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Transmission Replacement




Transmission Replacement

Special Tools

J 39580 Engine Support Table

Removal Procedure

Danger: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.

The High Voltage Disabling procedure will perform the following tasks:

* Identify how to disable high voltage.
* Identify how to test for the presence of high voltage.
* Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.

Failure to follow the procedures exactly as written may result in serious injury or death.

1. Disable the hybrid high voltage system. Refer to High Voltage Disabling (High Voltage Disabling).
2. Disconnect the 12-volt battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (HP5) (Service and Repair).
3. Remove the radiator opening upper cover. Refer to Radiator Opening Upper Cover Replacement (Radiator Opening Upper Cover Replacement)
4. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (LY7) (Service and Repair)Fuel Injector Sight Shield Replacement (LCS) (Service and Repair).
5. Drain the coolant from the generator control module. Refer Generator Control Module Cooling System Draining and Filling (Generator Control Module Cooling System Draining and Filling).
6. Remove the drive motor control module assembly. Refer to Drive Motor Generator Control Module Assembly Replacement (Drive Motor Generator Control Module Assembly Replacement).
7. Remove the engine control module. Refer to Engine Control Module Replacement (Service and Repair).
8. Disconnect the air conditioning evaporator outlet hose. Refer to Evaporator Outlet Hose Replacement (HP5) (Evaporator Outlet Hose Replacement)Evaporator Outlet Hose Replacement (LAT) (Evaporator Outlet Hose Replacement)Evaporator Outlet Hose Replacement (LE5, LZ4, LY7) (Evaporator Outlet Hose Replacement).
9. Disconnect the air conditioning liquid line from the condenser. Refer to Air Conditioning Condenser and Air Conditioning Evaporator Tube Replacement (HP5) (Air Conditioning Condenser and Air Conditioning Evaporator Tube Replacement)Air Conditioning Condenser and Air Conditioning Evaporator Tube Replacement (LAT) (Air Conditioning Condenser and Air Conditioning Evaporator Tube Replacement)Air Conditioning Condenser and Air Conditioning Evaporator Tube Replacement (LE5, LZ4, LY7) (Air Conditioning Condenser and Air Conditioning Evaporator Tube Replacement).
10. Disconnect the fuel lines from the engine. Refer to Fuel Line Replacement - Chassis (Service and Repair).
11. Disconnect the heater hoses from the engine. Refer to Heater Inlet Hose Replacement (LY7) (Service and Repair)Heater Inlet Hose Replacement (LAT) (Service and Repair)Heater Inlet Hose Replacement (LZ4) (Service and Repair)Heater Inlet Hose Replacement (LE5) (Service and Repair)Heater Inlet Hose Replacement (HP5) (Service and Repair) and Heater Outlet Hose Replacement (LZ4) (Service and Repair)Heater Outlet Hose Replacement (LE5) (Service and Repair)Heater Outlet Hose Replacement (LAT) (Service and Repair)Heater Outlet Hose Replacement (LY7) (Service and Repair)Heater Outlet Hose Replacement (HP5 Pump to Engine) (Service and Repair)Heater Outlet Hose Replacement (HP5 Pump to Heater Core) (Service and Repair).
12. Remove the underhood electrical center junction block. Refer to Underhood Electrical Center or Junction Block Replacement (HP7) (Service and Repair)Underhood Electrical Center or Junction Block Replacement (HP5) (Service and Repair).
13. Disconnect all necessary engine electrical connectors, cables and ground wires. Refer to Harness Routing Views ([1][2]Harness).
14. Remove the left powertrain mount bolts. Refer to Transmission Mount Replacement - Left Side (Removal and Replacement).
15. Remove the Right powertrain mount bolts. Refer to Engine Mount Replacement - Right Side (Service and Repair).
16. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
17. Remove the front tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (Service and Repair).
18. Disconnect the wheel speed sensors from the steering knuckles.
19. Remove the front brake disc calipers from the caliper mounting bracket, then suspend the calipers with mechanics wire or equivalent. DO Not disconnect the brake hoses.
20. Remove the engine splash shields. Refer to Engine Splash Shield Replacement (Service and Repair).
21. Remove the air deflector from the frame. Refer to Front Bumper Fascia Air Deflector Replacement (Front Bumper Fascia Air Deflector Replacement).
22. Remove the front catalytic converters. Refer to Catalytic Converter Replacement - Left Side (LZ4) (Catalytic Converter Replacement - Left Side)Catalytic Converter Replacement - Left Side (LY7 ) (Catalytic Converter Replacement - Left Side)Catalytic Converter Replacement - Left Side (LCS) (Catalytic Converter Replacement - Left Side).
23. Remove the strut to steering knuckle retaining bolts.




24. Disconnect the steering shaft coupling (1) from the steering gear. Refer to Steering Shaft Coupling Replacement (Service and Repair).
25. Disconnect the shift cable from the transaxle.




26. Disconnect the electrical connectors (1, 2) from the electronic power steering rack motor.
27. Disconnect the stabilizer links from the stabilizer bar. Refer to Stabilizer Shaft Link Replacement (Front Suspension).
28. Remove the steering gear electric motor ground strap from the underbody.





Note: Support the EBCM with mechanics wire to the vehicle underbody.

29. Remove the four bolts that attach the electric brake control module (EBCM) (1) to the frame.




30. Lower the vehicle until the frame contacts the J 39580 .




31. Remove the frame reinforcements. Refer to Drivetrain and Front Suspension Frame Reinforcement Replacement (2.4L LE5 and 2.4L LAT) (Service and Repair)Drivetrain and Front Suspension Frame Reinforcement Replacement (3.5L LZ4, 3.6L LY7 and 3.6L LSC) (Service and Repair).
32. Remove the front frame retaining bolts.




33. Raise the vehicle off of the frame with the radiator, condenser, engine, transaxle, electronic power steering rack (1) and stabilizer bar still attached the frame.
34. Remove the front wheel drive shafts. Refer to Front Wheel Drive Shaft Replacement (Front Wheel Drive Shaft Replacement).
35. Remove the intermediate drive shaft from the transaxle. Refer to Intermediate Shaft Replacement (LE5) ()Intermediate Shaft Replacement (LY7) ().
36. Disconnect the coolant hoses and pipes and electrical connectors from the radiator and condenser assembly.
37. Remove the radiator assembly from the frame.





Note: Rotate the engine clockwise only to access the bolts.

38. Remove the torque converter access shield, then remove the four torque converter bolts (1).
39. Using the engine removal brackets, slightly raise and support the engine assembly.
40. Remove the right exhaust manifold. Refer to Exhaust Manifold Replacement - Right Side (LZ4) (Exhaust Manifold Replacement - Right Side)Exhaust Manifold Replacement - Right Side (LY7 or LCS) (Exhaust Manifold Replacement - Right Side).
41. Remove the engine mount bracket. Refer to Engine Mount Bracket Replacement - Right Side (Service and Repair)
42. Install J 36857 or equivalent lift hook to center bracket bolt hole, use spacers as required.
43. Install two J 36857 or equivalent lift hooks to the transaxle left mount holes. Refer to Holding Fixture Installation (Overhaul) for lift hook locations.
44. Using a suitable engine lift, slightly raise the powertrain.




45. Remove the three lower transaxle to engine retaining bolts (1).
46. Remove the engine from the transaxle assembly.
47. Remove the transaxle front and rear mount retaining nuts.
48. Remove the five remaining transaxle to engine retaining bolts.
49. Separate the engine from the transaxle assembly.
50. Install the transaxle holding fixture. Refer to Holding Fixture Installation (Overhaul).

Installation Procedure

1. Install the engine to the transaxle assembly.
2. Remove the transaxle holding fixture.





Caution: Refer to Fastener Caution (Fastener Caution).

3. Install the eight transaxle to engine retaining bolts (1), then tighten the bolts to 80 Nm (60 lb ft).
4. Align a slot in flexplate to a hole in the torque converter.





Note: Rotate the engine clockwise only to access the bolts.

5. Install the four torque converter bolts (1), then tighten 62 Nm (46 lb ft).
6. Install the torque converter access shield.
7. Install the right exhaust manifold. Refer to Exhaust Manifold Replacement - Right Side (LZ4) (Exhaust Manifold Replacement - Right Side)Exhaust Manifold Replacement - Right Side (LY7 or LCS) (Exhaust Manifold Replacement - Right Side)
8. Install the engine mount bracket. Refer to Engine Mount Bracket Replacement - Right Side (Service and Repair)
9. Install the engine and transaxle to the frame.
10. Remove the lifting hooks from the transaxle and engine.

Note: Front and rear mounts are to be torqued after the powertrain is fully seated on the mounts. This will eliminate any twist in the rubber element induced to not preloading the mount before applying torque.

11. Tighten the transaxle front and rear mount retaining nuts to 100 Nm (74 lb ft).
12. Connect the coolant hoses and pipes to the radiator and condenser assembly.
13. Install the intermediate shaft to the transaxle. Refer to Intermediate Shaft Replacement (LE5) ()Intermediate Shaft Replacement (LY7) ()
14. Install the front wheel drive shafts. Refer to Front Wheel Drive Shaft Replacement (Front Wheel Drive Shaft Replacement).




15. Lower the vehicle on to the frame.
16. Install the front frame bolts, then tighten the bolts to 155 Nm (114 lb ft).




17. Install the frame reinforcements. Refer to Drivetrain and Front Suspension Frame Reinforcement Replacement (2.4L LE5 and 2.4L LAT) (Service and Repair)Drivetrain and Front Suspension Frame Reinforcement Replacement (3.5L LZ4, 3.6L LY7 and 3.6L LSC) (Service and Repair).
18. Raise the vehicle off of the J 39580 .




19. Install the steering shaft coupling (1) to the steering gear. Refer to Steering Shaft Coupling Replacement (Service and Repair).
20. Install the four EBCM bolts, then tighten the bolts to 40 Nm (30 lb ft).




21. Connect the two electric power steering rack electrical connectors (1, 2).
22. Install the steering gear electric motor ground strap to the underbody.




23. Install the lower ball joints to the steering knuckles. Refer to Lower Control Arm Replacement (Front Suspension).
24. Connect both left and right stabilizer links. Refer to Stabilizer Shaft Insulator Replacement (Front Suspension).
25. Connect the outer tie rod ends to the steering knuckle. Refer to Steering Linkage Outer Tie Rod Replacement (Steering Linkage Outer Tie Rod Replacement).
26. Install the strut to steering knuckle retaining bolts, then tighten the bolts to 180 Nm (133 lb ft).
27. Install the front brake disc calipers to the caliper mounting bracket, then tighten the bolts to 27 Nm (20 lb ft).
28. Install the front catalytic converters. Refer to Catalytic Converter Replacement - Left Side (LZ4) (Catalytic Converter Replacement - Left Side)Catalytic Converter Replacement - Left Side (LY7 ) (Catalytic Converter Replacement - Left Side)Catalytic Converter Replacement - Left Side (LCS) (Catalytic Converter Replacement - Left Side) and Catalytic Converter Replacement - Right Side (LZ4) (Catalytic Converter Replacement - Right Side)Catalytic Converter Replacement - Right Side (LY7) (Catalytic Converter Replacement - Right Side)Catalytic Converter Replacement - Right Side (LCS) (Catalytic Converter Replacement - Right Side).
29. Connect the fuel lines to the engine. Refer to Fuel Line Replacement - Chassis (Service and Repair).
30. Connect the heater hoses to the engine. Refer to Heater Inlet Hose Replacement (LY7) (Service and Repair)Heater Inlet Hose Replacement (LAT) (Service and Repair)Heater Inlet Hose Replacement (LZ4) (Service and Repair)Heater Inlet Hose Replacement (LE5) (Service and Repair)Heater Inlet Hose Replacement (HP5) (Service and Repair) and Heater Outlet Hose Replacement (LZ4) (Service and Repair)Heater Outlet Hose Replacement (LE5) (Service and Repair)Heater Outlet Hose Replacement (LAT) (Service and Repair)Heater Outlet Hose Replacement (LY7) (Service and Repair)Heater Outlet Hose Replacement (HP5 Pump to Engine) (Service and Repair)Heater Outlet Hose Replacement (HP5 Pump to Heater Core) (Service and Repair).
31. Connect all necessary engine electrical connectors. Refer to Harness Routing Views ([1][2]Harness).
32. Install the underhood electrical center junction block. Refer to Underhood Electrical Center or Junction Block Replacement (HP7) (Service and Repair)Underhood Electrical Center or Junction Block Replacement (HP5) (Service and Repair)
33. Connect the air conditioning evaporator outlet hose. Refer to Evaporator Outlet Hose Replacement (HP5) (Evaporator Outlet Hose Replacement)Evaporator Outlet Hose Replacement (LAT) (Evaporator Outlet Hose Replacement)Evaporator Outlet Hose Replacement (LE5, LZ4, LY7) (Evaporator Outlet Hose Replacement).
34. Connect the air conditioning liquid line to the condenser. Refer to Air Conditioning Condenser and Air Conditioning Evaporator Tube Replacement (HP5) (Air Conditioning Condenser and Air Conditioning Evaporator Tube Replacement)Air Conditioning Condenser and Air Conditioning Evaporator Tube Replacement (LAT) (Air Conditioning Condenser and Air Conditioning Evaporator Tube Replacement)Air Conditioning Condenser and Air Conditioning Evaporator Tube Replacement (LE5, LZ4, LY7) (Air Conditioning Condenser and Air Conditioning Evaporator Tube Replacement).
35. Install the engine control module. Refer to Engine Control Module Replacement (Service and Repair).
36. Install the drive motor control module assembly. Refer to Drive Motor Generator Control Module Assembly Replacement (Drive Motor Generator Control Module Assembly Replacement).
37. Install the air deflector to the frame. Refer to Front Bumper Fascia Air Deflector Replacement (Front Bumper Fascia Air Deflector Replacement).
38. Install the engine splash shields. Refer to Engine Splash Shield Replacement (Service and Repair).
39. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (Service and Repair).
40. Fill the coolant reservoir for the generator control module. Refer Generator Control Module Cooling System Draining and Filling (Generator Control Module Cooling System Draining and Filling).
41. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (LY7) (Service and Repair)Fuel Injector Sight Shield Replacement (LCS) (Service and Repair).
42. Install the radiator opening upper cover. Refer to Radiator Opening Upper Cover Replacement (Radiator Opening Upper Cover Replacement)
43. Enable the hybrid high voltage system. Refer to High Voltage Enabling (High Voltage Enabling).
44. Connect the 12-volt battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (HP5) (Service and Repair).
45. Check the wheel alignment. Refer to Wheel Alignment Measurement (Service and Repair).

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