SMU - Revised Case Side Cover Replacement Procedure

This bulletin is being issued to revise the Case Side Cover Replacement removal and installation procedures for the 4T65-E automatic transmission in the Automatic Transaxle-4T65-E subsection of the Service Manual.

The labor time for the Cover and/or Gasket, Valve Body -- Replace, Labor Operation K6540, has also been revised from 3.4 hours to 2.4 hours.

Tools Required

J 28467-A Engine Support Fixture

Caution: Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical leads must be OFF, unless instructed in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.

1. Disconnect the battery ground (negative) cable.
2. Remove the air cleaner assembly. Refer to the Air Cleaner Assembly Replacement (VIN K) or Air Cleaner Assembly Replacement (VIN 1) in the Engine Controls subsection of the Service Manual.
3. Disconnect the canister purge tube at the evaporator service valve.
4. Disconnect the shift cable from the transmission shift lever.
5. Remove the shift cable bracket bolts and position the bracket and the cable to one side.
6. Remove the throttle and cruise cables from the clip on the strut tower.
7. Disconnect the transmission electrical connector.
8. Disconnect the Park/Neutral Position switch electrical connector.
9. Install the engine support fixture J 28467-A.
10. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information subsection of the Service Manual.
11. Remove the left front tire/wheel assembly. Refer to the Tire and Wheel Removal and Installation in the Tires and Wheels subsection of the Service Manual.
12. Remove the left and right engine splash shields. Refer to the Splash Shield Replacement - Engine in the Body Front End subsection of the Service Manual.
13. Remove the air deflector. Refer to the Air Deflector Replacement - Front in the Body Front End subsection of the Service Manual.
14. Remove the pinch bolt at the intermediate steering shaft. Refer to the Intermediate Steering Shaft Replacement in the Steering Wheel and Column subsection of the Service Manual.
15. Separate the steering shaft from the gear.
16. Remove the rubber exhaust hangers at the intermediate pipe.
17. Remove the nut from the left tie rod end and separate the tie rod from the spindle. Refer to the Tie Rod End Replacement - Outer - Off Vehicle in the Suspension Section of the Service Manual.
18. Remove the left lower ball joint from the left steering knuckle. Refer to the Lower Ball Joint Replacement in the Front Suspension subsection of the Service Manual.
19. Remove the left stabilizer shaft link from the lower control arm. Refer to the Stabilizer Shaft Link Replacement in the Front Suspension subsection of the Service Manual.
20. Disconnect the wheel speed sensor harness connector.
21. Disconnect the left drive axle from the transaxle. Refer to the Wheel Drive Shafts Replacement in the Drive Axle subsection of the Service Manual.
22. Support the drive axle.
23. Remove the transmission line retainer at the trans mount.
24. Remove the transmission lines at the transmission.
25. Support the right side of the engine frame with jackstands.
26. Support the left side of the engine frame with jackstands.
27. Remove the three nuts from the rear transmission mount. Separate the transmission mount from the engine frame so that the mount stays with the transmission.
28. Remove the three nuts from the front transmission mount. Separate the mount from the engine frame so that the mount stays with the transmission.
29. Remove the left engine frame bolts.
30. Loosen the right engine frames bolts.
31. Adjust the jackstand to the lower left side of the engine frame using the J 28467-A.
32. Position a drain pan under the transaxle.



33. Remove the case side cover bolts (56-58).



34. Remove the case side cover pan (53).
35. Remove the case side cover gasket (54).
36. Remove the case side cover inner gasket (59).
37. Inspect the case side cover (53) for the following conditions:

•	Damaged or porous gasket sealing surfaces

•	Damaged or porous casting surfaces

•	Damaged or stripped bolt holes

38. Inspect the case side cover gasket (54) and case side cover inner gasket (59) for damage. The gaskets are reusable if they are NOT damaged.
39. Clean the case side cover.
40. Clean the case side cover gasket surfaces.

Notice: Proper alignment of the side cover is critical during installation. Improper alignment of the side cover may cause damage to the solenoids or pinch the wiring harness.

1. Install the case side cover inner gasket (59).
2. Install the case side cover gasket (54).
3. Install the case side cover pan (53).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.




4. Install the case side cover bolts.

Tighten
Tighten the case side cover bolts (56-58) to 25 N·m (18 lb ft).

5. Remove the drain pan from under the transaxle.
6. Install the wiring harness connector.
7. Adjust the jackstand to raise the left side of the engine frame.
8. Install the engine frame bolts. Refer to the Frame Removal in the Frame and Underbody subsection of the Service Manual for tightening sequence and specifications.
9. Install the rear transaxle mount fasteners. Refer to the Automatic Transaxle--4T65-E subsection of the Service Manual.
10. Install the front transaxle mount bracket fasteners. Refer to the Automatic Transaxle--4T65-E subsection of the Service Manual.
11. Remove the jackstand support from the right side of the engine frame.
12. Remove the jackstand support from the left side of the engine frame.
13. Install the transmission lines to transmission.
14. Install the transmission lines to the retainer at the mount.
15. Install the rubber exhaust hangers at the intermediate pipe.
16. Install the intermediate shaft to the steering gear. Refer to the Intermediate Steering Shaft Replacement in the Steering Wheel and Column On-Vehicle Service subsection of the Service Manual.
17. Install the pinch bolt at the intermediate steering shaft. Refer to the Intermediate Steering Shaft Replacement in the Steering Wheel and Column On-Vehicle Service subsection of the Service Manual.
18. Install the left drive axle to the transaxle. Refer to the Wheel Drive Shafts Replacement in the Drive Axle subsection of the Service Manual.
19. Install the left lower ball joint to the left steering knuckle. Refer to the Lower Ball Joint Replacement in the Front Suspension subsection of the Service Manual.
20. Install the wheel speed sensor harness connector.
21. Install the left tie rod end to the steering knuckle. Refer to the Tie Rod End Replacement - Outer - Off Vehicle in the Front Suspension subsection of the Service Manual.
22. Install the stabilizer shaft link to the lower control arm. Refer to the Stabilizer Shaft Link Replacement in the Front Suspension subsection of the Service Manual.
23. Install the left and right engine splash shields. Refer to the Splash Shield Replacement - Engine in Body Front End subsection of the Service Manual.
24. Install the air deflector. Refer to the Air Deflector Replacement - Front in the Body Front End subsection of the Service Manual.
25. Install the left front wheel. Refer to the Tire and Wheel Removal and Installation in the Tires and Wheels subsection of the Service Manual.
26. Lower the vehicle.
27. Remove the engine support fixture.
28. Install the throttle and cruise cables to the clip on the strut tower.
29. Connect the transmission electrical connector to the transmission.
30. Connect Park/Neutral Position switch electrical connector.
31. Install the shift cable bracket. Refer to the Automatic Transaxle--4T65-E subsection of the Service Manual.
32. Connect the shift cable to the transmission shift lever.
33. Connect the canister purge tube to the evaporator service valve.
34. Install the air cleaner assembly. Refer to the Air Cleaner Assembly Replacement (VIN K) or Air Cleaner Assembly Replacement (VIN 1) in the Engine Controls subsection of the Service Manual.
35. Connect the battery ground (negative) cable. Refer to the Battery Negative Cable Disconnect/Connect Procedure in the Engine Electrical subsection of the Service Manual.
36. Adjust the fluid level. Refer to the Maintenance and Lubrication subsection of the Service Manual.
37. Inspect for proper completion of the repairs.
38. Inspect for fluid leaks.