Removal and Replacement

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

CAUTION: Failure to install plugs may cause differential side gears to become improperly positioned.

26. Remove transaxle oil pan and drain transaxle fluid.
27. Install transaxle oil pan and drain plug.
28. Position transaxle jack under transaxle, then secure transaxle to jack with safety chains or suitable equipment.
29. Remove lower bolts securing transaxle to engine, then carefully lower transaxle from vehicle.

INSTALLATION

NOTE: The following procedure has been revised by a Technical Service Bulletin.

A pin is used to hold the throttle valve in a fixed position on new or remanufactured service replacement transaxle assemblies.

The pin is used during the assembling 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. 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 transaxle to engine, then install lower transaxle bolts. Torque bolts to 41-59 ft lbs.
2. Position torque converter to flex plate, then install torque converter to flexplate nuts. Torque nuts to 25-36 ft lbs.
3. Install torque converter inspection plate.
4. Remove two transaxle plugs from differential side gears, then install halfshaft assemblies.
5. Connect halfshaft mid-bearing bracket to back of engine.
6. Install crossmember to transaxle mounts. Torque lower crossmember to transaxle nuts to 27-38 ft lbs.
7. Install crossmember to chassis bolts. Torque bolts to 47-66 ft lbs.
8. Install lower transaxle to oil pan retaining bolts. Torque bolts to 27-38 ft lbs.
9. Install engine and transaxle splash guards to vehicle.
10. Install starter motor assembly.
11. Position lower ball joints into steering knuckle assemblies. Torque lower ball joint to steering knuckle assembly nuts and bolts to 32-43 ft lbs.
12. Position tie rod ends into steering knuckle assemblies. Torque retaining nuts to 31-42 ft lbs.
13. Install wheel and tire assemblies. Torque wheel lug nuts to 65-88 ft lbs.
14. Lower vehicle.
15. Install upper transaxle to engine retaining bolts. Torque to 41-59 ft lbs.
16. Install upper transaxle mount. Torque retaining nuts to 49-69 ft lbs.
17. Connect transaxle vent hose, then the vehicle speed sensor and oxygen sensor electrical connectors
18. Connect speedometer cable, cooler lines, then the kickdown cable at throttle body.
19. Remove three bar engine support tool No. T88C-7025-AH, then connect ground wires to transaxle.
20. Connect electrical connectors, then the transaxle wiring harness to retaining clips.
21. Connect manual lever position switch bracket and wiring connectors.
22. Connect shift control cable to cable bracket and selector lever. Torque selector lever attaching locknut to 33-47 ft lbs.

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

23. Install battery tray, then the battery.
24. Connect wiring harness clip to battery tray.
25. Install air cleaner assembly, then connect battery cables.
26. Add proper transaxle fluid, then check for proper fluid level and leaks.