Removal
Transaxle - 3.5L GTDI
Removal
NOTE: Refer to the Transmission Cooler Flushing Job Aid on the FMC Dealer website.
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Remove the Air Cleaner (ACL) assembly and outlet pipe.
3. Remove the battery tray.
4. Disconnect the selector lever cable end from the manual control lever.
5. Disconnect the wiring harness pin-type retainer.
6. Remove the selector lever cable bracket bolts and position aside the selector lever cable and bracket.
7. Remove the starter motor terminal cover.
8. Remove the starter terminals from the starter.
9. Disconnect the wiring harness fastener from the starter motor studbolt.
10. Remove the bolt, studbolt and the starter.
11. Disconnect the transaxle control electrical connector.
12. Detach the transaxle control wire harness retainer from the transaxle stud bolt.
13. Detach the 2 wiring harness retainers from the transaxle stud bolts.
14. Remove the top torque converter housing bolts.
15. Disconnect the 2 quick connect couplings and remove the crankcase vent tube.
16. Remove the engine cover mounting stud from the LH valve cover stud bolt.
17. Detach the wiring harness retainer from the valve cover stud bolt.
18. Remove the nut and the oil supply tube bracket from the LH valve cover stud bolt.
19. Remove the 4 bolts and position aside the LH exhaust manifold heat shield.
20. Install the Engine Lift Eye on the LH cylinder head and loosely install the 2 bolts.
21. Remove the RH turbocharger-to-Charge Air Cooler (CAC) hose nut.
22. NOTE: Index-mark the CAC (Charge Air Cooler) tube position for reference during installation.
Loosen the RH CAC (Charge Air Cooler) hose clamp and remove the CAC (Charge Air Cooler) hose from the RH turbocharger.
23. Remove the cowl panel grille.
24. Position the Engine Spreader Bar in the lift eyes and tighten the front 2 Engine Lift Eye bolts.
25. Remove the 4 nuts and the strut tower brace.
26. Install the Engine Support Bar and support the engine.
27. Remove the 3 nuts and the bolt from the transaxle support insulator bracket.
28. Remove the 2 lower transaxle support insulator bolts.
29. Remove the 2 upper transaxle support insulator bolts and remove the transaxle support insulator assembly.
30. Remove the front subframe. When removing the subframe, remove the roll restrictor bracket bolts from the torque converter housing instead of removing the roll restrictor-to-subframe bolts.
1. Roll restrictor bracket bolts.
2. Roll restrictor-to-subframe through bolts.
31. Remove the transmission fluid drain plug and allow the transmission fluid to drain.
32. Install the transmission fluid drain plug.
- Tighten to 9 Nm (80 lb-in).
33. Remove the LH halfshaft.
34. Inspect the halfshaft hub for damage and install a new halfshaft, if necessary.
1. Inspect the seal surface.
2. Inspect the halfshaft bushing surface. If this surface is damaged, inspect the halfshaft bushing for damage.
3. Inspect the differential side gear splines.
35. Remove the Power Transfer Unit (PTU).
36. Inspect the RH halfshaft for damage and replace if necessary.
1. Inspect the seal surface.
2. Inspect the bushing surface. If this surface is damaged, inspect the halfshaft bushing for damage.
3. Inspect the differential side gear splines.
37. Remove the 2 fasteners and the torque converter inspection cover.
38. Remove and discard the 3 torque converter bolts.
39. Remove the transmission fluid cooler tube secondary latches from the transmission fluid cooler tubes at the transmission fluid cooler thermal bypass valve.
40. Using the Transmission Cooler Line Disconnect Tool, disconnect the transmission fluid cooler tubes from the transmission fluid cooler thermal bypass valve.
41. Using the Transmission Jack Adapter, support the transaxle.
42. Remove the remaining torque converter housing bolts and remove the transaxle from the vehicle.
43. Remove and discard the transmission fluid cooler tube bolts.
44. Remove the nuts, pull the transmission fluid cooler thermal bypass valve and the transmission fluid cooler tubes straight up and remove the assembly from the transaxle.
45. Inspect the transaxle case to be sure that the transmission fluid cooler tube seals and backing rings were removed with the transmission fluid cooler tubes and are not stuck in the transaxle case. If the transmission fluid cooler tube seals or backing rings are stuck in the transaxle case, remove the seals and backing rings.
46. If the transaxle is to be overhauled or if installing a new or re-manufactured transaxle, carry out transmission fluid cooler backflushing and cleaning. For additional information, refer to Transmission Fluid Cooler Backflushing and Cleaning .