Installation

Transaxle - 3.0L













NOTICE: The use of any transmission fluid other than what is recommended for this transaxle will cause transaxle damage.

NOTE: If the transaxle was overhauled, or if installing a new transaxle and the transmission fluid cooler has not been flushed, flush the transmission fluid cooler at this time. For additional information, refer to Transmission Fluid Cooler - Backflushing and Cleaning Aisin AW21.

All vehicles

1. Prior to installing the transaxle, apply multi-purpose grease to the torque converter pilot hub.





2. Position the transaxle to the back of the engine.

3. Install the 5 transaxle-to-engine bolts.
- Tighten to 40 Nm (30 lb-ft).





4. Connect the transmission fluid cooler hoses to the transmission fluid cooler tubes.





5. Install 3 new torque converter nuts.
- Tighten to 36 Nm (27 lb-ft).





6. Install the inspection cover.





7. Connect the wiring harness fastener to the stud bolt and position the Heated Oxygen Sensor (HO2S) bracket in place and install the bolt.
- Tighten to 12 Nm (106 lb-in).





8. Position the transaxle insulator bracket in place. Apply threadlock and sealer to the threads and install the 2 nuts and the bolt.
- Tighten to 80 Nm (59 lb-ft).





9. Raise the transaxle. Apply threadlock and sealer to the threads and install the 2 transaxle insulator-to-frame bolts.
- Tighten to 62 Nm (46 lb-ft).





10. Remove the Engine Support Bar.





11. Remove the Engine Lifting Bracket and the Universal Adapter Bracket "L" hook from the from the LH side of the engine.





12. Remove the upper half of the Engine Lifting Bracket Set.





13. Remove the lower half of the Engine Lifting Bracket Set.





All-Wheel Drive (AWD) vehicles

14. Position the Power Transfer Unit (PTU) in place and install the 5 bolts.
- Tighten to 90 Nm (66 lb-ft).





15. Install a new intermediate shaft seal.

16. Position the PTU support bracket in place and install the 5 bolts.
- Tighten to 70 Nm (52 lb-ft).





17. Position the RH catalytic converter in place and install the catalytic converter-to-exhaust manifold nuts.
- Tighten to 40 Nm (30 lb-ft).





18. Install the catalytic converter band clamp LH half and the 2 bolts.
- Tighten to 40 Nm (30 lb-ft).





19. Install the catalytic converter band clamp RH half and install the 3 nuts.
- Tighten to 20 Nm (177 lb-in).





20. Install the RH exhaust manifold heat shield and the 6 bolts.
- Tighten to 11 Nm (97 lb-in).





21. Using the Exhaust Gas Oxygen Sensor Socket, install the RH HO2S.
- Tighten to 48 Nm (35 lb-ft).





22. Connect the RH HO2S electrical connector.





23. Using the Exhaust Gas Oxygen Sensor Socket, install the RH catalyst monitor sensor.
- Tighten to 48 Nm (35 lb-ft).





24. Connect the RH catalyst monitor sensor electrical connector and attach the wiring harness retainer.





25. Position the driveshaft in place, align the index marks made during removal and install the 4 driveshaft bolts.
- Tighten to 70 Nm (52 lb-ft).





Front Wheel Drive (FWD) vehicles

26. Install the catalytic converter-to-engine block bracket and install the 2 bolts.
- Tighten to 35 Nm (26 lb-ft).





27. Install the catalytic converter band clamp and the 2 bolts.
- Tighten to 20 Nm (177 lb-in).





28. Install the RH exhaust manifold heat shield and the 2 bolts.
- Tighten to 11 Nm (97 lb-in).





All vehicles

29. NOTE: Front Wheel Drive (FWD) shown, All-Wheel Drive (AWD) similar.

Loosely install the EGR tube nut on the RH exhaust manifold.





30. Position the subframe in place using a suitable powertrain lift.

31. NOTE: LH shown, RH similar.

Install the front subframe nuts.

- Tighten to 150 Nm (111 lb-ft).





32. Position the subframe support brackets in place and loosely install the bolts.





33. Install the rear subframe nuts.
- Tighten to 150 Nm (111 lb-ft).





34. Tighten the subframe support bracket bolts.
- Tighten to 103 Nm (76 lb-ft).





35. Position the power steering gear in place and install the 3 bolts.
- Tighten to 107 Nm (79 lb-ft).





36. Position the power steering line bracket in place and install the bolts.
- Tighten to 9 Nm (80 lb-in).





37. NOTE: FWD shown, AWD similar.

Install the 2 transaxle roll restrictor bolts.
- Tighten to 90 Nm (66 lb-ft).





38. If equipped, install the roll restrictor heat shield and the bolts.





39. Position the Y-pipe assembly in place and install the 2 exhaust flexible pipe-to-catalytic converter nuts.
- Tighten to 40 Nm (30 lb-ft).





40. Install the Y-pipe bolts and the Y-pipe nuts.
- Tighten to 40 Nm (30 lb-ft).





41. Install the LH and RH halfshafts.





42. Connect the HO2S to the RH halfshaft bearing support bracket.





43. Install the LH front structure to subframe splash shield and install the pin-type retainers.





44. Position the LH fender splash shield in place and install the 4 screws.





45. Position the RH front structure-to-subframe splash shield in place and install the 6 pin-type retainers.





46. Position the RH fender splash shield in place and install the 4 screws.





47. Position the power steering line bracket on the right cylinder head and install the bolt.
- Tighten to 7 Nm (62 lb-in).





48. Install a new gasket and the EGR valve and install the 2 bolts.
- Tighten to 25 Nm (18 lb-ft).





49. Install the EGR tube on the valve.
- Tighten to 40 Nm (30 lb-ft).





50. Connect the EGR valve electrical connector.





51. NOTE: FWD shown, AWD similar.

Tighten the EGR tube at the RH exhaust manifold.
- Tighten to 40 Nm (30 lb-ft).





52. Install the 3 upper transaxle-to-engine retaining bolts.
- Tighten to 40 Nm (30 lb-ft).





53. Install the starter and the 2 bolts.
- Tighten to 26 Nm (19 lb-ft).





54. Connect the 2 starter motor electrical connectors.
- Tighten the larger nut to 12 Nm (106 lb-in).

- Tighten the smaller nut to 5 Nm (44 lb-in).





55. Install the electrical cover for the starter motor electrical connectors.





56. Install the 2 ground wires and ground wire bolts.
- Tighten to 12 Nm (106 lb-in).





57. Connect the Transmission Control Module (TCM) electrical connector.





58. Position the selector lever cable and bracket in place and install the selector lever cable nut and 2 selector lever cable bolts.
- Tighten to 12 Nm (106 lb-in).





59. Connect the selector lever cable end.





60. Remove the transmission fluid fill plug.





61. Fill the transaxle with clean transmission fluid.

62. Install the transmission fluid fill plug.
- Tighten to 39 Nm (29 lb-ft).





63. Install the Air Cleaner (ACL) and outlet tube.

64. Install the battery tray and the battery.

65. Remove the transmission fluid level indicator and make sure that the transaxle has transmission fluid in it.

66. With the transaxle in PARK, the vehicle on a level surface, the engine at idle (680-780 rpm) and foot pressed on the brake, move the selector lever through each gear and allow engagement of each gear. Place the selector lever back in the PARK position.

67. Wipe the transmission fluid level indicator cap and remove the transmission fluid level indicator.

68. Wipe the transmission fluid level indicator with a clean cloth.

69. NOTE: In order to get an accurate transmission fluid level reading, the vehicle should be on a level surface. Idle the engine to reach the normal operating temperature. Using the scan tool, verify that the transaxle is at normal operating temperature 60°C-70°C (140°F-158°F), prior to adjusting the transmission fluid level.

If transmission fluid needs to be added, add transmission fluid in 0.25L (1/2 pt) increments through the transmission fluid fill plug located on the top of the transaxle near the transmission fluid level indicator. Do not overfill the transmission fluid. Install the transmission fluid level indicator back in the transmission fluid filler tube until it is fully seated, then remove the transmission fluid level indicator. The transmission fluid level should be at the upper most mark on the transmission fluid level indicator. Only fill to the upper most mark on the transmission fluid level indicator. Do not overfill. Damage to the transaxle will occur.





70. NOTE: The correct transmission fluid level at normal operating temperature of 60°C-70°C (140°F-158°F) is between the top 2 marks on the fluid level indicator.

Fill the transaxle to the correct fluid level.





71. NOTE: The correct transmission fluid level at cold operating temperature of 15°C-25°C (59°F-77°F) is at the bottom mark on the transmission fluid level indicator.

If the Transmission Fluid Temperature (TFT) is low, fill the transaxle with transmission fluid to the cold range on the transmission fluid level indicator. Recheck the transmission fluid level when the transaxle has reached the normal operating temperature.