Automatic Transaxle Removal and Installation
REMOVALWARNING:
- Make sure lifts, jacks, and safety stands are placed properly, and hoist brackets are attached to the correct position on the engine.
- Apply parking brake, and block rear wheels so vehicle will not roll off stands and fall on you while working under it.
CAUTION: Use fender covers to avoid damaging painted surfaces.
1. Before disconnecting power, make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset stations.
2. Remove the battery cover, then disconnect the battery negative terminal and positive terminal.
3. Remove the battery hold-down bracket, then remove the battery and battery tray.
4. Remove the intake air duct and air cleaner housing assembly.
5. Remove the cable holder from the battery base, then remove the battery base and the battery base bracket.
6. Raise the vehicle, and make sure it is securely supported. Remove the drain plug, and drain the Automatic Transmission Fluid (ATF). Reinstall the drain plug with a new sealing washer.
7. Remove the ATF cooler hose from the clamp on the starter.
8. Remove the ATF cooler hoses from the ATF cooler lines. Turn the ends of the ATF cooler hoses up to prevent ATF from flowing out, then plug the ATF hoses and lines.
NOTE: Check for any signs of leakage at the hose joints.
9. Remove the starter cables from the starter, then remove the starter.
10. Remove the transmission ground terminal.
11. Disconnect the shift control solenoid valve B and C connectors, then remove the harness clamp from the clamp bracket.
12. Disconnect the connectors from the 3rd clutch pressure switch, mainshaft speed sensor, and Automatic Transaxle (A/T) Clutch Pressure Control (CPC) solenoid valves A and B, then remove the harnesses from the clamp brackets.
13. Disconnect the lock-up control solenoid valve/shift control solenoid valve A assembly connector.
14. Remove the two bolts securing the harness cover, then push the harness cover in a rear direction to remove from the transmission hanger.
15. Disconnect the connectors from the Vehicle Speed Sensor (VSS) ('97 model), countershaft speed sensor, and 2nd clutch pressure switch.
NOTE: The '98 - '99 model does not have the VSS.
16. Remove the splash shield.
17. Remove the center beam.
18. Remove the cotter pins and castle nuts, then separate the ball joints from the lower arms.
19. Remove the damper fork bolts, then separate the damper fork and lower arm.
20. Pry the driveshafts out of the differential and the intermediate shaft.
21. Pull on the inboard joints to remove the left driveshaft from the differential and to remove the right driveshaft from the intermediate shaft.
22. Coat all precision finished surfaces with clean engine oil, then tie the plastic bags over the driveshaft ends.
23. Remove the left damper pinch bolt, then separate the damper fork and damper.
24. Remove the self-locking bolts and self-locking nuts, then remove the left radius rod.
25. Turn the left driveshaft toward the front of the vehicle.
26. Remove the intermediate shaft.
27. Coat all precision finished surfaces with clean engine oil, then tie the plastic bag over both ends of the intermediate shaft.
28. Remove the bolt securing the shift cable holder, then remove the shift cable cover.
NOTE: To prevent damage to the control lever joint, remove the bolt securing the holder before removing the bolt securing the cover.
29. Remove the lock bolt securing the control lever, then remove the shift cable with the control lever. Do not bend the shift cable excessively.
30. Install a 6 x 1.0 x 14 mm bolt and nut on the shift cable cover, then reinstall it to the torque converter housing. Otherwise the torque converter may stay on the engine, and the bolt head supports the torque converter, when the transmission is removed.
31. Remove the torque converter cover, then remove the eight drive plate bolts one at a time while rotating the crankshaft pulley.
32. Remove the engine stiffener mounting bolts.
33. Place a jack under the engine to support it, then lift the transmission with a hoist.
34. Loosen the rear mount bracket nut.
35. Remove the front engine mount bracket, then remove the front engine mount.
36. Remove the transmission housing mounting bolts and rear mount bracket bolt.
37. Remove the transmission mount.
38. Take the primary Heated Oxygen Sensor (H02S) (sensor 1) harness out of the harness holder, and remove the sensor harness out of the way. Remove the transmission housing mounting bolts (two bolts) and the rear mount bracket bolts (three bolts).
39. Lower the transmission, and tilt the engine just enough for the transmission to clear its left side from the body.
CAUTION: Do not let the A/C compressor pulley contact the body while tilting the engine.
40. Pull the transmission away from the engine until it clears the dowel pins, then lower it on a jack.
NOTE: If the torque converter is stuck to the drive plate, pull it in the hole of the starter toward the transmission housing.
41. Remove the shift cable cover, then remove the torque converter assembly from the transmission.
42. Inspect the drive plate, and replace it if it's damaged.
43. Remove the 6 x 1.0 x 14 mm bolt and nut from the shift cable cover.
INSTALLATION
1. Flush the Automatic Transmission Fluid (ATF) cooler as described.
2. Install the torque converter assembly securely with a new O-ring on the mainshaft.
3. Install the 14 mm dowel pin and 10 mm dowel pin in the torque converter housing.
4. Place the transmission under the vehicle, and attach a hoist to the transmission hanger.
5. Tilt the engine, and lift the transmission to the engine assembly level.
CAUTION: Do not let the A/C compressor pulley contact the body while tilting the engine.
6. Attach the transmission to the engine, then install the transmission housing mounting bolts (two bolts) and rear mount bracket bolts (three bolts). Put the primary Heated Oxygen Sensor (H02S) sensor (sensor 1) harness back in its holder.
7. Install the remaining transmission housing mounting bolts (three bolts) and the rear mount bracket bolt.
8. Install the front mount and the front mount bracket to the transmission, then install the front mount nut loosely.
9. Install the transmission mount. Tighten the bolt loosely, and tighten the nuts to the specified torque, then tighten the bolt to the specified torque.
10. Tighten the front mount and rear mount nut to the specified torque.
TORQUE: 54 Nm (5.5 kgf.m, 40 ft. lbs.)
11. Remove the jack from the engine, then remove the hoist from the transmission.
12. Attach the drive plate to the torque converter with eight bolts and torque:
Rotate the crankshaft as necessary to tighten the bolts to 1/2 of the specified torque, then to the final torque, in a crisscross pattern. After tightening the last bolt, check that the crankshaft rotates.
13. Install the torque converter cover.
14. Install the engine stiffener mounting bolts.
15. Tighten the crankshaft pulley bolt as necessary.
16. Install the control lever with the shift cable on the control shaft. Do not bend the shift cable excessively.
17. Install the lock bolt with a new lock washer, then bend the lock washer tab against the bolt.
18. Install the shift cable cover, then install the shift cable holder on the shift cable cover.
NOTE: To prevent damage to the control lever joint, be sure to install the shift cable holder after installing the shift cable cover to the torque converter housing.
19. Clean the areas where the intermediate shaft and driveshaft contact the transmission (differential) thoroughly with solvent or carburetor cleaner, and dry with compressed air.
20. Install the intermediate shaft. While installing the intermediate shaft in the differential, be sure not to allow dust or other foreign particles to enter into the transmission.
21. Install the left radius rod and damper fork.
NOTE: Check radius rod rubber bushings for deterioration and damage.
22. Install new set rings on the right and left driveshafts.
23. Install the right and left driveshaft. While installing the driveshaft in the differential, be sure not to allow dust or other foreign particles to enter into the transmission.
NOTE:
- Clean the areas where the left driveshaft contacts the transmission (differential) with solvent or carburetor cleaner, and dry with compressed air.
- Turn the right and left steering knuckle fully outward, and slide the left driveshaft into the differential until you feel its spring clip engage the side gear. Slide the right driveshaft into the intermediate shaft until you feel its spring clip engage the intermediate shaft.
24. Install the damper fork on the lower arm. Then install the ball joint on the lower arm. Use the castle nuts with new cotter pins.
25. Install the center beam.
26. Install the splash shield.
27. Connect the Vehicle Speed Sensor (VSS) ('97 model), countershaft speed sensor, and 2nd clutch pressure switch connectors. Do not allow water, fluid, oil, dust, or other foreign particles to enter the 2nd clutch pressure switch connector.
NOTE: The '98 - '99 model does not have the VSS.
28. Install the harness cover on the transmission hanger, then secure it with two bolts.
29. Connect the lock-up control solenoid valve/shift control solenoid valve A assembly connector.
30. Connect the 3rd clutch pressure switch, mainshaft speed sensor, and Automatic Transaxle (A/T) Clutch Pressure Control (CPC) solenoid valves A and B connectors, then clamp the harness clamp on the harness bracket. Do not allow water, fluid, oil, dust, or other foreign particles to enter the 3rd clutch pressure switch connector.
31. Connect the connectors to the shift control solenoid valve B and shift control solenoid valve C, then install the clamp on the clamp bracket.
32. Install the transmission ground terminal.
33. Install the starter on the torque converter housing. Connect the starter cables to the starter, and install the harness clamp on the clamp bracket.
NOTE: When installing the starter cable, make sure that the crimped side of the terminal is facing out.
34. Connect the ATF cooler hoses to the ATF cooler lines.
35. Install the battery base bracket and battery base.
36. Install the cable holder on the battery base.
37. Install the battery tray and battery, then secure the battery with its hold-down bracket.
38. Install the intake air duct and air cleaner housing assembly.
39. Refill the transmission with ATF.
40. Connect the battery positive and negative cables to the battery terminals.
41. Set the parking brake. Start the engine, and shift the transmission through all gears three times. Check the shift lever operation and the A/T gear position indicator operation.
42. Check and adjust the front wheel alignment.
43. Let the engine reach normal operating temperature (the radiator fan comes on) with the transmission in [P] or [N] position, then turn it off and check the ATF level.
44. Road test.
45. Enter the anti-theft code for the radio, then enter the customer's radio station presets.
46. Loosen the front mount and rear mount nut after the road test, then retighten the nuts to the specified torque.
TORQUE: 54 Nm (5.5 kgf.m, 40 ft. lbs.)