Installation
TRANSAXLE INSTALLATION- TOOLS REQUIRED
- 87-92-335 Shift Linkage Lock Pin
- SA9105E Engine Support Bar Assembly
- SA91112T Axle Seal Protector
- SA9140E Torque Angle Gauge
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 splines 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:
Transaxle-to-Engine Bolts:
65 Nm (48 ft. lbs.)
4. Remove transmission jack.
5. Install control shaft lever assembly pivot pin bracket onto transaxle case.
Torque: Control Shaft Lever Pivot Pin
Bracket-to-Transaxle Bolts:
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:
Transaxle Drain Plug: 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 lubricant (P/N 21018899).
10. Clean and apply sealant (P/N 21485278) to threads and reinstall transaxle fill plug.
Torque: Exhaust Manifold Pipe-to-Exhaust Manifold Nuts: 50 Nm (37 ft. lbs.)
11. Install left transaxle mount bracket onto transaxle. (Automatic shown, Manual similar)
Torque: Left Transaxle Mount Bracket-to-Transaxle Bolts: 55 Nm (41 ft. lbs.)
12. Raise left side of powertrain to correct height using Engine Support Bar Assembly SA9105E.
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:
Rear Transaxle Mount-to-Transaxle: 55 Nm (41 ft. lbs.)
16. Install front transaxle mount onto transaxle.
Torque:
Front Transaxle Mount-to-Transaxle: 55 Nm (41 ft. lbs.)
IMPORTANT: Be sure the frame alignment tool fully engages in all gauge holes.
17. Install new cage nuts into the body as torque retention of old nuts may not be sufficient.
18. Raise frame assembly to body.
IMPORTANT: Do not tighten fasteners at this time.
19. Install four new frame-to-body bolts.
20. Install new cage nuts into body for suspension supports. Torque retention of old nuts may not be sufficient.
21. Install suspension supports using new bolts and tighten all frame bolts.
Torque: Frame-to-Body Bolts: 90 Nm (60 ft. lbs.) then using Torque Angle Gauge SA9140E (or equivalent) tighten bolts an additional 45 to 60 degrees
22. Install ball stud into steering knuckle.
Torque:
Ball Stud into Steering Knuckle: 100 Nm (75 ft. lbs.)
23. Install frame-to-shifter link pivot pin clip.
24. Install steering gear-to-frame using new bolts and nuts. (Automatic shown, manual similar.)
Torque:
Steering Gear-To-Frame: 45 Nm (35 ft. lbs.) + 90 degrees
NOTICE: Hold ball stud from turning when tightening nut. The boot can become torn and damaged if the ball stud turns.
25. Install stabilizer bar links-to-strut assemblies using new nuts.
Torque:
Stabilizer Bar Links-to-Strut Assemblies: 65 Nm (50 ft. lbs.)
26. Inspect rubber boots for damage and replace part if damaged.
27. Install rear transaxle mount.
28. Install rear transaxle mount-to-frame bolts.
Torque:
Rear Transaxle Mount-to-Frame Bolts: 60 Nm (44 ft. lbs.)
29. Install front transaxle mount through bolt.
Torque:
Front Transaxle Mount Through Bolt: 55 Nm (41 ft. lbs.)
30. Position gasket on manifold pipe.
31. Position manifold pipe into vehicle.
IMPORTANT: Do not tighten fastener at this time.
32. Install exhaust manifold pipe to exhaust manifold nuts.
33. Install exhaust manifold pipe to exhaust manifold nuts. (Automatic shown, manual similar.)
34. Position gasket between manifold pipe and resonator.
35. Install exhaust manifold pipe to resonator bolts and tighten.
Torque:
Exhaust Manifold-to-Resonator: 20 Nm (15 ft. lbs.)
36. Tighten exhaust manifold pipe to exhaust manifold nuts.
Torque:
Exhaust Manifold Pipe-to-Exhaust Manifold: 30 Nm (25 ft. lbs.)
37. Reattach A/C line clip to front of frame assembly.
38. Install right front lower splash shield.
Torque:
Right Front Lower Splash Shield to Frame Assembly: 5 Nm (44 inch lbs.)
39. Install left front wheel liner push pin to the frame.
40. Install 02 sensor clamp to underbody attachment nut.
Torque:
02 Sensor Clamp-to-Heat Shield: 4 Nm (35 inch lbs.)
41. Connect 02 sensor electrical connector and reattach harness to frame.
NOTICE: Before installing wheels, remove rust or corrosion from wheel mounting surfaces and brake rotors. Failure to do so can cause wheel bolts to loosen in service.
42. Install wheel and tire assemblies onto hub.
43. Install wheel bolts and tighten in a star pattern.
43.1. Hand tighten all five wheel bolts.
43.2. Use a torque wrench to tighten wheel bolts using a star pattern.
Torque:
Wheel Bolts (Initial Torque): 63 Nm (46 ft. lbs.)
43.3. Use a torque wrench to final tighten wheel bolts using a star pattern.
Torque:
Wheel Bolts (Final Torque): 125 Nm (92 ft. lbs.)
44. Install remaining rear transaxle mount-to-frame bolts.
Torque:
Rear Transaxle Mount-to-Frame Bolts: 60 Nm (44 ft. lbs.)
45. Install rear transaxle mount through bolt.
Torque:
Rear Transaxle Mount Through Bolt: 90 Nm (66 ft. lbs.)
46. Perform vehicle alignment.
47. Lower vehicle.
48. Install upper transaxle-to-engine mounting bolts.
Torque:
Transaxle-to-Engine Bolts: 65 Nm (45 ft. lbs.)
NOTICE: If the transaxle mount is not reinstalled in its original position, it could lead to premature mount wear.
49. Reference alignment marks made during disassembly and install left transaxle mount bolts.
Torque:
Left Transaxle Mount Bolts: 55 Nm (41 ft. lbs.)
50. Remove SA910SE engine support bar assembly and J-43405 engine support fixture adapter.
51. Install back-up lamp switch electrical connector.
52. Install wire harness onto transaxle.
53. Install control shaft lever assembly onto pivot pin brackets.
54. Install retaining clips to hold control shaft lever assembly to transaxle and frame assembly brackets.
55. Install pin to retain control shaft lever to shift control shaft of transaxle.
56. 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.
57. Pull up control lever assembly boot to disengage from console.
58. Move shift lever to 5th/Reverse Gate and use a 3/8 inch punch to hold in place.
59. Tighten pinch bolt securing control assembly rod to control shaft lever assembly.
Torque: Control Arm Rod-to-Control Lever Arm Pinch Bolt: 12 Nm (9 ft. lbs.) + 180°
IMPORTANT: Spring loaded locking pin cannot be reused. Install a shift lever hole plug.
60. Remove 87-92-335 from transaxle and install shift lever hole plug.
61. Install clutch hydraulic fitting onto transaxle.
62. Bleed the clutch hydraulic system.
63. Install the hose clip to the two power steering lines.
64. Pull the A.I.R. tube back to the original position.
IMPORTANT: The clamp must be installed with the locking portion facing down.
65. Insert the tube into hose and install clamp.
NOTICE: There is a stand-off clip between the A.I.R. tube and the wiring harness at the front of the transaxle. This must be in place to eliminate the possibility of chafing between the tube and the harness.
66. Ensure the stand-off clip between the A.I.R. tube and the wiring harness is installed correctly.
67. Install battery tray fasteners and battery tray.
Torque:
Battery Tray Fasteners: 15 Nm (11 ft. lbs.)
68. Install Under Hood Fuse Block (UHFB) case to battery tray and install bolt.
Torque:
Under Hood Fuse Block Case Bolt: 9 Nm (80 inch lbs.)
69. Install wire harnesses to UHFB case. The wire harness grommets have retaining tabs that lock into the case (3) when the harnesses are fully installed.
70. Snap fuse block onto fuse block case hinges (1).
71. Install the following connectors to the UHFB:
1. Engine 68 way
2. Forward Lamp 68 way
3. I/P 68 way
4. Forward Lamp 2 way
5. I/P 2 way (Black)
6. I/P 2 way (Green)
7. I/P 2 way (Brown)
72. Secure UHFB to fuse block case by rotating down and snapping into place.
73. Install UHFB cover.
74. Install coolant hose into place on fuse block.
75. Install battery feed to under hood fuse block.
Torque:
Battery Feed Cable to Under Hood Fuse Block: 16 Nm (12 inch lbs.)
76. Install battery.
76.1. Install battery onto battery tray.
76.2. Install battery hold down bracket.
Torque: Battery Hold Down Bracket Fasteners: 20 Nm (15 ft. lbs.)
76.3. Install fan control module by sliding down onto battery hold bracket.
CAUTION: THE POSITIVE BATTERY TERMINAL MUST BE CONNECTED FIRST TO PREVENT ARCING.
76.4. Install battery cables (positive first, negative second).
Torque:
Battery Cable Terminals: 17 Nm (13 ft. lbs.)