Transmission Replacement
Transmission Replacement- Tools Required
- J 36346 Fascia Retainer Remover
- J 43405 Engine Support Fixture Adapter
- J 44015 Steering Linkage Installer
- J 44017 Stub Shaft Assembly Remover
- J 45341 Rear Wheel Drive Shaft Removal Tool
- SA9105E Engine Support Fixture - 3-Bar
- SA9133T Axle Seal Puller
- SA9173G Slide Hammer
- SA91100C Tie Rod Separator
- SA91112T Axle Seal Protector
Removal Procedure
Important: Record all pre-set radio stations.
1. Turn the ignition off.
2. Remove the battery cover.
Caution: Refer to Battery Disconnect Caution in Cautions and Notices.
3. Disconnect the negative battery cable.
4. Install the SA9105E and the J 43405.
5. Fasten the radiator to the upper radiator support.
6. Raise and support the vehicle.
7. Remove the wheels.
8. Remove the left inner splash shield.
9. Remove the ball joints.
10. Remove the tie rod outer to the knuckle nut.
Notice: Hold the ball stud from turning when removing/installing the nut. The boot can become torn and damaged if the ball stud turns.
Notice: Do not attempt to separate the joint using a wedge-type tool because seal may be damaged.
11. Using the SA91 100C or equivalent, separate the tie rod from the knuckle.
12. Remove the lower control arm ball stud cotter pin and nut. Discard the pin.
13. Disengage the ball stud from the knuckle.
Important: Do not allow the stud to rotate. Secure the link stud with a wrench in order to remove the nut.
14. Remove the lower stabilizer bar links.
15. Remove the steering gear from the steering column assembly.
15.1. Remove the rear transaxle mount-to-cradle bolts.
15.2. Remove the rear transaxle mount bracket-to-transaxle bolts.
16. Remove the front lower mount through bolt from the cradle.
Important: The front air dam deflector stays connected to the cradle.
17. Remove the front air dam deflector from the body.
18. Place a jack under the cradle and remove the cradle bolts.
19. Carefully remove the cradle from the vehicle.
Notice: Do not use too much force when disconnecting the shift cables or damage may result.
20. Using the J 36346 or equivalent, disconnect the shift lever cables from the shift control housing by prying with even pressure.
21. Disconnect the shift lever cables from the shift lever cable bracket.
22. Disconnect the pressure line from the clutch actuator cylinder by removing the C-clip, then pull the line away from the clutch actuator cylinder.
23. Disconnect the backup lamp switch (1) and front wheel speed sensor (2).
24. Drain the transaxle fluid.
25. Remove the front transaxle mount from the transaxle.
25.1. Using the J 45341 and the SA9173G, disengage the right drive axle from the intermediate drive shaft.
25.2. Secure the drive axle away from the intermediate drive shaft.
25.3. Remove the intermediate drive shaft bearing retainer-to-support bracket bolts.
Important: Remove the retaining ring from the stub shaft prior to tool installation. Discard the retaining ring.
26. Remove the intermediate drive shaft. If the intermediate drive shaft is difficult to remove, use the J 44017 and the SA9133T.
27. Using the J 45341 (1) and the SA9173G (2), remove the left drive axle.
28. Secure the drive axle out of the way.
29. Remove the bolts from the top transaxle mount.
30. Lower the vehicle.
31. Lower the transaxle, with the engine support fixture, enough to remove the transaxle.
32. Raise the vehicle.
33. Secure the transaxle to the transaxle jack.
34. Remove the transaxle housing bolts on the engine side.
35. Remove the transaxle housing bolt on the transaxle side.
36. Lower the transaxle support stand.
Installation Procedure
1. Place the transaxle securely on a jack and position under the vehicle.
2. Install the SA91112T into both axle seals.
3. Place the transaxle into any gear.
4. Raise the transaxle into the vehicle in order to align the input shaft to the center of the clutch. Guide the transaxle into position and rotate back and forth to align the input shaft splines to the clutch disc.
Notice: Refer to Fastener Notice in Cautions and Notices.
Important:
- Ensure the input shaft splines line up with the clutch disc splines before tightening the clutch housing bolts. Do not use the bolts to pull the transaxle up to the engine.
- Ensure that proper fastening locations are used.
5. Install the transaxle to engine bolt from the transaxle side.
- Tighten the bolts to 75 Nm (55 ft. lbs.).
6. Install the engine to transaxle bolts from the engine side.
- Tighten the bolts to 75 Nm (55 ft. lbs.).
7. Raise the transaxle jack until the transaxle lines up with the top of the transaxle mount.
8. Hand start the top transaxle mount bolts.
- Tighten the bolts to 50 Nm (37 ft. lbs.).
9. Remove the transaxle jack.
10. Install the drive axles into the transaxle. in Driveline/Axle.
11. Install the front transaxle mount to the transaxle.
12. Install the front transaxle mount bolts.
- Tighten the bolts to 50 Nm (37 ft. lbs.).
13. Install the rear transaxle mount and bracket to the transaxle.
14. Install the rear transaxle mount-to-transaxle bolts,
- Tighten the bolts to 50 Nm (37 ft. lbs.).
15. Raise the cradle and place the lower ball joints into the knuckles while installing.
Important: Ensure the following components are correctly positioned when raising the frame into the vehicle.
- The lower control arm studs to the knuckle
- The cooling module support bushings
- The front pitch restrictor
16. Tighten the cradle-to-body bolts.
- Tighten the bolts to 155 Nm (114 ft. lbs.).
17. Install the front air dam to body push pins.
18. Install the front transaxle mount through bolt.
- Tighten the bolt to 110 Nm (81 ft. lbs.).
19. Install the rear transaxle mount through bolt.
- Tighten the bolt to 110 Nm (81 ft. lbs.).
20. Connect the steering gear to the steering column assembly.
21. Install the steering gear-to-steering column bolt.
- Tighten the bolts to 34 Nm (25 ft. lbs.).
22. Install the lower control arm ball stud to the knuckle.
23. Install the lower control arm nut and a new cotter pin.
- Tighten the nut to 10 Nm +150° (89 inch lbs. +150°).
Important: Do not allow the stud to rotate.
24. Tighten the nut one additional flat in order to align the cotter pin hole, if necessary. Secure the cotter pin.
25. Install new stabilizer bar link nuts to the lower stabilizer bar links.
- Tighten the nuts to 65 Nm (48 ft. lbs.).
26. Insert the tie rod-to-knuckle.
27. Install the J 44015 and tighten.
- Tighten the tie rod end installation to 40 Nm (30 ft. lbs.).
28. Install the outer tie rod ends and tighten.
- Tighten the tie rod-to-steering knuckle nut to 50 Nm (37 ft. lbs.).
29. Install the backup lamp switch.
30. Install the front wheel speed sensor.
31. Connect the clutch hydraulic line to the actuator cylinder by inserting and pushing in the C-clip until it stops.
32. Connect the shift cables into the shift cable bracket.
33. Connect the shift cable ends to the transaxle.
34. Install the left inner splash shield.
35. Install the wheels.
36. Install the wheel nuts.
- Tighten the nuts in a crisscross pattern to 125 Nm (92 ft. lbs.).
37. Bleed the clutch system.
38. Connect the negative battery cable to the battery.
- Tighten the battery terminal bolts to 17 Nm (13 ft. lbs.).
39. Install the battery cover and screws.
- Tighten the battery cover screws to 2 Nm (18 inch lbs.).
40. Program the radio stations.