Tools Required

J 36850 Transjel

1. Remove the battery box. Refer to Battery Box Replacement in Engine Electrical.
2. Disconnect the air duct hose from the intake plenum. Refer to Air Cleaner Inlet Duct Replacement in Engine Controls 2.2 L (L61)



3. Disconnect the shift control cable (3) from the range select lever (4).
4. Release the shift control cable retaining clip (2) and remove the cable from the shift control cable bracket (1).



5. Remove the shift cable bracket bolt (3), nut (1), and bracket (2).
6. Remove the PNP switch. Refer to Park/Neutral Position Switch Replacement .
7. Remove the engine support fixture. Refer to Engine Support Fixture in Engine Mechanical 2.2 L (L61).
8. Tie the radiator, air conditioning condenser, and fan module assembly to the upper radiator support to keep the assembly with the vehicle when the frame is lowered.
9. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
10. Remove the left front tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
11. Remove the left front splash shield. Refer to Engine Splash Shield Replacement in Body Front End.
12. Separate the left ball joint from the steering knuckle. Refer to Lower Control Arm Ball Joint Replacement in Front Suspension.
13. Disconnect the left tie rod from the steering knuckle. Refer to Rack and Pinion Outer Tie Rod End Replacement in Power Steering System.
14. Disconnect the left stabilizer shaft link from the stabilizer shaft. Refer to Stabilizer Shaft Link Replacement in Suspension-Front Suspension.
15. Remove the left wheel drive shaft from the transmission. Refer to Front Wheel Drive Shaft Replacement in Wheel Drive Shafts.
16. Remove the power steering gear intermediate shaft pinch bolt. Refer to Intermediate Steering Shaft Replacement in Steering Wheel and Column.
17. Remove the front transmission mount. Refer to Transmission Front Mount Replacement .



18. Remove the rear transmission mount to frame bolts.
19. Remove the frame bolts and lower the frame allowing the frame to hang from the right side suspension components. Refer to Frame Replacement in Frame and Underbody.
20. Lower the vehicle.
21. Remove the left transmission mount. Refer to Transmission Mount Replacement - Left Side in Transmission/Transaxle.
22. Lower the engine and transmission with the engine support fixture until the transmission side cover will clear the inner fender.
23. Raise the vehicle.



24. Remove the transmission side cover bolts (3) and studs (4).
25. Separate the case side cover (1) from the transmission case at the dowel pin locations (45) to prevent damage to the sealing surfaces.
26. Remove the transmission side cover (1).
27. Remove the two side cover gaskets (5 and 6) if they do not remain with the side cover.
28. Remove the thrust washer (7) if it does not remain with the side cover.




Notice: Do not damage the case bore when removing the axle seal.

29. Remove the side cover axle seal (2). Use the handle end of a hammer.
30. Remove the sleeve from the output axle shaft. Refer to Front Wheel Drive Shaft Seal and Output Shaft Sleeve Replacement - Left Side .

1. Inspect the side cover for cracks or damage to the seal grooves and mounting bosses.
2. Inspect the side cover seals for damage. The side cover seals are reusable if not damaged.
3. Thoroughly clean the side cover and the side cover seals.
4. Clean and dry the seal grooves and the axle seal bore.
5. Install the side cover gaskets (5 and 6) into the grooves on the side cover (1).
6. Retain the seals with J 36850 or equivalent.
7. Install the side cover to drive sprocket thrust washer (7) onto the side cover.
8. Retain the thrust washer with J 36850 or equivalent.



9. Install the transmission side cover (1) to the transmission case.

Notice: Refer to Fastener Notice in the Preface section.

10. Install the transmission side cover bolts (3) and studs (4).

Tighten
Tighten the bolts and studs to 28 N·m (22 lb ft).

11. Install the output axle seal and sleeve. Refer to Front Wheel Drive Shaft Seal and Output Shaft Sleeve Replacement - Left Side .
12. Lower the vehicle.
13. Raise the engine and transmission with the engine support fixture.
14. Install the transmission mount. Refer to Transmission Mount Replacement - Left Side in Transmission/Transaxle.
15. Raise the vehicle.
16. Install the frame bolts. Refer to Frame Replacement in Frame and Underbody.



17. Install the rear transmission mount to frame bolts.

Tighten
Tighten the bolts to 50 N·m (37 lb ft).

18. Install the front transmission mount. Refer to Transmission Front Mount Replacement .
19. Install the power steering gear intermediate shaft pinch bolt. Refer to Intermediate Steering Shaft Replacement in Steering Wheel and Column.
20. Install the left wheel drive shaft to the transmission. Refer to Front Wheel Drive Shaft Replacement in Wheel Drive Shafts.
21. Connect the left ball joint to the steering knuckle. Refer to Lower Control Arm Ball Joint Replacement in Front Suspension.
22. Connect the left tie rod to the steering knuckle. Refer to Rack and Pinion Outer Tie Rod End Replacement in Power Steering System.
23. Connect the left stabilizer shaft link to the stabilizer shaft. Refer to Stabilizer Shaft Link Replacement in Suspension-Front Suspension.
24. Install the left front splash shield. Refer to Engine Splash Shield Replacement in Body Front End.
25. Install the left front tire and wheel. Refer to Front Wheel Drive Shaft Replacement in Wheel Drive Shafts.
26. Lower the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
27. Untie the radiator, air conditioning condenser, and fan module assembly.
28. Remove the engine support fixture. Refer to Engine Support Fixture in Engine Mechanical 2.2 L (L61).
29. Install the PNP switch. Refer to Park/Neutral Position Switch Replacement .



30. Install the shift cable bracket  (2), bolt (3), and nut (1).

Tighten
Tighten the bolt (3) and nut (1) to 22 N·m (16 lb ft).




31. Install the shift control cable to the shift control cable bracket (1). Ensure the cable retaining clip (2) is fully seated.
32. Connect the shift control cable (3) to the range select lever (4).
33. Connect the air duct hose to the intake plenum. Refer to Air Cleaner Inlet Duct Replacement in Engine Controls 2.2 L (L61)
34. Install the battery box. Refer to Battery Box Replacement in Engine Electrical.
35. Fill the transmission. Refer to Approximate Fluid Capacities in Maintenance and Lubrication.