Part 1

Transaxle

Installation (Steps 1-33)

Special Tool(s):

Special Tool(s):

Material:

Installation

All vehicles

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

NOTE: Prior to installation of a new or overhauled transaxle, flush out the cooler and cooler lines. For additional information, refer to Transmission Fluid Cooler backflushing and Cleaning.

1. Inspect the transmission fluid cooler tube backing rings and seals for damage and install a 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 tube.





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-in).





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





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 can 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. Remove the special tool from the transaxle.





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





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





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





11. Install the inspection cover and the 2 fasteners.





All wheel drive (AWD) vehicles
12. Position the power transfer unit (PTU) in place and install the 5 bolts.
^ Tighten to 90 Nm (66 lb-ft).





13. Position the PTU support bracket in place and install the 5 bolts.
^ Tighten to 70 Nm (52 lb-ft).





14. Position the RH catalytic converter in place and install the 4 nuts.
^ Tighten to 40 Nm (30 lb-ft).





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





16. Connect the RH catalyst monitor electrical connector.





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





18. Using a suitable driver, install a new intermediate shaft seal.
^ Make sure that the seal is fully seated against the drive gear.

19. NOTE: Do not overheat (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 deflector. Make sure the deflector is fully seated and there are no cracks on the face or inner diameter white colored tabs.





All vehicles
20. Position the roll restrictor bracket on the transaxle and install the 3 bolts.
^ Tighten to 90 Nm (66 lb-ft).





21. Position the subframe in place and install the 2 middle nuts.
^ Tighten to 150 Nm (111 lb-ft).





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





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





24. Install the rear subframe. nuts.
^ Tighten to 150 Nm (111 lb-ft).





25. Tighten the subframe. support bracket bolts.
^ Tighten to 103 Nm (76 lb-ft).





26. Position the roll restrictor in place, install the bracket and the 3 bolts.
^ Tighten to 90 Nm (66 lb-ft).





27. Install the roll restrictor heat shield and the 2 nuts.
^ Tighten to 11 Nm (8 lb-ft).





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





29. Position the power steering rack in place and install the 4 bolts.
^ Tighten to 107 Nm (79 lb-ft).





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





31. Install the 2 exhaust hangers and tighten the exhaust clamp.
^ Tighten to 40 Nm (30 lb-ft).





32. Position the LH halfshaft in the transaxle and in the steering knuckle.

Front wheel drive (FWD) vehicles
33. Position the RH halfshaft and intermediate shaft support bracket in the transaxle and in the steering knuckle. Install 1 stud bolt and 1 bolt.
^ Tighten to 55 Nm (41 lb-ft).