Transmission Removal and Installation

TRANSMISSION ASSEMBLY

Removal and Installation

Exploded View AT-251:

REMOVAL

CAUTION:
^ When removing the A/T assembly from engine, first remove the crankshaft position sensor (POS) from the A/T assembly.
^ Be careful not to damage sensor edge.

1. Disconnect the battery cable from the negative terminal.
2. Remove engine cover.





3. Remove A/T fluid level gauge.
4. Remove engine under cover with power tool.
5. Remove front cross bar with power tool.
6. Remove exhaust front tube and center muffler with power tool.
7. Remove three way catalyst.
8. Remove rear propeller shaft.





9. Remove control rod.
10. Remove crankshaft position sensor (POS) from A/T assembly.

CAUTION:
^ Do not subject it to impact by dropping or hitting it.
^ Do not disassemble.
^ Do not allow metal filings, etc. to get on the sensors front edge magnetic area.
^ Do not place in an area affected by magnetism.





11. Remove rear cover plate.
12. Remove starter motor.





13. Remove rear plate cover from converter housing part.





14. Turn crankshaft, and remove the four tightening bolts for drive plate and torque converter.

CAUTION: When turning crankshaft, turn it clockwise as viewed from the front of the engine.

15. Support A/T assembly with a transmission jack.

CAUTION: When setting the transmission jack, be careful not to allow it to collide against the drain plug.





16. Remove rear engine mounting member with power tool.





17. Remove engine mounting insulator (rear).
18. Remove air breather hose.
19. Disconnect A/T assembly harness connector.
20. Remove fluid cooler tube and A/T fluid charging pipe.
21. Remove O-ring from A/T fluid charging pipe.
22. Plug up openings such as the A/T fluid charging pipe hole, etc.
23. Remove bolts fixing A/T assembly to engine with power tool.





24. Remove A/T assembly from vehicle with a transmission jack.
^ Secure torque converter to prevent it from dropping.
^ Secure A/T assembly to a transmission jack.

INSPECTION

Installation and Inspection of Torque Converter





^ After inserting a torque converter to a A/T, be sure to check distance "A" to ensure it is within the reference value limit.
Distance "A": 25.0 mm (0.98 in) or more

INSTALLATION
Install the removed parts in the reverse order of the removal, while paying attention to the following work.








^ When installing A/T assembly to the engine, attach the fixing bolts in accordance with the following standard.





^ Align the positions of tightening bolts for drive plate with those of the torque converter, and temporarily tighten the bolts. Then tighten the bolts with the specified torque.

CAUTION:
^ When turning crankshaft, turn it clockwise as viewed from the front of the engine.
^ When tightening the tightening bolts for the torque converter after fixing the crankshaft pulley bolts, be sure to confirm the tightening torque of the crankshaft pulley mounting bolts.
^ After converter is installed to drive plate, rotate crankshaft several turns and check to be sure that A/T rotates freely without binding.

^ Install crankshaft position sensor (POS).
^ After completing installation, check A/T fluid leakage, A/T fluid level and A/T position.