
15. On models equipped with Active-ECS, connect the air compressor.
16. Make sure the vehicle is level and fill in hypoid gear oil type GL-4 in the manual transmission case. On AWD models, add oil to the transfer case.
17. Check the proper functioning of the manual transmission and transfer case. Assess the adequacy of the operation of the reverse lights.
Galant models since 1994
Removing
1. Disconnect the negative cable from the battery - start work at least 90 seconds after disconnecting the battery.
Attention! If the stereo system installed in the car is equipped with a security code, before disconnecting the battery, make sure that you have the correct combination to activate the audio system!
2. Remove the air cleaner assembly and air duct sleeve.
3. Prepare a suitable drain container and drain the oil from the gearbox housing into it.
4. Remove the cotter pins and disconnect the select and shift cables from the manual transmission assembly.
5. On models equipped with Active-ECS, disconnect the wiring from the air compressor.
6. Disconnect electroconducting from the gauge switch of stoplights. Move the wires to the side.
7. Disconnect the speedometer wiring from the gearbox.
8. Use tool type MZ203827 to hang out the power unit assembly.
9. Remove the engine rear jet mount support bracket.
10. Remove the manual transmission suspension support bracket.
11. Turn out the top bolts of fastening of a transmission.
12. Jack up the car and put it on stands.
13. Remove the front wheels.
14. Remove the right crankcase protection section.
15. Remove the cotter pin and disconnect the tie rod from the steering knuckle assembly.
16. Disconnect the anti-roll bar from the damper fork.
17. Disconnect the damper fork from the lower transverse suspension arm.
18. Disconnect from a rotary fist the lower transversal lever, the squeezing lever and the lower spherical support.
19. Release the drive shafts from the transmission housing and tie them with wire to the bottom of the car.
20. Remove the clutch slave cylinder and, without disconnecting the hydraulic lines, secure the assembly aside.
21. Remove the cover from the transmission dome.
22. Turn out a through bolt of a forward jet emphasis of a suspension bracket of the power unit.
23. Remove a cross beam and the right triangular rack.
24. Support the manual transmission assembly with a trolley jack and remove the bottom pinch bolt.
Note. The pinch bolt threads into the transmission from the engine side and is located directly above the hole for the drive shaft.
25. Move the gearbox back, lower it and carefully remove it from under the car.
Installation
1. Get a transmission on the regular place. Screw in the mounting bolts and tighten them with the required force (48 Nm). Screw in the bottom pinch bolt and tighten it with a force of 30÷34 Nm.
2. Install the cover on the transmission dome and tighten its fastening bolts to 9 Nm.
3. Install the cross beam. Screw in the mounting bolts and tighten them with the required force (88 Nm: front and 73 Nm: rear).
4. Install and hand-tighten the through bolt of the powertrain suspension front torque strut. Final tightening of the bolt to the required torque (57 Nm) done after the weight of the engine is completely transferred to the supports.
5. Install the triangular post bracket. Screw in the mounting bolts and tighten them with the required force (88 Nm).
6. Install the clutch slave cylinder.
7. Install the drive shafts, - do not forget to replace the circlips on the trunnions and try to keep the internal hinge assemblies perpendicular to the surface of the manual transmission case. Be careful not to damage the sealing lips of the glands with the splines of the shafts.
8. Fix in assembly of a rotary fist a tip of steering draft and spherical support. Tighten the ball joint self-locking nuts to 65 Nm and the tie rod joint nut to 28 Nm. Install a new pin.
9. Connect the damper fork to the lower suspension arm. Screw in the through bolt and tighten it to the required torque (88 Nm).
10. Connect to a fork a rack of the stabilizer of cross-section stability. Screw on the self-locking nut and tighten it to 39 Nm.
11. Install the crankcase protection.
12. Install the wheels and lower the vehicle to the ground.
13. Install the power unit suspension support bracket on the transmission and tighten the nuts of its fastening with the required force (43 Nm).
14. Install the powertrain rear strut support bracket.
15. Lower the engine and tighten the through bolt of the gearbox to it with a force of 69 N·m, then finally tighten the through bolt of the front jet stop.
16. Screw in and tighten as required (48 Nm) upper gearbox mounting bolts.
17. Establish a starter and connect to it electroconducting.
18. Connect electroconducting to the gauge switch of fires of a backing.
19. Connect the selection and shift cables to the transmission, secure the cable ends with new cotter pins.
20. Install the air cleaner assembly and air sleeves.
21. Connect the negative cable to the battery.
22. Make sure the vehicle is level and fill in hypoid gear oil type GL-4 in the manual transmission case.
23. Check the proper functioning of the manual transmission. Assess the adequacy of the operation of the reverse lights.