Removal and Replacement

REMOVAL
1. Remove the battery and battery carrier then disconnect the main fuse block.
2. Remove the air cleaner assembly then the speed control actuator mounting bolts and nuts.
3. Position speed control actuator aside.
4. Disconnect the vehicle speed sensor or speedometer cable from transaxle.
5. Disconnect transaxle fluid cooling lines from radiator assembly, then cap lines.
6. Disconnect electrical connectors from transaxle, then wiring harness from the routing brackets on the transaxle.
7. Disconnect the shift cable from the transaxle by removing the 21 mm retaining nut.
8. Remove the horseshoe clip from the shift cable and routing bracket, then disconnect the cable from the bracket.
9. Remove the transaxle wiring harness bracket.
10. Remove two ground straps from transaxle assembly.
11. Loosen the transaxle kickdown cable adjusting nuts at the cable bracket then disconnect the cable from the bracket.
12. Disconnect the kickdown cable from the throttle cam.
13. Install Engine support Bar tool No. D88L-6000-A with the necessary support hooks to support the engine and transaxle.
14. Remove all accessible transaxle to engine retaining bolts from the top of the engine compartment.
15. Remove the upper transaxle mounting nuts.
16. Raise and support vehicle, then remove the front wheels.
17. Remove the inner fender splash shields.
18. Drain the transaxle fluid.
19. Remove the stabilizer link assemblies from the lower control arms.
20. Remove lower control arm ball joint to steering knuckle pinch bolts, then separate the ball joints from the steering knuckle by prying downward on the lower control arm while pushing inward on the rotor.
21. Remove the mounting bolts from the righthand halfshaft dynamic damper.
22. Remove the halfshaft from the transaxle by prying with a bar inserted between the shaft and the transaxle case.
23. Install two transaxle plugs tool No. T88C-7025-AH or equivalent into the differential side gears.

CAUTION: Failure to install these plugs will result in the side gears dropping out of position.

24. Remove the starter motor and bracket, then transaxle support bracket.
25. Remove the inspection plate from the transaxle, then torque converter retaining nuts.
26. Position a transmission jack under the support.
27. Remove the transaxle rear lower mount bolts.
28. Remove the transaxle front lower mount through bolt.
29. Remove the lefthand front crossmember and lower control arm assembly.
30. Remove the remaining transaxle to engine bolts.
31. Before the transaxle can be lowered out of the vehicle, the torque converter studs must be clear of the flexplate. Insert a screwdriver between the flexplate and converter, then carefully disengage the studs.
32. Lower the transaxle assembly from the vehicle.

INSTALLATION

NOTE: The following procedure has been revised by a Technical Service Bulletin.
a. A pin is used to hold the throttle valve in a fixed position on new or remanufactured service replacement transaxle assemblies.
b. The pin is used during the assembly process to make installation of the control valve easier. When installing a new or remanufactured 4EAT transaxle, ensure to remove the pin and install a new retaining bolt.

CAUTION: Failure to remove pin from the throttle cam will hold the transaxle throttle lever in a fixed position resulting in a shift concern.

1. Place the transaxle on transmission jack. Ensure transaxle is secure.
2. Raise the transaxle to the proper height, then align the torque converter studs and flexplate holes.
3. Position the transaxle to the engine, then install the transaxle retaining bolts. Torque retaining bolts to 66-86 ft lbs.
4. Install the lefthand front crossmember and lower control arm assembly. Torque the retaining bolts to 27-40 ft lbs, then crossmember retaining nut to 55-69 ft lbs.
5. Install the transaxle front lower mount through bolt, then torque to 66-86 ft lbs.
6. Install the transaxle rear lower mount bolts. Torque retaining bolts to 49-69 ft lbs.
7. Install the torque converter nuts, then torque to 32-45 ft lbs.
8. Install inspection plate, then transaxle support bracket.
9. Install starter motor and bracket.
10. Install new circlips located on the end of each halfshaft.
11. Remove the transaxle plug, then install the halfshafts.
12. Remove the mounting bolts to the righthand halfshaft dynamic damper. Torque retaining bolts to 31-46 ft lbs.
13. Install the lower control arm ball joints in the steering knuckles.
14. Install ball joint pinch bolts, then torque to 27-40 ft lbs.
15. Install the stabilizer link assemblies. Turn the nuts until 1.0 inch of bolt thread can be measured from the upper nut. When this length is reached, secure the upper nut with lower nut until a torque of 12-17 ft lbs is reached.
16. Install the righthand inner fender splash guard. Installation of the lefthand splash guard will be done after the kickdown cable has been adjusted.
17. Install the front wheels, then torque wheel lug nuts to 65-88 ft lbs.
18. Lower the Vehicle.
19. Install the transaxle upper mount nuts. Torque retaining nuts to 47-66 ft lbs.
20. Install remaining transaxle to engine retaining bolts. Torque bolts to 66-86 ft lbs.
21. Remove the engine support bar.
22. Connect the transaxle kickdown cable to the throttle cam.
23. Connect the kickdown cable to the cable bracket, then tighten the adjusting nuts.
24. Connect the two ground straps to the transaxle.
25. Install the transaxle wiring harness bracket.
26. connect the shift cable to its routing bracket, then install the horseshoe clip.
27. Connect the shift cable to the transaxle, then install retaining nut.

CAUTION: Do not use any type of power wrench to tighten the retaining nut. Damage to the transaxle will result.

28. Connect the 4EAT electrical connectors, then connect the wiring harness routing brackets to the transaxle.
29. Install transaxle cooling lines to the radiator assembly.
30. connect the vehicle speed sensor or speedometer cable to the transaxle assembly.
31. Install the speed control actuator, then air cleaner assembly.
32. Connect the main fuse block then install the battery tray and battery.
33. Add the manufacturer recommended transaxle fluid, then check for fluid leakage.
34. Adjust the kickdown cable.