Transmission/Transaxle Replacement

REMOVAL
1. Remove level gauge.





2. Remove filler pipe. Remove the bolt and filler pipe.
3. Disconnect throttle cable, as follows:
a. Remove the bolt, two nuts and V-bank cover.





b. Disconnect the throttle cable from the throttle body.





c. Disconnect the throttle cable from clamps.
4. Remove propeller shaft.
5. Remove engine under cover.
6. Remove shift control rod, as follows:





a. Remove the nut and disconnect the rod.
Torque: 13 Nm (108 inch lbs.).





b. Remove the nut and control rod with the shift control lever.
7. Remove exhaust pipe support bracket. Remove the two bolts and bracket.
Torque: 44 Nm (32 ft. lbs.).
8. Remove catalytic converter. Remove the six nuts and both side catalytic converters.
Torque: 62 Nm (46 ft. lbs.).

INSTALLATION NOTE: Replace the used nuts and gaskets with new nuts and gaskets.

9. Remove both side heat insulator. Remove the eight bolts, six nuts and both side heat insulators.
10. Disconnect oil cooler pipe, as follows:





a. Loosen the two union nuts.
Torque: 44 Nm (32 ft. lbs.).

NOTICE: Be careful no to damage the oil cooler pipe.





b. Disconnect the three bolts and clamp.
c. Disconnect the two oil cooler pipes from the transmission.
11. Remove torque converter clutch mounting bolt, as follows:





a. Remove the two bolts and converter clutch plate.





b. Turn the crankshaft to gain access to each bolt.
c. Hold the crankshaft pulley nut with a wrench and remove the six bolts.
Torque: 41 Nm (30 ft. lbs.).

INSTALLATION NOTE. First install black colored bolt and then the five other bolts.





12. Support transmission with jack.
13. Remove engine rear mounting. Remove the A bolts, nuts and engine rear mounting.
Torque:
Bolt: 25 Nm (19 ft. lbs.).
Nut: 13 Nm (10 ft. lbs.).
14. Disconnect connectors and clamp, as follows:





a. Tilt down the transmission.

NOTICE: Take care so that the cooling fan does not come in contact with the fan shroud.





b. Disconnect the following connectors:
1. Overdrive (O/D) direct clutch speed sensor connector.
2. Vehicle speed sensor connector
3. Park/neutral position switch connector
4. Solenoid connector
c. Disconnect the three wire harness clamps from the bracket on transmission.





15. Remove transmission. Remove the 10 bolts and transmission.
Torque:
14 mm bolt: 37 Nm (27 ft. lbs.).
17 mm bolt: 72 Nm (53 ft. lbs.).





INSTALLATION NOTE: Lift the engine front side.

TORQUE CONVERTER CLUTCH AND DRIVE PLATE INSPECTION
1. Inspect one-way clutch, as follows:





a. Install Special Service Tool (SST) 09350-30020 (09351-32020) or equivalents, so that it fits in the notch of the converter hub and outer race of the one-way clutch.





b. Press on the serrations-of starter with a finger and rotate it. Check if it rotates smoothly when turned clockwise and locks up when turned counterclockwise.
2. Measure drive plate runout and inspect ring gear.





Set up a dial indicator and measure the drive plate runout.
Maximum runout: 0.20 mm (0.0079 inch).
If runout exceeds 0.20 mm (0.0079 inch) or if the ring gear is damaged, replace the drive plate. If installing a new drive plate, note the orientation of spacers and tighten the bolts.
Torque: 83 Nm (61 ft. lbs.).
3. Measure torque converter clutch sleeve runout, as follows:





a. Temporarily mount the torque converter clutch to the drive plate. Set up a dial indictor.
Maximum runout: 0.30 mm (0.0118 inch).
If runout exceeds 0.30 mm (0.0118 inch), try to correct by reorienting the installation of the torque converter clutch. If excessive runout cannot be corrected, replace the torque converter clutch.

NOTE: Mark the position of the torque converter clutch to ensure correct installation.

b. Remove the torque converter clutch.

TORQUE CONVERTER CLUTCH INSTALLATION





Check Torque Converter Clutch Installation
Using calipers and a straight edge, measure from the installed surface of the torque converter clutch to the front surface of the transmission housing.
Correct distance: More than 17.1 mm (0.673 inch)
If the distance is less than the standard, check for an improper installation.

INSTALLATION
Installation is in the reverse order of removal.

NOTE: After installation, check and inspect items as follows.
- Check fluid level.
- Road test the vehicle.