Automatic Transaxle Replacement

REPLACEMENT
1. REMOVE ENGINE UNDER COVER SUB-ASSY NO.1
2. REMOVE ENGINE UNDER COVER ASSY REAR
3. DISCONNECT OXYGEN SENSOR
4. REMOVE EXHAUST PIPE ASSY
5. REMOVE PROPELLER SHAFT ASSY
6. DRAIN AUTOMATIC TRANSMISSION FLUID
a) Remove the drain plug, gasket and drain ATF.
b) Install a new gasket and drain plug.
Torque: 20 Nm (205 kgf-cm, 15 ft. lbs.)





7. REMOVE FRONT SUSPENSION MEMBER BRACKET
a) Remove the 4 bolts and front suspension member bracket.
8. REMOVE FRONT SUSPENSION MEMBER BRACKET LH
a) Remove the 4 bolts and front suspension member bracket LH.
9. REMOVE TRANSMISSION OIL FILLER TUBE SUB-ASSY
a) Remove the ATF level gauge.
b) Remove the bolt and oil filler tube.
c) Remove the O-ring from the oil filler tube.





10. DISCONNECT OIL COOLER OUTLET TUBE NO.1
a) Remove the 3 bolts and 3 clamps





b) Using SST, disconnect the oil cooler outlet tube No.1
SST 09023-12700
11. REMOVE OIL COOLER INLET TUBE NO.1
a) Using SST, disconnect the oil cooler inlet tube No.1.
SST 09023-12700





12. DISCONNECT TRANSMISSION CONTROL CABLE ASSY
a) Remove the nut and disconnect the transmission control cable.
b) Remove the lock plate and disconnect the transmission control cable.
13. REMOVE TRANSMISSION CONTROL CABLE BRACKET NO.1
a) Remove the 2 bolts and transmission control cable bracket No.1.





14. SUPPORT AUTOMATIC TRANSMISSION ASSY





15. REMOVE FRAME CROSSMEMBER SUB-ASSY NO.3
a) Remove the 4 bolts on the frame crossmember sub-assy No.3.
b) Remove the 4 nuts, 4 bolts and frame crossmember sub-assy No.3.





16. DISCONNECT CONNECTOR
a) Tilt down the transmission.

NOTICE: Take care so that the cooling fan does not come in contact with the fan shroud.

b) Disconnect the park/neutral position switch connector.
c) Disconnect the transmission wire connector.
d) Disconnect the 2 speed sensor connectors.
17. DISCONNECT WIRE HARNESS
18. REMOVE STARTER ASSY
19. REMOVE MANIFOLD STAY
a) Remove the 3 bolts and manifold stay.
20. REMOVE MANIFOLD STAY NO.2
a) Remove the 3 bolts and manifold stay No.2.





21. REMOVE TRANSMISSION ASSY
a) Turn the crankshaft to gain access to each bolt.
b) Hold the crankshaft pulley nut with a wrench and remove the 6 bolts.





c) Remove the 9 bolts.
d) Separate and remove the automatic transmission.





22. REMOVE ENGINE MOUNTING INSULATOR REAR NO.1
a) Remove the 4 bolts and engine mounting insulator rear from the automatic transmission.
23. REMOVE TORQUE CONVERTER CLUTCH ASSY
24. INSPECT TORQUE CONVERTER CLUTCH ASSY
25. INSTALL TORQUE CONVERTER CLUTCH ASSY
a) Install the torque converter clutch to the automatic transmission.





b) Using calipers and a straight edge, measure dimension A between the transmission and the end surface of the drive plate.
Standard:
A: 22.28 mm (0.8772 inch)





c) Using calipers and a straight edge, measure the dimension B shown in the illustration and check that B is greater than A measured in (b).
Standard:
A + 1 mm (0.03937 inch) or more





26. INSTALL ENGINE MOUNTING INSULATOR REAR NO.1
a) Install the engine mounting insulator rear and 4 bolts to the automatic transmission.
Torque: 65 Nm (663 kgf-cm, 48 ft. lbs.)





27. INSTALL TRANSMISSION ASSY
a) Install the automatic transmission and 9 bolts to the engine.
Torque:
17 mm head: 71 Nm (720 kgf-cm, 53 ft. lbs.)
14 mm head: 37 Nm (380 kgf-cm, 27 ft. lbs.)





b) Install the 6 torque converter clutch mounting bolts.
Torque: 48 Nm (490 kgf-cm 35 ft. lbs.)

HINT: First install black colored bolt and then the 5 bolts.

28. INSTALL MANIFOLD STAY NO.2
a) Install the manifold stay No.2 with 3 bolts.
Torque: 40 Nm (408 kgf-cm, 30 ft. lbs.)
29. INSTALL MANIFOLD STAY
a) Install the manifold stay with 3 bolts.
Torque: 40 Nm (408 kgf-cm, 30 ft. lbs.)
30. INSTALL STARTER ASSY
31. INSTALL WIRE HARNESS





32. INSTALL FRAME CROSSMEMBER SUB-ASSY NO.3
a) Install the frame crossmember sub-assy No 3 with 4 bolts and 4 nuts.
Torque: 72 Nm (735 kgf-cm, 53 ft. lbs.)
b) Install the frame crossmember sub-assy No.3 with 4 bolts.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)





33. INSTALL TRANSMISSION CONTROL CABLE BRACKET NO.1
a) Install the transmission control cable bracket No 1 with 2 bolts.
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)
34. CONNECT TRANSMISSION CONTROL CABLE ASSY
a) Connect the transmission control cable with lock plate
b) Connect the transmission control cable with nut.
Torque: 12 Nm (122 kgf-cm, 9 ft. lbs.)
35. INSTALL OIL COOLER OUTLET TUBE NO.1
a) Temporarily install the oil cooler outlet tube No.1.
b) Temporarily install the oil cooler inlet tube No 1.





c) Install the 3 clamps and 3 bolts.
Torque: 5 Nm(50 kgf-cm, 43inch lbs.)





d) Using SST, tighten the oil cooler outlet tube No.1.
SST 09023-12700
Torque: 34 Nm (346 kgf-cm, 25 ft. lbs.)
36. INSTALL OIL COOLER INLET TUBE NO.1
a) Using SST, tighten the oil cooler inlet tube No.1.
SST 0902-12700
Torque: 34 Nm (346 kgf-cm, 25 ft. lbs.)
37. INSTALL TRANSMISSION OIL FILLER TUBE SUB-ASSY
a) Coat a new O-ring with ATF, and install them to the oil filler tube.
b) Install the oil filler tube and bolt to the automatic transmission.
Torque: 12 Nm (122 kgf-cm, 9 ft. lbs.)
c) Install the ATF level gauge.





38. INSTALL FRONT SUSPENSION MEMBER BRACKET LH
a) Install the front suspension member bracket LH with 4 bolts.
Torque: 33 Nm (336 kgf-cm, 24 ft. lbs.)
39. INSTALL FRONT SUSPENSION MEMBER BRACKET
a) Install the front suspension member bracket with 4 bolts.
Torque: 33 Nm (336 kgf-cm, 24 ft. lbs.)
40. INSTALL PROPELLER SHAFT ASSY
41. ADJUST SHIFT LEVER POSITION
42. INSTALL EXHAUST PIPE ASSY
43. INSTALL OXYGEN SENSOR
44. INSTALL ENGINE UNDER COVER SUB-ASSY NO.1
Torque: 26 Nm (296 kgf-cm, 21 ft. lbs.)
45. INSTALL ENGINE UNDER COVER ASSY REAR
Torque: 26 Nm (296 kgf-cm, 21 ft. lbs.)
46. ADD AUTOMATIC TRANSMISSION FLUID
47. INSPECT AUTOMATIC TRANSMISSION FLUID
48. INSPECT SHIFT LEVER POSITION
49. CHECK FOR EXHAUST GAS LEAKS