4T65-E Automatic Transaxle

Case Side Cover Replacement

Removal Procedure

Caution: Refer to Battery Disconnect Caution in Service Precautions.





1. Disconnect the negative battery cable.
2. Install the engine support fixture.
3. Remove the air intake duct.
4. Remove the shift cable and bracket at the transaxle.
5. Remove the accelerator and cruise control cables from the retainer on the left strut tower.
6. Unbolt but do not remove the ABS modulator.
7. Raise the vehicle. Refer to Vehicle Lifting.
8. Remove the left front tire and wheel assembly.
9. Remove the inner splash shield.
10. Remove the tie rod end from the knuckle assembly.
11. Remove the stabilizer shaft link from the lower control arm.
12. Remove the ball joint from the steering knuckle.
13. Remove the left drive axle from the transmission.
14. Remove the pinch bolt from the steering gear intermediate shaft at steering column.

Caution: Failure to disconnect the intermediate shaft from the rack and pinion steering gear stub shaft can result in damage to the steering gear or to the intermediate shaft. This damage may cause loss of steering control, which could result in an accident and possible personal injury.

15. Remove the intermediate shaft from the steering gear.
16. Remove the three frame-to-body bolts on the left side.
17. Loosen but do not remove the bolts on the right side.
18. Remove the transaxle oil cooler hoses at the case.
19. Lower the vehicle and loosen the engine support fixture adapters until adequate clearance is available at the case side cover to frame rail area.
20. Raise the vehicle.
21. Remove the case side cover bolts.
22. Remove the case side cover (53).
23. Clean the case and side cover gasket surfaces.

Installation Procedure





1. Inspect the case side cover for the following conditions:
^ Damaged or porous gasket sealing surfaces
^ Damaged or porous casting surfaces
^ Damaged or stripped bolt holes
2. Install the new gaskets (54 and 59) on the case (53).
3. Install the case side cover.





4. Install the new side cover bolts (56) and one side cover to case stud (58) in the locations shown. These bolts will properly locate the case side cover to the case.
5. Install the remaining bolts:

Notice: Refer to Fastener Notice in Service Precautions.

^ Nine case side cover bolts (56)
^ Four side cover TORX (R) bolts (57)
^ Four side cover to case stud bolts (58)
^ Tighten the side cover bolts to 25 Nm (18 ft. lbs.).
6. Install the transaxle oil cooler hoses to the transmission.
7. Raise the transmission and frame using a transmission jack so that the frame bolts can be installed.
8. Install the three frame-to-body bolts and tight the right side bolts.
9. Remove the transmission jack.
10. Install the intermediate shaft to the steering gear and the pinch bolt at the intermediate shaft.
11. Install the drive axle to the transmission.
12. Install the ball joint to the steering knuckle.
13. Install the stabilizer shaft link to the lower control arm.
14. Install the tie rod end to the knuckle.
15. Install the inner splash shield.
16. Install the left front tire and wheel assembly.
17. Lower the vehicle.
18. Remove the engine support fixture.
19. Install the shift cable and bracket at the transaxle.
20. Install the accelerator and cruise control cables from the retainer on the left strut tower.
21. Install the ABS modulator.
22. Install the air intake duct.
23. Connect the negative battery cable.
24. Check the fluid level.
25. Inspect for leaks.