Removal and Replacement

Transmission Replacement

Tools Required
- J42640 Steering Column Anti-Rotation Pin

Removal Procedure

Notice: The wheels of the vehicle must be straight ahead and the steering column in the LOCK position before disconnecting the steering column or intermediate shaft from the steering gear. Failure to do so will cause the SIR coil assembly to become uncentered, which may cause damage to the coil assembly.





1. Lock the steering column by installing J42640 into the underside of the steering column.
2. Disconnect the negative battery cable.
3. Remove the air cleaner assembly.





4. Use a large flat-bladed tool in order to remove the range selector cable from the range selector lever.
5. Remove the range selector cable with bracket from the transmission case and set aside.





6. Disconnect the transaxle electrical connector C100 (2).
7. Remove the wiring harness (3) from the wiring harness retainer (1) on the transaxle.





8. Remove the ground cable bolt (1) from the transaxle.
9. Install the engine support fixture.





10. Remove the upper engine to transaxle case bolts (2-5).
11. Raise and Support the vehicle. Refer to Vehicle Lifting.





12. Remove the front tire and wheel assembly.
13. Remove both of the front fascia extensions (3).
14. Remove the front air deflector.

Caution: Failure to disconnect the intermediate shaft from the racer and pinion steering gear stub shaft can result in damage to the steering gear or to the intermediate shaft. This damage may cause loss of steering control, which could result in an accident and possible personal injury.





15. Remove the intermediate shaft lower pinch bolt.
16. Disconnect the intermediate shaft from the power steering gear.
17. Remove the power steering gear heat shield.





18. Remove the power steering gear mounting bolts.
19. Remove the power steering line retainers from the frame.
20. Secure the power steering gear to the exhaust manifold.





21. Loosen the two mounting nuts (2) in order to allow removal of the brake pressure modulator valve (1) from the bracket (3).
22. Remove the brake line retainers from the frame.





23. Remove the left transaxle mount.
24. Remove the frame.
25. Remove the front transaxle mount bracket with mount attached.
26. Remove the right and left drive axles from the transaxle.





27. Disconnect the transmission oil cooler hose from the transaxle.
28. Remove the transaxle fluid filler tube.
29. Remove the torque converter cover.
30. Mark the flywheel to converter relationship to ensure proper reassembly. Remove the flywheel to torque converter bolts.





31. Support transaxle using an appropriate transaxle jack.





32. Disconnect vehicle speed sensor electrical connector.
33. Remove the torque strut bracket to transaxle bolts.





34. Remove the torque strut bracket to engine bolts.
35. Remove the torque strut bracket.





36. Remove the engine to transaxle case bolt (6), which is accessible through right wheel opening.
37. Remove the remaining transaxle to engine bolt (1).
38. Remove the transaxle from vehicle using an appropriate transaxle jack.





39. Remove the rear transaxle bracket (1) from the transaxle.





40. Remove the left transaxle bracket (1) from the transaxle.

Installation Procedure





1. Install the left transaxle bracket (1) to the transaxle.

Notice: Refer to Fastener Notice in Service Precautions.

2. Install the left transaxle bracket bolts.
Tighten the left transaxle bracket bolts to 110 Nm (81 ft. lbs.).





3. Install the rear transaxle bracket (1) to the transaxle.
4. Install the rear transaxle bracket bolts.
Tighten the rear transaxle bracket bolts to 63 Nm (46 ft. lbs.).





5. Install the transaxle into the vehicle and align the engine alignment dowels (1 and 5).
6. Install the transaxle case to engine bolts (1 and 6).
Tighten the lower transaxle bolts to 75 Nm (55 ft. lbs.).





7. Install the torque strut bracket.
8. Install the torque strut bracket to engine bolts.
Tighten the torque strut bracket to engine bolts to 65 Nm (48 ft. lbs.).





9. Install the torque strut bracket to transaxle bolts.
Tighten the torque strut bracket to transaxle bolts to 36 Nm (26 ft. lbs.).
10. Connect vehicle speed sensor electrical connector.
11. Remove the transaxle jack

Important:
- Align the mark made on the torque converter with the mark made on the flywheel made in the disassembly unless installing a new converter.
- Tighten all the torque converter to flywheel bolts twice.





12. Install the flywheel to torque converter bolts.
Tighten the flywheel to torque converter bolts to 63 Nm (47 ft. lbs.).
13. Install the torque converter cover.
14. Install the transaxle fluid filler tube.
15. Connect the transmission oil cooler hoses to the transaxle.

Important: Use care when installing the right side drive axle into the transaxle case. The splined shaft of the drive axle can easily damage the seal.





16. Install the left and the right drive axle into the transaxle.
17. Install the front transaxle mount bracket with mount attached.
18. Install the frame.
19. Install the left transaxle mount.





20. Position the brake pressure modulator valve (1) into the bracket (3).
Tighten the two nuts (2) to 10 Nm (89 inch lbs.).
21. Install the brake line retainers onto the frame.





22. Install the power steering gear mounting bolts.
Tighten the bolts to 70 Nm (95 ft. lbs.).
23. Install the power steering line retainers onto the frame.
24. Install the power steering gear heat shield.

Caution: When installing the intermediate shaft make sure that the shaft is seated prior to pinch bolt installation. If the pinch bolt is inserted into the coupling before shaft installation, the two mating shafts may disengage. Disengagement of the two mating shafts will cause loss of steering control, which could result in personal injury.





25. Connect the intermediate shaft to the power steering gear.
26. Install the intermediate shaft lower pinch bolt.
Tighten the bolt to 45 Nm (33 ft. lbs.).





27. Install both of the front fascia extensions (3).
28. Install the front air deflector.
29. Install the front tire and wheel assembly.
30. Lower the vehicle.





31. Install the upper transaxle case to engine bolts (2-5).
Tighten the transaxle bolts to 75 Nm (55 ft. lbs.).
32. Remove the engine support fixture.





33. Install the range selector cable. bracket and cable.
Tighten the range selector cable bracket nuts to 25 Nm (18 ft. lbs.).
34. Install the range selector cable onto the range selector lever.
35. Check adjustment of the range selector cable. Re-adjust as needed.





36. Install ground cable and bolt (1) to transaxle.
Tighten the ground cable bolt to 17 Nm (13 ft. lbs.).





37. Connect the transaxle electrical connector C100 (2).
38. Install the wiring harness (3) into the wiring harness retainer (1) on the transaxle.
39. Install the air cleaner assembly.
40. Connect the negative battery cable.





41. Remove the J42640 from the steering column.
42. Flush the transmission cooler.
43. Fill the transaxle to the proper level.
44. Inspect the transaxle fluid level.
45. Inspect for fluid leaks.
46. Clear TAPS (Transmission Adaptive Pressures).
47. Check the front end alignment.
48. Road test the vehicle and check for transaxle leaks.