Removal and Replacement

REMOVAL
1. Disconnect battery cables, then remove battery.

2. On 1992-93 models, remove air cleaner assembly.
3. On 1994 models, proceed as follows:
a. Remove battery tray and battery tray support bracket.
b. Release wiring harness retaining strap from battery support bracket.
c. Remove air cleaner/volume air flow sensor assembly and support brackets.
d. Disconnect ground strap at front of transaxle.
4. On all models, disconnect speedometer cable at cable connector.
5. Ensure transaxle is in Park position, then remove shift cable retaining nut from neutral safety switch.
6. Remove shift cable retaining bolts.
7. Disconnect kickdown cable from throttle body housing. Route cable out of straps for removal with transaxle.
8. Disconnect electrical connectors from transaxle, then remove dipstick tube bracket retaining bolt and ground wire.
9. Remove upper starter retaining bolts.
10. Remove two upper intake manifold support retaining bolts.
11. Remove heater bypass tube bracket.
12. Remove transaxle to engine upper retaining bolts.
13. Install three bar engine support tool No. D88L-6000-A or equivalent, then raise and support vehicle.
14. On 1994 models, remove splash shields.
15. On all models, drain transaxle fluid, then remove three lower intake manifold support retaining bolts.
16. Disconnect starter motor electrical connectors, then remove starter motor lower retaining bolt and starter.
17. Remove front wheels, then the caliper brake hose retaining clips from strut brackets.
18. Remove ball joint pinch bolts, then separate ball joints from control arms.
19. On 1992-93 models, remove inner fender splash guards.
20. On all models, remove lefthand control arm front retaining bolt.
21. Remove righthand control arm front retaining bolt.
22. Remove frame brace to crossmember retaining bolt.
23. Remove front and rear transaxle mount to crossmember retaining nuts, then the crossmember braces.
24. Remove shift cable retaining nut or screw from crossmember, then the crossmember from vehicle.
25. Remove lefthand axle shaft from vehicle.
26. Disconnect righthand axle shaft from transaxle. Install transaxle plug set tool No. T88C-7025-AH or equivalent, into halfshaft openings on transaxle.

CAUTION: Failure to install transaxle plugs may result in misalignment of differential side gears.

27. Remove gusset plate center transaxle mount retaining bolts from transaxle, then loosen center transaxle mount retaining bolts on engine.
28. Remove torque converter cover plate, then the exhaust manifold support bracket.
29. Remove front and rear transaxle mounts.
30. On 1994 models, remove front mount bracket, then disconnect two oil cooler lines. Save plastic retainers on male tube ends.
31. On all models, lower vehicle.
32. Lower, but do not remove, engine transaxle assembly with support bar.
33. Raise vehicle.
34. Remove torque converter to drive plate retaining nuts.
35. Position transaxle jack under transaxle and secure with safety chains.
36. Remove lower transaxle to engine retaining bolts, then lower transaxle assembly from vehicle.

INSTALLATION

NOTE: The following procedure has been revised by a Technical Service Bulletin.

A pin is used to hold the throttle valve in a fixed position on new or remanufactured service replacement transaxle assemblies.

The pin is used during the assembling process to make installation of the control valve easier. When installing a new or remanufactured transaxle, be sure to remove the pin and install a new retaining bolt. Failure to remove pin from the throttle cam will hold the transaxle throttle lever in a fixed position resulting in a shift concern.

1. Slowly raise transaxle assembly into vehicle.

NOTE: Ensure dipstick tube clears battery tray, then align torque converter studs to drive plate.

2. Install lower transaxle to engine retaining bolts. Torque bolts to 63-89 ft lbs.
3. Install torque converter to drive plate retaining nuts. Torque nuts to 32-44 ft lbs.
4. Remove transaxle jack, then lower vehicle.
5. Raise engine and transaxle assembly into position with support fixture.

CAUTION: Use care in raising engine and transaxle to avoid damage to air conditioning or other engine compartment components.

6. Raise vehicle.
7. On 1994 models, install front mount bracket.
8. On all models, install front and rear mounts to transaxle. Torque retaining bolts to 27-39 ft lbs.
9. Install exhaust manifold support. Torque exhaust manifold support to transaxle bolt to 50-68 ft lbs, then the exhaust manifold support to transaxle nut to 23-34 ft lbs.
10. Install torque converter cover plate. Torque retaining bolts to 71-97 in lbs.
11. Align center transaxle mount, then install retaining bolts. Torque retaining bolts to 37-52 ft lbs.
12. Position crossmember to transaxle mounts. Align rear transaxle mount stud first, then loosely install retaining nut.
13. Align front transaxle mount studs, then loosely install retaining nuts.
14. Install crossmember retaining bolts. Torque bolts to 27-39 ft lbs.
15. Torque front and rear transaxle mount retaining nuts to 21-33 ft lbs.
16. Install new circlips to inner CV joint shafts, then the axle shafts into transaxle assembly.
17. Install new hub nut on lefthand axle shaft. Torque retaining nut to 116-173 ft lbs.

NOTE: Ensure shafts are completely seated.

18. Position shift cable, then install shift cable lower retaining bolt.
19. Install crossmember braces. Torque retaining bolts to 27-39 ft lbs.
20. Install frame brace. Torque crossmember bolt to 27-39 ft lbs.
21. Install control arm front bolt on both sides. Torque bolt to 69-86 ft lbs.
22. Install ball joint pinch bolts. Torque bolts to 32-39 ft lbs.
23. Install brake hose retaining clips.
24. On 1992-93 models, remove splash guards.
25. On all models, install starter motor and lower retaining bolts. Torque retaining bolts to 18-36 ft lbs.
26. Connect starter motor electrical connectors.
27. Install intake manifold support bracket, then the retaining bolts loosely.
28. On 1994 models, connect oil cooler lines and install splash shields. Ensure oil cooler fittings are secured to male ends by plastic retainers. Verify by pulling back on connectors.
29. On all models, install tire and wheel assemblies, then lower vehicle.
30. Install transaxle to engine upper retaining bolts. Torque bolts to 47-65 ft lbs.
31. Remove engine support fixture, then install heater bypass tube bracket.
32. Install intake manifold support upper bolts. Torque all support retaining bolts to 23-33 ft lbs.
33. Install starter motor upper retaining bolts. Torque to 23-33 ft lbs.
34. Position ground wire and install dipstick tube retaining bolt.
35. Route shift cable and connect to neutral safety switch, then route and install kickdown cable to throttle housing.
36. Connect transaxle electrical connectors, then the speedometer cable.
37. On 1994 models, proceed as follows:
a. Connect ground strap at front of transaxle.
b. Install air cleaner/volume air flow sensor assembly support brackets, then the air cleaner/volume air flow sensor assembly.
c. Install harness retaining strap to battery support bracket, then the battery support bracket, battery, and battery tray.
38. On 1992-93 models, install air cleaner assembly, then the battery.
39. On all models, connect battery terminals, then fill transaxle with proper fluid.
40. Start engine, then check for leaks.