SMU - Revised Transmission Replacement Procedure and Fastener Tightening Specifications

This bulletin is being issued to revise the Transmission Replacement Procedure and Fastener Tightening Specifications in the Automatic Transmission sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information.

The following information has been updated within SI2000. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page.

Tools Required

J 42640 Steering Column Anti-Rotation Pin

Notice:  The front wheels of the vehicle must be maintained in the straight ahead position and the steering column must be in the LOCK position before disconnecting the steering column or intermediate shaft. Failure to follow these procedures will cause improper alignment of some components during installing and result in damage to the SIR coil assembly.

1. Turn the steering wheel so that the front wheels are pointing straight ahead.
2. Turn the ignition lock cylinder to the lock position and remove the key.
3. Lock the steering column through the access hole in the lower steering column trim cover using J 42640.
4. Remove the exhaust system. Refer to Exhaust System Replacement in Engine Exhaust.
5. Remove the catalytic converter hanger bracket. Refer to Catalytic Converter Hanger Bracket Replacement.
6. Remove the oxygen sensor from bank 1 sensor 2. Refer to Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 2 in Engine Controls - 2.6L and 3.2L.
7. Remove the oxygen sensor from bank 2 sensor 2. Refer to Heated Oxygen Sensor (HO2S) Replacement Bank 2 Sensor 2 in Engine Controls - 2.6L and 3.2L.



8. Disconnect the propeller shaft coupler (1) from the transmission flange. Refer to Propeller Shaft Replacement in Driveline/Axle.
9. Push the front propeller shaft toward the rear of the vehicle in order to release the propeller shaft coupler (1) from the transmission flange.



10. Disconnect the vehicle speed sensor electrical connector.



11. Disconnect the backup lamp electrical connector (2) from the backup lamp switch (1).



12. Remove the clutch hydraulic hose retaining clip (1) from the clutch slave cylinder.
13. Disconnect the clutch hydraulic hose (2) from the clutch slave cylinder. It is not necessary to plug the lower hose end or slave cylinder fitting as they are equipped with check valves. Only minimal fluid loss may be experienced.
14. Support and secure the transmission with a suitable transmission jack.
15. Remove the transmission mount. Refer to Transmission Mount Replacement.



16. Remove the shift control rod pin and reaction arm pin retaining clips (1).
17. Lower the rear of the transmission only enough to allow removal of the shift control rod pin and reaction arm pin.
18. Remove the reaction arm retaining pin (5) and disconnect the reaction arm (4) from the transmission.
19. Remove the shift control rod pin (3) and disconnect the shift control rod (2) from the transmission.



20. Remove the steering gear intermediate shaft retaining bolt.
21. Disconnect the intermediate shaft from the power steering gear.



22. Support the rear of the frame (1) with an adjustable jack stand.
23. Remove the 2 rear frame mounting bolts (2).
24. Loosen the 2 front frame mounting bolts (2).
25. Lower the jack stand and rear of the frame 38 mm (1.5 in).



26. Lower the transmission jack only enough to gain access to the top transmission bolts and engine wiring harness retaining clips (1).
27. Disconnect the engine wiring harness retaining clips (1) from the transmission mounting bolts.



28. Remove the upper transmission mounting bolts (1-3).
29. Remove the lower transmission mounting bolt (4).



30. Remove the lower transmission mounting bolts (3-4).
31. Pull the transmission free from the engine dowels (1).
32. Swing the rear of the transmission to the right side of the vehicle in order to gain additional clearance between the clutch pressure plate and the transmission input shaft.

Important: Ensure clearance is maintained between the transmission and the following:

•	The clutch assembly

•	The input shaft

•	The catalytic converters

•	The wiring harnesses

•	The propeller shaft

33. Using the transmission jack, carefully lower the transmission from the vehicle.

Important: Ensure clearance is maintained between the transmission and the following:

•	The clutch assembly

•	The input shaft

•	The catalytic converters

•	The wiring harnesses

•	The propeller shaft

1. Using the transmission jack, carefully raise the transmission to the vehicle.



2. Align the engine dowels (1) with the transmission.

Notice: Refer to Fastener Notice in Cautions and Notices.

3. Install the transmission mounting bolts (2-3).

Tighten
Tighten the transmission mounting bolts (2-3) to 75 N·m (55 lb ft).

4. Install the transmission mounting bolt (4).

Tighten
Tighten the transmission mounting bolt (4) to 50 N·m (37 lb ft).




5. Install the remaining transmission mounting bolts (1-2, 4).

Tighten
Tighten the transmission mounting bolts (1-2, 4) to 75 N·m (55 lb ft).




6. Connect the engine wiring harness retaining clips (1) to the transmission mounting bolts.



7. Raise the jack stand supporting the frame (1).
8. Install the 2 rear frame mounting bolts (2).

Tighten
Tighten all 4 frame bolts (2) to 191 N·m (141 lb ft).

9. Remove the jack stand supporting the frame.



10. Connect the intermediate shaft to the steering gear.
11. Install the power steering gear intermediate shaft retaining bolt.

Tighten
Tighten the bolt to 48 N·m (35 lb ft).




12. Connect the shift control rod (2) to the transmission and install the shift control rod pin (3).
13. Connect the reaction arm (4) to the transmission and install the reaction arm pin (5).
14. Install the shift control rod pin and reaction arm pin retaining clips (1).
15. Install the transmission mount. Refer to Transmission Mount Replacement.
16. Remove the transmission jack.



17. Install the clutch hydraulic hose retaining clip (1) to the clutch slave cylinder.

Important: Ensure the clutch hydraulic hose is routed in an upward direction above the clutch slave cylinder with no sharp bends, kinks, or downward loops. Ensure the clutch hydraulic hose does not come in contact with any sharp or potentially hot surfaces.

18. Install the clutch hydraulic hose to the vehicle.
19. Align the clutch hydraulic hose locating tab with the notch in the slave cylinder hose fitting.
20. Push the clutch hydraulic hose (2) into the clutch slave cylinder until a "click" is heard.
21. Tug gently on the clutch hydraulic hose (2) to ensure proper retention to the clutch slave cylinder.



22. Install the propeller shaft coupler (1) to the transmission flange. Refer to Propeller Shaft Replacement in Driveline/Axle.
23. Install the catalytic converter hanger bracket. Refer to Catalytic Converter Hanger Bracket Replacement.
24. Install the oxygen sensor to bank 1 sensor 2. Refer to Heated Oxygen Sensor (HO2S) Replacement Bank 1 Sensor 2 in Engine Controls - 2.6L and 3.2L.
25. Install the oxygen sensor to bank 2 sensor 2. Refer to Heated Oxygen Sensor (HO2S) Replacement Bank 2 Sensor 2 in Engine Controls - 2.6L and 3.2L.
26. Install the exhaust system. Refer to Exhaust System Replacement in Engine Exhaust.



27. Connect the vehicle speed sensor electrical connector.



28. Connect the backup lamp electrical connector (2) to the backup lamp switch (1).
29. Inspect the transmission fluid level. Refer to Transmission Fluid Level.
30. Lower the vehicle.



31. Unlock the steering column by removing the J 42640 from the steering column lower trim cover access hole.
32. Bleed the clutch hydraulic system. Refer to Hydraulic Clutch Bleeding.

Complete the following procedure after the transmission is installed in the vehicle:

1. With the ignition OFF or disconnected and clutch pedal depressed, crank the engine several times. Listen for any unusual noises or evidence that any parts are binding.
2. Place transmission in neutral, start the engine and listen for any unusual noises or evidence that any parts are binding.
3. While the engine continues to idle, raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
4. Perform a final inspection for the proper fluid level. Refer to Transmission Fluid Level Inspection.
5. Lower the vehicle.
6. Road test the vehicle.