Transaxle Installation
NOTICE:Cooler lines must be flushed prior to transaxle installation.
Oil Line Cooler Flusher SA9165T should be used when flushing of transaxle oil cooler in radiator assembly is required. Follow instructions provided with the tool when performing flushing procedure.
Cooler Flusher Adapter J35944-440 is used in combination with flushing tool and allows you to attach cooler flusher to transaxle oil cooler line assembly and flush cooler and cooler lines at the same time.
The transaxle oil cooler and lines should be flushed in any of the following situations:
^ Performing a transaxle replacement.
^ Oil cooler lines should be flushed after oil cooler replacement.
^ Any internal transaxle failure that caused debris (clutch plate material, metal shavings, etc.) to enter the transaxle oil cooler and oil cooler lines.
1. Install new turbine shaft 0-ring P/N 08677453 on end of turbine shaft.
2. Install new torque converter P/N 24211330 onto transaxle.
3. Transfer range switch to new transaxle.
4. Place transaxle on hydraulic lift table and position table under vehicle. Slowly lower vehicle and position transaxle to engine.
NOTICE:
Transaxle cooler lines must be flushed before transaxle installation.
IMPORTANT:
The bottom two and top three engine-to-transaxle mounting bolts will be installed later in this procedure.
5. Install engine-to-transaxle mounting bolts as shown.
Torque:
Engine-to-Transaxle Bolts: 65 N.m (48 ft-lbs)
6. Raise vehicle and remove hydraulic lift table.
7. Lower vehicle.
NOTICE:
If the powertrain mount is not reinstalled in its original position, it could lead to premature mount wear.
8. Reference alignment marks made during disassembly and install left transaxle mount bolts.
Torque:
Transaxle Mount (Left)-to-Transaxle Mount
Bracket Bolts: 55 N.m (41 ft-lbs)
9. Raise vehicle.
10. Install two bottom engine-to-transaxle mounting bolts.
Torque:
Engine-to-Transaxle Bolts: 65 N.m (48 ft-lbs)
NOTICE:
Failure to lubricate the inside of the cooler line seals with DEXRON(R) III P/N 21019223 automatic transaxle fluid before installing the cooler line assembly into the seals may cause damage to the seals.
11. Install transaxle oil cooler line assembly to transaxle.
Torque:
Transaxle Oil Cooler Line Assembly
Nut: 8 N.m (71 in-lbs)
NOTICE:
Torque Converter Bolt Magnetic Socket must be used to install the flex plate to torque converter bolts. Care must be taken not to drop the bolts inside the torque converter housing of the transaxle. If a bolt is dropped inside the housing, the transaxle must be separated from the engine to retrieve it.
12. Loosely install flex plate to torque converter bolts using torque converter bolt magnetic socket J44014 through starter opening. After all bolts are installed, torque to specification.
Torque:
Flex Plate-to-Torque Converter
Bolts: 45 N.m (33 ft-lbs)
13. Install starter assembly.
Torque:
Starter Assembly Bolts: 40 N.m (30 ft-lbs)
14. Connect starter solenoid electrical connections.
(1) Torque: Engine Harness-to-Starter Solenoid Nut: 4.5 N.m (40 in-lbs)
(2) Torque: Battery Terminal-to-Starter Solenoid Nut: 9 N.m (80 in-lbs)
15. Install engine-to-transaxle bracket.
Torque:
Engine-to-Transaxle Bracket
Bolts: 35 N.m (26 ft-lbs)
NOTICE:
In order to prevent damage to axle shaft splines during vehicle operation, add grease P/N 07847638 (or equivalent) to splines prior to installing axle shafts.
16. Install new axle shaft retaining rings on end of output shafts of transaxle and install axle shafts into transaxle.
NOTICE:
Install new cage nuts into the body as torque retention of old nuts may not be sufficient.
IMPORTANT:
Be sure the frame alignment tool fully engages in all gauge holes.
17. Raise frame assembly to body.
IMPORTANT:
Do not tighten fasteners at this time.
18. Install new frame-to-body bolts P/N 11097811.
19. Install new cage nuts P/N 90468617 into body for suspension supports, as torque retention of old nuts may not be sufficient.
20. Install suspension supports using new bolts P/N 11095961. Tighten all frame bolts.
Torque:
Suspension Support-to-Frame
Bolts: 90 N.m (66 ft-lbs) + 45° to 60°.
21. Install ball stud into steering knuckle.
Torque:
Lower Control Arm-to-Steering Knuckle Nut and Bolt: 100 N.m (75 ft-lbs)
22. Install steering gear-to-frame using new bolts P/N 11099501 and nuts P/N 11094487.
Torque:
Steering Gear-to-Frame Assembly
Bolts: 45 N.m (33 ft-lbs) + 45° to 60°.
23. Install steering gear heat shield.
Torque:
Steering Gear Heat Shield: 4 N.m (35 in-lbs)
24. Install stabilizer bar link-to-strut assembly.
Torque:
Stabilizer Bar Link-to-Strut
Assembly: 65 N.m (48 ft-lbs)
25. Install rear transaxle mount to frame bolts.
Torque:
Transaxle Mount (Rear)-to-Frame Assembly
Bolts: 60 N.m (44 ft-lbs)
26. Install front transaxle mount through bolt.
Torque:
Front Transaxle Mount Through
Bolt: 55 N.m (41 ft-lbs)
27. Reattach A/C line clip to front of frame assembly.
28. Install right front lower splash shield.
Torque:
Splash Shield Fasteners: 5 N.m (44 ft-lbs)
29. Install left front wheel liner push pin to frame.
30. Connect 02 sensor electrical connector and reattach harness to frame.
31. Lower vehicle and remove engine support fixture.
32. Connect output speed sensor electrical connector. Secure harness to mounting stud.
33. Install remaining engine-to-transaxle mounting bolts.
Torque:
Engine-to-Transaxle Bolts: 65 N.m (48 ft-lbs)
34. Install transaxle electrical connector and ground wire to transaxle.
Torque:
Ground Wire Bolt: 25 N.m (18 ft-lbs)
35. Install remaining wire harness attachments to transaxle side cover.
Torque:
Wiring Harness Attachment
Fasteners: 20 N.m (15 ft-lbs)
36. Install control cable mounting bracket to rear powertrain mount.
Torque:
Control Cable Mounting Bracket
Bolts: 20 N.m (15 ft-lbs)
37. Connect control cable to transaxle range switch lever.
38. Install battery tray and battery tray fasteners.
Torque:
Battery Tray Bolts: 15 N.m (11 ft-lbs)
39. Install underhood fuse block case to battery tray and install bolt.
Torque:
Underhood Fuse Block Case
Bolt: 9 N.m (80 in-lbs)
40. Install wire harnesses to fuse block case. The wire harness grommets have retaining tabs that lock into the case when the harnesses are fully installed.
A. Engine
B. Forward Lamp
C. Instrument Panel (I/P)
41. Snap fuse block onto fuse block case hinges.
42. Install following connectors to underhood fuse block:
(1) Engine 68 way
(2) Forward Lamp 68 way
(3) I/P 68 way
(4) Forward Lamp 2 way (White)
(5) I/P 2 way (Black)
(6) I/P 2 way (Green)
(7) I/P 2 way (Brown)
43. Secure underhood fuse block to fuse block case by rotating down and snapping into place.
44. Install underhood fuse block cover.
45. Secure coolant hose into place on fuse block cover.
46. Install battery feed cable to underhood fuse block.
Torque:
Battery Feed Cable-to-Underhood Fuse Block
Bolt: 16 N.m (12 ft-lbs)
47. Install battery.
47.1 Install battery into battery tray.
47.2 Install battery hold-down bracket.
Torque:
Battery Hold Down Bracket
Bolt: 20 N.m (15 ft-lbs)
47.3 Install fan control module by sliding down onto battery hold-down bracket.
CAUTION:
THE POSITIVE BATTERY TERMINAL MUST BE CONNECTED FIRST TO PREVENT ARCING.
47.4 Install battery cables (positive first, negative second).
Torque:
Battery Cables-to-Battery: 17 N.m (13 ft-lbs)
CAUTION:
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.
48. Install wheel and tire assemblies onto hub.
49. Install wheel bolts and tighten in a crisscross pattern.
49.1 Hand tighten all five wheel bolts.
49.2 Use a torque wrench to tighten wheel bolts using a crisscross pattern.
Torque:
Wheel Bolts (Initial Torque): 63 N.m (46 ft-lbs)
49.3 Use a torque wrench to final tighten wheel bolts using a crisscross pattern.
Torque:
Wheel Bolts (Final Torque): 125 N.m (92 ft-lbs)
IMPORTANT:
If a new transaxle assembly was installed, the transaxle was filled with the proper amount of transaxle fluid at the factory. No additional fluid is required.
50. Start engine and operate vehicle until transaxle fluid temperature reaches at least 40°C (104°F).
51. Depress brake pedal and move shift lever through all gear ranges, pausing a few seconds in each range. Return shift lever to PARK range.
CAUTION:
MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED ON THE 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.
52. Raise vehicle. Vehicle must be level, with engine running.
CAUTION:
THE TRANSAXLE FLUID IS HOT. CAUTION MUST BE TAKEN TO PREVENT PERSONAL INJURY IN THE EVENT TRANSAXLE FLUID DOES DRAIN FROM THE PLUG HOLE AFTER THE PLUG IS REMOVED.
53. Remove transaxle level plug with engine running.
54. Check fluid level. The fluid level should be even with the bottom of threaded plug hole.
NOTICE:
Saturn ATF (P/N 21005966) is not compatible with this transaxle. If Saturn ATF is used, transaxle damage will result. This transaxle uses DEXRON(R) III ATF (P/N 21019223).
55. If fluid level is low, add DEXRON(R) III automatic transaxle fluid in increments of 0.5 qts until fluid drains from plug hole.
IMPORTANT:
Before re-installing the transaxle level plug, apply Loctite Threadlocker 242(R).
56. Allow fluid to finish draining from plug hole. Install plug, and wipe any excess fluid from transaxle with a rag or shop towel.
Torque:
Transaxle Fluid Level Plug: 12 N.m (9 ft-lbs)
57. Install the hose clip to the two power steering lines.
58. Pull the A.I.R. tube back to the original position.
IMPORTANT:
The clamp must be installed with the locking portion facing down.
59. 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 chaffing between the tube and the harness.
60. Ensure the stand-off clip between the A.I.R. tube and the wiring harness is installed correctly.
61. Install remaining rear transaxle mount-to-frame bolts.
Torque:
Transaxle Mount (Rear)-to-Frame Assembly
Bolts: 60 N.m (44 ft-lbs)
62. Install rear powertrain mount through bolt.
Torque:
Transaxle Mount (Rear) Through
Bolts: 90 N.m (66 ft-lbs)
63. After the frame assembly has been installed it will be necessary to adjust the front wheel toe.
IMPORTANT:
When performing front wheel toe adjustment, ensure that steering wheel is locked in the straight-ahead position.
64. Position and lock steering in the straight-ahead position.
65. Loosen left side and right side inner tie rod-to-outer tie rod jam nuts.
NOTICE:
Make sure seals on steering gear assembly do not rotate and become twisted. If these seals rotate and become twisted, seal damage may result.
66. Use a wrench on inner tie rod flats to turn inner tie rods in direction of desired change.
67. After toe adjustment is complete, tighten left side and right side inner tie rod-to-outer tie rod jam nuts.
Torque:
Inner Tie Rod-to-Outer Tie Rod Jam
Nuts: 60 N.m (44 ft-lbs)
68. Re-check toe angles to ensure proper adjustment and re-adjust if necessary.
69. Road test vehicle to verify proper operation.
IMPORTANT:
Do not cover any existing underhood labels when affixing Campaign Completion Label.
70. Affix Campaign Completion Label on a clean and dry surface of radiator core support, in an area clearly visible when hood is raised. (For more information, refer to "Campaign Completion Label" in this bulletin.)