Installation
Tools Required- SA105E Engine Support Bar Assembly
- J43405 Engine Support Fixture Adapter
- 87-92-335 Shift Linkage Lock Pin
- SA91 112T Axle Seal Protector
1. Securely place transaxle on transmission jack. Place transaxle in any gear.
2. Raise transaxle into vehicle and align transaxle input shaft to center of clutch disc. Guide transaxle into position, rotate back and forth to align input shaft splines to clutch disc.
NOTICE: Make sure input shaft splices line up with the clutch disc splines before tightening transaxle-to-engine mounting bolts. Do not use bolts to pull transaxle up to engine.
3. Install lower transaxle-to-engine mounting bolts.
Torque: 65 Nm (48 ft. lbs.)
4. Remove transmission jack.
5. Install control shaft lever assembly pivot pin bracket onto transaxle case.
Torque: 24 Nm (18 ft. lbs.)
6. Using axle seal protector SA91112T, insert axle shafts into transaxle. After splines clear seal protector but before snapping axle into place, remove seal protector.
7. Ensure transaxle drain plug is installed in transaxle case. If it is not installed, clean and apply sealant (P/N 21485278) to threads and install plug.
Torque: 50 Nm (37 ft. lbs.)
8. Lower vehicle.
9. Remove transaxle fill plug from top of transaxle. Fill transaxle with two quarts of manual transaxle fluid (P/N 21018899).
10. Reinstall transaxle fill plug.
Torque: 30 Nm (22 ft. lbs.)
11. Install left transaxle mount bracket onto transaxle.
Torque: 55 Nm (41 ft. lbs.)
12. Raise left side of powertrain to correct height using engine support bar assembly SA105E.
13. Raise vehicle.
14. Reposition A/C line against body and install A/C line retaining clips.
15. Install rear transaxle mount onto transaxle.
Torque: 55 Nm (41 ft. lbs.)
16. Install front transaxle mount onto transaxle.
Torque: 55 Nm (41 ft. lbs.)
17. Install frame assembly.
18. Lower vehicle.
19. Install upper transaxle-to-engine mounting bolts.
Torque: 65 Nm (48 ft. lbs.)
NOTICE: If the transaxle mount is not reinstalled in its original position, it could lead to premature mount wear.
20. Reference alignment marks made during disassembly and install left transaxle mount bolts.
Torque: 55 Nm (41 ft. lbs.)
21. Install back up lamp switch electrical connector.
22. Install wire harness onto transaxle.
23. Install control shaft lever assembly onto pivot pin brackets.
24. Install retaining clips to hold control shaft lever assembly to transaxle and frame assembly brackets.
25. Install pin to retain control shaft lever to shift control shaft of transaxle.
26. Rotate transaxle shift control shaft clockwise (toward passenger side of vehicle) and install shift linkage lock pin 87-92-335 into hole in top of transaxle.
27. Pull up control lever assembly boot to disengage from console.
28. Move shift lever to 5th/Reverse Gate and use a 3/8 inch punch to hold in place.
29. Tighten pinch bolt securing control assembly rod to control shaft lever assembly.
Torque: 12 Nm (9 ft. lbs.) + 180°
IMPORTANT: Spring loaded locking pin cannot be reused. Install a shift lever hole plug.
30. Remove 87-92-335 from transaxle and install shift lever hole plug.
31. Install clutch hydraulic fitting onto transaxle.
32. Bleed the clutch hydraulic system.
33. Install battery tray fasteners and battery tray.
Torque: 15 Nm (11 ft. lbs.)
34. Install under hood fuse block case to battery tray and install bolt.
Torque: 9 Nm (80 inch lbs.)
35. Install wire harnesses to fuse block case. The wire harness grommets have retaining tabs that lock into the case (3) when the harnesses are fully installed.
36. Snap fuse block onto fuse block case hinges (1).
37. Install the following connectors to the under hood fuse block:
(1) Engine 68 way
(2) Forward Lamp 68 way
(3) I/P 68 way
(4) Forward Lamp 2 way
(5) VP 2 way (Black)
(6) I/P 2 way (Green)
(7) I/P 2 way (Brown)
38. Secure under hood fuse block to fuse block case by rotating down and snapping into place.
39. Install under hood fuse block cover.
40. Install coolant hose into place on fuse block.
41. Install battery feed to under hood fuse block.
Torque: 16 Nm (12 inch lbs.)
42. Install battery.
a. Install battery onto battery tray.
b. Install battery hold down bracket.
Torque: 20 Nm (15 ft. lbs.)
c. Install fan control module by sliding down onto battery hold bracket.
d. Install battery cables (positive first, negative second).
Torque: 17 Nm (13 ft. lbs.)