Transmission/Transaxle Replacement

ASSEMBLY REMOVAL AND INSTALLATION
Remove and install the parts as shown in image.

TRANSAXLE REMOVAL
1. DISCONNECT AND REMOVE BATTERY
2. REMOVE AIR CLEANER ASSEMBLY
3. REMOVE THROTTLE CABLE FROM ENGINE

(w/ Cruise Control System)
4. REMOVE CRUISE CONTROL ACTUATOR COVER
5. DISCONNECT CONNECTOR FROM CRUISE CONTROL ACTUATOR

6. REMOVE GROUND EARTH TERMINAL

7. REMOVE STARTER
(a) Disconnect the connector and remove the nut.

(b) Remove the two bolts and the starter.

8. DISCONNECT NO.1 SPEED SENSOR CONNECTOR

9. DISCONNECT NO.2 SPEED SENSOR CONNECTOR

10. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR

11. DISCONNECT SOLENOID CONNECTOR

12. DISCONNECT SHIFT CONTROL CABLE
(a) Remove the clip from the shift control cable.

(b) Remove the unit.

13. DISCONNECT OIL COOLER HOSE

14. REMOVE TWO FRONT SIDE TRANSAXLE MOUNTING BOLTS

15. REMOVE TWO FRONT SIDE ENGINE MOUNTING BOLTS

16. REMOVE OIL COOLER CLAMPING BOLTS FROM FRONT FRAME ASSEMBLY

17. REMOVE THREE UPPER TRANSAXLE - TO - ENGINE BOLTS

18. INSTALL ENGINE SUPPORT FIXTURE
19. TIE STEERING GEAR HOUSING TO ENGINE SUPPORT FIXTURE BY CORD OR EQUIVALENT

20. RAISE AND SUITABLY SUPPORT VEHICLE
21. REMOVE FRONT WHEEL
22. REMOVE EXHAUST PIPE
(a) Remove four nuts.

(b) Remove the two bolts and nuts from the rear exhaust pipe.

23. REMOVE DIFFERENTIAL FLUID DRAIN PLUG AND GASKET
24. DRAIN DIFFERENTIAL FLUID INTO A SUITABLE CONTAINER

25. REMOVE RIGHT AND LEFT ENGINE SIDE COVER NO.2
26. REMOVE ENGINE UNDER FRONT COVER NO.1 AND NO.2

27. REMOVE DRIVE SHAFT (See page SA-20)
28. REMOVE FRONT SIDE ENGINE MOUNTING NUT

29. REMOVE REAR SIDE ENGINE MOUNTING BOLTS
(a) Remove two hole plugs.

(b) Remove two bolts and nuts.

30. REMOVE FOUR LEFT SIDE TRANSAXLE MOUNTING BOLTS

31. REMOVE STEERING GEAR HOUSING
(a) Remove the four bolts and disconnect the stabilizer bar bush bracket from the front frame assembly.

(b) Remove two bolts and nuts from the steering gear housing.

(c) Remove the steering gear housing.

32. REMOVE FRONT FRAME ASSEMBLY
(a) Hold the front frame assembly with a jack.

(b) Remove two set screws from the right and left fender liners.

33. HOLD TRANSAXLE WITH A JACK
34. REMOVE REAR END PLATE
(a) Remove six bolts.

(b) Remove the rear end plate.

35. REMOVE TORQUE CONVERTER CLUTCH MOUNTING BOLTS
(a) Turn the crankshaft to gain access to each bolt

(b) Hold the crankshaft pulley nut with a wrench and remove the six bolts.

36. REMOVE TRANSAXLE TO ENGINE BOLT8

37. REMOVE TRANSAXLE ASSEMBLY
Separate transaxle and engine, and lower the transaxle.

38. REMOVE TORQUE CONVERTER CLUTCH FROM TRANSAXLE

TRANSAXLE INSTALLATION
1. INSTALL TORQUE CONVERTER CLUTCH IN TRANSAXLE
If the torque converter clutch has been drained and washed, refill with new ATF.

Fluid type: ATF DEXRON II

2. CHECK TORQUE CONVERTER CLUTCH INSTALLATION
Using calipers and a straight edge, measure from the installed surface to the front surface of the transmission housing.

Correct distance: More than 13.7 mm (0.539 in.)

3. ALIGN TRANSAXLE AT INSTALLATION POSITION
(a) Align the two knock pins on the block with the converter housing.

(b) Temporarily install one bolt.

4. INSTALL TRANSAXLE TO ENGINE BOLTS
Install the transaxle-to -engine bolts. 12 mm head bolt

Torque: 64 N.m (650 kgf.cm, 47 ft.lbf) 10 mm head bolt
Torque: 46 N.m (470 kgf.cm, 34 ft.lbf)

5. INSTALL TORQUE CONVERTER CLUTCH MOUNTING BOLTS
(a) Clean the threads of the bolts with gasoline.

(b) Coat the threads of the bolts with sealer.

Sealer:
Part No.08833 - 00070, THREE BOND 1324 or equivalent

(c) Tighten the bolts evenly.

Torque: 27 N.m (280 kgf.cm, 20 ft.lbf)

HINT: First install dark green colored bolt and then the five bolts.

6. INSTALL REAR END PLATE
(a) Install the rear end plate with the six bolts.

(b) Torque the six bolts.
Torque: 37 N.m (380 kgf.cm, 27 ft.lbf)

7. INSTALL FRONT FRAME ASSEMBLY
(a) Hold the front frame assembly.

(b) Install the six bolts and four nuts.

(c) Torque the bolts and nuts.

19 mm head bolt
Torque: 181 N.m (1,850 kgf.cm, 134 ft.lbf)
12 mm head bolt
Torque: 32 N.m (330 kgf.cm, 24 ft.lbf) Nut
Torque: 36 N.m (370 kgf.cm. 27 ft.lbf)

(d) Install the two set screws in the right and left fender liners.

8. INSTALL STEERING GEAR HOUSING
(a) Install the steering gear housing to the front frame assembly.

(b) Install and torque the two bolts and nuts.

Torque: 181 N.m (1.850 kgf.cm. 134 ft.lbf)

9. INSTALL FOUR LEFT SIDE TRANSAXLE MOUNTING BOLTS

Torque: 52 N.m (530 kgf.cm. 38 ft.lbf)

10. INSTALL REAR SIDE MOUNTING BOLTS AND NUTS
(a) Install and torque the two bolts and nuts.

Torque: 66 N.m (670 kgf.cm. 48 ft.lbf)

(b) Install two hole plugs.

11. INSTALL FRONT SIDE ENGINE MOUNTING NUT

Torque: 80 N.m (820 kgf.cm. 59 ft.lbf)

12. INSTALL DRIVE SHAFT

13. INSTALL RIGHT AND LEFT ENGINE SIDE COVER NO.2
14. INSTALL ENGINE UNDER FRONT COVER NO.1 AND NO.2

15. INSTALL DIFFERENTIAL FLUID DRAIN PLUG WITH A NEW GASKET
16. FILL DIFFERENTIAL

Fluid Type: ATF DEXRON II
Capacity: Differential 0.8 liters (0.8 US qts, 0.7 Imp. qts)

17. CHECK DIFFERENTIAL FLUID LEVEL

18. INSTALL EXHAUST PIPE
(a) Install and torque the four nuts.

Torque: 62 N.m (630 kgf.cm, 46 ft.lbf)

(b) Install the rear exhaust pipe with the two bolts and nuts.

Torque: 43 N.m (440 kgf.cm, 32 ft.lbf)

19. INSTALL FRONT WHEEL AND LOWER VEHICLE

Torque: 103 N.m (1050 kgf.cm, 76 ft.lbf)

20. UNTIE STEERING GEAR HOUSING TO ENGINE SUPPORT FIXTURE BY CORD OR EQUIVALENT REMOVE ENGINE SUPPORT FIXTURE

21. INSTALL THREE UPPER TRANSAXLE - TO - ENGINE BOLTS

Torque: 64 N~m (650 kgf.cm, 47 ft.lbf)

22. INSTALL OIL COOLER CLAMPING BOLTS TO FRONT FRAME ASSEMBLY

23. INSTALL TWO FRONT SIDE ENGINE MOUNTING BOLTS

Torque: 80 N.m (820 kgf.cm, 59 ft~lbf)

24. INSTALL TWO FRONT SIDE TRANSAXLE MOUNTING BOLTS

Torque: 80 N.m (820 kgf.cm, 59 ft.lbf)

25. CONNECT OIL COOLER HOSE

26. CONNECT SHIFT CONTROL CABLE
(a) Install the clip from the shaft control cable.

(b) Install and torque the nut.

(c) Adjust the shift control cable.

27. CONNECT SOLENOID CONNECTOR

28. CONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR

29. CONNECT NO.2 SPEED SENSOR CONNECTOR

30. CONNECT NO.1 SPEED SENSOR CONNECTOR

31. INSTALL STARTER
(a) Install the starter with the two bolts.

(b) Torque the two bolts.

Torque: 39 N.m (400 kgf.cm. 29 ft.lbf)

(c) Connect the connector and install the nut.

32. INSTALL GROUND EARTH TERMINAL

(w/ Cruise Control System)
33. CONNECT CONNECTOR TO CRUISE CONTROL ACTUATOR
34. INSTALL CRUISE CONTROL ACTUATOR COVER

35. INSTALL THROTTLE CABLE TO ENGINE
(a) Torque the nuts.

Torque: 15 Nm (150 kgf.cm, 11 ft.lbf)

(b) Adjust the throttle cable

36. INSTALL AIR CLEANER ASSEMBLY
37. INSTALL BATTERY

38. CHECK FLUID LEVEL
39. INSPECT FRONT WHEEL ALIGNMENT
40. PERFORM ROAD TEST
Check for abnormal noise and smooth shifting.