26. Transaxle Installation
TRANSAXLE INSTALLATION^ TOOLS REQUIRED
- J 41239 Cooler Line Seal Installer
- J 41239 Cooler Line Seal Remover
- J 44015 Tie Rod Installer
- SA91112T Axle Seal Protector
CAUTION: MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED ON HOIST. TO HELP AVOID PERSONAL INJURY WHEN A VEHICLE IS ON A HOIST, PROVIDE ADDITIONAL SUPPORT FOR THE VEHICLE ON THE OPPOSITE END FROM WHICH COMPONENTS ARE BEING REMOVED.
1. Position vehicle on hoist and raise vehicle.
2. Install new stub shaft retaining rings.
3. Install power take-off unit bolts and power take-off unit to transaxle.
Torque: Power Take-Off Unit Bolts: 60 N.m (44 ft. lbs.)
4. Install stub shaft into transaxle.
5. Install PTU vent hose.
6. With transaxle supported, carefully raise transaxle. It may be helpful to lower the vehicle down around the transaxle.
7. Assemble engine to transaxle carefully.
8. Install upper and lower transaxle-to-engine bolts.
Torque: Transaxle-to-Engine (18 mm) Bolts: 75 N.m (55 ft. lbs.)
Torque: Transaxle-to-Engine (15 mm) Bolts: 50 N.m (37 ft. lbs.)
9. Install engine-to-transaxle bolt located above the PTU.
Torque: Transaxle-to-Engine Bolts: 75 N.m (55 ft. lbs.)
10. Install PTU-to-engine bracket assembly.
Torque: PTU to Engine Bracket Assembly: 60 N.m (44 ft. lbs.)
11. Install exhaust downpipe.
12. Rotate crank and align net hole of flexplate through starter opening.
13. Install torque converter-to-flexplate bolts through starter hole.
Torque: Torque Converter-to-Flexplate Bolts: 60 N.m (44 ft. lbs.)
14. Install starter and starter bolts.
Torque: Starter Bolts: 40 N.m (30 ft. lbs.)
15. Install starter wiring harness.
Torque: B+ Cable-to-Starter Nut: 10 N.m (89 inch lbs.)
Torque: S-Terminal Nut: 5 N.m (44 inch lbs.)
16. Install right axle shaft to PTU stub shaft.
17. Install new retaining ring on left axle shaft.
18. Install Axle Seal Protector SA91112T inside left axle seal.
NOTICE: Lubricate axle with transaxle fluid, then use caution when inserting axle into transaxle. Be sure not to damage seal.
19. Install left axle shaft into transaxle.
20. Remove seal protector tool after splines clear the seal protector, but before axle shaft is fully installed.
21. Push left axle shaft all the way into transaxle.
22. With cradle on support table, install cradle and cradle fasteners carefully to vehicle.
Torque: Cradle Fasteners: 200 N.m (148 ft. lbs.)
23. Remove support table.
24. Install rear pitch restrictor thru-bolt.
Torque: Rear Pitch Restrictor Bolts: 110 N.m (81 ft. lbs.)
25. Install front pitch restrictor bolts, thru-bolt and front pitch restrictor.
Torque: Front Pitch Restrictor Bolts: 50 N.m (37 ft. lbs.)
Torque: Front Pitch Restrictor Thru-Bolt: 110 N.m (81 ft. lbs.)
26. Install knuckle to outer tie rod using Tie Rod Installer J44015.
27. Install outer tie rod-to-knuckle nut.
Torque: Tie Rod-to-Knuckle Nut: 50 N.m (37 ft. lbs.)
28. Install lower control arm ball stud-to-knuckle.
IMPORTANT: ^ Tighten nut one additional flat to align cotter pin hole if necessary.
29. Install nut and new cotter pin.
Torque: Lower Control Arm Nut: 110 N.m (81 ft. lbs.) + 1500
30. Install rack and pinion bolts to cradle.
Torque: Rack and Pinion Bolts: 110 N.m (81 ft. lbs.)
31. Connect lower stabilizer nut to cradle on both sides of vehicle.
Torque: Lower Stabilizer Nut: 65 N.m (48 ft. lbs.)
32. Install drive shaft to PTU.
Torque: Drive Shaft Bolts: 25 N.m (18 ft. lbs.)
33. If transaxle being installed is not new, then transaxle oil cooler line seals must be removed and replaced.
33.1. Use a long chisel with 1/4 in. blade (or equivalent) to partially collapse the seal in one place only.
33.2. Using Cooler Line Seal Remover J41239, remove seals and discard.
33.3. Clean case bores for the cooler line seals.
33.4. Remove nub of Cooler Line Sea] Installer J41239.
33.5. Using the nub of Cooler Line Seal Installer J41239, install new cooler line seals.
34. Connect transaxle cooler lines and nut to transaxle.
Torque: Transaxle Cooler Line Nut: 8 N.m (71 inch lbs.)
35. Install front air dam deflector-to-cradle pushpins.
36. Install left-side and right-side inner splash shields.
37. Install left-side and right-side wheel and tire assemblies. Tighten bolts in a crisscross pattern.
Torque: Wheel Nuts: 125 N.m (92 ft. lbs.)
38. Lower vehicle.
39. Install upper left-hand transaxle mount and bolts.
Torque: Upper Left Hand Transaxle Mount Bolts: 50 N.m (37 ft. lbs.)
40. Install fluid level indicator assembly.
Torque: Fluid Level Indicator Bolt: 12 N.m (9 ft. lbs.)
41. Remove engine support tool.
42. Remove tie straps from radiator.
43. Install positive battery cable to transaxle stud.
44. Install harness to transaxle range switch stud and control cable bracket.
45. Connect input and output speed sensor harness connectors.
46. Connect transaxle range switch harness connectors.
47. Connect control cable to control cable bracket.
48. Connect control cable to transaxle range switch assembly lever.
49. Install battery tray bracket.
49.1. Position battery tray bracket and tighten screws.
Torque: Battery Tray Bracket Screws: 16 N.m (12 ft. lbs.)
50. Install battery cooling box.
51. Install battery.
51.1. Insert battery and tighten battery hold-down screw.
Torque: Battery Hold-Down Screw: 15 N.m (11 ft. lbs.)
51.2. Connect positive battery cable to battery.
Torque: Battery Terminal Bolts: 17 N.m (13 ft. lbs.)
51.3. Connect negative battery cable to battery.
Torque: Battery Terminal Bolts: 17 N.m (13 ft. lbs.)
51.4. Install battery cooling box cover and tighten screws.
Torque: Battery Cooling Box Cover Screws: 2 N.m (18 inch lbs.)
51.5. Reprogram radio stations.
52. Fill transaxle to proper level using Saturn transaxle fluid (P/N 22689186). Verify fluid level using the "Transaxle Fluid Replacement".
53. Perform wheel alignment.