Case Cover Replacement

Case Cover Replacement

Removal Procedure

Danger:
Do not use a service jack in locations other than those specified to lift this vehicle. Lifting the vehicle with a jack in those other locations could cause the vehicle to slip off the jack and roll; this could cause injury or death.


1. Place the vehicle on a hoist. Refer to Lifting and Jacking the Vehicle Service and Repair.

Danger:
Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.


The High Voltage Disabling procedure will perform the following tasks:


* Identify how to disable high voltage.


* Identify how to test for the presence of high voltage.


* Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.


Failure to follow the procedures exactly as written may result in serious injury or death.


2. Disable the high voltage system. Refer to High Voltage Disabling High Voltage Disabling.

3. Remove the air cleaner resonator outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement Air Cleaner Resonator Outlet Duct Replacement.

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




5. Remove the three-phase cable fasteners (1) and reposition the cables.

6. Discard the cable housing seals and the cable fastener seals.




7. Disconnect the transmission range selector lever cable terminal (1) from the transmission manual pin.




8. Remove the shift control cable bracket fasteners (1), then the bracket (2) from the transmission, then position the cable out of the way.

9. Secure the steering wheel in order to prevent rotation, inside the passenger compartment, disconnect the intermediate steering shaft from the steering gear. Refer to Intermediate Steering Shaft Replacement Intermediate Steering Shaft Replacement.





Note: DO NOT reuse the bolts. Discard and replace with NEW bolts only.

10. Prior to removing the mount, mark the mount location using a marker for correct positioning during installation.

11. Remove the transmission mount to transmission bolts (1). Discard the bolts.

12. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.

13. Remove the front wheelhouse liners. Refer to Front Wheelhouse Front Liner Replacement .




14. Disconnect drive motor position stator assembly connectors (1).

15. Remove the connector fastener (2).

16. Position the connector (3) to the case cover.

17. Remove tie straps and disconnect left front ABS connector.

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




19. Using the proper size allen wrench, hold the stabilizer shaft link ball stud while removing the left stabilizer shaft nut (1) from the left front stabilizer link. Remove and discard the nut. DO NOT re-use the nut, replace with NEW only.

20. Disconnect the left stabilizer link from the strut assembly.

21. Disconnect the transmission fluid cooler outlet pipe from the transmission. Refer to Transmission Fluid Cooler Outlet Pipe Replacement Transmission Fluid Cooler Outlet Pipe Replacement.

22. Position a suitable jack stand under the transmission.




23. Loosen the right rear cradle retaining bolts (4, 5).

24. Remove the left rear cradle retaining bolt (2).

25. Remove 2 frame reinforcement bolts (1) and the left rear frame reinforcement (3) from the left rear of the frame.




26. Loosen the right front cradle retaining bolt (1).

27. Remove the left front cradle retaining bolt (2).

Note: It may be necessary to lower rear engine support fixture to gain access to the A/Trans case cover bolts.

28. Lower the transmission and cradle assembly far enough to gain access to the A/Trans case cover bolts.





Note: Do not use force on dowel pins to loosen corrosion or damage to the case may occur. Apply penetrating oil to dowel pins (1) to aid in removal of cover.

29. Remove the case cover. Refer to Case Cover Removal Case Cover Removal.

Installation Procedure




1. Install the case cover. Refer to Case Cover Assembly Installation Case Cover Assembly Installation.

2. Raise the transmission and cradle assembly back into position.





Caution: Refer to Fastener Caution Fastener Caution.

Note: It may be necessary to raise the rear engine support fixture to allow the cradle to return to its proper position.

3. Install the left front cradle retaining bolt (2), then tighten to the fastener to 160 Nm (118 lb ft).

4. Tighten the right front cradle retaining bolt (1) to 160 Nm (118 lb ft).




5. Position the left rear frame reinforcement (3) to the left rear of the frame.

6. Install the 2 left rear frame reinforcement bolts (1), then tighten the fasteners to 22 Nm (16 lb ft)

7. Install the left rear cradle retaining bolt (2), then tighten to the fastener to 160 Nm (118 lb ft).

8. Tighten the right rear cradle retaining bolts (5) to 22 Nm (16 lb ft).

9. Tighten the right rear cradle retaining bolt (4) to 160 Nm (118 lb ft).

10. Install the transmission cooler outlet pipe to the transmission. Refer to Transmission Fluid Cooler Outlet Pipe Replacement Transmission Fluid Cooler Outlet Pipe Replacement.




11. Connect the stabilizer link to the strut assembly.

12. Install a new left stabilizer shaft nut (1).

13. Using the proper size allen wrench, hold the stabilizer shaft link ball stud while installing the left stabilizer shaft nut (1) to the left front stabilizer link, then tighten nut to 65 Nm (48 lb ft).

14. Connect left front ABS connector and install tie straps.




15. Connect drive motor position stator assembly connectors (1).

16. Position the connector (3) to the case cover.

17. Install the connector fastener (2).

18. Install the front wheelhouse liners. Refer to Front Wheelhouse Front Liner Replacement .

19. Remove the transmission jack from under the transmission.

20. Lower the vehicle.





Note: DO NOT reuse the bolts, replace with NEW bolts only.

21. Install new transmission mount bolts to transmission. Refer to Transmission Mount Transmission-Side Bracket Replacement Transmission Mount Transmission-Side Bracket Replacement.

22. Remove the engine support fixture.

23. Position the shift control cable to the transmission.




24. Install the shift control cable bracket fasteners (1), then the bracket (2) to the transmission, then tighten the fasteners (1) to 22 Nm (16 lb ft).

25. Connect the intermediate steering shaft to the steering gear. Refer to Intermediate Steering Shaft Replacement Intermediate Steering Shaft Replacement.

26. Unsecure the steering wheel.




27. Connect the transmission range selector lever cable terminal (1) to the transmission manual pin.





Note: Start the three-phase cable fasteners by hand.

28. With NEW connector housing and fastener seals, install the three-phase cables and tighten the fasteners (1) to 9 Nm (80 lb in).

29. Install the air cleaner resonator outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement Air Cleaner Resonator Outlet Duct Replacement.

30. Enable the high voltage system. Refer to High Voltage Enabling High Voltage Enabling.

31. Fill the transmission with transmission fluid. Refer to Transmission Fluid Drain and Fill Transmission Fluid Drain and Fill.