Part 2

Transmission - All Wheel Drive (AWD)

Special Tool(s)






Material(s)






Installation

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

NOTE: Prior to installing a new, re-manufactured or overhauled transaxle, flush out the cooler and cooler tubes. REFER to Transmission Fluid Cooler Backflushing and Cleaning Transmission Fluid Cooler Backflushing and Cleaning. Hand clean the transmission mounted transmission fluid cooler tubes and thermal bypass valve.

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 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 nuts.

- Tighten to 9 Nm (80 lb-in).





3. Install new transmission fluid cooler tube-to-transaxle case bolts.

- Tighten to 9 Nm (80 lb-in).





4. Lubricate the torque converter pilot hub with grease.

5. NOTICE: 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. Using 209-00152, support the transaxle.





7. Position the transmission behind the engine and remove 307-346 (T97T-7902-A) .





8. Position the transaxle on the dowel pins and install the lower torque converter housing bolts.

- Tighten to 48 Nm (35 lb-ft).





9. Install the transaxle support insulator bracket, the nuts and the bolt.

- Tighten the bolt to 80 Nm (59 lb-ft).

- Tighten the nuts to 63 Nm (46 lb-ft).





10. Remove 303-F072 and 303-1454.





11. Remove 303-1245 from the LH (Left Hand) cylinder head.





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





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





14. Install 3 new torque converter bolts.

- Install the first torque converter bolt in the slotted hole on the flexplate.

- Tighten to 55 Nm (41 lb-ft).





15. Install the inspection cover and the 2 fasteners.





16. Install the PTU (Power Transfer Unit). REFER to Power Transfer Unit (PTU) Removal and Replacement.

17. NOTE: Using 300-OTC1585AE , raise the subframe into the installed position.

NOTE: RH (Right Hand) shown, LH (Left Hand) similar.

Loosely install the RH (Right Hand) and LH (Left Hand) front subframe bolts.





18. NOTE: RH (Right Hand) shown LH (Left Hand) similar.

Position the RH (Right Hand) and LH (Left Hand) subframe support brackets in place and loosely install the bracket bolts.





19. NOTE: RH (Right Hand) shown LH (Left Hand) similar.

Loosely install the RH (Right Hand) and LH (Left Hand) rear subframe bolts.





20. NOTE: RH (Right Hand) shown LH (Left Hand) similar.

Tighten the RH (Right Hand) and LH (Left Hand) front subframe bolts.

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





21. NOTE: RH (Right Hand) shown LH (Left Hand) similar.

Tighten the RH (Right Hand) and LH (Left Hand) rear subframe bolts.

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





22. NOTE: RH (Right Hand) shown LH (Left Hand) similar.

Tighten the RH (Right Hand) and LH (Left Hand) subframe support bracket bolts.

- Tighten to 55 Nm (41 lb-ft).





23. Install the EPAS (Electronic Power Assist Steering) wiring harness pin-type retainer on the steering gear.





24. Connect the 2 EPAS (Electronic Power Assist Steering) electrical connectors.

- Install the EPAS (Electronic Power Assist Steering) wiring harness bracket pin-type retainer on the steering gear.





25. Position the EPAS (Electronic Power Assist Steering) wiring harness bracket in place and install the bolt.

- Tighten to 9 Nm (80 lb-in).





26. Position the EPAS (Electronic Power Assist Steering) heat shield in place and install the bolt.

- Tighten to 9 Nm (80 lb-in).





27. NOTICE: Do not allow the intermediate shaft to rotate while it is disconnected from the gear or damage to the clockspring may occur. If there is evidence that the intermediate shaft has rotated, the clockspring must be removed and centered. REFER to Clockspring Service and Repair.

Install the steering intermediate shaft onto the steering gear and install a new bolt.

- Tighten to 20 Nm (177 lb-in).





28. Install the cooler hose retainer on the subframe.





29. Install the exhaust Y-pipe. REFER to Exhaust Y-Pipe Exhaust Y-Pipe.

30. NOTE: The hex-holding feature can be used to prevent turning of the stud while installing the nuts.

NOTE: RH (Right Hand) shown, LH (Left Hand) similar.

Install the tie rod ends in the knuckles and install the nuts.

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





31. NOTE: RH (Right Hand) shown, LH (Left Hand) similar.

Install new upper stabilizer bar link nuts.

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





32. Install the RH (Right Hand) and LH (Left Hand) front halfshafts. REFER to Halfshaft - RH, All Wheel Drive (AWD) Halfshaft - RH and REFER to Halfshaft - LH Halfshaft - LH.

33. Install the underbody air duct and the 3 twist lock retainers.





34. Install the 2 lower retainers in the RH (Right Hand) fender splash shield.





35. Install the front wheels. REFER to Wheel and Tire Removal and Replacement.

36. Install the top torque converter housing bolts.

- Tighten to 48 Nm (35 lb-ft) .





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





38. Connect the 2 wiring harness retainers on the transaxle studs.





39. Install the starter. REFER to Starter Motor - 3.5L Ti-VCT Service and Repair.

40. Position the selector lever cable and bracket in place and install the bolts.

- Tighten to 12 Nm (106 lb-in).





41. Place the selector lever in DRIVE.

42. Place the manual control lever in DRIVE.

1. Rotate the manual control lever clockwise until it stops.

2. Rotate the manual control lever counterclockwise one detent.





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





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





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





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





47. Install the upper intake manifold. REFER to Upper Intake Manifold Upper Intake Manifold.

48. Install the battery tray. REFER to Battery and Battery Tray - Exploded View Battery and Battery Tray - Exploded View.

49. Install the ACL (Air Cleaner) assembly. REFER to Intake Air System Components - Exploded View [1][2]Diagrams.

50. Fill with clean transmission fluid to the correct level. REFER to Transmission Fluid Drain and Refill Transmission Fluid Drain and Refill.

51. If a new solenoid body is installed, the solenoid body strategy will need to be updated. REFER to Solenoid Body Strategy Download Solenoid Body Strategy Download.