Automatic Transmission/Transaxle: Service and Repair
4T80-E TRANSAXLE ASSEMBLY REMOVAL AND INSTALLATIONTools Required
^ J 28467 Engine Support Fixture
REMOVE OR DISCONNECT
1. Negative battery cable at battery.
2. Headlamp housing upper filler panel and diagonal brace.
3. Air cleaner assembly.
4. Range control cable and bracket at transaxle.
5. Torque struts.
6. Oil cooler lines at cooler and oil sending line at transaxle.
7. Upper bell housing bolts (2).
8. Power steering return hose at auxiliary cooler. Install plugs in cooler and return hose to prevent fluid leakage or contamination.
9. Install engine support fixture J 28467.
IMPORTANT
^ It is necessary to 'load' the support fixture by tightening the wing nuts several turns to take the weight of the powertrain off of the mounts and frame.
10. Raise vehicle and support.
11. Both front tires and wheels.
12. Both front wheel opening splash shields.
13. Both front suspension position sensors from lower control arms and position out of way.
14. Both stabilizer links from struts.
15. Both tie rod cotter pins and nuts and separate both tie rods from steering knuckles.
16. Both lower ball joint cotter pins and nuts separate both ball joints from struts.
17. Both drive axle nuts and separate both drive axles from hubs.
18. Both drive axles from transaxle.
19. Power steering filter at cradle.
20. A/C splash shield from frame.
21. ABS modulator from bracket and support.
22. Engine oil pan to transaxle bracket.
23. Torque converter cover.
24. Flywheel to converter bolts.
IMPORTANT
^ Mark flywheel to converter position so that they can be assembled in the same position.
25. Powertrain mount nuts from cradle.
26. Rotate the steering intermediate shaft so that the steering gear stub shaft clamp bolt is accessible from the left wheel opening and remove the clamp bolt.
27. Steering intermediate shaft from steering gear.
CAUTION: Failure to disconnect the intermediate shaft from the rack and pinion stub shaft can result in damage to the steering gear and/or Intermediate shaft. This damage can cause loss of steering control which could result in personal injury.
NOTICE: Do not rotate the steering wheel or move the position of the steering gear once the intermediate shaft is disconnected as this will uncenter the Inflatable Restraint coil in the steering column. If the Inflatable Restraint coil becomes uncentered, it may be damaged during vehicle operation.
28. Support rear of cradle with jack stand.
29. Remove four rear cradle bolts.
30. Lower jack stand a few inches to gain access to power steering gear heat shield and return line fitting.
31. Brake line.
32. Powersteering gear heat shield and powersteering return line at gear. Install plugs in steering gear and pressure line to prevent fluid leakage or contamination.
33. Powersteering electrical connector.
34. Raise jack stand and reinstall one rear cradle bolt on each side finger tight to support cradle.
35. Remove jack stand.
36. Support frame.
37. Six frame mount bolts.
38. Lower frame and/or raise vehicle with steering gear attached.
39. Electrical connectors.
^ Three transaxle connectors
^ VSS connector
^ Ground
^ Transaxle harness from transaxle clip
40. Fuel line bundle from transaxle.
41. Left transaxle mount and bracket from transaxle.
42. Right transaxle mount and bracket from transaxle.
43. Install transaxle support fixture.
44. Engine to transaxle heat shield and bracket.
45. Engine to transaxle bolts (2).
46. Lower transaxle.
47. Manual shaft linkage and neutral start switch.
48. Vehicle Speed Sensor.
49. Oil return pipe.
INSTALL OR CONNECT
1. Oil return pipe.
2. Vehicle Speed Sensor.
3. Neutral start switch and manual shaft linkage.
Tighten
^ Torque transaxle range switch bolts to 12 N.m (106 lb. in.).
^ Torque manual shaft nut to 20 N.m (15 lb ft.).
4. Raise transaxle on support fixture.
5. Engine to transaxle bolts (2 lower ones).
Tighten
^ Torque bolts to 47 N.m (35 lb. ft.).
6. Engine to transaxle bracket and heat shield.
Tighten
^ Torque bolts to 47 N.m (35 lb. ft.).
7. Remove transaxle support fixture.
8. Right transaxle bracket and mount to transaxle.
Tighten
^ Torque bolts and nuts to 47 N.m (35 lb. ft.).
9. Left transaxle bracket and mount to transaxle.
Tighten
^ Torque bolts and nuts to 47 N.m (35 lb. ft.).
10. Fuel line bundle to transaxle.
11. Electrical connectors.
^ Three transaxle connectors.
^ VSS connector.
^ Ground.
^ Transaxle harness to transaxle clip.
12. Raise frame and/or lower vehicle while locating engine and transaxle mount studs into frame, harnesses at cradle, and frame mount bolt holes to underbody.
13. Install two front and two rear cradle bolts finger tight to support cradle.
14. Remove cradle support fixture.
15. Support rear of cradle with jack stand.
16. Remove two rear cradle bolts.
17. Lower jack stand a few inches to gain access to powersteering gear.
18. Power steering pressure hose at steering gear.
Tighten
^ Torque fitting to 27 N.m (20 lb. ft.).
19. Power steering gear electrical connector and power steering gear heat shield.
20. Brake line at rear of cradle.
21. Raise jack stand.
22. Six frame mount bolts in the following order:
^ Left side #2 mount bolt into body.
^ Left side #1 mount bolt into body.
^ Remaining frame mount bolts (no specific order).
Tighten
^ Torque bolts to 100 N.m (74 lb. ft.).
23. Steering intermediate shaft to steering gear and install clamp bolt.
Tighten
^ Torque bolt to 47 N.m (35 lb. ft.).
NOTICE: Do not rotate the steering wheel or move the position of the steering gear once the intermediate shaft is disconnected as this will uncenter the Inflatable Restraint coil in the steering column. If the Inflatable Restraint coil becomes uncentered, it may be damaged during vehicle operation.
24. Left and right transaxle mount nuts and right engine mount nuts at frame.
Tighten
^ Torque nuts to 47 N.m (35 lb. ft.).
25. Flywheel to converter bolts.
Tighten
^ Torque bolts to 47 N.m (35 lb. ft.).
22. Electrical harness to front of cradle.
IMPORTANT
^ Line up flywheel and converter using marks made at disassembly.
26. Torque converter cover.
Tighten
^ Torque bolt to 12 N.m (106 lb. in.).
27. Engine oil pan to transaxle bracket.
Tighten
^ Torque bolts to 47 N.m (35 lb. ft.).
28. ABS modulator to bracket.
29. A/C splash shield at frame.
30. Both drive axles into transaxle.
31. Both drive axles into hubs and both drive axle nuts.
Tighten
^ Torque nuts to 145 N.m (110 lb. ft.).
32. Both lower ball joints into steering knuckles and both ball joint nuts and cotter pins.
Tighten
^ Ball joint nut to 10 N.m (84 in. lbs.) using J 35551 90° to torque wrench. Tighten nut an additional 120°. When tightening nut a minimum torque of 50 N.m (37 lbs. ft.) must be obtained. If 50 N.m (37 lbs. ft.) is not obtained, inspect for stripped threads. If threads are satisfactory, replace ball joint and knuckle. If required, turn the nut up to an additional 60° to allow for installation of the cotter pin.
33. Both tie rods into steering knuckles and both tie rod nuts and cotter pins.
Tighten
^ Tie rod end nut to 10 N.m (7.5 lbs. ft.) then an additional 1/3 turn (2 flats).
IMPORTANT
^ When tightening tie rod end nut, a minimum torque of 45 N.m (33 lbs. ft.) must be obtained. If 45 N.m (33 lbs. ft.) is not obtained, inspect for stripped threads. If threads are satisfactory, replace tie rod end and knuckle.
^ After tightening castellated nut to specification, align slot in nut to cotter pin hole by tightening only. Do not loosen nut for cotter pin installation.
34. Both stabilizer links to struts.
Tighten
^ Torque nuts to 65 N.m (49 lb. ft.).
35. Both front suspension position sensors to lower control arms.
36. Powersteering filter to cradle.
37. Both front wheel opening splash shields.
38. Both front tire and wheel assemblies.
39. Lower vehicle.
40. Remove engine support fixture J 28467.
41. Powersteering hose at auxiliary cooler.
42. Upper bell housing bolts. (2).
43. Perform oil cooler flushing procedure.
44. Transaxle cooler pipe fittings at transaxle. Install fittings finger tight.
Tighten
^ Torque cooler pipe fittings at transaxle to 22 N.m (16 lb. ft.).
45. Oil sending pipe to transaxle.
46. Torque struts.
47. Adjust neutral start switch.
ADJUST
^ Transaxle range switch.
48. Range control cable and bracket at transaxle.
Tighten
^ Torque bracket bolts to 12 N.m (106 lb.).
ADJUST
^ Range control cable.
49. Air cleaner assembly.
50. Headlamp housing upper filler panel and diagonal brace.
51. Negative battery cable at battery.
52. Bleed powersteering system.
53. Add DEXRON� - IIE transmission fluid as required.
54. Check front suspension alignment, set toe as necessary.
55. Reset transaxle adapts.
56. Reset transaxle oil life indicator.