Transmission Replacement

Transmission Replacement

Tools Required

J 28467-B (DW 117) Universal Engine Support Fixture

Removal Procedure





1. Remove the air cleaner assembly.

Caution: Refer to Batteries Produce Explosive Gases Caution.

2. Remove the battery and battery tray.
3. Remove the shift cable pins (1).
4. Remove the washers (2).
5. Disconnect the select and the shift cable (3).
6. Remove the cable E-rings (4).
7. Disconnect the shift cables from the cable bracket.





8. Remove the engine wiring harness bending strap.
9. Remove the ground wire bolt (2).
10. Disconnect the ground wire (1).
11. Disconnect the backup lamp switch connector (3).





12. Remove the radiator lower hose bolts (1).
13. Disconnect the radiator lower hose (2).
14. Remove the crankshaft position (CKP) sensor bolt (3).
15. Disconnect the CKP sensor connector and remove the CKP sensor.





16. Disconnect the vehicle speed sensor (VSS) connector.
17. Remove the VSS.
18. Remove the starter motor.





Caution: While engine is operating, the exhaust system will become extremely hot. To prevent burns avoid contacting a hot exhaust system.

19. Install J 28467-B (1).





20. Remove the transaxle upper exhaust manifold side bolt (1) and the thermostat housing side bolt (2).





21. Drain the transaxle fluid.
22. Remove the cable adjust nut (1).
23. Disconnect the cable from the wire clip.
24. Disconnect the clutch cable from the transaxle mount hole (2).





25. Remove the front under longitudinal frames and stabilizer.
26. Remove the drive axle, only from the transaxle side.
27. Remove the clutch housing lower plate bolts (1) and lower plate (2).





Caution: While engine is operating, the exhaust system will become extremely hot. To prevent burns avoid contacting a hot exhaust system.

28. Remove the front exhaust pipe nuts from the exhaust manifold side.
29. Remove the gasket and separate the exhaust manifold pipe.
30. Remove the front exhaust pipe.





31. Remove the 3 transaxle mounting bracket bolts.





32. Support the transaxle with a transaxle support jack.





33. Remove the damping block connection nut and bolt (2).
34. Remove the 3 rear mounting bracket bolts (1).
35. Remove the rear mounting bracket from the transaxle.





36. Remove the 2 rear damping block retaining bolts.
37. Remove the rear damping block.





38. Remove the transaxle lower bolts (1, 2).





Notice: Support the engine in the normal position when removing the transaxle. Damage to related parts can occur.

39. Remove the transaxle.
40. Slide the transaxle sideways from the engine block.
41. Lower the transaxle.

Installation Procedure





1. Support the transaxle with a transaxle support jack.
2. Install the transaxle by inserting the transaxle input shaft into the clutch disc and sliding the transaxle sideways into the engine block.





Notice: Refer to Fastener Notice.

3. Install the transaxle lower bolts (1, 2).

Tighten
Tighten the bolts to 55-65 N.m (41-48 lb ft).





4. Install the 2 rear damping block retaining bolts.

Tighten
Tighten the bolts to 50-60 N.m (37-44 lb ft).





5. Install the bracket, the 3 rear mounting bracket bolts (1), and the damping block connection nut.

Tighten
^ Tighten the bracket bolts to 55-65 N.m (41-48 lb ft).
^ Tighten the connection nut and bolt to 75-85 N.m (55-63 lb ft).





6. Install the 3 rear transaxle mounting bracket bolts.

Tighten
Tighten the bolts to 45-55 N.m (33-41 lb ft).





7. Install the front exhaust pipe nuts.

Tighten
Tighten the nuts to 25-35 N.m (18-25 lb ft).





8. Install the clutch housing lower plate (2).
9. Install the clutch housing lower plate bolts (1).

Tighten
Tighten the bolts to 8-12 N.m (71-106 lb in).

10. Install the drive axle.
11. Install the front under longitudinal frames and stabilizer.





12. Install the clutch cable to the transaxle mount (2).
13. Install the cable to the wire clip (1).
14. Install the clutch cable adjusting nut (3).





15. Install the transaxle upper bolts (1, 2).

Tighten
Tighten the bolts to 55-65 N.m (41-48 lb ft).





16. Install the starter motor.
17. Remove J 28467-B (1).





18. Install the VSS.
19. Install the VSS mounting bolt.

Tighten
Tighten the bolt to 4-7 N.m (35-62 lb in).

20. Connect the VSS connector.





21. Install the radiator lower hose and CKP sensor.

Tighten
^ Tighten the hose bolt to 8-15 N.m (70-132 lb in).
^ Tighten the sensor bolt (3) to 5-8 N.m (44-70 lb in).





22. Connect the ground wire (1) and the backup lamp switch connector (3).
23. Install the engine wiring harness bending strap.

Tighten
Tighten the bolt to 10-16 N.m (7-12 lb ft).





24. Connect the shift cables to the cable bracket.
25. Install the cable E-rings (4).
26. Connect the select and shift cable (3).
27. Install the washers (2).
28. Install the shift cable pins (1).





29. Install the drain plug (2).

Tighten
Tighten the drain plug to 25-30 N.m (18-22 lb ft).

30. Remove the oil level plug (1).
31. Fill recommended fluid to the proper level.

Specification
^ The classification is 75W-85 (GL-4).
^ The capacity is 2.1 liters (2.21 quarts).

32. Install the oil level plug (1).

Tighten
Tighten the oil level plug to 25-30 N.m (18-22 lb ft).

33. Install the air cleaner assembly
34. Adjust the clutch cable.
35. Install the battery and battery tray in the vehicle.