Automatic Transaxle Replacement

REPLACEMENT
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE ENGINE UNDER COVER SUB-ASSEMBLY NO.1
3. REMOVE ENGINE UNDER COVER ASSEMBLY REAR
4. DISCONNECT OXYGEN SENSOR
5. REMOVE EXHAUST PIPE ASSEMBLY
6. REMOVE PROPELLER SHAFT ASSEMBLY FRONT
7. REMOVE PROPELLER SHAFT ASSEMBLY





8. DRAIN AUTOMATIC TRANSMISSION FLUID
a. Remove the drain plug and gasket, and drain the ATF.
b. Install a new gasket and the drain plug.
Torque: 28 Nm (285 kgf-cm, 21 ft. lbs.)
9. REMOVE PROPELLER SHAFT HEAT INSULATOR
a. Remove the 2 bolts and propeller shaft heat insulator.





10. REMOVE FRONT SUSPENSION MEMBER BRACKET
a. Remove the 4 bolts and front suspension member bracket.
11. REMOVE FRONT SUSPENSION MEMBER BRACKET LH
a. Remove the 4 bolts and front suspension member bracket LH.
12. DISCONNECT OIL COOLER OUTLET TUBE NO.1





a. Remove the 2 bolts and 2 clamps.





b. Using SST, disconnect the oil cooler outlet tube No. 1.
SST 09023-12701
13. REMOVE OIL COOLER INLET TUBE NO.1
a. Using SST, disconnect the oil cooler inlet tube No. 1.
SST 09023-12701





14. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY
a. Remove the nut and clip and disconnect the transmission control cable assembly from the transmission control cable bracket No. 1.





15. SUPPORT AUTOMATIC TRANSMISSION ASSEMBLY
a. Support the transmission with a transmission jack.





16. REMOVE FRAME CROSSMEMBER SUB-ASSEMBLY NO.3
a. Remove the 4 nuts, 8 bolts and frame crossmember sub-assembly No.3.
17. 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. Transmission side:





1. Disconnect the park/neutral position switch connector.
2. Disconnect the transmission wire connector.
3. Disconnect the speed sensor NT connector.
4. Remove the bolt and wire harness from the transmission and transfer.





5. Disconnect the speed sensor SP2 connector.
c. Transfer side:





1. Disconnect the transfer shift actuator connector.
18. REMOVE STARTER ASSEMBLY
19. REMOVE MANIFOLD STAY
20. REMOVE MANIFOLD STAY NO.2
21. SEPARATE FRONT DIFFERENTIAL ASSEMBLY





22. REMOVE ENGINE MOUNTING INSULATOR REAR NO.1
a. Remove the 4 bolts and engine mounting insulator rear No.1.
23. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY





a. Remove the torque converter housing side cover from the engine.
b. Turn the crankshaft to gain access to each bolt.
c. Hold the crankshaft pulley nut with a wrench and remove the 6 bolts.





d. Remove the 9 bolts.
e. Separate and remove the automatic transmission assembly.





24. SEPARATE TRANSFER BREATHER HOSE SUB-ASSEMBLY
a. Separate the transfer breather hose sub-assembly from the transmission assembly.





25. REMOVE TRANSMISSION CONTROL CABLE BRACKET NO.1
a. Remove the 2 bolts and transmission control cable bracket No.1 from the transmission assembly.
26. REMOVE TRANSFER ASSEMBLY





27. REMOVE TORQUE CONVERTER ASSEMBLY
a. Put matchmarks on the transmission case and torque converter assembly.
b. Remove the torque converter assembly from the automatic transmission assembly.
28. INSPECT TORQUE CONVERTER ASSEMBLY
SST 09350-32014 (09351-32010, 09351-32020)
29. INSTALL TORQUE CONVERTER ASSEMBLY





a. Using calipers and a straight edge, measure dimension A between the transmission and the end surface of the drive plate.





b. Aligning the matchmarks on the transmission case and torque converter assembly, engage the splines of the input shaft and turbine runner.





c. Engage the splines of the stator shaft and stator while turning the torque converter assembly.

HINT: Turn the torque converter assembly approximately 180°.





d. Turn the torque converter assembly and align the matchmarks on the torque converter assembly and transmission case to engage the key of the oil pump drive gear into the slot on the torque converter assembly.

NOTICE: Do not push on the torque converter when aligning the matchmarks.





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





31. INSTALL TRANSMISSION CONTROL CABLE BRACKET NO.1
a. Install the transmission control cable bracket No.1 to the transmission assembly with the 2 bolts.
Torque: 14 Nm (143 kgf-cm, 10 ft. lbs.)





32. INSTALL TRANSFER BREATHER HOSE SUB-ASSEMBLY
a. Install the transfer breather hose sub-assembly.
33. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY





a. Install the automatic transmission assembly to the engine with the 9 bolts.
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 the black colored bolt and then the remaining 5 bolts.

c. Install the torque converter housing side cover to the engine.





34. INSTALL ENGINE MOUNTING INSULATOR REAR NO.1
a. Install the engine mounting insulator rear No. 1 to the automatic transmission with the 4 bolts.
Torque: 65 Nm (663 kgf-cm, 48 ft. lbs.)
35. INSTALL FRONT DIFFERENTIAL ASSEMBLY
36. INSTALL MANIFOLD STAY NO.2
Torque: 40 Nm (408 kgf-cm, 30 ft. lbs.)
37. INSTALL MANIFOLD STAY
Torque: 40 Nm (408 kgf-cm, 30 ft. lbs.)
38. INSTALL STARTER ASSEMBLY
39. CONNECT CONNECTOR
a. Transmission side:





1. Connect the speed sensor SP2 connector.





2. Install the wire harness with the 2 bolts.
Torque: 8.0 Nm (83 kgf-cm, 71 inch lbs.)
3. Connect the speed sensor NT connector.
4. Connect the transmission wire connector.
5. Connect the park/neutral position switch assembly connector.





b. Transfer side:
1. Connect the transfer shift actuator connector. (w/ transfer shift actuator)





40. INSTALL FRAME CROSSMEMBER SUB-ASSEMBLY NO.3
a. Install the frame crossmember sub-assembly No.3 with the 4 bolts and 4 nuts.
Torque: 72 Nm (735 kgf-cm, 53 ft. lbs.) (A)
b. Tighten the 4 bolts to the frame crossmember sub-assembly No.3 and engine mounting insulator rear No.1.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.) (B)





41. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY
a. Connect the transmission control cable assembly to the automatic transmission.
b. Install the nut and clip on the transmission control cable assembly.
Torque: 14 Nm (143 kgf-cm, 10 ft. lbs.)
42. 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 2 clamps and 2 bolts.
Torque: 5 Nm (50 kgf-cm, 43 inch lbs.)





d. Using SST, tighten the oil cooler outlet tube No. 1.
SST 09023-12701
Torque: 34 Nm (346 kgf-cm, 25 ft. lbs.)
43. INSTALL OIL COOLER INLET TUBE NO.1
a. Using SST, tighten the oil cooler inlet tube No. 1.
Torque: 34 Nm (346 kgf-cm, 25 ft. lbs.)
SST 09023-12701





44. INSTALL FRONT SUSPENSION MEMBER BRACKET LH
a. Install the front suspension member bracket LH with the 4 bolts.
Torque: 33 Nm (336 kgf-cm, 24 ft. lbs.)
45. INSTALL FRONT SUSPENSION MEMBER BRACKET
a. Install the front suspension member bracket with the 4 bolts.
Torque: 33 Nm (336 kgf-cm, 24 ft. lbs.)
46. INSTALL PROPELLER SHAFT HEAT INSULATOR
a. Install the propeller shaft heat insulator with the 2 bolts.
Torque: 16 Nm (163 kgf-cm, 12 ft. lbs.)
47. INSTALL PROPELLER SHAFT ASSEMBLY
48. INSTALL PROPELLER SHAFT ASSEMBLY FRONT
49. INSTALL EXHAUST PIPE ASSEMBLY
50. INSTALL OXYGEN SENSOR
51. INSTALL ENGINE UNDER COVER SUB-ASSEMBLY NO.1
Torque: 29 Nm (296 kgf-cm, 21 ft. lbs.)
52. INSTALL ENGINE UNDER COVER ASSEMBLY REAR
Torque: 29 Nm (296 kgf-cm, 21 ft. lbs.)
53. ADD AUTOMATIC TRANSMISSION FLUID
54. INSPECT AUTOMATIC TRANSMISSION FLUID
55. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
56. ADJUST SHIFT LEVER POSITION
57. INSPECT SHIFT LEVER POSITION
58. CHECK FOR EXHAUST GAS LEAKS
59. RESET MEMORY

NOTICE: Perform the RESET MEMORY (AT initialization) when replacing the automatic transmission assembly, engine assembly or ECM.

HINT: RESET MEMORY cannot be completed by only disconnecting the battery terminal.