Case: Service and Repair

Case Side Cover Replacement

Removal Procedure




1. Remove the engine sight shield.
2. Remove the air cleaner intake duct.




3. Remove the range selector cable from the range selector lever.
4. Remove the range elector cable bracket nuts.
5. Remove the range selector cable bracket from the transmission case and set aside.




6. Disconnect the transaxle electrical connector C100 (2).
7. Disconnect the wiring harness (3) from the wiring harness retainer (1) on the transaxle.
8. Remove the upper transmission case side cover bolt.
9. Install the engine support fixture.
10. Raise and Support the vehicle. Refer to Vehicle Lifting.
11. Remove the left front tire and wheel assembly.




12. Remove the left inner wheelhouse liner (1).
13. Remove the front air deflector.
14. Remove the left ball joint from the steering knuckle. Refer to Lower Control Arm Replacement.




15. Remove the stabilizer bar links.
16. Rotate the stabilizer bar to gain access to the power steering mounting bolts.
17. Remove the power steering gear mounting bolts.
18. Remove the power steering line retainers from the frame.
19. Secure the power steering gear to the vehicle body.




20. Remove the mounting bolt (2) in order to allow removal of the brake pressure modulator valve from the bracket.
21. Remove the brake line retainers (1) from the frame.




22. Remove the lower nuts (1-3) from the powertrain mounts.
23. Support the left side of the frame with an appropriate jack.




24. Remove the three frame-to-body bolts (3) on the left side.

Important: DO NOT loosen the front and rear frame-to-body bolts on the right side.

25. Loosen, but do not remove, the right center frame-to-body bolt.

Important: Ensure that all pipes, hoses and wires are clear and not being bound or stressed when lowering the frame.

26. Lower the left side of the frame.
27. Lower the vehicle enough to gain access to the engine support fixture.
28. Using the engine support fixture, lower the transaxle.
29. Raise the vehicle.
30. Position an oil drain pan under the left side of the transaxle.
31. Remove the left drive axle from the transaxle.




32. Remove the case side cover bolts.




33. Remove the case side cover (53).
34. If replacing the side cover, remove the transmission mount bracket.
35. Clean the case and side cover gasket surfaces.

Installation Procedure




1. Assemble the case side cover inner gasket (59) to the case side cover (53). Use J 36850 on the seal surfaces.
2. Install the case side cover gasket (54) and case side cover (53) onto the case. Make sure the gaskets and electrical connector are positioned correctly.





Notice: Refer to Fastener Notice.

3. Install the transmission side case bolts.

Tighten all bolts to 25 N.m (18 lb ft).

4. If removed, install the transmission mount bracket.
5. Install the drive axle into the transaxle.
6. Lower the vehicle enough to gain access to the engine support fixture.
7. Using the engine support fixture, raise the transaxle to the original position.
8. Raise the vehicle.
9. Using an appropriate jack. Carefully raise the left side of the frame so that the frame-to-body bolts can be installed.




10. Using 16 mm (0.630 in) dowel pins in the alignment holes (1), align the engine frame (2) with the body.
11. Install the frame-to-body bolts (3).

Tighten the bolts to 112 N.m (83 lb ft).

12. Remove the jack stand and oil drain pan.




13. Install the lower powertrain mount nuts (2, 3).

Tighten the nut to 70 N.m (52 lb ft).

14. Install the two left transaxle mount nuts (1).

Tighten the nut to 50 N.m (37 lb ft).




15. Position the brake pressure modulator valve into the bracket and install the mounting bolt (2).

Tighten the bolt to 10 N.m (89 lb in).

16. Install the brake line retainers (1) onto the frame.




17. Install the power steering gear mounting bolts.

Tighten the bolts to 70 N.m (95 lb ft).

18. Install the power steering line retainers onto the frame.
19. Install the ball joint into the steering knuckle. Refer to Lower Control Arm Replacement.
20. Install the stabilizer bar links.
21. Install the front air deflector.




22. Install the left inner wheelhouse liner (1).
23. Install the left front tire and wheel assembly.
24. Lower the vehicle.
25. Remove the engine support fixture.
26. Install the upper transmission side case bolt.

Tighten all bolts to 25 N.m (18 lb ft).




27. Connect the transaxle electrical connector C100 (2).
28. Install the wiring harness (3) into the wiring harness retainer (1) on the transaxle.




29. Install the range selector cable bracket to the transmission case.
30. Install the range selector cable bracket nuts.

Tighten the nuts to 25 N.m (18 lb ft).

31. Install the range selector cable to the range selector lever.
32. Check adjustment of the range selector cable. Re-adjust as needed. Refer to Range Selector Lever Cable Adjustment.




33. Install the engine sight shield.
34. Install the air cleaner intake duct.
35. Fill the transaxle to the proper level. Refer to Fluid Capacity Specifications.
36. Inspect the transaxle fluid level.
37. Inspect for fluid leaks.