Case: Service and Repair

Case Side Cover Replacement
^ Tools Required
- J 36850 Transjel
- J 42640 Steering Column Anti-Rotation Pin

Removal Procedure

Notice: The wheels of the vehicle must be straight ahead and the steering column in the LOCK position before disconnecting the steering column or intermediate shaft from the steering gear. Failure to do so will cause the SIR coil assembly to become uncentered, which may cause damage to the coil assembly.





1. Lock the steering column by installing J 42640 into the underside of the steering column.
2. Disconnect the negative battery cable.




3. Remove the air cleaner assembly.

Important: Remove both the throttle and the cruise control cables in order to prevent kinking of the cables during lowering of the transaxle.

4. Remove both the throttle and the cruise control cables (1) from the throttle body and the accelerator control bracket (2).





5. Use a large flat-bladed tool in order to remove the range selector cable from the range selector lever.
6. Remove the range selector cable bracket from the transmission case and set aside.





7. Disconnect the transaxle electrical connector C100 (2).
8. Disconnect the wiring harness (3) from the wiring harness retainer (1) on the transaxle.





9. Remove the ground cable bolt (1) from the transaxle.
10. Install the engine support fixture.





11. Raise and Support the vehicle.
12. Remove the left front tire and wheel assembly.
13. Remove both of the front fascia extensions (3).
14. Remove the front air deflector.
15. Remove the left tie rod end from the steering knuckle.
16. Remove the left ball joint from the steering knuckle.
17. Remove the left drive axle from the transaxle.

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.





18. Remove the intermediate shaft lower pinch bolt.
19. Disconnect the intermediate shaft from the power steering gear.





20. Remove the power steering gear heat shield.
21. Remove the power steering gear mounting bolts.
22. Remove the power steering line retainers from the frame.
23. Secure the power steering gear to the exhaust manifold.





24. Remove the four nuts securing the catalytic converter to the exhaust manifold pipe.
25. Separate the catalytic converter from the exhaust manifold pipe.
26. Suitably secure the exhaust system to the underside of the vehicle.
27. Remove the catalytic converter gasket. Do not reuse the gasket.





28. Loosen the two mounting nuts (2) in order to allow removal of the brake pressure modulator valve (1) from the bracket (3).
29. Remove the brake line retainers from the frame.





30. Remove the left transaxle mount.
31. Remove the two lower bolts and lower nut from the rear transaxle mount (1).





32. Remove the lower nut (1) from the front transaxle mount.





33. Support the left side of the frame with an appropriate jack.
34. Remove the three frame-to-body bolts (3) on the left side.
35. Loosen, but do not remove, the three frame-to-body bolts (3) on the right side.

Important: Insure that all pipes, hoses and wires are clear and not being bound or stressed when lowering the frame.

36. Carefully lower the left side of the frame and let hang.





37. lower the vehicle enough to gain access to the engine support fixture.

Important: Insure that all pipes, hoses and wires are clear and not being bound or stressed when lowering the transaxle.

38. Using the engine support fixture, carefully lower the transaxle in order to allow access to the case side cover.
39. Raise the vehicle enough to gain access to the transaxle case side cover.





40. Remove the left transaxle bracket (1) from the case side cover.





41. Remove the case side cover bolts.





42. Remove the case side cover (53).
43. Clean the case and side cover gasket surfaces.

Installation Procedure





1. Inspect the case side cover (53) for the following conditions:
^ Damaged or porous gasket sealing surfaces
^ Damaged or porous casting surfaces
^ Damaged or stripped bolt holes
2. Inspect the case side cover gaskets (54, 59) for damage. The gaskets are reusable if they are NOT damaged.





3. Assemble the case side cover inner gasket (59) to the case side cover (53). Use J 36850 on the seal surfaces.
4. Install the case side cover gasket (54) and case side cover (53) onto the case. Make sure the gaskets and electrical connector are positioned correctly.





5. Install case side cover bolt (56) and one side cover to case stud bolt (58) in the locations shown. These bolts will properly locate the case side cover and gasket to the case.

Notice: Refer to Fastener Notice in Service Precautions.

6. Install the remaining bolts as indicated:
^ Nine case side cover bolts (56)
^ Four side cover TORX(R) head bolts (57)
^ Four side cover to case stud bolts (58)
^ Tighten all bolts to 25 Nm (18 ft. lbs.).





7. Install the left transaxle bracket (1) to the case side cover.
8. Install the left transaxle bracket bolts.
^ Tighten the left transaxle bracket bolts to 110 Nm (81 ft. lbs.).





9. lower the vehicle enough to gain access to the engine support fixture.

Important: Insure that all pipes, hoses and wires are clear and not being bound or stressed when raising the transaxle.

10. Using the engine support fixture, carefully raise the transaxle to it's original position.
11. Raise vehicle.

Important: Insure that all pipes, hoses and wires are clear and not being bound or stressed when raising the frame.

12. Using an appropriate jack. Carefully raise the left side of the frame so that the frame-to-body bolts can be installed.
13. Using 16 mm (0.630 inch) dowel pins in the alignment holes (1), align the engine frame (2) with the body.
14. Install the frame-to-body bolts (3).
^ Tighten the bolts to 112 Nm (83 ft. lbs.).





15. Install the left transaxle mount.
16. Install the lower nut (1) onto the front Transaxle mount.
^ Tighten the nut to 70 Nm (52 ft. lbs.).





17. Install the two lower bolts and lower nut onto the rear transaxle mount (1).
^ Tighten the two lower bolts and lower nut to 50 Nm (37 ft. lbs.).





18. Position the brake pressure modulator valve (1) into the bracket (3).
^ Tighten the two nuts (2) to 10 Nm (89 inch lbs.).
19. Install the brake line retainers onto the frame.





20. Place a NEW catalytic converter gasket over the catalytic converter studs.

Notice: Do not over-flex or damage the flex decoupler joint when moving the flex decoupler joint from the normal mounting position. The flex decoupler joint will flex a maximum of six degrees which is equivalent to the pipes connected at the joint which move 1 inch for each foot length of pipe. A three foot pipe would move a maximum of three inches.

21. Position the catalytic converter onto the exhaust manifold pipe.
22. Install the four catalytic converter nuts.
^ Tighten the catalytic converter nuts to 25 Nm (18 ft. lbs.).





23. Install the power steering gear mounting bolts.
^ Tighten the bolts to 70 Nm (95 ft. lbs.).
24. Install the power steering line retainers onto the frame.
25. Install the power steering gear heat shield.

Caution: When installing the intermediate shaft make sure that the shaft is seated prior to pinch bolt installation. If the pinch bolt is inserted into the coupling before shaft installation, the two mating shafts may disengage. Disengagement of the two mating shafts will cause loss of steering control which could result in personal injury.





26. Connect the intermediate shaft to the power steering gear.
27. Install the intermediate shaft lower pinch bolt.
^ Tighten the bolt to 45 Nm (33 ft. lbs.).





28. Install the drive axle into the transaxle.
29. Install the ball joint into the steering knuckle.
30. Install the tie rod end into the steering knuckle.
31. Install the front air deflector.
32. Install both of the front fascia extensions (3)
33. Install the left front tire and wheel assembly.




34. Lower the vehicle.
35. Remove the engine support fixture.
36. Install the ground cable bolt (1) onto the transaxle.
^ Tighten the ground cable bolt to 17 Nm (13 ft. lbs.).





37. Install the range selector cable bracket and cable onto the transmission case.
38. Install the range selector cable bracket nuts.
^ Tighten the range selector cable bracket nuts to 25 Nm (18 ft. lbs.).
39. Install the range selector cable onto the range selector lever.
40. Check adjustment of the range selector cable. Re-adjust as needed.





41. Connect the transaxle electrical connector C100 (2).
42. Install the wiring harness (3) into the wiring harness retainer (1) on the transaxle.





43. Install the throttle and cruise control cables (1) into the throttle body and the accelerator control bracket (2).
44. Install the air cleaner assembly.
45. Connect the negative battery cable.





46. Remove the J 42640 from the steering column.
47. Fill the transaxle to the proper level.
48. Inspect the transaxle fluid level.
49. Inspect for fluid leaks.
50. Check the front end alignment.