Installation

INSTALLATION





1. Install transaxle into position. Install two (2) transaxle-to-engine lower bolts and torque to 95 Nm (70 ft. lbs.).
2. Remove transmission jack.
3. Lower vehicle.
4. Raise engine/transaxle assembly into position with overhead fixture.
5. Install and torque four transaxle-to-engine upper bolts and torque to 95 Nm (70 ft. lbs.).
6. Raise vehicle.
7. Install four torque converter-to-driveplate bolts and torque to 88 Nm (65 ft. lbs.)
8. Install torque converter dust shield.




9. Loosely assemble engine-to-transmission collar.
10. Install the PTU (if equipped) Installation.
11. Install the propeller shaft (if equipped) Propeller Shaft - Installation.




12. Install starter motor and shim.Starter Motor - Installation.
13. Install starter motor electrical connectors.




14. Install engine front mount/bracket assembly and torque to 67 Nm (50 ft. lbs.).




15. Install cradle and fixture into position under vehicle.
16. Slowly lower vehicle. Have helper guide power steering and brake hydraulic lines into position, while aligning cradle to body. While lowering vehicle, align engine front and rear mount studs to their respective thru-holes in cradle.
17. Aligning index/scribe mark placed upon disassembly, Install four cradle-to-body bolts and torque to 162 Nm (120 ft. lbs.).
18. Verify that power steering and brake hydraulic lines can be properly routed and installed.
19. Remove overhead powertrain support fixture from engine compartment:
a. Remove rear support/lift bracket and connect coolant temperature sensor.
b. Remove front support/lift bracket. Install and torque engine oil dipstick fastener.
20. Raise vehicle on hoist and remove driveline support table.
21. Install and torque engine front and rear mount-to-cradle nuts to 54 Nm (40 ft. lbs.).




22. Install steering shaft (1) to (3) gear.




23. Using Installer 6831A, install steering shaft-to-gear coupler (3).




24. Connect power steering hoses to steering gear. Torque fittings to 31 Nm (23 ft. lbs.).




25. Install power steering cooler and fasten to cradle.




26. Fasten steering hose routing clip to cradle.




27. Install torque strut and torque (1) nuts to 54 Nm (40 ft. lbs.).
28. Install halfshaft assemblies Half Shaft - Installation.
29. Install sway bar links to strut attaching points. Torque link-to-strut nuts to 88 Nm (65 ft. lbs.).




30. Install ABS sensor brackets to struts.




31. Connect ABS sensors.




32. Install both front tire/wheel assemblies.
33. Connect front brake lines to hydraulic control unit.




34. Install coolant bypass tube fasteners.
35. Connect solenoid/pressure switch connector (5), Torque screw to 4 Nm (35 in. lbs.).
36. Connect transaxle range sensor connector (1).
37. Connect input speed sensor connector (4).
38. Connect VLP connector (2).
39. Connect output speed sensor connector (3).




40. Secure transaxle harness with respective retainers.




41. Install and connect crankshaft position sensor.




42. Install ground cable to case and torque bolt.
43. Connect oil cooler lines to transaxle. An audible 'click' should be heard. Verify connection by pulling outward.
44. Connect gearshift cable to transaxle manual valve lever. Verify adjustment.
45. Install battery tray. Connect battery temperature sensor.




46. Install battery.
47. Install battery hold-down clamp.
48. Connect battery cables.
49. Bleed brake hydraulic system. REFER TO Brake Bleeding.
50. Add power steering fluid as required.
51. Check and adjust transaxle fluid level. REFER TO Fluid Level and Condition Check - 40/41TE
52. AWD models: Check and adjust PTU fluid level.
53. Align front end. REFER TO Service and Repair.