Repair 2
REPAIR 2: Transmission Breather Pipe And Fluid Check ProcedureAUTOMATIC TRANSMISSION BREATHER PIPE INSTALLATION - REPAIR 2
1. Inspect new breather pipe (TES100050K) to ensure it has been modified to the following correct specification:
a) 180 mm (7.5 in.) from the tip of the breather pipe snap end fitting has been removed.
CAUTION:
Ensure that the angle of the end cut has been made so that the opening is oriented toward the inner fender wall.
b) The breather pipe has been cut at a 45 degree angle as shown in Figure 5.
c) A slit has been cut at the top side of the pipe back about 15 to 20 mm (5/8 to 3/4 in.) as illustrated in Figures 5.
CAUTION:
The banjo bolt and the seal washers must remain in position on the new breather pipe assembly during installation.
2. Verify that the plastic cap on the banjo is firmly in place and that there are two copper sealing washers, one under the head of the banjo bolt and the other beneath the plastic cap.
3. Place vehicle on lift and open hood.
NOTE:
The new breather pipe is pre-bent to follow the bulkhead to the LH side of the vehicle.
4. Feed the banjo end of the new breather down between the rear of the engine and bulkhead adjacent to Number 6 ignition coil plug lead until it comes in contact with the torque converter housing.
5. Raise the vehicle on the lift and from under the vehicle carefully pull the new breather toward the rear, following the route of the oil cooler pipes to the existing gearbox breather pipe connection location.
6. Clean the area around existing breather banjo bolt and remove from the gearbox.
7. Remove plastic protective piece from new breather pipe banjo.
8. Fit banjo to the gearbox and torque to 14 Nm (120 lbf.in.). (Figure 6)
9. Remove the tie wrap securing the old breather pipe to the transfer gearbox breather pipe.
10. Install a new tie wrap at the same location and secure the new breather pipe to the transfer gearbox breather pipe.
11. Cut the banjo connection from the old breather pipe to ease removal and push the old pipe upward into the engine bay.
12. Secure the new breather pipe to the top of the torque converter housing by firmly pressing the preinstalled clip onto the uppermost stiffener rib of the housing. (Figure 7)
13. Lower vehicle to access under-hood area, identify the old breather pipe and gently pull upward to remove it from the engine bay.
14. Discard the old pipe.
15. Feed the free end of the new breather pipe following the line of the bulkhead. Position the pipe behind components that are situated in this area.
CAUTION:
Do not remove hoses from the purge canister in an effort to aid installation of the breather.
16. Remove the bolt securing the purge canister to provide access to the inner fender area and feed the breather behind the purge canister. Direct the pipe down to the inner fender area adjacent to the bulkhead.
CAUTION:
Routing of the breather pipe for this campaign repair is to the LH inner fender. Routing of the breather in production AFTER the safe VIN is to an alternate location on the RH inner fender.
Refer to TIB D352 for modification instructions for the breather pipe after the safe VIN.
17. Secure the breather pipe to the two bulkhead mounted pipe clips. (Figure 7)
18. Install the purge canister.
CAUTION:
Kinks, deformation or pinching of the breather pipe can result in pressure buildup in the transmission. Fluid loss from the dipstick may result.
19. Verify that there are no kinks or deformations in the breather pipe created during the installation process.
AUTOMATIC GEARBOX FLUID LEVEL CHECK - REPAIR 2
CAUTION:
Always check the transmission fluid level under either fully "HOT" or fully "COLD" conditions. Under normal circumstances automatic gearbox fluid level should be checked when the fluid is "COLD," when the vehicle has stood for approximately 6 to 8 hours.
^ If the transmission is "COLD" follow the check procedure in the workshop manual for the "COLD" check.
^ If the transmission fluid is "HOT" because the vehicle has been driven recently, refer to TIB 44/01/98/NAS and to the measurement method specified below.
1. Position the vehicle on a level surface with the parking brake applied and the transmission in Park.
2. Apply the foot brake and start the engine.
WARNING:
Ensure that the foot brake and parking brake are firmly applied during the following procedure:
3. With the foot brake still applied, move the gear shift lever slowly through each gear position starting from Park (P-R-N-D-3-2-1).
4. Return the gearshift lever to Neutral (N) and leave the engine running.
5. Remove the transmission dipstick and wipe clean.
6. Insert the clean dipstick into the gearbox and ensure that it is pushed in completely.
7. Remove the dipstick immediately and observe the fluid level (Figure 8).
8. If HOT check has been conducted, the fluid must be below the "Max HOT" level for transmission fluid [19mm (0.750 in.) above the Max "COLD" mark] and above the "Min COLD" mark.
9. If the COLD check has been conducted, the fluid must be below the "Max COLD" mark and above the "Min COLD" mark on the dipstick.
WARNING:
If the fluid is above "Max HOT" level (hot check) or "Max COLD" level (cold check), the gearbox has been overfilled and the fluid level must be adjusted.
10. If fluid level is above applicable maximum, remove excess fluid and repeat fluid check.
11. If fluid level is below "Min COLD" mark, add fluid to obtain fluid reading above "Min COLD" mark and repeat fluid check.
TRANSFER GEARBOX FLUID LEVEL CHECK - REPAIR 2
1. Ensure vehicle is on level ground.
2. Place a drain tray under the transfer gearbox.
3. Thoroughly clean the area around the filler level plug.
4. Remove the filler level plug and allow any excess oil to drain. (Figure 9)
WARNING:
Spilled fluids can be a hazard. Ensure that any fluids spilled during repairs are cleaned up.
5. If no oil drains from inspection hole, fill transfer box with Dexron III ATF to level of level inspection plug.
6. Clean filler-level plug and apply Loctite 270 or 272 sealant to the plug threads.
7. Refit the level plug and tighten to 30 Nm (22 lbf.ft.).