Removal and Replacement

Transmission Replacement

^ Tools Required
- J 41623-B Cooler Quick Connect Tool
- J 41160 Transmission Jack Adapter

Removal Procedure
1. Remove the front compartment sight shield.
2. Remove the upper and lower air cleaner assemblies.





3. Disconnect the range selector cable terminal from the transaxle range selector lever.
4. Remove the nuts securing both the range selector cable bracket and heater pipe to the transaxle. Position the range selector cable bracket and heater pipe aside.
5. Remove the Magnasteer wire from the retaining clip.
6. Disconnect the master cylinder brake pipe retainers from the side rail.

7. Important: Supporting the brake pipes above the body side rail is necessary while removing the transaxle in order to prevent pinching of the brake pipes.

Remove the brake pipe retainers from the side rail and using mechanics wire, support the brake pipes above the side rail.





8. Reposition the main wiring harness to gain access to the upper transaxle to engine bolts (1).
9. Remove the transaxle to engine bolts (1). The remaining bolt (2) will temporally retain the transaxle and will be removed from the underside of the vehicle.
10. Place a drain pan under the vehicle.





11. Remove the upper transaxle oil cooler pipe retaining bolt from the radiator fan shroud.
12. Disconnect the upper transaxle oil cooler pipe from the radiator using the J 41623-B. Install plugs in the oil cooler pipe and the radiator to prevent fluid loss and contamination.





13. Disconnect the lower transaxle oil cooler pipe from the transaxle and Install plugs in the oil cooler pipe and the transaxle to prevent fluid loss and contamination.
14. Disconnect the transaxle vent tube from the accelerator bracket.
15. Install the engine support fixture.
16. Raise and support the vehicle. Refer to Vehicle Lifting.

17. Caution: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed.

Secure the vehicle to the front hoist pads.
18. Remove the stabilizer shaft links.
19. Swing the stabilizer shaft downward in order to gain access to the power steering gear retaining bolts.
20. Remove the left front wheelhouse liner.

21. Important: The following are exceptions while following the frame removal procedure:

^ Do not remove the front stabilizer shaft from the frame.
^ Do not remove the A.I.R. pump assembly from the vehicle. Retain the pump to the body using mechanics wire.
^ Do not remove the insulators from the frame.
^ Do not remove the control arms from the frame.

Remove the front frame.
22. Remove the left transaxle mount and bracket from the transmission.
23. Support the transaxle using the J 41160 and a suitable transmission jack.
24. Secure the J 41160 to the transaxle.





25. Remove the bolt securing the left transaxle brace to the transaxle.
26. Loosen the nut securing the left transaxle brace to the engine.
27. Remove the left transaxle brace from the powertrain assembly.





28. Remove the 3 ground connections from the side of the transaxle.
29. Disconnect the transaxle main electrical harness connector.





30. Remove the bolt (2) securing the front transaxle brace (1) to the transaxle.
31. Remove the nut securing the secondary AIR pipe to the transaxle.





32. Remove the nuts (2, 3) securing the vehicle speed sensor heat shield (1) to the transaxle.
33. Remove the vehicle speed sensor heat shield (1) from the vehicle.
34. Disconnect the vehicle speed sensor electrical connector.





35. Remove only the bolts securing the front transaxle brace to the transaxle.





36. Remove only the bolts securing the center transaxle brace to the transaxle.





37. Disengage the right and left drive shafts (2) from the transaxle (1). The drive shafts do not have to be removed from the wheels.
38. Using mechanics wire, support the wheel drive shafts out of the way by tying them up to the strut spring.
39. Remove the torque converter cover.





40. Important: Mark the flywheel to torque converter position so that they can be assembled in the same position.

Remove the flywheel to torque converter bolts.
41. Position the power steering gear pressure hose to the right side of the vehicle in order to clear the transaxle during removal.





42. Remove the remaining transaxle to engine bolt (2).
43. Separate the transaxle from the engine.
44. Tilt the transaxle using the support jack enough to allow clearance for the starter nose cone.

45. Important: Ensure clearance is maintained between the transaxle and the following:

^ The brake pipes
^ The secondary AIR pipe
^ The power steering pressure hose
^ The wiring harnesses

Carefully lower the transaxle from the vehicle.
46. Complete the following if transaxle replacement is necessary:
^ Remove the transaxle cooler pipe,
^ Remove the left transaxle bracket, refer to Transmission Mount Bracket Replacement - Left.
^ Remove the rear transaxle bracket, refer to Transmission Mount Bracket Replacement - Rear.
^ Flush the transmission oil cooler. Refer to Automatic Transmission Oil Cooler Flushing and Flow Test (J 45096) Automatic Transmission Oil Cooler Flushing and Flow Test (J 35944-A).

Installation Procedure
1. Complete the following if previously removed from the transaxle:
^ Install the rear transaxle bracket, refer to Transmission Mount Bracket Replacement - Rear.
^ Install the left transaxle bracket, refer to Transmission Mount Bracket Replacement - Left.
^ Install the transaxle cooler pipe, refer to Transmission Fluid Cooler Hose/Pipe Replacement.

2. Important: Ensure clearance is maintained between the transaxle and the following:

^ The brake pipes
^ The secondary AIR pipe
^ The power steering pressure hose
^ The wiring harnesses
Carefully raise the transaxle to the engine in a tilted position in order to clear the starter nose cone.





3. Align the transaxle with the engine and position the transaxle onto the engine dowels.

Notice: Refer to Fastener Notice in Service Precautions.

Install the engine to transaxle bolt (2).
Tighten the bolt to 75 Nm (55 ft. lbs.).





4. Connect the vehicle speed sensor electrical connector.
5. Install the engine to transaxle center brace and heat shield.





6. Install the bolts securing the front transaxle brace to the transaxle.
Tighten the bolts to 50 Nm (37 ft. lbs.).





7. Important: Line up the flywheel and converter using the alignment marks made during disassembly.

Install the flywheel to converter bolts.
Tighten the bolts to 60 Nm (44 ft. lbs.).
8. Install the torque converter cover assembly.





9. Install the engine to transaxle bracket lower bolt (1).
Tighten the bolt to 50 Nm (37 ft. lbs.).





10. Install the right and left drive shafts (2) to the transaxle (1).





11. Install the 3 ground connections to the side of the transaxle.
Tighten the bolts to 50 Nm (37 ft. lbs.).
12. Connect the transaxle main electrical harness connector.





13. Install the left transaxle brace to the powertrain assembly.
14. Install the bolt securing the left transaxle brace to the transaxle.
Tighten the left transaxle brace bolt to 50 Nm (37 ft. lbs.).
Tighten the left transaxle brace nut to 41 Nm (30 ft. lbs.).
15. Remove the transmission jack and the J 41160.
16. Install the left transaxle mount and bracket to the transmission.
17. Install the front frame assembly to the vehicle.
18. Install the left front wheelhouse liner.
19. Install the stabilizer shaft links.
20. Lower the vehicle.





21. Connect the lower transaxle oil cooler pipe to the transaxle.





22. Install the upper transaxle oil cooler pipe to the radiator.





23. Install the remaining transaxle to engine bolts (1).
Tighten the bolts to 75 Nm (55 ft. lbs.).
24. Remove the engine support fixture.





25. Install the range selector cable bracket to the studs on the transaxle.
26. Install the heater pipe to the stud on the transaxle.
27. Install the nuts that retain the heater pipe and the range selector cable bracket to the transaxle.
Tighten the nuts to 25 Nm (18 ft. lbs.).
28. Connect the range selector cable terminal to the transaxle range selector lever.
29. Install the Magnisteer wire to the retaining clip.
30. Connect the transaxle vent tube to the accelerator bracket.
31. Install the Magnisteer wire to the retaining clip.
32. Connect the transaxle vent tube to the accelerator bracket.
33. Install the brake pipe retainers to the side rail.
34. Install the upper and lower air cleaner assemblies.





35. Install the front compartment sight shield (1).
36. Flush the transmission cooler.
37. Add DEXRON(r) VI transmission fluid as required. Refer to Fluid Capacity Specifications and Transmission Fluid Checking Procedure.
38. Check the front suspension alignment, adjust the toe as necessary.
39. Clear the transmission adaptive pressures (TAPS). Refer to Scan Tool Output Controls.
40. Check the front end alignment.
41. Road test the vehicle and check for transaxle leaks.