Part 3

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.

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 tube thermal bypass valve.





10. NOTICE: Use only the specified bolts for the torque converter. Standard length fasteners 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 PTU (Power Transfer Unit).

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 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. Remove the 2 front Engine Lift Eye bolts and remove the Engine Spreader Bar and the front Engine Lift Eye.





20. Install the cowl panel grille.

21. Install the strut tower brace and the 4 nuts.
- Tighten to 30 Nm (22 lb-ft).






22. Attach the 2 brake booster vacuum hose retainers (1 shown) to the strut tower brace.





23. Connect the turbocharger wastegate regulating valve electrical connector.





24. Position the RH CAC (Charge Air Cooler) tube, aligning the index marks made during removal and tighten the clamp.
- Tighten to 5 Nm (44 lb-in).






25. Connect the LH turbocharger bypass valve electrical connector and the turbocharger bypass valve hose.