- Record all preset radio stations.
Caution: Do not tip the battery over a 45 degree angle or acid could spill causing
serious personal injury.
- Remove the battery.
2.1. | Remove the battery cover. |
2.2. | Disconnect the negative battery cable. |
2.3. | Disconnect the positive battery cable. |
2.4. | Loosen the battery hold-down screw and remove the battery. |
- Remove the battery cooling box. Refer to Battery Cooling Box
Battery Box Replacement
removal procedure in Engine
Electrical.
- Remove the battery tray bracket.
- Use the
J 36346
to disconnect the control cable from
transaxle range switch assembly lever.
- Disconnect the control cable from the control cable bracket.
- Disconnect the transaxle range switch harness connectors.
- Disconnect the input and output speed sensor harness connectors.
- Disconnect the harness from the transaxle range switch stud and the shifter cable bracket.
- Remove the positive battery cable from the transaxle stud.
- Remove the headlamp fasteners and wire the radiator to the radiator core support to hold the radiator in place as the cradle is removed.
- Install the engine support tool.
- Remove the transaxle fluid level indicator assembly.
- Remove the upper left-hand transaxle mount bolts and remove the mount.
Caution: Ensure that the vehicle is properly supported and squarely positioned.
To help avoid personal injury when a vehicle is on a hoist, provide additional support
for the vehicle on the opposite end from which the components are being removed.
- Position the vehicle on a hoist and raise the vehicle.
- Remove both front wheel and tire assemblies.
- Remove the left-side and the right-side inner splash shields.
- Remove the front air deflector-to-cradle pushpins to allow the deflector to flex. The front air deflector does not
need to be removed.
- Drain the transaxle fluid.
- Remove the transaxle cooler line assembly nut from the transaxle.
- Remove the transaxle cooler lines from the transaxle.
Important: Mark the alignment position of the PTU and the drive shaft.
- Disconnect the drive shaft from the power take-off unit - PTU and support the drive shaft. Mark the alignment position of the PTU and the drive shaft.
- Disconnect the lower stabilizer nut from the cradle on both sides of the vehicle.
- Remove the rack and pinion bolts from the cradle.
- Remove the lower control arm ball stud cotter pin and nut.
- Discard the cotter pin.
- Separate the ball stud from the knuckle.
- Use the
SA91100C
to separate the knuckle from the tie rod on both sides of
the vehicle.
- Remove the front pitch restrictor bolts, through-bolt, and the front pitch restrictor.
- Remove the rear pitch restrictor through-bolt from the cradle.
- Position the support table under the cradle.
- Remove the cradle bolts and lower the cradle onto the support table.
- Use the
J 45341
and the
SA9173G
to separate the left axle shaft from the
transaxle and tie the strap out of the way.
Important: Do not damage the
J 45341
.
Important: The stub shaft may disengage from the PTU and separate from the axle. If this occurs, plug the PTU stub shaft hole to prevent fluid loss.
- Use the
J 45341
and the
SA9173G
to separate the right axle shaft from the PTU and tie the strap out of the way.
- Remove the PTU-to-engine bracket bolts and remove bracket.
- Disconnect the starter wiring harness.
- Remove the starter bolts and starter.
- Turn the crankshaft clockwise to gain access to the torque converter-to-flexplate bolts.
- Remove the torque converter-to-flexplate bolts through the starter hole.
- Remove 3 lower transaxle-to-engine bolts.
- Remove 1 engine-to-transaxle bolt located above the PTU.
- Lower the vehicle and secure the transaxle to a transaxle jack or support table for separating the engine and the transaxle.
Important: The torque converter has a long pilot shaft. Do not put an excessive load on the shaft. Do not lower the transaxle until the shaft is clear of the engine crankshaft.
Important: Do not damage the mating surfaces of the engine or the transaxle.
- Separate the transaxle from the engine carefully.
- Lower the transaxle from the vehicle carefully.
- Remove the PTU vent hose.
- Remove the PTU bolts and separate the PTU from the transaxle.
- Remove the stub shaft from the transaxle.
Caution: Ensure that the vehicle is properly supported and squarely positioned.
To help avoid personal injury when a vehicle is on a hoist, provide additional support
for the vehicle on the opposite end from which the components are being removed.
- Position the vehicle on a hoist and raise the vehicle.
- Install new stub shaft retaining rings.
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.
- Install the power take-off unit (PTU) bolts and the PTU unit to the transaxle.
Tighten
Tighten the PTU bolts to 60 N·m(44 lb ft)
- Install stub shaft into transaxle.
- Install PTU vent hose.
- With the transaxle supported, carefully raise the transaxle. It may be helpful to lower the vehicle down around the transaxle.
- Carefully assemble the engine to the transaxle.
- Install the upper and lower transaxle-to-engine bolts.
Tighten
Tighten the transaxle-to-engine (18 mm) bolts to 75 N·m(55 lb ft)
Tighten
Tighten the transaxle-to-engine (15 mm) bolts to 50 N·m(37 lb ft)
- Install the engine-to-transaxle bolt located above the PTU.
Tighten
Tighten the engine-to-transaxle bolt to 75 N·m(55 lb ft)
- Install PTU-to-engine bracket assembly.
Tighten
Tighten the PTU-to-engine bracket bolts to 60 N·m(44 lb ft)
- Install exhaust downpipe.
- Rotate the crank and align the net hole of the flexplate through the starter opening.
- Install the torque converter-to-flexplate bolts through the starter hole.
Tighten
Tighten the converter-to-flexplate bolts to 60 N·m(44 lb ft)
- Install the starter and the starter bolts
Tighten
Tighten the starter bolts to 40 N·m(30 lb ft)
- Install starter wiring harness.
Tighten
Tighten the B+ Cable-to-starter nut to 10 N·m(89 lb in)
Tighten
Tighten the S-terminal nut to 5 N·m(44 lb in)
- Install the right axle shaft to PTU stub shaft.
- Install a new retaining ring on the left axle shaft.
- Install the
SA91112T
inside the left axle seal
Important: Do not damage the left axle seal
- Lubricate the axle with transaxle fluid.
- Carefully install the left axle shaft into the transaxle.
- Remove the
SA91112T
after the splines clear the seal protector, but before the axle shaft is fully installed.
- Push left axle shaft all the way into the transaxle.
- With the cradle on a support table, install the cradle and the cradle fasteners carefully into the vehicle.
Tighten
Tighten the frame-to-body bolts to 155 N·m(114 lb ft)
- Remove the support table.
- Install the rear pitch restrictor through-bolt.
Tighten
Tighten the rear pitch restrictor bolt to 110 N·m(81 lb ft)
- Install the front pitch restrictor bolts, through-bolt and front pitch restrictor.
Tighten
Tighten the Front pitch restrictor bolts to 50 N·m(37 lb ft)
Tighten
Tighten the Front pitch restrictor through-bolts to 110 N·m(81 lb ft)
- Use the
J 44015
to install the knuckle to the outer tie rod.
- Install the outer tie rod-to-knuckle nut.
Tighten
Tighten the rod-to-knuckle nut to 50 N·m(37 lb ft)
- Install the lower control arm ball stud-to-knuckle.
Important: Tighten the nut one additional flat to align cotter pin hole if necessary.
- Install the nut and new cotter pin.
Tighten
Tighten the lower control arm nut to 110 N·m(81 lb ft) plus 150 degrees.
- Install the rack and pinion bolts to the cradle.
Tighten
Tighten the rack and pinion bolts to 110 N·m(81 lb ft)
- Connect the lower stabilizer nut to the cradle on both sides of the vehicle.
Tighten
Tighten the lower stabilizer nut to 65 N·m(48 lb ft)
- Install drive shaft to PTU.
Tighten
Tighten the drive shaft bolts to 25 N·m(18 lb ft)
- If the transaxle being installed is not new, then the transaxle oil cooler line seals must be removed and replaced. Refer to Transaxle Oil Cooler Line Seals removal and installation procedure in this service manual.
- Connect the transaxle cooler lines and the nut to the transaxle.
Tighten
Tighten the transaxle cooler line nut to 7 N·m(62 lb in)
- Install the front air dam deflector-to-cradle pushpins.
- Install the left-side and right-side inner splash shields.
- Install the left-side and right-side wheel and tire assemblies.
Tighten the bolts in a criss-cross pattern.
Tighten
Tighten the wheel nuts to 125 N·m(92 lb ft)
- Lower the vehicle.
- Install the upper left-hand transaxle mount and bolts.
Tighten
Tighten the upper left-hand transaxle mount bolts to 50 N·m(37 lb ft)
- Install the fluid level indicator assembly.
Tighten
Tighten the fluid level indicator bolt to 12 N·m(9 lb ft)
- Remove the engine support tool.
- Remove the tie straps from the radiator.
- Install the positive battery cable to the transaxle stud.
- Install the harness to the transaxle range switch stud and the control cable bracket.
- Connect the input and output speed sensor harness connectors.
- Connect the transaxle range switch harness connectors.
- Connect the control cable to the control cable bracket.
- Connect the control cable to the transaxle range switch assembly lever.
Important: It is recommended that transmission adaptive pressure (TAP) information be reset.
Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The ECM, PCM or TCM will
need to relearn TAP values. Transmission performance may be affected as new TAP values are learned.
- Reset the TAP values. Refer to
Transmission Adaptive Functions
.