Transmission Replacement

Transmission Replacement

Special Tools

EN-45059 - Angle Meter

For equivalent regional tools, refer to Special Tools Tools and Equipment.

Removal Procedure

1. Remove the battery tray. Refer to Battery Tray Replacement Battery Tray Replacement.

2. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement Service and Repair.




3. Secure the radiator with radiator safety belts (1).

4. Remove the engine sight shield. Refer to Engine Sight Shield Replacement Engine Sight Shield Replacement.

5. Remove the charge air cooler inlet hose. Refer to Charge Air Cooler Inlet Hose Replacement (Turbocharger) Charge Air Cooler Inlet Hose Replacement (Turbocharger)Charge Air Cooler Inlet Hose Replacement (Charge Air Cooler) Charge Air Cooler Inlet Hose Replacement (Charge Air Cooler).




6. Disconnect the neutral position sensor electrical connector (1) from the shift control housing.




7. Disconnect backup lamp switch electrical connector (1).





Note: Before disconnecting the clutch actuator cylinder front pipe, remove the clutch/brake fluid from the reservoir tank. Place basin underneath.

8. Remove the clutch actuator cylinder front pipe retainer (1).

9. Remove the clutch actuator cylinder front pipe (2) from the clutch actuator cylinder pipe elbow.

10. Remove the transmission shift lever cable from transmission. Refer to Manual Transmission Shift Lever and Selector Lever Cable Replacement Manual Transmission Shift Lever and Selector Lever Cable Replacement.




11. Remove the wiring harness starter motor from the transmission. Remove the 4 clips (1).




12. Remove the 2 bracket bolts (2).

13. Remove the upper middle wiring harness starter motor bracket (1).




14. Remove the 2 upper transmission bolts from engine (1).

15. Install the engine support fixture. Refer to Engine Support Fixture Engine Support Fixture.

16. Remove the drivetrain and front suspension frame. Refer to Drivetrain and Front Suspension Frame Replacement Service and Repair.

17. Drain the transmission fluid. Refer to Transmission Fluid Drain and Fill Transmission Fluid Drain and Fill.




18. Remove the transmission front mount from the transmission (2).

19. Remove the 2 bolts (1).




20. Remove the transmission mount bracket - rear from the transmission (2).

21. Remove the 3 bolts (1).

22. Remove the three-way catalytic converter. Refer to Three-Way Catalytic Converter Replacement (2.4L LEA) Three-Way Catalytic Converter ReplacementThree-Way Catalytic Converter Replacement (2.0L LHU) Three-Way Catalytic Converter Replacement.

23. Disconnect the left front wheel drive shaft from the transmission. The left front wheel drive shaft stays in the left wheel hub. Secure the left front wheel drive shaft to the body. Refer to Front Wheel Drive Shaft Replacement - Left Side Front Wheel Drive Shaft Replacement - Left Side.

24. Remove the front wheel drive intermediate shaft. The right front wheel drive shaft stays in the right wheel hub. Secure the right front wheel drive shaft to the body. Refer to Front Wheel Drive Intermediate Shaft Replacement Front Wheel Drive Intermediate Shaft Replacement.

25. Remove the starter. Refer to Starter Replacement (2.4L LEA) Service and RepairStarter Replacement (2.0L LHU) Service and Repair.

26. Lower the vehicle.




27. Remove and DISCARD the transmission left mount bolts (1) from the transmission mount bracket.

28. Lower the engine and the transmission on the left hand side with the engine support fixture.




29. Remove the transmission mount bracket - left side. Remove the 3 transmission mount bracket bolts (1).

30. Raise the vehicle.





Note: Do not remove the front transmission bolt.

31. Remove 4 lower transmission bolts (2) and 2 rear transmission bolts (1).

Caution: Refer to Fastener Caution Fastener Caution.

32. Install the NEW oil drain plug and tighten to 50 Nm (37 lb ft).

33. Support the transmission with a hydraulic jack.




34. Remove the last transmission bolt from the engine (1).

35. Separate the transmission from the engine.

36. Lower the transmission with the hydraulic jack.

Installation Procedure

Warning

Use care when cleaning the clutch hub. The clutch hub may have sharp edges and can cause personal injury if contact is made. Wear protective gloves to avoid personal injury.

1. Clean the hub and the input shaft from any debris and contaminates with a lint free towel.





Caution:
Applying too much or the wrong type of grease on the transmission input shaft may cause damage, clutch slippage or failure. Always apply the correct type of grease. Never apply more grease than is necessary to coat the transmission input shaft with a very thin film of grease.

2. For the approved type of grease, refer to Adhesives, Fluids, Lubricants, and Sealers Fluid Type Specifications.

3. Use a clean flat brush (1) to apply very light coating of grease to input shaft until the metal is only shiny. No visible clumps of grease are permissible regardless of size. Smear away from the transmission in direction of the shown arrow.





Caution:
Ensure that no grease remains on the lead surface of the transmission input shaft. Clean the lead surface of the transmission input shaft prior to the assembly of the transmission to the engine. Failure to maintain a clean surface may cause clutch slippage or failure.

4. Clean the entire lead surface of the input shaft with a NEW lint free towel (1).

5. Raise the transmission with the hydraulic jack.





Caution: Refer to Fastener Caution Fastener Caution.

6. Install the front transmission bolt to the engine (1) and tighten loosely.

7. Remove the hydraulic jack.




8. Install the 4 lower transmission bolts (2) to the engine and tighten to 60 Nm (44 lb ft).

9. Install the 2 rear transmission bolts (1) to the engine and tighten to 60 Nm (44 lb ft).

10. Tighten the front transmission bolt to 60 Nm (44 lb ft).

11. Lower the vehicle.




12. Install the transmission mount bracket - left side. Install the 3 transmission mount bracket bolts (1) and tighten to 100 Nm (74 lb ft).

13. Raise the engine and the transmission on the left hand side with the engine support fixture.




14. Install the 3 NEW transmission mount bolts (1) but do not tighten yet.

15. Raise the vehicle.

16. Install the starter. Refer to Starter Replacement (2.4L LEA) Service and RepairStarter Replacement (2.0L LHU) Service and Repair.

17. Install the front wheel intermediate drive shaft to the transmission. Refer to Front Wheel Drive Intermediate Shaft Replacement Front Wheel Drive Intermediate Shaft Replacement.

18. Install the left front wheel drive shaft to the transmission. Refer to Front Wheel Drive Shaft Replacement - Left Side Front Wheel Drive Shaft Replacement - Left Side.

19. Install the three-way catalytic converter. Refer to Three-Way Catalytic Converter Replacement (2.4L LEA) Three-Way Catalytic Converter ReplacementThree-Way Catalytic Converter Replacement (2.0L LHU) Three-Way Catalytic Converter Replacement.




20. Install the transmission mount bracket - rear (2) and tighten the 3 bolts (1) to 100 Nm (74 lb ft).




21. Install the transmission front mount to transmission (2).

22. Install the 2 transmission front mount bolts (1) and tighten to 100 Nm (74 lb ft).

23. Install the drivetrain and front suspension frame. Refer to Drivetrain and Front Suspension Frame Replacement Service and Repair.

24. Lower the vehicle.

25. Remove the engine support fixture. Refer to Engine Support Fixture Engine Support Fixture.

26. Install the drivetrain and front suspension frame. Refer to Drivetrain and Front Suspension Frame Replacement Service and Repair.





Caution: Refer to Torque-to-Yield Fastener Caution Torque-to-Yield Fastener Caution.

27. Tighten the NEW transmission mount bolts - left side (1) a first pass to 50 Nm (37 lb ft).

28. Tighten the NEW transmission mount bolts - left side (1) a final pass to an additional 60 - 75 degrees.




29. Install the upper transmission to engine bolts (1) and tighten to 60 Nm (44 lb ft).




30. Install the upper middle wiring harness starter motor bracket (1).

31. Install 2 wiring harness starter motor bracket bolts (2) and tighten to 22 Nm (16 lb ft).




32. Install the wiring harness starter motor to the transmission.

33. Install the 4 clips (1).

34. Install the transmission shift lever cable to transmission. Refer to Manual Transmission Shift Lever and Selector Lever Cable Replacement Manual Transmission Shift Lever and Selector Lever Cable Replacement.




35. Connect the clutch actuator cylinder front pipe (2) to the clutch actuator cylinder pipe elbow.

36. Install the clutch actuator cylinder front pipe retainer (1) to the clutch actuator cylinder pipe elbow.




37. Connect the neutral position sensor electrical connector (1) to the shift control housing.




38. Connect the electrical connector (1) to the backup lamp switch.

39. Install the charge air cooler inlet hose. Refer to Charge Air Cooler Inlet Hose Replacement (Turbocharger) Charge Air Cooler Inlet Hose Replacement (Turbocharger)Charge Air Cooler Inlet Hose Replacement (Charge Air Cooler) Charge Air Cooler Inlet Hose Replacement (Charge Air Cooler).

40. Install the engine sight shield. Refer to Engine Sight Shield Replacement Engine Sight Shield Replacement.

41. Adjust the shift lever and selector cable. Refer to Manual Transmission Shift Lever and Selector Lever Cable Adjustment Manual Transmission Shift Lever and Selector Lever Cable Adjustment.

42. Fill up the transmission fluid. Refer to Transmission Fluid Drain and Fill Transmission Fluid Drain and Fill.

43. Bleed the clutch hydraulic system. Refer to Hydraulic Clutch System Bleeding Service and Repair.




44. Remove the radiator safety belts (1).

45. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement Service and Repair.

46. Install the battery tray. Refer to Battery Tray Replacement Battery Tray Replacement.

47. Road test the vehicle.