Automatic Transaxle Replacement

REMOVAL
1. REMOVE BATTERY
2. REMOVE SUSPENSION UPPER BRACE
3. REMOVE AIR CLEANER ASSEMBLY
4. DISCONNECT THROTTLE CABLE





5. REMOVE CRUISE CONTROL ACTUATOR
a. Disconnect the connector.
b. Remove the 3 bolts and disconnect cruise control actuator with the bracket.





6. DISCONNECT 2 OIL COOLER HOSES
7. DISCONNECT VEHICLE SPEED SENSOR CONNECTOR
8. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR
9. DISCONNECT SHIFT SOLENOID VALVE NO. 1 AND NO. 2 CONNECTOR
10. DISCONNECT SHIFT SOLENOID VALVE SL CONNECTOR





11. REMOVE 2 FRONT SIDE ENGINE MOUNTING BOLTS





12. DISCONNECT GROUND CABLE
Remove the bolt and ground cable.
13. REMOVE STARTER
a. Disconnect the connector and remove the nut.
b. Remove the 2 bolts, shift cable clamp and starter.
14. REMOVE 3 TRANSAXLE-TO-ENGINE BOLTS
Remove the 3 bolts and ground cable.





15. REMOVE EXHAUST MANIFOLD STAY
Remove the 2 bolts and exhaust manifold stay.
16. REMOVE TRANSAXLE-TO-ENGINE BOLT
17. REMOVE ENGINE HOOD
a. Disconnect the washer pipe.
b. Remove the 4 bolts and engine hood.
18. RAISE AND SUPPORT VEHICLE SECURELY
19. REMOVE FRONT WHEELS
20. REMOVE ENGINE UNDER COVER AND CENTER ENGINE UNDER COVER





21. DISCONNECT SHIFT CONTROL CABLE
a. Remove the nut and disconnect the shift control cable from the control shaft lever.
b. Remove the clip and disconnect the shift control cable from the bracket.





22. REMOVE DIFFERENTIAL FLUID DRAIN PLUG AND GASKET
23. DRAIN DIFFERENTIAL FLUID
24. REMOVE LH AND RH FENDER APRON SEALS
25. REMOVE LH AND RH DRIVE SHAFTS





26. REMOVE EXHAUST FRONT PIPE
a. Remove the 2 nuts and exhaust front pipe clamp.
b. Remove the 2 bolts and exhaust pipe No. 1 support bracket.
c. Remove the 3 nuts.
d. Remove the 2 bolts, nuts and front exhaust pipe.
e. Remove the 2 gaskets.





27. REMOVE FR ENGINE MOUNTING INSULATOR BOLT





28. REMOVE RR ENGINE MOUNTING NUT
a. Remove the 2 grommets.
b. Remove the 3 nuts.





29. REMOVE LH TRANSAXLE MOUNTING NUT
a. Remove the 2 grommets.
b. Remove the 2 nuts.





30. REMOVE STEERING GEAR HOUSING
a. Remove the 4 bolts, LH and RH stabilizer bar brackets and 2 bushings.
b. Remove the front stabilizer bar.
c. Remove the 2 steering gear housing mounting bolts and nuts.
31. TIE STEERING GEAR HOUSING TO REAR ENGINE MOUNTING BRACKET BY CORD OR EQUIVALENT





32. ATTACH ENGINE SLING DEVICE TO ENGINE HANGERS

CAUTION: Do not attempt to hang the engine by hooking the chain to any other part.

33. REMOVE FRONT FRAME ASSEMBLY





a. Remove the 2 bolts and steering return pipe mounting brackets.





b. Remove the screws and turn over the front side and rear side of the LH and RH fender liners.





c. Remove the 6 bolts and 4 nuts.
d. Remove the front frame assembly.
34. SUPPORT TRANSAXLE WITH A TRANSMISSION JACK





35. REMOVE FRONT SIDE STIFFENER PLATE
Remove the nut, 2 bolts and stiffener plate.
36. REMOVE REAR END PLATE
a. Remove the 2 bolts and No. 1 exhaust pipe support bracket.
b. Remove the 2 bolts and rear end plate with oil pan insulator.





37. REMOVE TORQUE CONVERTER CLUTCH MOUNTING BOLT
Turn the crankshaft to gain access to each bolt, remove the 6 bolts while holding the crankshaft pulley set bolt with a wrench.
38. REMOVE REAR SIDE STIFFENER PLATE
a. Remove the 2 bolts and manifold stay.
b. Remove the 4 bolts and stiffener plate.
39. REMOVE TRANSAXLE ASSEMBLY
Separate the transaxle and engine, and lower the transaxle.

INSTALLATION





1. CHECK TORQUE CONVERTER CLUTCH INSTALLATION
Using a scale and a straight edge, measure the distance from the installed surface to the transaxle housing.
Correct distance: 13.0 mm (0.512 inch) or more
2. INSTALL TRANSAXLE ASSEMBLY
a. Using a jack, lift up the transaxle.
b. Install the transaxle to the engine.





3. TEMPORARILY INSTALL TRANSAXLE-TO-ENGINE BOLT
4. INSTALL REAR SIDE STIFFENER PLATE
a. Install the stiffener plate with the 4 bolts.
Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.)
b. Install the manifold stay with the 2 bolts.
Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.)
5. TIGHTEN TRANSAXLE-TO-ENGINE BOLT
Torque: 66 Nm (670 kgf-cm, 48 ft. lbs.)





6. INSTALL TORQUE CONVERTER CLUTCH MOUNTING BOLT
Align the holes in drive plate with the bolt holes in the torque converter clutch to install the 6 bolts while holding the crank shaft pulley set bolt with a wrench.
Torque: 27 Nm (280 kgf-cm, 20 ft. lbs.)

HINT: First install the green colored bolt and then 5 other bolts.





7. INSTALL REAR END PLATE
a. Install the rear end plate and oil pan insulator with the 2 bolts.
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
b. Install the No.1 exhaust pipe support bracket with the 2 bolts.
Torque: 19 Nm (195 kgf-cm, 14 ft. lbs.)
8. INSTALL FRONT SIDE STIFFENER PLATE
Install the stiffener plate with a nut and 2 bolts.
Torque: 42 Nm (430 kgf-cm, 31 ft. lbs.)
9. INSTALL FRONT FRAME ASSEMBLY
a. Install the front frame assembly.





b. Bend the fender liners under to install the front frame assembly with lower suspension arm, LH and RH, front and rear braces, then install the 6 bolts and 4 nuts.
Torque:
19 mm head bolt: 181 Nm (1,850 kgf-cm, 134 ft. lbs.)
14 mm head bolt: 32 Nm (330 kgf-cm, 24 ft. lbs.)
Nut: 36 Nm (370 kgf-cm, 27 ft. lbs.)





c. Install the steering return pipe mounting brackets with the 2 bolts.
Torque: 10 Nm (1100 kgf-cm, 7 ft. lbs.)





d. Install the 8 screws on the front and rear side of the LH and RH fender liners.
10. REMOVE ENGINE SLING DEVICE FROM ENGINE HANGERS





11. INSTALL STEERING GEAR HOUSING
a. Connect the steering gear housing to front frame assembly.
b. Install the 2 steering gear housing mounting bolts and nuts.
Torque: 181 Nm (1,850 kgf-cm, 134 ft. lbs.)
c. Install the front stabilizer bar.
d. Install the 4 bolts, LH and RH stabilizer bar brackets and 2 bushings.
Torque: 19 Nm (195 kgf-cm, 14 ft. lbs.)





12. INSTALL REAR SIDE ENGINE MOUNTING NUT
a. Install the 3 nuts.
Torque: 66 Nm (670 kgf-cm, 48 ft. lbs.)
b. Install the 2 grommets.





13. INSTALL LEFT SIDE TRANSAXLE MOUNTING NUT
a. Install the 2 nuts.
Torque: 80 Nm (820 kgf-cm, 59 ft. lbs.)
b. Install the 2 grommets.





14. INSTALL FRONT SIDE ENGINE MOUNTING INSULATOR BOLT
Torque:
Green color bolt: 66 Nm (670 kgf-cm, 48 ft. lbs.)
Silver color bolt: 44 Nm (450 kgf-cm, 32 ft. lbs.)





15. INSTALL EXHAUST FRONT PIPE
a. Install the front exhaust pipe, then install the No.1 exhaust pipe support bracket with the 2 bolts.
Torque: 33 Nm (330 kgf-cm, 24 ft. lbs.)
b. Install the gasket, 2 bolts and new nuts.
Torque: 56 Nm (570 kgf-cm, 41 ft. lbs.)
c. Install the gasket and 3 new nuts to exhaust manifold.
Torque: 62 Nm (630 kgf-cm, 46 ft. lbs.)
d. Install the exhaust pipe clamp and 2 nuts.
Torque: 33 Nm (330 kgf-cm, 24 ft. lbs.)
16. INSTALL LH AND RH DRIVE SHAFTS
17. INSTALL LH AND RH FENDER APRON SEALS





18. INSTALL DIFFERENTIAL FLUID DRAIN PLUG AND NEW GASKET
19. FILL DIFFERENTIAL FLUID
Fluid type: ATF D-II or DEXRON(R) III (DEXRON(R) II)
Capacity: 1.6 liters (1.7 US qts, 1.4 Imp. qts)





20. CONNECT SHIFT CONTROL CABLE
a. Install the shift control cable and clip to the bracket.
b. Install the shift control cable and nut to the park/neutral position switch.
Torque: 15 Nm (150 kgf-cm, 11 ft. lbs.)
21. INSTALL ENGINE UNDER COVER AND CENTER ENGINE UNDER COVER
22. INSTALL FRONT WHEELS
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
23. LOWER VEHICLE
24. INSTALL ENGINE HOOD
a. Install the engine hood with 4 bolts.
Torque: 14 Nm (145 kgf-cm, 10 ft. lbs.)
b. Connect the washer pipe.
25. ADJUST ENGINE HOOD





26. INSTALL EXHAUST MANIFOLD STAY
Install the exhaust manifold stay with 2 bolts.
Torque: 42 Nm (430 kgf-cm, 31 ft. lbs.)





27. INSTALL 3 TRANSAXLE-TO-ENGINE BOLTS
Install the ground cable with 3 bolts.
Torque: 66 Nm (670 kgf-cm, 48 ft. lbs.)
28. INSTALL STARTER
a. Install the starter, shift cable clamp and 2 bolts.
Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.)
b. Install the connector and nut.
29. CONNECT GROUND CABLE
Install the ground cable with bolt.





30. INSTALL 2 FRONT ENGINE MOUNTING BOLTS
Torque:
Green color bolt: 66 Nm (670 kgf-cm, 48 ft. lbs.)
Silver color bolt: 44 Nm (450 kgf-cm, 32 ft. lbs.)
31. CONNECT SHIFT SOLENOID VALVE SL CONNECTOR
32. CONNECT SHIFT SOLENOID VALVE NO.1 AND NO.2 CONNECTORS
33. CONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR
34. CONNECT VEHICLE SPEED SENSOR CONNECTOR





35. CONNECT 2 OIL COOLER HOSES





36. INSTALL CRUISE CONTROL ACTUATOR
a. Install the cruise control actuator with the bracket and the 3 bolts.
b. Connect the connector.
37. CONNECT THROTTLE CABLE
38. INSTALL AIR CLEANER ASSEMBLY
39. INSTALL SUSPENSION UPPER BRACE
Torque: 80 Nm (820 kgf-cm, 59 ft. lbs.)
40. INSTALL BATTERY
41. CHECK AND ADJUST TRANSMISSION CONTROL ROD AND PARK/NEUTRAL POSITION SWITCH
42. CHECK ATF LEVEL
43. CONDUCT ROAD TEST OF VEHICLE