Installation

See TSB 06-14-4

Transaxle

Special Tools





Part 1 of 2





Part 2 of 2

Installation

All vehicles

1. NOTE: The self-locking nuts must he reserved.

General Instructions
^ The location of engine mountings and roll resistors are described looking from the automatic transaxle to the engine.





2. CAUTION: The torque converter is heavy. Install the special tool before raising the transaxle

CAUTION: The torque converter must remain at the correct installation depth throughout the whole installation procedure.

NOTE: The torque converter studs must be aligned with the flywheel holes before any transaxle to engine bolts are installed.

Install the special tool.





3. NOTE: The torque converter hub must engage fully in the oil pump drive gear.

NOTE: Apply a thin layer of High-temperature grease to the centering spigot bore on the torque converter.

Check the installation depth of the torque converter.
1. Lay a steel straightedge on the automatic transaxle flange.
2. Check the installation depth between the transaxle flange and the torque converter centering spigot for the correct clearance.





4. NOTE: Remove the special tool.

Using the transmission jack and the CD4E transaxle adapter raise and position the transaxle.





5. Install the transaxle to engine bolts.





6. Install the transaxle to engine lower bolts.





7. Install the torque converter nuts.
^ Install torque converter inspection cover.





8. Connect the main control cover tube.





9. CAUTION: To avoid damage to joints and boots, do not bent the inner halfshaft joint by more than 18 degrees, the outer one by more than 45 degrees.

NOTE: Do not damage the oil seal.

Install the right-hand halfshaft and intermediate shaft.





10. Install a new snap ring.





11. CAUTION: To avoid damage to joints and boots, do not bent the inner halfshaft joint by more than 18 degrees, the outer one by more than 45 degrees.

NOTE: Do not damage the oil seal. Check that the snap ring engages correctly.

Install the left-hand halfshaft.





12. CAUTION: Do not loosen the connector cooler inlet to the transaxle.

Position and install the transaxle lower cooling tube.





13. CAUTION: Do not loosen the connector cooler inlet to the transaxle.

Position and install the transaxle upper cooling tube.





14. NOTE: Do not tighten the bolt

Install the right-hand roll restrictor center bolt.





15. WARNING: Support the subframe using Rotunda powertrain lift. Place a wooden block approximately one meter (40 inches) in length secured to the lift under the subframe.

NOTE: Do not tighten the bolts at this stage.

Install the subframe.





16. Install the steering intermediate shaft.





17. Install the transaxle cooler line brackets, and bolt.
^ Position the suction Accumulator (A/C), if equipped.





18. Install the power steering hoses to the subframe (one nut and two bolts).





19. Using the special tool, install the steering gear (two bolts) (left-hand side shown).





20. Install the steering gear heat shod.





22. Using the special tool, align the sub-frame and tighten the bolts.
1. Install the special tool.
2. Align the subframe with the locating holes in the body.
3. Install the subframe bolts working diagonally.





23. Remove the left-hand support insulator and install the special tool.
1. Install the special tool.
2. Install the bolts.
3. Install the through bolt.
24. Lower the vehicle.





25. Tighten the transaxle rear support bracket nuts.
26. Raise and support the vehicle.





27. Tighten the right-hand support insulator through bolt.





28. Remove the special tool and install the left-hand support isolator.
1. Install the through bolt.
2. Install the bolts.





29. CAUTION: Do not damage the boot or the ABS sensor ring.

Connect the lower suspension arm ball joints and the stabilizer link rods.
^ Attach the ABS wiring harness bracket to the suspension strut.





30. CAUTION: Extreme extension of the flexible tube can lead to damage.

Install the flexible tube and the rear Three-Way Catalytic Converter (TWC).
^ Install the new gaskets.
^ Remove the protection collar.





31. Install the flexible tube and the TWC to the exhaust manifold..
^ Install the gaskets.





32. Install the cable ties.

Vehicles with air conditioning





33. Install the suction accumulator bracket bolts.

All Vehicles





34. Install the bumper brackets on both sides (left-hand side shown).





35. Install the right-hand fender splash shield.





36. Install the radiator splash shield.
^ Install the bolts and clips.

37. Install both front wheels.





38. Connect the selector cable from the transaxle.
1. Selector lever selector cable
2. Bracket





39. Connect the Turbine Shaft Speed (TSS) sensor (shown from below).
^ Clip the cable.





40. Connect the Output Shaft Speed (OSS) sensor connector.





41. NOTE: Ground cable.

Install the upper bellhousing bolts.





42. Remove the special tools.





43. Check that the selector lever position indicator agrees with the transaxle operation.
^ Parking lock in selector lever position "P", reverse gear in selector lever position "R" and forward in selector lever position "D".

44. If the selector lever position indicator does not agree with the transaxle operation in all settings:
^ Raise the vehicle and disconnect the head shield (four clips).





45. NOTE: The mark line up in position "D". There is no need to hold after engaging a gear as there is an integral detent mechanism.

Move the selector lever to position "D".
1. Prevent the selector cable from turning.
2. Disconnect the selector cable adjusting cap.
3. Move the selector lever to position "D".
46. Adjust the selector lever scale position.
^ Remove the selector lever nuts.

47. NOTE: The selector lever has if own detent mechanism. Holding the selector lever is not necessary.

Slide the whole selector assembly forwards or backwards until the reading on the scale and the position of the selector lever indicator corresponds.





48. Tighten the selector lever nuts.





49. NOTE: The selector lever has its own detent mechanism. It is not necessary to hold in after engaging a gear.

Move the automatic transaxle selector lever to position "D".





50. Lock the selector cable.
1. Prevent the selector cable from turning.
2. Lock the selector cable adjustment cap.
^ Fit the heat shield.





51. Install the starter motor bolts.





52. Install the water pump cover.
^ Attach the engine coolant hose and install the bolts.





53. Connect the electrical connectors.
1. Ground cable
2. Automatic transaxle control
3. Transmission Range (TR) switch
4. Wiring harness retaining clip





54. NOTE: Use an Allen key to prevent the piston rod from turning.

Tighten the suspension strut locknuts on both sides (right-hand side shown).





55. Remove the radiator supports.





56. Fill the transaxle with MERCON(R) Multi-purpose automatic transmission fluid. MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid, as per TSB 06-14-4.

57. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.

Install the battery tray.
58. Fill and bleed the power steering system.