43. Transmission Replacement

Transmission Replacement

Special Tools
* J 41623-B Cooler Quick Connect Tool
* J 42640 Steering Column Anti-Rotation Pin

Removal Procedure





Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components:

* The steering column
* The intermediate shaft(s)
* The steering gear

After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become un-centered and cause possible damage to the SIR coil. If you think the SIR coil has became un-centered, refer to your specific SIR coil's centering procedure to re-center SIR Coil.

1. Lock the steering column by installing J 42640 into the underside of the steering column.
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Replacement (Battery Negative Cable Replacement).
3. Remove the front compartment sight shield. Refer to Front Compartment Sight Shields Replacement (Front Compartment Sight Shields Replacement).
4. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair).




5. Remove the range select cable terminal from the transaxle range select lever.
6. Remove the range selector cable bracket nuts.
7. Remove the range selector cable with bracket from the transmission case and position aside.




8. Disconnect the transaxle electrical connector C100 (2).
9. Remove the wiring harness (3) from the wiring harness retainer (1) on the transaxle.




10. Remove the ground cable bolt (1) from the transaxle.
11. Install the engine support fixture. Refer to Engine Support Fixture (Engine Support Fixture).




12. Remove the upper engine to transaxle case bolts (2-5).
13. Raise and Support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
14. Remove the front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (Service and Repair).




15. Remove the left front wheelhouse liner (1). Refer to Front Wheelhouse Liner Replacement (Service and Repair).




16. Remove the front air deflector. Refer to Front Air Deflector Replacement (Front Air Deflector Replacement).
17. Remove the stabilizer shaft links. Refer to Stabilizer Shaft Link Replacement (Front Suspension).
18. Swing the stabilizer shaft downward in order to gain access to the power steering gear retaining bolts.





Warning

Failure to disconnect the intermediate shaft from the rack and pinion steering gear stub shaft can result in damage to the steering gear or to the intermediate shaft. This damage may cause loss of steering control, which could result in an accident and possible personal injury.

19. Remove the intermediate shaft lower pinch bolt.
20. Disconnect the intermediate shaft from the power steering gear.
21. Remove the power steering gear heat shield. Refer to Steering Gear Heat Shield Replacement (Steering Gear Heat Shield Replacement).




22. Remove the power steering gear mounting bolts.
23. Remove the power steering line retainers from the frame.
24. Secure the power steering gear to the exhaust manifold.




25. Remove the mounting bolts (2) in order to allow removal of the brake pressure modulator valve from the bracket.
26. Remove the brake line retainers (1) from the frame.

Note: The following are exceptions while following the frame removal procedure:

* Do not remove the front stabilizer shaft from the frame.
* Do not remove the insulators from the frame.
* Do not remove the control arms from the frame.

27. Remove the frame. Refer to Drivetrain and Front Suspension Frame Replacement (Drivetrain and Front Suspension Frame Replacement).
28. Remove the right and left drive axles from the transaxle. Refer to Wheel Drive Shaft Replacement (Service and Repair).
29. Disconnect the transmission oil cooler hoses from the transaxle using the J 41623-B . Refer to Transmission Fluid Cooler Hose/Pipe Replacement (34. Transmission Fluid Cooler Hose/Pipe Replacement).
30. Remove the transaxle fluid filler tube. Refer to Transmission Fluid Filler Tube and Seal Replacement (6. Transmission Fluid Filler Tube and Seal Replacement).
31. Remove the torque converter cover. Refer to Torque Converter Cover Replacement (41. Torque Converter Cover Replacement).




32. Mark the flywheel to converter relationship to ensure proper reassembly. Remove the flywheel to torque converter bolts (1).




33. Support transaxle using an appropriate transaxle jack.
34. Disconnect vehicle speed sensor electrical connector.




35. Remove the right engine to transaxle brace bolts (1).




36. Remove the front transaxle to engine brace bolt (1).




37. Remove the engine to transaxle case bolt (6) which is accessible through right wheel opening.
38. Remove the remaining transaxle to engine bolt (1).
39. Remove the transaxle from vehicle using an appropriate transaxle jack.




40. Remove the rear transaxle mount bracket from the transaxle.




41. Remove the left transaxle mount bracket from the transaxle.
42. Flush the transmission cooler and lines. Refer to Transmission Fluid Cooler Flushing and Flow Test (Transmission Fluid Cooler Flushing and Flow Test).

Installation Procedure




1. Install the left transaxle mount bracket to the transaxle.

Caution: Refer to Fastener Caution (Fastener Caution).

2. Install the left transaxle bracket bolts and tighten to 70 Nm (52 lb ft).




3. Install the rear transaxle mount bracket to the transaxle.
4. Install the rear transaxle mount bracket bolts and tighten to 50 Nm (37 lb ft).




5. Install the transaxle into the vehicle and align the engine alignment dowels (1 and 5).
6. Install the transaxle case to engine bolts (1 and 6) and tighten to 75 Nm (55 lb ft).




7. Install the front transaxle to engine brace bolt (1) and tighten to 50 Nm (37 lb ft).




8. Install the right engine to transaxle brace bolts (1) and tighten to 50 Nm (37 lb ft).
9. Connect vehicle speed sensor electrical connector.
10. Remove the transaxle jack





Note:
* Align the mark made on the torque converter with the mark made on the flywheel made in the disassembly unless installing a new converter.
* Tighten all the torque converter to flywheel bolts twice.

11. Install the flywheel to torque converter bolts (1) and tighten to 63 Nm (47 lb ft).
12. Install the torque converter cover. Refer to Torque Converter Cover Replacement (41. Torque Converter Cover Replacement).
13. Install the transaxle fluid filler tube. Refer to Transmission Fluid Filler Tube and Seal Replacement (6. Transmission Fluid Filler Tube and Seal Replacement).
14. Connect the transmission oil cooler hoses to the transaxle. Refer to Transmission Fluid Cooler Hose/Pipe Replacement (34. Transmission Fluid Cooler Hose/Pipe Replacement).

Note: Use care when installing the right side drive axle into the transaxle case. The splined shaft of the drive axle can easily damage the seal.

15. Install the left and the right drive axle into the transaxle. Refer to Wheel Drive Shaft Replacement (Service and Repair).
16. Install the front frame assembly to the vehicle. Refer to Drivetrain and Front Suspension Frame Replacement (Drivetrain and Front Suspension Frame Replacement).
17. Install the left transaxle mount. Refer to Transmission Mount Replacement - Left Side (39. Transmission Mount Replacement - Left Side).




18. Position the brake pressure modulator valve into the bracket.
19. Install the mounting bolt (2) and tighten to 10 Nm (89 lb in).
20. Install the brake line retainers (1) onto the frame.




21. Install the power steering gear mounting bolts and tighten to 75 Nm (55 lb ft).
22. Install the power steering line retainers onto the frame.
23. Install the power steering gear heat shield. Refer to Steering Gear Heat Shield Replacement (Steering Gear Heat Shield Replacement).





Warning

When installing the intermediate shaft make sure that the shaft is seated prior to pinch bolt installation. If the pinch bolt is inserted into the coupling before shaft installation, the two mating shafts may disengage. Disengagement of the two mating shafts will cause loss of steering control which could result in personal injury.

24. Connect the intermediate shaft to the power steering gear.
25. Install the intermediate shaft lower pinch bolt and tighten to 45 Nm (33 lb ft).
26. Install the stabilizer shaft links. Refer to Stabilizer Shaft Link Replacement (Front Suspension).




27. Install the air deflector extension. Refer to Front Air Deflector Replacement (Front Air Deflector Replacement).




28. Install the left front wheelhouse liner (1). Refer to Front Wheelhouse Liner Replacement (Service and Repair).
29. Install the front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (Service and Repair).
30. Lower the vehicle.




31. Install the upper transaxle case to engine bolts (2-5) and tighten to 75 Nm (55 lb ft).
32. Remove the engine support fixture.




33. Install the range selector cable with bracket.
34. Install the range selector cable bracket nuts and tighten to 25 Nm (18 lb ft).
35. Install the range selector cable onto the range selector lever.
36. Check adjustment of the range selector cable. Re-adjust as needed. Refer to Range Selector Lever Cable Adjustment (3. Range Selector Lever Cable Adjustment).




37. Install ground cable and bolt (1) to transaxle and tighten the bolt to 17 Nm (13 lb ft).




38. Connect the transaxle electrical connector C100 (2).
39. Install the wiring harness (3) into the wiring harness retainer (1) on the transaxle.
40. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair).
41. Install the front compartment sight shield. Refer to Front Compartment Sight Shields Replacement (Front Compartment Sight Shields Replacement).
42. Connect the negative battery cable. Refer to Battery Negative Cable Replacement (Battery Negative Cable Replacement).




43. Remove the J 42640 from the steering column.
44. Fill the transaxle to the proper level. Refer to Fluid Capacity Specifications (Capacity Specifications).
45. Inspect the transaxle fluid level. Refer to Transmission Fluid Level and Condition Check (Transmission Fluid Level and Condition Check).
46. Inspect for fluid leaks.
47. Clear transmission adaptive pressures (TAPS). Refer to Transmission Adaptive Functions (Transmission Adaptive Functions).
48. Check the front end alignment.
49. Road test the vehicle and check for transaxle leaks.