Inspection and Service Procedures
TRANSAXLE CASE ASSEMBLY TO TORQUE CONVERTER AND DIFFERENTIAL HOUSING ASSEMBLY BOLT REPLACEMENTINSPECTION AND SERVICE PROCEDURES TRANSAXLE INSPECTION
1. Test drive vehicle to determine if transaxle exhibits any unusual noises or performance-related concerns. Note any unusual noises or performance-related concerns.
2. Place transaxle in "N" Neutral.
3. Raise and support vehicle. Refer to "Lifting and Jacking the Vehicle" procedure in the General Information section of the 2002-2003 VUE Transaxle service manual.
4. Using a shop light or flashlight and a mirror (if necessary), carefully inspect transaxle for evidence of leaks between transaxle case assembly and torque converter and differential housing assembly.
^ If a transaxle fluid leak is not detected and there are no unusual noises or performance-related concerns, go to the "On-Vehicle Bolt Replacement" procedure in this bulletin.
^ If a transaxle fluid leak is detected without additional transaxle concerns, go to the "Transaxle Removal and Repair (Leak Detected During Transaxle Case/Converter Housing Inspection)" procedure in this bulletin.
^ If a transaxle fluid leak is detected with additional transaxle concerns, replace the transaxle. Refer to the "Transaxle Removal and Repair (Leak Detected During Transaxle Case/Converter Housing Inspection)" procedure in this bulletin.
ON-VEHICLE BOLT REPLACEMENT (LEAK NOT DETECTED DURING TRANSAXLE CASE/CONVERTER HOUSING INSPECTION)
The following repair instructions apply to transaxles that are to be retrofitted using special service-only bolts (P/N 24227740).
Important
Refer to illustration for bolt identification while performing the on-vehicle repair. Bolts located behind the torque converter will not be serviced during an on-vehicle repair.
Important
Replace and tighten one bolt at a time. When a bolt is removed from the transaxle, replace it immediately with the correct service bolt (P/N 24227740) before continuing to the next bolt.
Important
Ensure all service-only bolts are tightened to 28 Nm (21 lb-ft).
1. Remove the bolt-labeled number 1. Discard the bolt.
2. Install a new service-only bolt (P/N 24227740) to replace bolt number 1.
3. Using a torque wrench, tighten the new bolt to 28 Nm (21 lb-ft).
4. Continue to remove and replace, one bolt at a time, bolts numbered 2 through 10. Tighten each bolt with a torque wrench immediately after installing. Discard the old bolts.
5. Support the transaxle using a transaxle jack.
6. Remove the transaxle rear mount through-bolt.
7. For All-Wheel Drive (AWD) vehicles:
A. Remove the two bolts securing the right front stabilizer shaft and insulator to the frame. Move the shaft and insulator in order to gain access to the right-hand bolt securing the steering gear to the frame bracket.
B. Remove the two bolts securing the steering gear to the frame.
C. Remove the three bolts securing the transaxle rear mount to the frame.
D. Support the frame (3) with a frame support jack.
E. Loosen the two front frame bolts (5). Do not remove the bolts.
F. Remove the two rear frame bolts (4). Discard the bolts.
G. Lower the cradle slightly.
H. Remove the three bolts securing the transaxle rear-mounting bracket to the power transfer unit (PTU).
I. Remove the transaxle rear mounting bracket (1) and the transaxle rear mount (2).
8. For Front-Wheel Drive (FWD) vehicles:
A. Remove the three bolts securing the transaxle rear-mounting bracket to the transaxle.
B. Remove the transaxle rear-mounting bracket.
9. Remove and replace, one bolt at time, bolts numbered 11 and 12. Tighten each bolt to 28 Nm (21 lb-ft) immediately after installing. Discard the old bolts.
Important
In order to ensure safety and component stability, it is necessary to reinstall the removed chassis components before proceeding to bolts 13 through 17.
10. For All-Wheel Drive (AWD) vehicles:
A. Install the transaxle rear mounting bracket (1) and transaxle rear mount (2). Do not install bolts at this time.
B. Install the transaxle rear mount through-bolt. Do not tighten the through-bolt at this time. The bolt will be tightened after the procedure has been performed and the powertrain has been rebalanced.
C. Secure the transaxle rear-mounting bracket to the PTU with the three bolts. Tighten the bolts to 110 Nm (81 lb-ft).
D. Install the transaxle rear mount to the frame bolts. Tighten the bolts to 50 Nm (37 lb-ft).
E. Install two new rear frame bolts (4) (P/N 11588565). Tighten the bolts, but do not torque yet.
F. Reposition the frame support to the front of the frame.
G. Remove the two loosened front frame bolts and discard.
H. Install two new front frame bolts (5) (P/N 11588565). Tighten the bolts (5) to 155 Nm (114 lb-ft).
I. Tighten the rear frame bolts to 155 Nm (114 lb-ft).
J. Remove the frame support.
K. Install the steering gear to the frame and secure with the two bolts. Tighten the bolts to 110 Nm (81 lb-ft).
L. Install the right front stabilizer shaft and insulator to the frame and secure with the two bolts. Tighten the bolts to 50 Nm (37 lb-ft).
11. For Front-Wheel Drive (FWD) vehicles:
A. Install the transaxle rear-mounting bracket to the transaxle rear mount and transaxle and secure with the through-bolt and the three bolts. Do not tighten the through-bolt at this time. This bolt will be tightened after the procedure has been performed and the powertrain has been rebalanced.
B. Tighten the three rear mounting bracket-to-transaxle bolts to 55 Nm (41 lb-ft).
12. Remove the two bolts and the transaxle range selector lever cable bracket from the transaxle.
13. Remove and replace, one bolt at time, bolts numbered 13 through 15. Tighten each bolt to 28 Nm (21 lb-ft) immediately after installing. Discard the old bolts.
14. Install transaxle range selector lever cable bracket to the transaxle and secure with the two bolts.
15. Loosen the transaxle front mount through-bolt before lowering the vehicle. This is in preparation for the powertrain rebalance procedure.
16. Remove the transaxle support and lower the vehicle.
17. Using Fascia Retainer Remover J36346, remove control cable assembly from transaxle range switch lever.
18. Disconnect electrical connectors from transaxle range switch.
19. Remove transaxle range switch lever nut and lever.
20. Remove transaxle range switch bolts and remove switch.
Important
It may be necessary to use a crowfoot in order to remove bolts 16 and 17.
21. Remove and replace, one bolt at time, bolts numbered 16 and 17. Tighten each bolt to 28 Nm (21 lb-ft) immediately after installing. Discard the old bolts.
22. Align flats on transaxle shift shaft with flats on transaxle range switch and install switch.
23. Loosely install transaxle range switch bolts.
24. Insert transaxle range switch alignment tool J44810 as shown and rotate switch until tool drops into position. The switch is aligned when the pin on the tool drops into the hole on the transaxle range switch.
25. Tighten transaxle range switch bolts to 11 Nm (8 lb-ft).
26. Remove alignment tool.
27. Install transaxle range switch lever and nut, and tighten nut to 16 Nm (12 lb-ft).
28. Connect transaxle range switch electrical connectors.
29. Install control cable assembly to transaxle range switch lever and verify proper operation.
30. Balance the powertrain mounts by shaking the powertrain vigorously (front-to-rear) and allow the powertrain to settle.
31. Raise the vehicle.
32. Tighten the transaxle rear mount through-bolt to 110 Nm (81 lb-ft).
33. Tighten the transaxle front mount through-bolt to 110 Nm (81 lb-ft). Tighten the transaxle front mount through-bolt to 110 Nm (81 lb-ft).
TRANSAXLE REMOVAL AND REPAIR (LEAK DETECTED DURING TRANSAXLE CASE/CONVERTER HOUSING INSPECTION)
1. Remove the transaxle from the vehicle. Refer to "Transaxle Replacement" procedure in the 2002-2003 VUE Transax/e service manual.
2. Place the transaxle, converter side up, on a repair bench.
3. Carefully remove the torque converter.
4. Remove all 22 bolts securing the torque converter and differential housing assembly to the transaxle case assembly.
Important
There are two pry points on the torque converter and differential housing assembly.
5. Using a pry bar, carefully separate the torque converter and differential housing assembly from the transaxle case assembly.
6. Remove the torque converter and differential housing assembly.
7. Thoroughly clean both flange surfaces using a flat edge scraper. Remove as much old, cured sealant as possible, taking care to not gouge the mating surfaces. Any remaining sealant will bond to the new sealant. Wipe clean to minimize the amount of transaxle oil on the flange surface and Now any residue from the bolt holes.
Important
Apply the sealant on the inside mating surface around the bolt holes.
8. Apply a 3 mm (0.12 in) bead of sealant (P/N 22722716) to the mating surface of the transaxle case assembly.
9. carefully install the torque converter and differential housing assembly on the transaxle case assembly.
10. Secure the torque converter and differential housing assembly to the transaxle case assembly with the 22 bolts.
11. Tighten the bolts to 28 Nm (21 lb-ft) in the sequence shown in illustration.
12. Install the transaxle in the vehicle. Refer to "Transaxle Replacement" in the 2002-2003 VUE Transaxle service manual.
13. Affix Identification Label to radiator support.