Automatic Transmission/Transaxle: Service and Repair
NOTE:^ Removal, refer to steps 1 through 88
^ Installation, refer to steps 89 through 170
1. Position vehicle on "4-post" ramp.
2. Select LOW range gear and leave vehicle in neutral.
3. Disconnect battery negative lead.
4. Drain gearbox oil.
5. Drain transfer gearbox oil.
6. Remove center console.
7. Remove carpet from transmission tunnel.
8. Remove hi-low selector housing cover from tunnel.
9. Working through hi-low gear lever aperture, disconnect inhibitor/reverse light switch multiplug.
10. Remove 2 cable ties securing gearbox and transfer box breather pipes to harness.
11. Remove 3 trim studs securing hand brake boot.
12. Release hand brake boot to access cable linkage.
13. Remove split pin and clevis pin securing hand brake cable to lever.
14. Remove 2 screws securing fan cowl to upper retaining brackets.
15. Release 2 clips securing upper fan cowl.
16. Remove upper fan cowl.
17. Remove kick-down cable clevis pin.
18. Release kick-down outer cable lock nut.
19. Release kick-down outer cable from abutment bracket.
20. Release kick-down outer cable from clip on rear of LH cylinder head.
21. Remove bolt securing 2 breather pipe P-clips to rear of RH cylinder head.
22. Remove 6 bell housing to engine bolts.
23. Raise vehicle.
24. Remove exhaust front pipe.
25. Remove 2 nuts securing intermediate pipe to tail pipe.
26. Release intermediate pipe from tail pipe and remove from mounting.
27. Remove 8 bolts securing chassis crossmember.
28. With assistance, and using a body jack between chassis rails, jack chassis sufficiently to enable removal of crossmember.
29. Remove crossmember.
30. Remove body jack.
31. Remove bolt securing LH and RH catalyst heat shields to chassis.
32. Remove catalyst heat shields.
33. Using a center punch, mark relationship between front propeller shaft to transfer box flanges.
34. Using a center punch, mark relationship between rear propeller shaft to brake drum flanges.
35. Remove 4 nuts securing front propeller shaft to transfer box flange.
NOTE: Rotate propeller shaft to gain access to all fixing.
36. Release propeller shaft from transfer box flange bolts and tie aside.
37. Remove 4 nuts securing rear propeller shaft to brake drum flange.
NOTE: Rotate propeller shaft to gain access to all fixing.
38. Release propeller shaft from brake drum bolts and tie aside.
39. Remove 7 bolts securing bell housing closing plate and remove plate.
40. Remove 3 bolts securing bell housing access plate and remove plate.
41. Mark relationship between converter and drive plate.
42. Rotate crankshaft to access drive plate to converter fixing.
43. Remove 4 bolts securing drive plate to converter.
44. Install suitable piece of wood through bell housing access hole to retain converter.
45. Remove clamp bolt securing gearbox cooler pipes to engine oil pan bracket.
46. Loosen gearbox cooler pipe unions and disconnect from gearbox.
47. Remove and discard O-rings from pipes.
CAUTION: Plug the connections.
48. Tie cooler pipes aside.
49. Loosen gearbox filler tube union and remove from fluid pan.
50. Remove and discard O-ring from union.
CAUTION: Plug the connections.
51. Remove split pin from selector cable yoke and collect washer.
52. Release yoke from lever.
53. Remove bolt securing selector outer cable clamp to transfer box LH mounting.
54. Remove nut securing oxygen sensor multiplug bracket from transfer box earth bolt and collect bracket.
55. Remove nut securing earth strap to transfer box and release strap.
56. Release hand brake outer cable from body.
Ground Wire To Transfere Box:
57. Remove bolt securing earth lead to RH side of transfer box.
58. Install transmission cradle LRT-99-008A to transmission jack.
59. Install and tighten bolts securing cradle to jack.
60. Remove 2 lower bolts securing transfer box rear cover.
61. Collect hand brake cable heat shield.
62. Raise jack and align cradle to transmission.
63. Install previously removed transfer box rear cover bolts to secure cradle.
64. Remove 2 nuts and bolts securing heat shield to transfer box LH mounting bracket.
65. Remove heat shield.
66. Remove 3 nuts and bolts securing transfer box LH mounting bracket to chassis.
67. Release earth lead from fixing.
68. Remove nut securing transfer box RH mounting.
69. Remove 3 nuts and bolts securing transfer box RH mounting bracket to chassis.
70. Remove transfer box RH mounting bracket and collect flexible mount heat shield.
71. Lower transmission on jack to access harness connectors.
72. Disconnect the following multiplugs/connectors from transfer box: Speed transducer Parking solenoid Neutral detection switch Differential lock Temperature sensor switch
73. Remove 2 cable ties securing harness to transfer box.
74. Position jack to support engine oil pan.
CAUTION: Use a block of wood or hard rubber pad to protect oil pan.
75. Remove 2 remaining bell housing to engine bolts.
76. With assistance, lower transmission and engine jacks until hi-low selector lever is clear of transmission tunnel aperture.
77. Separate transmission from engine and lower on jack.
78. Remove transmission assembly from beneath ramp.
79. Position lifting eyes to transmission and secure with bolts.
80. Install lifting chains to eyes and connect.
81. Position lifting hoist and connect lifting chains.
82. Raise hoist until chains are taught.
83. Remove bolts securing cradle to transfer box.
84. Raise transmission from cradle.
85. Install transfer box rear cover plate bolts.
86. Lower transmission assembly onto work bench.
87. Disconnect lifting chains from eyes.
88. Remove bolts securing eyes to transmission and remove eyes.
INSTALLATION
89. Position lifting eyes to transmission and secure with bolts.
90. Connect lifting chains to eyes.
91. Raise transmission assembly from bench and position above transmission cradle.
92. Remove 2 transfer box rear cover plate bolts.
93. Lower transmission onto cradle, align to transfer box rear cover plate and secure with previously removed bolts.
94. Lower hoist and disconnect lifting chains from eyes.
95. Remove chains from hoist.
96. Remove bolts securing lifting eyes to transmission and remove eyes.
97. Position transmission assembly beneath vehicle.
98. Clean engine to gearbox mating faces.
99. Clean engine to gearbox dowels and dowel holes.
100. With assistance, raise transmission on jack and position to engine dowels.
101. Install 2 lower bell housing to engine bolts and tighten to 45 Nm (33 ft. lbs.).
102. With assistance, raise engine and transmission jacks to position transmission assembly.
NOTE: Do not fully raise transmission at this stage as access is required for connection of connectors to transfer box.
103. Remove engine jack from beneath vehicle.
104. Secure harness to transfer box with cable ties.
105. Connect multiplugs/connectors to transfer box.
106. Raise transmission and align to mounting locations.
107. Install transfer box RH flexible mounting heat shield and mounting bracket.
108. Align RH mounting to chassis and secure with nuts and bolts.
109. Install and tighten nut securing RH mounting.
110. Align LH mounting to chassis and secure with nuts and bolts.
NOTE: Position earth lead to mounting fixing.
111. Position heat shield to LH mounting bracket and secure with fixings.
112. Remove bolts securing transmission cradle to transfer box.
113. Lower transmission jack and remove from beneath ramp.
114. Install and tighten transfer box rear cover bolts.
NOTE: Position heat shield to cover plate fixing.
115. Position earth lead to RH side of transfer box and secure with bolt.
116. Feed hand brake outer cable through body.
NOTE: Apply a soap solution to aid installation of cable to body.
117. Position earth strap to transfer box stud and secure with nut.
118. Install oxygen sensor multiplug bracket to transfer box earth bolt and secure with nut.
119. Position selector outer cable clamp to transfer box LH mounting and secure with bolt.
120. Position selector cable yoke to lever, install washer and secure with split pin.
121. Remove plug from transmission filler tube union.
122. Lubricate new O-ring with gearbox oil and install to filler tube.
123. Install filler tube to gearbox and tighten union.
124. Release cooler pipes and remove plugs from connections.
125. Lubricate new O-rings with gearbox oil and install to pipes.
126. Position cooler pipes to gearbox and tighten unions.
127. Position cooler pipes to engine oil pan bracket, install clamp and secure with bolt.
128. Remove piece of wood from bell housing access hole.
129. Align converter to drive plate.
130. Install bolts securing converser to drive plate and tighten to 45 Nm (33 ft. lbs.).
NOTE: Rotate crankshaft during the above procedure.
131. Install bell housing access plate and secure with bolts tightened to 9 Nm (84 inch lbs.).
132. Clean bell housing cover plate and mating face.
133. Install plate and secure with bolts tightened to 9 Nm (84 inch lbs.).
134. Clean rear propeller shaft to brake drum mating faces.
135. Release rear propeller shaft, align flange markings and connect to studs.
136. Install nuts securing rear propeller shaft to brake drum and tighten to 47 Nm (35 ft. lbs.).
NOTE: Rotate propeller shaft to gain access to all fixings.
137. Clean front propeller shaft to transfer box mating faces.
138. Release front propeller shaft, align flange markings and connect to studs.
139. Install nuts securing front propeller shaft to transfer box and tighten to 47 Nm (35 ft. lbs.).
NOTE: Rotate propeller shaft to gain access to all fixings.
140. With assistance and using a body jack between chassis rails, jack chassis sufficiently to enable installation of crossmember.
141. Install crossmember and align fixings.
142. Remove body jack.
143. Install nuts and bolts securing chassis crossmember, but do not tighten.
144. Install LH and RH catalyst heat shields to chassis, install bolts but do not tighten.
145. Align LH and RH catalyst heat shields to chassis crossmember fixings and tighten all fixings.
146. Clean intermediate to tail pipe flange.
147. Install intermediate pipe to mounting rubber, connect to tail pipe and secure with nuts.
148. Install exhaust front pipe.
149. Lower vehicle.
150. Install bolts securing bell housing to engine and tighten to 46 Nm (34 ft. lbs.).
NOTE: Align harness brackets to 2 uppermost bell housing retaining bolts.
151. Align breather pipe P-clips to rear of RH cylinder head and secure with bolt.
152. Secure kick-down outer cable to clip on rear of LH cylinder head.
153. Secure kick-down outer cable to abutment bracket.
154. Secure kick-down outer cable lock nut.
155. Align kick-down cable to linkage and secure clevis pin.
156. Adjust kick-down cable.
157. Install upper fan cowl and secure with clips.
158. Align fan cowl to upper retaining brackets and secure with screws.
159. Align hand brake cable to lever, install clevis pin and secure with split pin.
160. Position hand brake boot and secure with trim studs.
161. Secure gearbox and transfer box breather pipes to harness with cable ties.
162. Connect inhibitor/reverse light switch multiplug.
163. Install hi-low selector housing cover to tunnel.
164. Install carpet to transmission tunnel.
165. Install center console.
166. Refill transfer gearbox oil.
167. Refill gearbox oil.
168. Reconnect battery negative lead.
169. Select Hi range gear and park.
170. Remove vehicle from ramp.