Installation
1. Using special tool 307-186 install a new converter hub seal. See Figure 29.
2. Using special tool 307-091 install the new torque converter. See Figure 27.
3. Apply multi-purpose grease to the torque converter pilot hub. See Figure 27.
4. NOTICE: The torque converter can fall out from the transmission. Use caution not to tip the transmission at an angle that would allow the torque converter to fall out.
Raise the transaxle assembly into the engine compartment and position it onto the back of the engine.
5. Align the torque converter studs with the flexplate.
6. Install the transaxle bracket retaining bolts. See Figure 26.
Tighten to 47 Nm (35 lb-ft).
7. Install the RH oil pan-to-transaxle retaining bolt. See Figure 25.
Tighten to 62 Nm (46 lb-ft).
8. Install the LH oil pan-to-transaxle retaining bolt. See Figure 24.
Tighten to 62 Nm (46 lb-ft).
9. Install the front lower retaining bolt. See Figure 23.
Tighten to 62 Nm (46 lb-ft).
10. Install the rear lower retaining bolt. See Figure 22.
Tighten to 62 Nm (46 lb-ft).
11. Remove the high-lift transmission jack from under the transaxle.
12. Install 4 new torque converter nuts.
Tighten to 35 Nm (26 lb-ft).
13. Install the transmission inspection cover.
a. Install both halves of the transmission inspection cover.
b. Install the push pin.
c. Install the bolt.
d. Tighten the bolt to 10 Nm (89 lb-in).
14. Reinstall the starter. See Figure 20.
a. Install the bolt and stud bolt.
b. Tighten the bolt and stud bolt to 25 Nm (18 lb-ft).
c. Install the ground wire and nut.
d. Tighten the nut to 20 Nm (15 lb-ft).
15. Connect the turbine shaft speed (TSS) sensor connector. See Figure 21.
16. Install the RH and LH halfshafts into the transaxle.
17. Connect the fluid cooler tubes. See Figure 19.
18. Install the fluid cooler tube retaining clips. See Figure 18.
19. Using a suitable lift, raise the subframe assembly into position.
^ Rotate the sway bar as needed to gain clearance around the power steering rack.
^ Attach the exhaust heat shield to the back of the subframe.
^ Remove the power steering rack support.
20. Using a 19 mm (0.76 in) dowel, check the front subframe alignment. See Figure 30.
^ The dowel should slide directly through the front subframe and body on both the LH and RH sides, without tilting.
^ Adjust the subframe as required.
NOTE:
LH shown, RH similar.
21. Install the 4 subframe bolts.
^ Tighten to 90 Nm (66 lb-ft).
22. Remove the suitable lift from under the subframe.
23. Install the rear transaxle support nut. See Figure 17.
24. Install the rear engine mount nut. See Figure 16.
^ Tighten to 90 Nm (66 lb-ft).
25. Install the front engine mount nut. See Figure 15.
^ Tighten to 90 Nm (66 lb-ft).
26. Attach the power steering hose push pin retainer to the subframe.
27. Install the bolts for the power steering line brackets. See Figure 14.
^ Tighten to 6 Nm (53 lb-in).
28. Install the 2 nuts for the power steering rack.
^ Tighten to 133 Nm (98 lb-ft).
29. Clean the mating surfaces of the exhaust manifold outlet flare and the catalytic converter inlet flare.
NOTE:
Exhaust fasteners are of a torque prevailing design. Use only new fasteners with the same part number as the original. Torque values must be used as specified during reassembly to make sure of correct retention of exhaust components.
30. Install the catalytic converter assembly.
31. Install 4 new catalytic converter-to-exhaust manifold nuts.
Tighten to 40 Nm (30 lb-ft).
32. Install the upper catalytic converter bracket nut. See Figure 13
Tighten to 40 Nm (30 lb-ft).
33. Install the lower catalytic converter bracket bolt. See Figure 12.
Tighten to 40 Nm (30 lb-ft).
34. Install a new converter-to-flex pipe gasket and 2 new bolts.
Tighten to 40 Nm (30 lb-ft).
35. Remove the tie straps and splint from the flex pipe. See Figure 11.
36. Connect the 2 catalyst monitor sensor electrical connectors.
37. Connect the front heated oxygen sensor (HO2S) electrical connector and position the connector push-pin onto the subframe.
38. Install the LH and RH lower control arms to the steering knuckles and install the pinch bolts.
Tighten to 62 Nm (46 lb-ft).
39. NOTE: Use the hex holding feature to prevent the studs from turning while removing or installing the stabilizer bar link nuts.
40. Install both front wheels. For additional information, refer to WSM, Section 204-04.
41. Install the anti-roll bracket and install the bolts. See Figure 10.
^ Attach the 2 wire harness push-pin retainers.
^ Tighten to 62 Nm (46 lb-ft).
42. Install the two transaxle top retaining bolts. See Figure 9.
^ Tighten to 62 Nm (46 lb-ft).
43. Install the upper transmission fluid filler tube and the bolt.
44. Remove the Three Bar Engine Support Kit.
45. Remove the Engine Lifting Brackets and reinstall the LH upper generator bolt. See Figures 6 and 7.
^ Tighten the LH upper generator bolt to 47 Nm (35 lb-ft).
46. Connect the speed sensor and rear heated oxygen sensor (HO2S) electrical connectors. See Figure 5.
47. Connect the wire harness to the bracket. See Figure 4.
48. Install and connect the transmission selector cable. See Figure 3.
a. Connect the transmission selector cable to the bracket.
b. Connect the transmission selector cable end to the manual lever.
49. Connect the transaxle and Transmission Range (TR) sensor electrical connectors. See Figure 2.
50. Install the air cleaner housing. See Figure 1.
a. Connect and install the air cleaner housing.
b. Install the clips at the air cleaner housing.
c. Tighten the clamp to 4 Nm (35 lb-in).
51. Connect the Mass Air Flow (MAF) sensor electrical connector.
52. Connect the crankcase vent tube to the air cleaner outlet pipe.
53. Install the lower cowl panel into the vehicle.
a. Install the lower cowl panel into the vehicle.
b. Connect the windshield wiper motor electrical connector.
c. If equipped, connect the anti-theft hood ajar switch connector.
54. Install the upper cowl panel grill.
a. Install the washer hose grommet onto the cowl panel.
b. Connect the windshield washer hose to the hose elbow.
c. Install the push-pin type retainers.
55. Install the windshield wiper arms.
^ Tighten to 27 Nm (20 lb-ft).
56. Install the battery. For additional information, refer to WSM, Section 414-01.
57. Cycle and park the windshield wipers to check for correct alignment.
58. Check the transaxle fluid and fill as required.
59. Verify that the digital transmission range (TR) sensor is correctly adjusted. For additional information, refer to WSM, Section 307-01.
60. Start the engine. Move the transaxle range selector lever through all positions. Check the fluid level. For additional information, refer Preliminary Inspection in WSM, Section 307-01.