Removal
TRANSAXLE REMOVAL (OFF VEHICLE)TOOLS REQUIRED
- J43405 Engine Support Fixture Adapter
- J43628 Frame Alignment Fixture
- SA9105F. Engine Support Bar Assembly
REMOVAL
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.
1. Position vehicle on hoist.
2. Remove battery.
2.1 Disconnect battery cables (negative first, positive second.)
2.2 Move fan control module. Leave wiring connected, lift module up and away from bracket, and position out of the way.
2.3 Remove battery hold down bracket.
2.4 Remove battery.
3. Disconnect battery feed to Underhood Fuse Block (UHFB).
4. Disconnect coolant hose from UHFB.
5. Release retaining tabs on UHFB cover and remove.
6. Release retaining tabs (2) on UHFB and roll fuse block back (1) to access electrical connectors.
7. Remove following connectors from UHFB:
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)
8. Lift fuse block off case.
IMPORTANT: There are two tabs that hold the hard shell grommets in place at the bottom of the grommet. Disengage tabs to remove grommet from case.
9. Remove harnesses from UHFB case.
A) Engine
B) Forward Lamp
C) Instrument Panel (I/P)
10. Remove UHFB case fastener, and remove case from battery tray.
11. Remove battery tray fasteners and battery tray.
IMPORTANT: Note the original position of the A.I.R. components.
12. Remove clamp from A.I.R. hose behind the cooling fan.
13. Separate the A.I.R. tube from the hose and push the tube back towards the transaxle.
14. Remove the hose clip holding the two power steering lines together.
15. Loosen pinch bolt securing control assembly rod to control shaft lever assembly.
NOTICE: The control shaft lever retaining pin has a spring loaded locking feature securing the pin in place. If this spring is not depressed before attempting to remove the pin, damage to the pin will result.
16. Remove pin retaining control shaft lever to shift control shaft of transaxle.
17. Remove retaining clips holding control shaft lever assembly to transaxle and frame assembly brackets.
18. Remove control shaft lever assembly by pulling straight up off pivot pins.
19. Disconnect back-up lamp switch electrical connector.
20. Remove wire harness from transaxle.
21. There is a hole on top of transaxle that will have either a spring loaded locking pin or a hole plug.
- If hole has a spring loaded locking pin, remove it and discard. A new hole plug will be installed.
- If hole has a hole plug, remove it and retain for reuse.
22. Remove clutch hydraulic fitting from transaxle. Elevate and secure fitting to prevent excessive loss of brake fluid.
23. Remove upper transaxle-to-engine mounting bolts.
24. Install Engine Support Bar Assembly SA9105E with adapter kit Engine Support Fixture Adapter J43405 as shown.
25. Mark position of and remove left transaxle mount bolts.
26. Remove rear transaxle mount through bolt, and transaxle mount-to-frame bolt.
27. Fasten radiator to upper radiator support.
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.
28. Raise vehicle on hoist.
29. Remove front wheel and tire assemblies.
30. Remove right front lower splash shield
31. Remove left front wheel liner push pin from frame.
32. Disconnect rear O2 sensor connection, and remove harness from frame at two attachment points.
33. Remove O2 sensor clamp to underbody attachment nut.
34. Remove exhaust manifold pipe to exhaust manifold nuts. (Automatic shown, Manual similar.)
35. Remove exhaust manifold pipe to exhaust resonator pipe bolts.
36. Remove exhaust manifold pipe.
37. Remove front transaxle mount through bolt.
38. Remove remaining rear transaxle mount-to-frame bolts.
39. Remove rear transaxle mount.
40. Remove A/C line to frame attachment clip at front of vehicle.
41. Remove frame-to-shifter link pivot pin clip.
42. Remove steering gear-to-frame assembly bolts. (Automatic shown, manual similar.)
43. Using mechanics wire, secure steering gear assembly to body of vehicle.
NOTICE: Hold ball stud from turning when removing nut. The boot can become torn and damaged if the ball stud turns.
44. Remove stabilizer bar links from strut assemblies and discard nuts.
NOTICE: Do not attempt to separate joint using a wedge-type tool because seal may be damaged.
45. Remove lower ball stud bolt and separate ball stud from steering knuckle assembly.
46. Remove suspension support assemblies.
47. Remove suspension support cage nuts from body. Discard cage nuts and support bolts. New nuts and bolts must be used for assembly.
48. Using powertrain fitting table and Frame Alignment Fixture J43628, support frame assembly.
49. Remove remaining four frame-to-body attachment fasteners.
50. Carefully lower frame assembly from vehicle.
51. Remove frame assembly cage nuts from body. Discard cage nuts and frame bolts. New nuts and bolts must be used during assembly.
52. Remove front transaxle mount from transaxle.
53. Remove rear transaxle mount from transaxle.
54. Drain transaxle fluid by removing transaxle drain plug (1)
NOTICE: To prevent damage to CV joint boots, be careful not to allow them to contact other parts during the removal process. Also, never pull on the shaft assembly.
55. Use a pry bar to remove axle shafts from transaxle. Leave axle shafts in steering knuckles and secure axle shafts up and out of way of transaxle removal path.
NOTICE: If A/C line is not removed and lowered from body prior to lowering powertrain, engine crankshaft pulley will damage A/C line possibly causing a freon leak to occur.
56. Remove A/C line retaining clips and drop A/C line down from body as shown.
57. Lower vehicle.
58. Lower driver side of powertrain with engine support bar assembly SA9IOSE to allow transaxle to clear engine compartment rail.
59. Remove left transaxle mount bracket from transaxle.
60. Raise vehicle.
61. Remove control shaft lever assembly pivot pin bracket from transaxle case.
62. Support transaxle securely with transmission jack.
63. Remove remaining engine-to-transaxle mounting bolts.
64. Separate transaxle from engine and lower transaxle from vehicle.