Installation - Transaxle

Transaxle






WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury.

WARNING: To prevent exposure to high voltage, do not for any reason open the electronically controlled, continuously variable transmission (eCVT) cover. Failure to follow these instructions may result in personal injury.

All vehicles

NOTICE: The damper contains a clutch which designed to slip briefly during vehicle operation. It is essential that no grease, oil or cleaning solvents be allowed to contaminate the slip clutch. Do not use grease on transmission input shaft or input shaft splines.

Should the damper become contaminated it must be replaced.

NOTE: Due to packaging requirements, the correct bolt must be used at the damper locations.






1. Install the transaxle damper.
- Tighten to 29 Nm (21 lb-ft).

NOTICE: When positioning the engine to the transaxle, care must be taken to maintain alignment of the damper spline with the transaxle input shaft.

NOTE: Transaxle removed from view for clarity.






2. Using the engine crane and spreader bar, position the engine and transaxle together. Install the 6 transaxle-to-engine bolts.
- Tighten to 47 Nm (35 lb-ft).






3. Position the wiring harness in place and install the wiring harness fasteners on the transaxle stud bolts.






4. Connect the high voltage wiring harness electrical connector.
5. Using the engine crane and spreader bar, position the engine and transaxle onto the lift table.

NOTICE: Due to the weight of the transaxle, special care should be taken to mount the powertrain securely to the lift table.






6. Using the special tools, secure the engine to the lift table.
7. Raise the engine and transaxle into the vehicle.






8. Install the rear transaxle mount.
- Tighten to 90 Nm (66 lb-ft).






9. Install the rear transaxle mount bracket.
- Tighten to 25 Nm (18 lb-ft).






10. Install the RH transaxle mount bracket.
- Tighten to 90 Nm (66 lb-ft).






11. Install the RH transaxle mount bracket nut.
- Tighten to 90 Nm (66 lb-ft).






12. Install the engine mount bracket.
- Tighten to 115 Nm (85 lb-ft).






13. Install the engine mount bracket bolt.
- Tighten to 115 Nm (85 lb-ft).






14. Install the 2 transaxle-to-engine bolts.
- Tighten to 47 Nm (35 lb-ft).






15. Install the 2 transaxle-to-engine bolts.
- Tighten to 47 Nm (35 lb-ft).






16. Install the engine support crossmember, bolts and install a new nut.
- Tighten the bolts to 90 Nm (66 lb-ft).
- Tighten the nut to 175 Nm (129 lb-ft).






17. Position the roll restrictor bracket on the transaxle and install the rear roll restrictor bracket bolts.
- Tighten to 90 Nm (66 lb-ft).






18. Install the front roll restrictor bolt.
- Tighten to 115 Nm (85 lb-ft).






19. Install the A/C compressor.
- Tighten to 25 Nm (18 lb-ft).






20. Connect the lower radiator hose to the radiator.






21. Install the motor electronics coolant pump.
- Tighten to 20 Nm (15 lb-ft).






22. Install the wiring harness fasteners, the ground cable and nut.
- Tighten to 20 Nm (15 lb-ft).






23. Connect the transaxle coolant hoses.






24. Connect the motor electronics coolant temperature sensor electrical connector and pin-type retainer.






25. Install the selector lever cable in the retainer.






26. Connect the transaxle control cable.
- Install the transaxle control cable bracket and the 2 nuts finger tight.
- Attach the transaxle control cable to the control lever.
- Tighten to 22 Nm (16 lb-ft).






27. Position the control lever between the 2 casting ribs on the transaxle case.
28. Place the selector lever in the D position.
29. Tighten the transaxle control cable bracket nuts to 22 Nm (16 lb-ft).
30. To verify the correct cable adjustment, observe the control lever on the transaxle while an assistant shifts the selector lever to each range position ending in the D position.






31. Install the transaxle control splash shield.
- Tighten to 15 Nm (11 lb-ft).






32. Connect the steering gear electrical connector and wiring harness retainer.






33. Install the motor auxiliary coolant pump and connect the electrical connector.
- Tighten to 10 Nm (89 lb-in).

NOTE: Parts removed from view for clarity.






34. If equipped, install the block heater wiring harness.
- Route the harness through the radiator support.
- Attach the 3 harness retainer clips.






35. Position the DC-to-DC converter in place and install the 3 nuts.
- Tighten to 12 Nm (9 lb-ft).






36. Connect the DC-to-DC converter electrical connector and pin-type retainer.






37. Connect the 2 low voltage electrical connectors and the engine harness-to-body harness retainer.






38. Connect the transaxle harness electrical connector and install the bolt.
- Tighten to 25 Nm (18 lb-ft).






39. Install the selector lever cable fasteners on the transaxle stud bolts.






40. Connect the engine control harness electrical connector and the pin-type retainer.






41. Install the ground strap on the PCM stud and install the nut.
- Tighten to 6 Nm (53 lb-in).






42. Connect the engine control harness.
- Engage the powertrain control module (PCM) connector.
- Install the harness retaining nut.
- Tighten to 6 Nm (53 lb-in).






43. Connect the upper radiator and coolant vent hoses.






44. Attach the heater hose retaining clip to the transaxle mount stud.






45. Connect the heater hoses to the heater core.

4WD vehicles






46. Position the transfer case in place and install the 4 bolts.
- Tighten to 45 Nm (33 lb-ft).






47. Connect the transfer case vent hose.






48. Position the transfer case-to-engine support bracket and install the bolts.
- Tighten to 40 Nm (30 lb-ft).






49. Install the transfer case heat shield and the bolts.
- Tighten to 14 Nm (10 lb-ft).
50. Install the driveshaft.

All vehicles






51. Install the lateral support crossmember and the 4 bolts.
- Tighten to 115 Nm (85 lb-ft).
52. Install the front drive intermediate halfshaft.
53. Install the LH front drive halfshaft.
54. Install the engine coolant degas bottle.
55. Install the catalytic converter.
56. Install the intake manifold.
57. Install the engine air cleaner.
58. Enable the vehicle high voltage electrical system.
59. Connect the battery ground cable.
60. Reset the passive anti-theft system (PATS).
61. Check and fill the transmission fluid level.
62. Fill and bleed the motor electronics cooling system.
63. Fill and bleed the engine cooling system.