Attention! If it becomes necessary to roll the car with the drive shafts removed, then the outer CV joints must be inserted into the wheel hubs to avoid damaging the bearings!
Mirage Models
Removal
1. Remove the battery and its mounting tray (see Chapters Settings and ongoing maintenance и Engine electrical equipment).
2. Remove the air cleaner assembly and vacuum hoses (see Chapters Engine и Power and exhaust systems).
3. After marking, disconnect the gear shift drive cables.
4. On 1.6L models, remove the tension rod.
5. Disconnect the wiring from the reverse light switch sensor and the starter. Remove the starter assembly (see Chapter Engine electrical equipment).
6. Jack up the car and place it on supports.
7. Remove the front wheels and wheel arch protectors.
8. Remove the crankcase guard and lower splash guard.
9. Prepare a suitable container and drain the transmission oil from the manual transmission housing.
10. Support the engine with a jack and remove the cross member.
11. Remove the upper mounting bolt and remove the gearbox support bracket.
12. Disconnect the anti-roll bar, tie rod ends and lower ball joints.
13. Remove the clutch slave cylinder and the clutch drive hydraulic line support bracket - do not disconnect the hydraulic lines, move the cylinder to the side and tie it up with wire.
14. If the vehicle is equipped accordingly, remove the clutch cable.
15. Using a pry bar, release the drive shafts from the transmission housing (try not to damage the seal) - do not pull on the shaft to avoid damaging 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 a complete assembly with the steering knuckles. Alternatively, the shafts can be tied with wire to the suspension components.
16. Remove the lower transmission dome cover.
17. Remove the mounting bolts, disconnect the gearbox from the engine and remove it from under the vehicle.
Installation
Attention! The final tightening of the suspension element fasteners should be done after the vehicle has been lowered to the ground!
Note: The retaining rings installed on the inner journals of the drive shafts must be replaced during assembly.
1. Place the gearbox in its regular place, press it against the engine and screw in the mounting bolts. Tighten the fasteners with the required force (31÷40 N·m: for models up to 1992 and 48 N·m: for models from 1993).
2. Install the transmission dome cover.
3. Insert the drive shafts into the transmission, being careful not to damage the sealing lips of the oil seals.
4. Install the clutch slave cylinder.
5. Connect the ball joints, tie rod ends and stabilizer bar.
6. Install the upper support bracket and screw in the mounting bolt.
7. Install the cross beam.
8. Install the crankcase guard.
9. Screw in the upper transmission-to-engine mounting bolts and tighten them to the required torque (43÷55 Nm: for models up to 1992 and 48 Nm: for models from 1993).
10. Install the starter in place (see Chapter Engine electrical equipment).
11. Connect the wiring to the speedometer and reverse light switch sensor.
12. Connect and adjust the gear shift cables (see Section Adjusting the gear shift drive).
13. Install the air cleaner assembly and restore the original vacuum hose connections (see Chapters Engine и Power and exhaust systems).
14. Wheel arch protection liners and front wheels.
15. Align the vehicle with the horizontal plane and fill the gearbox with GL-4 type transmission oil (see Chapter Settings and ongoing maintenance).
16. Connect the negative cable to the battery.
17. Check the proper functioning of the clutch and the clear operation of the reverse lights.
Galant models up to 1993.
Removal
1. Remove the battery and air duct sleeves.
2. On models equipped with Active-ECS, disconnect the electrical wiring from the compressor.
3. Remove the speed control actuator and bracket located on the right wing splash guard in the engine compartment of the vehicle.
4. Drain the transmission oil from the manual transmission and transfer case housings.
5. Unscrew the mounting bolt and disconnect the speedometer drive cable from the gearbox.
6. Remove the retaining pin and disconnect the gear selection and shift cable ends from the manual transmission assembly.
7. Loosen 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 the electrical wiring from the brake light switch sensor. Move the wires to the side.
9. Disconnect the electrical wiring from the starter. Release the fasteners and move the starter to the side.
10. Remove the transmission mount bracket.
11. Remove the upper gearbox mounting bolts.
12. Jack up the car and place it on supports.
13. Remove the crankcase guard and front wheels.
14. Remove the cotter pins and disconnect the steering rods from the steering knuckles.
15. Remove the drive shaft self-locking nuts.
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 downpipe from the exhaust manifold, then loosen the mounting bolts and remove the transfer case by sliding it to the left and lowering the front part. Being careful not to damage the seal, remove the transfer case from the rear propeller shaft, the end of which is immediately tied to the bottom of the car. Seal the holes in the transfer case housing to prevent dirt from getting into the assembly.
19. Remove the cover from the transmission dome.
20. On AWD models, remove the crossmember and A-arm.
21. Remove the lower tie 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. Suspend the engine from above on a winch, support the gearbox with a dolly jack and loosen the remaining lower mounting bolts.
23. On turbocharged models, be careful not to damage the lower radiator hose when removing the gearbox. Slide the gearbox assembly to the right, carefully lower it down and remove it from under the car.
Installation
1. Place the gearbox assembly in its regular place, screw in the mounting bolts and tighten them with a force of 48 N·m. Screw in the lower tie bolt and tighten it with the required force (30÷34 N·m).
2. Install the tray guard, crossbar 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 retaining rings on the journals and try to keep the internal joint assemblies perpendicular to the surface of the gearbox housing. Be careful - do not damage the sealing lips of the oil seals with the splines of the shafts.
5. Secure the ball joints and steering rod ends in the steering knuckles.
6. Install the manual transmission suspension support bracket.
7. Install the front wheels, lower the vehicle to the ground and tighten the drive shaft hub nuts to the required torque (200÷260 Nm).
8. Install the starter assembly.
9. Connect the wiring to the starter and the reverse light switch sensor.
10. Install the clutch slave cylinder.
11. Connect the gear selector and shift cables and secure their ends with new cotter pins.
12. Install the air duct sleeves.
13. Install the speed control 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 add hypoid transmission oil type GL-4 to the manual transmission housing. On AWD models, add oil to the transfer case.
17. Check the correct operation of the manual transmission and transfer case. Assess the adequacy of the operation of the reverse lights.
Galant models since 1994.
Removal
1. Disconnect the negative cable from the battery - start work at least 90 seconds after disconnecting the battery.
Warning! If the car stereo system is equipped with a security code, make sure you have the correct combination to activate the audio system before disconnecting the battery!
2. Remove the air cleaner assembly and air duct sleeves.
3. Prepare a suitable drain container and drain the oil from the gearbox housing into it.
4. Remove the cotter pins and disconnect the gear selection and shift cables from the manual transmission assembly.
5. On models equipped with Active-ECS, disconnect the electrical wiring from the air compressor.
6. Disconnect the electrical wiring from the brake light switch sensor. Move the wires to the side.
7. Disconnect the speedometer wiring from the gearbox.
8. Using the MZ203827 type tool, support the power unit assembly.
9. Remove the engine rear strut support bracket.
10. Remove the manual transmission suspension support bracket.
11. Remove the upper gearbox mounting bolts.
12. Jack up the car and place it on supports.
13. Remove the front wheels.
14. Remove the right section of the crankcase guard.
15. Remove the cotter pin and disconnect the steering rod from the steering knuckle assembly.
16. Disconnect the anti-roll bar strut from the damper fork.
17. Disconnect the damper fork from the lower wishbone.
18. Disconnect the lower wishbone, clamp arm and lower ball joints from the steering knuckle.
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 to the side.
21. Remove the cover from the transmission dome.
22. Unscrew the through bolt of the front torque strut of the power unit suspension.
23. Remove the cross beam and the right triangular pillar.
24. Support the manual transmission assembly with a trolley jack and unscrew the lower tie bolt.
Note: The tie rod bolt is threaded into the transmission from the engine side and is located directly above the drive shaft mounting hole.
25. Slide the gearbox back, lower it and carefully remove it from under the vehicle.
Installation
1. Place the gearbox in its regular place. Screw in the mounting bolts and tighten them with the required force (48 N·m). Screw in the lower tension bolt and tighten it with a force of 30÷34 N·m.
2. Install the cover on the transmission dome and tighten its mounting bolts to 9 N·m.
3. Install the cross member. Screw in the mounting bolts and tighten them to the required torque (88 Nm: front and 73 Nm: rear).
4. Screw in and tighten by hand the through bolt of the front jet stop of the power unit suspension. The final tightening of the bolt with the required force (57 N·m) is carried out after the weight of the engine has been completely transferred to the supports.
5. Install the triangular pillar bracket. Screw in the mounting bolts and tighten them to the required torque (88 N·m).
6. Install the clutch slave cylinder.
7. Install the drive shafts - do not forget to replace the retaining rings on the journals and try to keep the inner joint assemblies perpendicular to the surface of the gearbox housing. Be careful - do not damage the sealing lips of the oil seals with the splines of the shafts.
8. Secure the steering tie rod end and ball joints to the steering knuckle assembly. Tighten the ball joint self-locking nuts to 65 N·m and the steering tie rod joint nut to 28 N·m. Install a new cotter pin.
9. Connect the damper fork to the lower suspension arm. Screw in the through bolt and tighten it to the required torque (88 N·m).
10. Connect the anti-roll bar to the fork. Screw on the self-locking nut and tighten it to 39 N·m.
11. Install the crankcase guard.
12. Install the wheels and lower the car to the ground.
13. Install the powertrain suspension support bracket onto the transmission and tighten its mounting nuts to the required torque (43 N·m).
14. Install the rear torque strut support bracket of the powertrain suspension.
15. Lower the engine and tighten the through bolt securing the gearbox to it with a torque of 69 N·m, then finally tighten the through bolt of the front torque strut.
16. Screw in and tighten to the required torque (48 Nm) the upper gearbox mounting bolts.
17. Install the starter and connect the electrical wiring to it.
18. Connect the wiring to the reverse light switch sensor.
19. Connect the gear selection and shift cables to the transmission, secure the cable ends with new cotter pins.
20. Install the air cleaner assembly and air hoses.
21. Connect the negative cable to the battery.
22. Make sure the vehicle is level and fill the gearbox housing with hypoid transmission oil type GL-4.
23. Check the correct operation of the manual transmission. Assess the adequacy of the operation of the reverse lights.