Installation

Transaxle











Installation

All vehicles

CAUTION: Prior to installation of a new, re-manufactured or overhauled transaxle, the transmission fluid cooler tubes must be cleaned, otherwise transaxle failure may occur.

NOTE: Prior to installation of a new, re-manufactured or overhauled transaxle, flush out the cooler and cooler tubes.

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 automatic 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 2 nuts.
^ Tighten to 9 Nm (80 lb-inch).





3. Install 2 new transmission fluid cooler tube bolts.
^ Tighten to 9 Nm (80 lb-inch).





4. Lubricate the torque converter pilot hub with grease.

5. CAUTION: 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. Position the transaxle in place and install the 7 torque converter housing bolts.
^ Tighten to 48 Nm (35 lb-ft).





7. Install the transaxle support insulator bracket, the 3 nuts and the bolt.
^ Tighten to 63 Nm (46 lb-ft).





8. Raise the transaxle and install the transaxle support insulator through bolt.
^ Tighten to 175 Nm (129 lb-ft).





9. Install the transmission fluid cooler tubes in the transmission fluid cooler thermal bypass valve.





10. Install the 2 secondary latches on the transmission fluid cooler tubes at the transmission fluid cooler thermal bypass valve.





11. Install 3 new torque converter bolts.
^ Tighten to 55 Nm (41 lb-ft).





12. Install the inspection cover and the 2 fasteners.





All wheel drive (AWD) vehicles

13. Position the power transfer unit (PTU) in place and install the 5 bolts.
^ Tighten to 90 Nm (66 lb-ft).





14. Using the special tools, install a new intermediate shaft seal.





15. NOTE: Do not overhaul (melt) the seal deflector. If the deflector is damaged, a new one must be used.

Using a suitable heat gun, heat the new seal deflector. Concentrate the heat across the back of the deflector near the white colored tabs. Install the seal deflector immediately after heating.
^ If necessary, use special tools 308-430 and 308-431 to seat the seal deflector. Make sure the deflector is fully seated and there are no cracks on the face or inner diameter white colored tab.
^ An alternate method to heat the seal deflector, place the deflector in boiling water for 3 to 5 minutes. Dry the deflector and install.
^ Make sure the deflector is completely seated all the way around.





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 loosely install the 4 nuts (2 shown).





18. Install the 2 RH catalytic converter support bracket bolts.
^ Tighten to 20 Nm (15 lb-ft).





19. Tighten the 4 RH catalytic converter nuts (2 shown).
^ Tighten to 40 Nm (30 lb-ft).





20. Connect the RH catalyst monitor electrical connector.





21. Line up the index marks on the rear driveshaft to the index marks on the PTU flange made during removal and install 4 new bolts (3 shown).
^ Tighten to 70 Nm (52 lb-ft).





All vehicles

22. NOTE: RH shown, LH similar.

Loosely install the 2 front subframe bolts.
^ Tighten to 150 Nm (111 lb-ft).





23. NOTE: RH shown, LH similar.

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





24. NOTE: RH shown, LH similar. Loosely install the rear subframe bolts.





25. NOTE: RH shown, LH similar.

Tighten the 2 front subframe bolts.
^ Tighten to 150 Nm (111 lb-ft).





26. NOTE: RH shown, LH similar. Tighten the rear subframe bolts.

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





27. NOTE: RH shown, LH similar.

Tighten the subframe support bracket bolts.
^ Tighten to 55 Nm (41 lb-ft).





28. Position the roll restrictor in place and install the 2 bolts.
^ Tighten to 90 Nm (66 lb-ft).





29. Position the stabilizer bar in place and install 4 new bolts.
^ Tighten to 48 Nm (35 lb-ft).





30. Position the power steering rack in place and install 2 new bolts and nuts.
^ Tighten to 117 Nm (86 lb-ft).





31. Position the exhaust Y-pipe assembly in place and install the 4 nuts.
^ Tighten to 40 Nm (30 lb-ft).





32. Install the exhaust hanger and the exhaust clamp nuts.
^ Tighten to 40 Nm (30 lb-ft).





33. Position the LH halfshaft in the transaxle and in the steering knuckle.
34. Install the RH halfshaft and install the RH halfshaft bearing support bracket nuts.
^ Tighten to 40 Nm (30 lb-ft).





35. NOTE: RH side shown, LH side similar. Install new ball joint nuts.

^ Tighten to 115 Nm (85 lb-ft).





36. CAUTION: Install and tighten the new front axle wheel end nut to specification in a continuous rotation. Stopping the rotation during installation will cause the nylon lock to seat incorrectly. This will cause incorrect torque readings while tightening the front axle wheel end nut and lead to bearing failure. Always install a new front axle wheel end nut after loosening or when not tightened to specifications in a continuous rotation.

CAUTION: Never use power tools to tighten the front axle wheel end nut or damage to the nut or wheel bearing may occur.

NOTE: RH side shown, LH side similar.

NOTE: Apply the brake to keep the halfshaft from rotating.

Install new halfshaft nuts.
^ Tighten to 350 Nm (258 lb-ft).





37. Position the power steering tube in place on the LH side of the subframe and install the power steering tube bracket bolts.
^ Tighten to 9 Nm (80 lb-inch).





38. Install the front splash shield, the 3 screws and the 5 pushpin fasteners.





39. Install the RH splash shield and the 7 pushpin fasteners (6 shown).





40. Remove the special tools.





41. Remove the special tool from the LH cylinder head.





42. Install the fluid filler tube and the nut.
^ Tighten to 11 Nm (8 lb-ft).





43. Install the transmission fluid level indicator.





44. Route the coolant hoses in the transmission fluid filler tube.





45. Install the top 4 torque converter housing bolts.
^ Tighten to 48 Nm (35 lb-ft).





46. Connect the transaxle electrical connector and install the wiring harness fastener on the main control cover stud.





47. If equipped, position the auxiliary coolant pump on the transaxle studs and install the 2 nuts.
^ Tighten to 20 Nm (15 lb-ft).





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





49. Install the wiring harness fastener on the starter motor studbolt.





50. Connect the starter motor terminals and position the starter terminal boot over the battery cable terminal.
^ Tighten to 12 Nm (9 lb-ft).
^ Tighten to 6 Nm (53 lb-inch).





51. Install the starter motor positive terminal cover.





52. Position the selector lever cable and bracket in place and install the 3 bolts.
^ Tighten to 12 Nm (9 lb-ft).





53. Place the selector lever in DRIVE.





54. Place the manual lever in DRIVE.
1 Rotate the manual lever clockwise until it stops.
2 Rotate the manual lever counterclockwise one detent until it stops.





55. Unlock the selector lever cable adjuster by sliding the locking tab over.





56. Slide the cable end forward or backward to align it with the manual lever.





57. With the adjuster locking tab released, connect the selector lever cable end to the manual lever.





58. Slide the release tab back to lock the adjuster.





59. Install the upper intake manifold.
60. Install the battery tray and bracket, install the battery tray bolt and the nut.
^ Tighten to 9 Nm (80 lb-inch).





61. Install the 2 lower battery tray bracket bolts.
^ Tighten to 9 Nm (80 lb-inch).





62. Attach the 5 pin-type wiring harness fasteners to the battery tray.





63. Install the battery.
64. Position the air cleaner assembly in place and install the 2 air cleaner assembly bracket bolts.
^ Tighten to 11 Nm (8 lb-ft).





65. Connect the brake booster vacuum hose to the air cleaner outlet pipe.





66. Tighten the air cleaner outlet pipe clamp at the throttle body.
^ Tighten to 5 Nm (44 lb-inch).





67. Connect the engine breather to the air cleaner assembly.





68. Connect the mass air flow (MAF) sensor electrical connector.





69. Install the front wheels.
70. Fill with clean automatic transmission fluid to the correct level.
71. If a new solenoid body is installed, the solenoid body strategy will need to be updated. Refer to Solenoid Body Strategy.