Installation

Transaxle









Installation

All vehicles

NOTICE: 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 transmission fluid cooler thermal bypass valve bracket nuts.
- Tighten to 9 Nm (80 lb-in).






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






4. Lubricate the torque converter pilot hub with grease and install the torque converter into the transaxle.

5. NOTICE: Make sure that when installing the manual control lever it is fully seated onto the manual control lever shaft or damage to the manual control lever shaft will occur and the lever will come loose.

NOTICE: Make sure to hold the manual control lever while tightening the manual control lever nut or damage to the manual control lever and park components will occur.

Install the manual control lever and nut.
- Tighten to 18 Nm (159 lb-in).






6. NOTICE: 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.






7. Position the transaxle in place and install the 7 torque converter housing bolts.
- Tighten to 48 Nm (35 lb-ft).






8. Remove the Transmission Jack Adapter from the transaxle.





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





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





11. NOTICE: Use only the specified bolts for the torque converter. Standard length fasteners may bottom out and damage the torque converter clutch apply surface.

Install 3 new torque converter bolts (W714722).
- Install the first torque converter bolt in the slotted hole on the flexplate.

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






12. Install the inspection cover and the 2 fasteners.





All-Wheel Drive (AWD) vehicles

13. Position the Power Transfer Unit (PTU) in place and install the 5 PTU (Power Transfer Unit) -to-transaxle bolts.
- Tighten to 90 Nm (66 lb-ft).






14. Position the PTU (Power Transfer Unit) support bracket in place and install the 5 bolts.
- Tighten to 70 Nm (52 lb-ft).






15. NOTE: Make sure to tighten the 4 new nuts in the following sequence.
Install a new RH catalytic converter gasket, position the RH catalytic converter and tighten the 4 new nuts in the sequence shown.

- Tighten to 40 Nm (30 lb-ft).






16. Connect the RH CMS (Catalyst Monitor Sensor) electrical connector.





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






All vehicles

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






19. NOTE: Align the front subframe index marks to the body index marks made during removal.
Using the Powertrain Lift With Tilting Plate, position the subframe in place and install the 2 middle nuts.

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






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






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





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






23. Tighten the subframe support bracket bolts.
- Tighten to 90 Nm (66 lb-ft).






24. Position the roll restrictor in place, install the 2 roll restrictor-to-transaxle through bolts.
- Tighten to 115 Nm (85 lb-ft).






25. Install the roll restrictor heat shield and the 2 nuts.
- Tighten to 9 Nm (80 lb-in).






26. NOTE: RH shown, LH similar.
Install the tie-rod ends and nuts.

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

- Install the cotter pins.






27. NOTICE: Do not allow the intermediate shaft to rotate while it is disconnected from the gear or damage to the clockspring can occur. If there is evidence that the intermediate shaft has rotated, the clockspring must be removed and recentered. For additional information, refer to Restraints and Safety Systems &/or Air Bag Systems.

Install the intermediate shaft onto the steering gear and install a new bolt.
- Tighten to 23 Nm (17 lb-ft).






28. Using a new banjo bolt and 2 new seals, install the Power Steering Pressure (PSP) tube.
- Tighten to 48 Nm (35 lb-ft).






29. Install the exhaust Y-pipe.

30. Install the LH halfshaft and the intermediate shaft.

31. Install the power steering cooler bracket bolt to the RH side of the subframe.
- Tighten to 9 Nm (80 lb-in).






32. Connect the power steering cooler hose.





33. Position the lower bumper on the subframe and install the 3 LH lower bumper-to-subframe nuts.
- Tighten to 10 Nm (89 lb-in).






34. Install the 3 RH lower bumper-to-subframe nuts.
- Tighten to 10 Nm (89 lb-in).






35. Install the front splash shield and install the screws and the pushpin fasteners.





36. Position the RH fender splash shield in place and install the retainers.
1. Install the screws.

2. Install the pushpin fasteners.






37. Install the transaxle support insulator bracket, bolt and the 3 nuts.
1. Tighten the transaxle support insulator bracket bolt to 80 Nm (59 lb-ft).

2. Tighten the transaxle support insulator bracket nuts to 63 Nm (46 lb-ft).






38. Install the transaxle support insulator through bolt.
- Tighten to 175 Nm (129 lb-ft).






39. Remove the Engine Support Bar and Engine Spreader Bar.





40. Remove the Engine Lift Eye from the LH cylinder head.





41. If a new solenoid body was installed, wipe the surface of the existing solenoid body strategy tag on top of the transaxle case clean and install the new solenoid body strategy tag (supplied with the solenoid body service kit) over it.





42. Install the top 4 torque converter housing bolts.
- Tighten to 48 Nm (35 lb-ft).






43. Connect the transaxle electrical connector.





44. NOTICE: The fuel tube retainer is damaged when it is removed from the transaxle stud and will no longer secure the fuel tubes to the transaxle stud. Failure to discard the old fuel tube retainer and install a new fuel tube retainer can result in damage to the fuel tubes.

Install a new fuel tube retainer on the transaxle studbolt.






45. NOTICE: Be sure the fuel tubes are installed in the fuel tube retainer in the same position and orientation as noted during removal. The fuel vapor tube is in the top groove of the retainer and the fuel supply tube is in the bottom groove of the retainer. Failure to install the fuel tubes in the correct position and orientation can result in the fuel tubes rubbing on components in the engine compartment causing damage to the fuel tubes.

Install the fuel supply tube and the fuel vapor tube in the fuel tube retainer.
1. Fuel supply tube

2. Fuel vapor tube

3. Fuel tube retainer






46. Install the starter studbolt.
- Tighten to 26 Nm (19 lb-ft).






47. Install the wiring harness fastener on the starter motor studbolt.





48. Connect the starter motor terminals and position the starter terminal boot over the battery cable terminal.
1. Tighten to 12 Nm (106 lb-in).

2. Tighten to 6 Nm (53 lb-in).






49. Install the starter motor electrical terminal cover.





50. Place the selector lever in DRIVE.

51. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket.

NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place. Press the selector lever cable into the selector lever cable bracket and listen for the selector lever cable retainer to click in place. Pull back on the selector lever cable to make sure that the selector lever is locked into the selector lever cable bracket.
Install the selector lever cable in the selector lever cable bracket.






52. 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 until it stops.






53. Unlock the selector lever cable adjuster.
1. Pry the latch up.

2. Push the lock tab to slide it over.






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





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





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





57. Install the upper intake manifold.

58. Install the battery tray.

59. Install the Air Cleaner (ACL) and ACL (Air Cleaner) outlet pipe.

60. Fill the power steering system.

61. Fill with clean transmission fluid to the correct level. For additional information, refer to Transmission Fluid Drain and Refill .

62. If a replacement transaxle assembly is being installed or a new solenoid body is installed, the PCM will must be reflashed with a new solenoid body strategy and identification data file. For additional information, refer to Solenoid Body Strategy Automatic Transmission - 6F50/6F55.

63. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions.