Removal and Replacement

REMOVAL
1. Disconnect battery cables from battery, then remove battery and battery tray from vehicle.
2. Remove air cleaner assembly.
3. Disconnect shift control cable from manual lever.
4. Disconnect speedometer cable from transaxle by unsnapping cable at speedometer driven gear.
5. Disconnect transaxle electrical connectors, then separate wiring harness from transaxle clips.
6. Remove the manual lever position switch wiring brackets from the top of the transaxle.
7. Disconnect ground wires from top of transaxle.
8. Remove starter motor, then disconnect manual lever position switch wiring connectors.
9. Install three bar engine support tool No. D88L-6000-A or equivalent.
10. Disconnect kickdown cable at throttle cam.
11. Place drain pan under transaxle, then disconnect cooler lines at transaxle.
12. Remove upper transaxle mount nuts, then the mount.
13. Remove upper transaxle housing to engine retaining bolts.
14. Disconnect oxygen sensor electrical connector, then the transaxle vent hose and vehicle speed sensor.
15. Raise and support vehicle, then remove front wheel and tire assemblies.
16. Using hammer and flat punch, straighten detent in halfshaft nut.
17. Remove halfshaft hub nuts, then the lower control arm ball joint to steering knuckle pinch bolts.
18. Separate the lower ball joints from the steering knuckles, then remove halfshafts from both steering knuckles.
19. Disconnect tie rod to steering knuckle assemblies, then remove three lower engine and transaxle splash guards from vehicle..
20. Remove the torque converter inspection cover, then torque converter to flexplate retaining nuts.
21. Remove the lower transaxle to engine oil pan retaining bolts.
22. Remove the lower crossmember from the vehicle chassis.
23. Remove the halfshafts from the transaxle, then install Transaxle Plugs tool No. T88C-7025-AH or equivalent into the differential side gears.

CAUTION: Failure to install the plugs will cause the differential side gear to become improperly positioned.

24. Drain transaxle fluid from the differential cavity and the transaxle assembly.
25. Position transmission jack under transaxle, then secure transaxle to jack with safety chains.
26. Remove lower bolts retaining the transaxle to the engine, then carefully lower transaxle from vehicle.

INSTALLATION

NOTE: The following procedure has bee revised by a Technical Service Bulletin.
a. A pin is used to hold the throttle valve in a fixed position on new or remanufactured service replacement transaxle assemblies.
b. The Pin is used during the assembly process to make installation of the control valve easier. When installing a new or remanufactured transaxle, ensure to remove the pin and install a new retaining bolt.

CAUTION: Failure to remove pin from the throttle cam will hold the transaxle throttle lever in a fixed position resulting in a shift concern.

1. Position the transaxle to the engine, then install lower transaxle retaining bolts. Torque retaining bolts to 41-59 ft lbs.
2. Install torque converter to flexplate retaining nuts. Torque retaining nuts to 25-36 ft lbs.
3. Install the torque converter inspection cover.
4. Remove the two Transaxle Plugs from differential side gears, then install halfshaft assemblies.
5. Install the crossmember to the transaxle mounts. Torque retaining nuts to 27-38 ft lbs.
6. Install crossmember to chassis retaining bolts then torque to 47-66 ft lbs.
7. Install the lower transaxle to engine oil pan retaining bolt then torque bolts to 27-38 ft lbs.
8. Install the engine and transaxle splash guards to the vehicle's undercarriage.
9. Install starter motor assembly.
10. Position the lower ball joints into the steering knuckle assemblies, then torque pinch bolts to 32-43 ft lbs.
11. Position tie rod ends into steering knuckle assemblies, then toque retaining nuts to 31-42 ft lbs.
12. Install wheel and tire assemblies, then torque wheel lug nuts to 65-88 ft lbs.
13. Lower vehicle.
14. Install upper transaxle to engine retaining bolts, then torque to 41-59 ft lbs.
15. Install upper transaxle mount, then torque retaining nuts to 49-69 ft lbs.
16. Connect the transaxle vent hose.
17. Connect the vehicle speed sensor electrical connector, then oxygen sensor.
18. Connect cooler lines, then kickdown cable at the throttle body.
19. Remove the Three Bar Engine Support tool, then connect ground wires to transaxle.
20. Connect the 4EAT electrical connectors, then transaxle wiring harness to retaining clips.
21. Connect the manual lever position switch bracket and wiring connectors.
22. Connect the shift control cable to the cable bracket and to the selector lever. Torque the selector lever retaining nut to 33-47 ft lbs.

CAUTION: Do not use any type of power wrench to tighten the locknut. Damage to the transaxle will result.

23. Install battery tray, then battery.
24. Install air cleaner assembly, then connect the battery ground cable.
25. Connect battery positive cable.
26. Fill transaxle with fluid according to manufacturers specification, then check for proper operation.