Repair Procedures (A5SR2)

REMOVAL

1. Remove the battery (-) terminal(A).




2. Remove the engine cover(A).




3. Remove the O2 sensor connectors(A).








4. Remove the under cover(A).




5. Drain the automatic transmission fluid.




6. Remove the front propeller shaft(A). (4WD)




7. Remove the front muffler(A) and the heat protector.




8. Remove the rear propeller shaft(A).




9. Remove the transmission oil level gauge(A).




10. Remove the shift cable cover(A).




11. Remove the shift cable(A).




12. Remove the oil cooler pipes(A).




13. Remove the drive plate cover(A).




14. Remove the drive plate bolts(A).

NOTE:
Remove the bolts(A-6ea) while rotating the crankshaft clockwise.




15. Remove the transmission lower mounting bolts(A).




16. Remove the starter motor mounting bolts(A) and the other bolts(B).




17. Remove the mounting bolts(A) while supporting the transmission with a jack.




18. Lower the jack slightly to simplify removal of electrical connectors and bolts on the upper part of the transmission.




19. Disconnect the transmission wire harness connectors(A).




20. Remove the vehicle speed sensor connector(A).




21. Remove the transfer case connectors(A). (4WD)




22. Remove the transmission upper mounting bolts(A,B).




23. Remove the transmission (2WD) or transmission/transfer case assembly(4WD)(A).






INSTALLATION

1. Using a transmission jack, install the transmission (2WD) or transmission/transfer case assembly(4WD)(A).




2. Tighten the transmission mounting bolts(A,B).

TORQUE
A : 30 - 42Nm (3.0 - 4.2kgf.m, 21.6 - 30.3lb-ft)
B : 78.4 - 98Nm (8.0 - 10kgf.m, 57.8 - 72.3lb-ft)





3. Install the transfer case connectors(A). (4WD)




4. Install the vehicle speed sensor connector(A).




5. Connect the transmission wire harness connectors(A).




6. Install the crossmember mounting bolts(A).




7. Install the starter motor mounting bolts(A) and the other bolts(B).

TORQUE
A: 50 - 65Nm(5.0 - 6.5kgf.m, 36.2 - 47.0lb-ft)
B : 34.3 - 46Nm (3.5 - 4.7kgf.m,25.3 - 33.9 lb-ft)





8. Install the Tighten the transaxle lower mounting bolts(A).




9. Install the drive plate bolts (A) by turning the timing gear.

TORQUE :
34.3 - 41.1Nm (3.5 - 4.2kgf.m, 25.3 - 30.3lb-ft)


NOTE:
Install the bolts(A-6ea) rotating the crankshaft clockwise.




10. Install the drive plate cover(A).




11. Install the oil cooler pipes(A).




12. Install the shift cable(A).




13. Install the shift cable cover(A).




14. Install the transmission oil level gauge(A).




15. Install the rear propeller shaft(A).

TORQUE :
58.83 - 68.64Nm(6 - 7kgf.m, 43.39 - 50.63lb-ft)





16. Install the front muffler(A) and the heat protector.




17. Install the front propeller shaft(A). (4WD)

TORQUE :
58.83 - 68.64Nm(6 - 7kgf.m, 43.39 - 50.63lb-ft)





18. Refill the transmission fluid. (see 'Service adjustment procedure')
19. Install the under cover(A).




20. Install the O2 sensor connectors(A).








21. Install the engine cover(A).




22. Install the battery (-) terminal(A).




23. Refill the transmission fluid.