Installation
Transaxle - 3.5L GTDI
Installation
NOTICE: Prior to installation of a new, re-manufactured or overhauled transaxle, the transmission fluid cooler tubes must be cleaned, otherwise transaxle failure may occur.
NOTE: Prior to installation of a new, re-manufactured or overhauled transaxle, flush out the cooler and cooler tubes. For additional information, refer to Transmission Fluid Cooler Backflushing and Cleaning .
1. Inspect the transmission fluid cooler tube backing rings and seals for damage and install new backing rings or seals if necessary. Lubricate the transmission fluid cooler tube seals with clean transmission fluid and install the backing rings and seals on the transmission fluid cooler tubes.
2. Position the transmission fluid cooler thermal bypass valve and transmission fluid cooler tube assembly in place and install the thermal bypass valve nuts.
- Tighten to 9 Nm (80 lb-in).
3. Install new transmission fluid cooler tube-to-transaxle case bolts.
- Tighten to 9 Nm (80 lb-in).
4. Lubricate the torque converter pilot hub with grease.
5. NOTICE: If the transaxle is not positioned on the dowel pins, damage to the transaxle may occur.
If the dowel pins were pulled out of the engine block during removal, install new dowel pins in the engine block.
6. Using the Transmission Jack Adapter, support the transaxle and position it in place on the engine dowel pins.
7. Install the lower torque converter housing bolts.
- Tighten to 48 Nm (35 lb-ft).
8. Install the transmission fluid cooler tubes in the transmission fluid cooler thermal bypass valve.
9. Install the transmission fluid cooler tube secondary latches on the transmission fluid cooler tubes at the transmission fluid cooler thermal bypass valve.
10. NOTICE: Use only the specified bolts for the torque converter. Standard length fasteners may bottom out and damage the torque converter clutch apply surface.
Install 3 new torque converter bolts (W714722).
- Install the first torque converter bolt in the slotted hole on the flexplate.
- Tighten to 55 Nm (41 lb-ft).
11. Install the inspection cover and the 2 fasteners.
12. Install the Power Transfer Unit (PTU).
13. Install the LH halfshaft.
14. Install the front subframe.
- Tighten the roll restrictor bracket bolts to 90 Nm (66 lb-ft).
15. Position the transaxle support insulator in place and install the 2 upper bolts.
- Tighten to 55 Nm (41 lb-ft).
16. Install the 2 lower transaxle support insulator bolts.
- Tighten to 55 Nm (41 lb-ft).
17. Install the transaxle support insulator bracket and install the bolt and the 3 nuts.
- Tighten the bolt to 80 Nm (59 lb-ft).
- Tighten the nuts to 63 Nm (46 lb-ft).
18. Remove the Engine Support Bar.
19. Install the strut tower brace and the 4 nuts.
- Tighten to 30 Nm (22 lb-ft).
20. Remove the 2 front Engine Lift Eye bolts and remove the Engine Spreader Bar and the front Engine Lift Eye.
21. Install the cowl panel grille.
22. Align the index marks made during removal and install the Charge Air Cooler (CAC) hose on the RH turbocharger and tighten the clamp.
- Tighten to 5 Nm (44 lb-in).
23. Install the RH CAC (Charge Air Cooler) hose nut.
- Tighten to 10 Nm (89 lb-in).
24. Position the LH exhaust manifold heat shield in place and install the 4 bolts.
- Tighten to 15 Nm (133 lb-in).
25. Install the oil supply tube bracket on the LH valve cover stud bolt and install the nut.
- Tighten to 8 Nm (71 lb-in).
26. Attach the wiring harness retainer to the valve cover stud bolt.
27. Install the engine cover mounting stud to the LH valve cover stud bolt.
- Tighten to 6 Nm (53 lb-in).
28. Install the crankcase vent tube and connect the 2 quick connect couplings.
29. Install the top torque converter housing bolts.
- Tighten to 48 Nm (35 lb-ft).
30. Attach the 2 wiring harness retainers to the transaxle stud bolts.
31. Attach the transaxle control wire harness retainer to the transaxle stud bolt.
32. Connect the transaxle control electrical connector.
33. Install the starter, the starter bolt and starter studbolt.
- Tighten to 26 Nm (19 lb-ft).
34. Install the wiring harness fastener on the starter motor studbolt.
35. Connect the starter motor terminals.
- Tighten the starter battery terminal nut to 12 Nm (106 lb-in).
- Tighten the starter solenoid terminal nut to 6 Nm (53 lb-in).
36. Install the starter motor terminal cover.
37. Position the selector lever cable and bracket in place and install the selector lever cable bracket bolts.
- Tighten to 12 Nm (106 lb-in).
38. Attach the wiring harness pin-type retainer.
39. Place the selector lever in DRIVE.
40. Place the manual control lever in DRIVE.
1. Rotate the manual control lever clockwise until it stops.
2. Rotate the manual control lever counterclockwise one detent until it stops.
41. Unlock the selector lever cable adjuster by sliding the locking tab over.
42. Slide the cable end forward or backward to align it with the manual lever.
43. With the adjuster locking tab released, connect the selector lever cable end to the manual control lever.
44. Slide the release tab back to lock the adjuster.
45. Install the battery tray.
46. Fill the transaxle with clean transmission fluid. For additional information, refer to Transmission Fluid Drain and Refill .
47. If a new solenoid body is installed, the solenoid body strategy will need to be updated. For additional information, refer to Solenoid Body Strategy Solenoid Body Strategy.
48. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions.