Transaxle Installation

TRANSAXLE INSTALLATION

^ TOOLS REQUIRED
- J 44015 Steering Linkage Installer
- SA91112T Axle Sea] Protector





1. Place transaxle securely on jack and position under vehicle. Install Axle Sea] Protector SA91112T into both axle seals.
2. Place transaxle into any gear.
3. Raise transaxle into vehicle to align input shaft to the center of clutch. Guide transaxle into position, rotate back and forth to align input shaft splines to clutch disc.

NOTICE: Make sure input shaft splines line up with clutch disc splines before tightening clutch housing bolts. Do not use bolts to pull transaxle up to engine.





IMPORTANT: Ensure that proper fastening locations are used. Refer to illustration for location that is not used.

4. Install transaxle to engine bolt from transaxle side.
Torque: Transaxle-to-Engine Bolts: 75 Nm (55 ft. lbs.)
5. Install engine to transaxle bolts from the engine side.
Torque: Engine-to-Transaxle Bolts: 75 Nm (55 ft. lbs.)
6. Raise transaxle jack until transaxle lines up with top transaxle mount.
7. Hand start top transaxle mount bolts.
Torque: Top Mount-to-Transaxle Bolts: 50 Nm (37 ft. lbs.)
8. Remove transaxle jack.





9. Install left axle shaft into transaxle.
10. After spines clear the seal protector but before snapping shaft into place, remove seal protector tool.

NOTICE: Use caution not to damage axle seal when intermediate shaft is installed into transaxle.





NOTICE: Use caution not to damage axle seal when axle shaft is installed into transaxle.

11. Install intermediate shaft into transaxle.
12. After spines clear the seal protector but before snapping shaft into place, remove seal protector tool.
13. Install front transaxle mount to transaxle.
Torque: Front Transaxle Mount Bolts: 50 Nm (37 ft. lbs.)
14. Install rear transaxle mount and bracket to transaxle.
Torque: Rear Transaxle Mount-to-Transaxle Bolts: 50 Nm (37 ft. lbs.)
15. Raise cradle and place lower ball joints into knuckles while installing.

IMPORTANT: Make sure the following parts are correctly positioned when raising frame into vehicle:
^ Lower control arm studs to knuckle
^ Cooling module support bushings
^ Front pitch restrictor

16. Tighten cradle-to-body bolts.
Torque: Cradle-to-Body Bolts: 190 Nm (140 ft. lbs.)
17. Install front air dam to body push pins.
18. Install front transaxle mount through bolt.
Torque: Front Transaxle Mount Through Bolt: 110 Nm (81 ft. lbs.)
19. Install rear transaxle mount through bolt.
Torque: Rear Transaxle Mount Through Bolt: 110 Nm (81 ft. lbs.)
20. Connect steering gear to steering column assembly.
Torque: Steering Gear-to-Steering Column Bolt: 34 Nm (25 ft. lbs.)





21. Install lower control arm ball stud to knuckle.
22. Install nut and new cotter pin.
Torque: Lower Control Arm Nut: 10 Nm (89 inch lbs.) + 1500
^ Tighten nut one additional flat to align cotter pin hole if necessary. Secure cotter pin.

NOTICE: Do not allow stud to rotate. Secure link stud with wrench to remove nut.





23. Install new nuts to lower stabilizer bar links and tighten.
Torque: Stabilizer Bar Link Nut: 65 Nm (48 ft. lbs.)





24. Insert tie rod-to-knuckle and install Steering Linkage Installer J44015 and tighten.
Torque: Tie Rod End Installation: 40 Nm (30 ft. lbs.)
25. Install outer tie rod ends and tighten.
Torque: Tie Rod-to-Steering Knuckle Nut: 50 Nm (37 ft. lbs.)
26. Connect back-up lamp switch and front wheel speed sensor.





27. Connect clutch hydraulic line to actuator cylinder by inserting and pushing in C-clip until it stops.
28. Connect shift cables into shift cable bracket.
29. Connect shift cable ends to transaxle.
30. Install left inner splash shield.





31. Install wheels.
32. Install wheel nuts and tighten in a crisscross pattern.
Torque: Wheel Nuts: 125 Nm (92 ft. lbs.)
33. Bleed clutch system.
34. Connect negative battery cable to battery.
Torque: Battery Terminal Bolts: 17 Nm (13 ft. lbs.)
35. Install battery cover and tighten screws.
Torque: Battery Cover Screws: 2 Nm (18 inch lbs.)
36. Reprogram radio stations.