Transmission

Transmission

WARNING: Before beginning any service procedure, REFER to Safety Warnings . Failure to follow this instruction may result in serious personal injury.

Special Tool(s)






Material(s)






Removal

1. With the vehicle in NEUTRAL, position it on a hoist. REFER to Lifting Points .

2. NOTE: TCM (Transmission Control Module) information does not need to be recovered unless the transmission is replaced or the TCM (Transmission Control Module) is replaced.

Using the scan tool, recover all module information before removing the TCM (Transmission Control Module) or transmission. REFER to Transmission Adaptive Learning .

3. Remove the battery and battery tray. REFER to Battery and Battery Tray - Exploded View .

4. Remove the ACL (Air Cleaner) assembly. REFER to Exploded View .

5. Detach the wiring harness from the battery tray bracket.





6. Remove the selector lever cable bracket nut from the transmission support insulator bracket and remove the selector lever cable bracket from the transmission support insulator bracket.





7. Disconnect the selector lever cable from the manual control lever.





8. Remove the selector lever cable from the radiator hose retainer.





9. Remove the 2 transmission selector lever cable bracket bolts from the transmission and position the bracket aside.





10. Remove the ground wire nut and the ground wire from the transmission.





11. Remove the 4 top clutch housing-to-engine bolts.





12. Detach the transmission vent hose retainer from the crankcase vent tube and position aside.





13. Disconnect the engine harness electrical connector from the TCM (Transmission Control Module).





14. Remove the starter motor. REFER to Starter Motor - 2.0L GDI .

15. Remove the starter isolator.





16. Remove the RH (Right Hand) front wheel and tire. REFER to Wheel and Tire .

17. Remove the drain plug and drain the transmission fluid.





18. Install the drain plug.
- Tighten to 43 Nm (32 lb-ft).

19. Remove the brake hose retainer bolt and the brake hose retainer from the RH (Right Hand) strut.





20. Remove and discard the RH (Right Hand) ball joint bolt and nut.





21. Separate the RH (Right Hand) ball joint from the knuckle.

22. Remove and discard the bearing retainer strap nuts and the bearing retainer strap.





23. Detach the RH (Right Hand) intermediate shaft assembly from the transmission and position aside. Support the RH (Right Hand) intermediate shaft assembly.

24. Remove the LH (Left Hand) halfshaft assembly. REFER to Halfshaft - LH .

25. NOTICE: Rotate the engine in a clockwise direction only or engine damage will occur.

NOTICE: To prevent the flexplate-to-clutch nuts from falling into the clutch housing and causing damage, use a magnetic socket to remove the 6 flexplate-to-clutch nuts.

NOTE: Index mark one clutch stud and the flexplate for installation reference.

Rotate the crankshaft in a clockwise direction to gain access to the flexplate-to-clutch nuts. Remove and discard the 6 flexplate-to-clutch nuts.





26. Remove the wiring harness push pin from the transmission.





27. Remove the roll restrictor bolts.





28. Remove the roll restrictor-to-transmission bracket bolts and the roll restrictor bracket.





29. Remove the cowl panel grille. REFER to Cowl Panel Grille .

30. Install 303-F072 , and support the engine.





31. Remove the 4 transmission support insulator nuts, the transmission support insulator bolt and remove the transmission support insulator.





32. Remove the transmission support insulator bracket bolts and the transmission support insulator bracket from the transmission.

33. Using 303-F072 , lower the transmission.





34. Remove the 2 rear lower clutch housing-to-engine bolts.





35. NOTICE: Use caution not to damage the transmission wiring harness or sensors.

Position a high-lift transmission jack under the transmission and secure the transmission.





36. Remove the 4 lower clutch housing-to-engine bolts.





37. Remove the transmission.





Installation

1. NOTICE: If installing the existing transmission, the halfshaft seals must be replaced or damage to the transmission can occur.

Remove and discard the LH halfshaft seal.





2. Install the LH halfshaft seal onto 307-677 and 205-153 (T80T-4000-W).





3. Using 307-677 and 205-153 (T80T-4000-W) , install the LH halfshaft seal.





4. Remove and discard the RH (Right Hand) halfshaft seal.





5. Install the RH halfshaft seal onto 307-677 and 205-153 (T80T-4000-W).





6. Using 307-677 and 205-153 (T80T-4000-W) , install the RH halfshaft seal.





7. If using a new clutch assembly, make sure the clutch-to-flexplate alignment marks are aligned.





8. NOTICE: Use caution not to damage the transmission wiring harness or sensors.

NOTE: If using the existing clutch assembly, align the index marks on the flexplate and the clutch stud made during removal.

Install the transmission.





9. Install the 4 lower clutch housing-to-engine bolts.
- Tighten to 48 Nm (35 lb-ft).





10. NOTICE: Rotate the engine in a clockwise direction only or engine damage will occur.

NOTICE: Tighten the flexplate-to-clutch nuts in a star pattern or transmission damage can occur.

NOTE: To prevent the flexplate-to-clutch nuts from falling into the clutch housing and causing damage, use a magnetic socket to install the 6 flexplate-to-clutch nuts.

NOTE: Align the index mark on the clutch stud made during removal.

Install the 6 new flexplate-to-clutch nuts. Tighten the nuts in a star pattern in 2 stages.

1. Stage 1: Tighten nuts 1, 5 and 3 to 12 Nm (106 lb-in).

2. Stage 2: Tighten all nuts to 25 Nm (18 lb-ft).






11. Using 303-F072 , raise the transmission.





12. Install the transmission support insulator bracket and the transmission support insulator bracket bolts.
- Tighten to 80 Nm (59 lb-ft).

13. Install the transmission support insulator, the 4 transmission support insulator nuts, and the transmission support insulator bolt.
- Tighten the transmission support insulator nuts to 50 Nm (37 lb-ft).
- Tighten the transmission support insulator bolt to 150 Nm (111 lb-ft)





14. Install the cowl grille panel. REFER to Cowl Panel Grille .

15. Install the 2 rear lower clutch housing-to-engine bolts.
- Tighten to 48 Nm (35 lb-ft).





16. Install the roll restrictor-to-transmission bracket and the roll restrictor-to-transmission bracket bolts.
- Tighten to 86 Nm (63 lb-ft).





17. Install the roll restrictor bolts.
- Tighten to 86 Nm (63 lb-ft).





18. Install the wiring harness push pin on the transmission.





19. Install the LH (Left Hand) halfshaft assembly. REFER to Halfshaft - LH .

20. Using the RH (Right Hand) halfshaft seal protector provided with the new RH (Right Hand) halfshaft seal, install the RH (Right Hand) intermediate shaft assembly partially into the transaxle.





21. Remove the RH (Right Hand) halfshaft seal protector and install the RH (Right Hand) intermediate shaft assembly into the transaxle.





22. Install the new bearing retainer strap and the bearing retainer strap nuts. Tighten the bearing strap retainer nuts in 2 stages.

1. Stage 1: Tighten to 6 Nm (53 lb-in).

2. Stage 2: Tighten to 25 Nm (18 lb-ft).






23. Install the RH (Right Hand) ball joint into the knuckle.

24. Install the new RH (Right Hand) ball joint bolt and nut.
- Tighten to 87 Nm (64 lb-ft).





25. Install the brake hose retainer and the brake hose retainer bolt on the RH (Right Hand) strut.
- Tighten to 11 Nm (97 lb-in).





26. Install the RH (Right Hand) front wheel and tire. REFER to Wheel and Tire .

27. Install the starter motor isolator.





28. Install the starter motor. REFER to Starter Motor - 2.0L GDI .

29. Fill the transmission with transmission fluid. REFER to Transmission Fluid Level Check .

30. Connect the engine harness electrical connector to the TCM (Transmission Control Module).





31. Attach the transmission vent hose retainer to the crankcase vent tube.





32. Install the 4 top clutch housing-to-engine bolts.
- Tighten to 48 Nm (35 lb-ft).





33. Install the ground wire and the ground wire nut on the clutch housing-to-engine stud.
- Tighten to 25 Nm (18 lb-ft).





34. Install the transmission selector lever cable bracket and the 2 transmission selector lever cable bracket bolts on the transmission.
- Tighten to 10 Nm (89 lb-in).





35. Connect the selector lever cable to the manual control lever.





36. Attach the selector lever cable to the radiator hose retainer.





37. Install the selector lever cable bracket to the transmission support insulator bracket and install the selector lever cable bracket nut.
- Tighten to 25 Nm (18 lb-ft).





38. Attach the wiring harness to the battery tray bracket.





39. Install the ACL (Air Cleaner) assembly. REFER to Exploded View .

40. Install the battery tray and battery. REFER to Battery and Battery Tray - Exploded View .

41. NOTE: Only install recovered TCM (Transmission Control Module) information if the transmission was replaced.

Using the scan tool, install all recovered TCM (Transmission Control Module) information. REFER to Transmission Adaptive Learning .