Transmission/Transaxle Replacement

Captions Are Nm (ft. Lbs.) Part 1 Of 2:

Part 2 Of 2:

REMOVAL
1. Remove battery and battery tray.





2. Remove two bolts and loosen fan shroud of cooling fan to avoid damage to fan.
Torque: 5.0 Nm (43 inch lbs.).
3. Disconnect throttle cable, as follows:





a. Loosen the adjusting nut and disconnect the cable from the bracket.
b. Disconnect the throttle cable from the linkage.





4. Remove upper side starter mounting bolt.
Torque: 39 Nm (29 ft. lbs.).
5. Remove transmission select lever and transfer shift lever, as follows:





a. Remove the clip, washer and wave washer, and disconnect the transfer control rod.





b. Remove the nut and washer, and disconnect the transmission control rod.
Torque: 13 Nm (108 inch lbs.).





c. Remove the transfer shift lever knob.
d. Remove the four screws and console.





e. Remove the four screws and transfer shift lever boot.





f. Remove the two nuts, four screws and console box.





g. Disconnect the three connectors.





h. Remove the six screws and transmission shift lever assembly.
Torque: 5.4 Nm (48 inch lbs.).





i. Remove the four bolts and transfer shift lever.
Torque: 18 Nm (13 ft. lbs).
j. Remove the two cushions.
6. Disconnect these connectors:
- No.1 vehicle speed sensor connector
- No.2 vehicle speed sensor connector
- Park/neutral position switch connector
- Solenoid wire connector
- Automatic Transmission Fluid (ATF) temperature sensor connector
- Center differential lock indicator switch connector
- L4 position switch connector
- Transfer neutral position switch connector
7. Disconnect bleeder hose from transfer.
8. Remove front and rear propeller shaft.
9. Remove oil filler pipe, as follows:
a. Remove the level gauge.





b. Remove the upper side mounting bolt.





c. Remove the bolt and filler pipe.

INSTALLATION NOTE: Replace the used O-ring with a new one.





10. Loosen two oil cooler pipe union nuts.
Torque: 34 Nm (25 ft. lbs.).





11. Remove four stabilizer bar bracket mounting bolts
Torque: 18 Nm (13 ft. lbs.).





12. Remove engine under cover. Remove the four bolts and engine under cover.
Torque: 28 Nm (21 ft. lbs.).
13. Remove torque converter clutch mounting bolt, as follows:





a. Remove the converter hole plug.
b. Turn the crankshaft to gain access to each bolt.





c. Hold the crankshaft pulley bolt with a wrench and remove the six bolts.
Torque: 55 Nm (40 ft. lbs.)

INSTALLATION NOTE: First install the gray colored bolt and then five other bolts.

14. Remove front exhaust pipe assembly, as follows:
a. Remove the two nuts, bolts and gasket, and disconnect the front exhaust pipe assembly.
Torque: 39 Nm (29 ft lbs.).

INSTALLATION NOTE: Replace the used nuts and gasket with new nuts and gasket.

b. Loosen the clamp bolt and disconnect the clamp from the No.1 support bracket.
Torque: 19 Nm (14 ft. lbs.).
c. Remove the two bolts and No.1 support bracket.
Torque: 24 Nm (17 ft. lbs.).
d. Remove the four nuts and two gaskets, shift the front exhaust pipe assembly to the vehicle's outside.
Torque: 62 Nm (46 ft. lbs.).

INSTALLATION NOTE: Replace the used gaskets and nuts with new gaskets and nuts.

15. Remove starter, as follows:





a. Remove the nut and disconnect the starter wire and connector.
b. Remove the lower side mounting bolt and starter.
Torque: 39 Nm (29 ft. lbs.).
16. Remove crossmember, as follows:
a. Support the transmission with the transmission jack.





b. Remove the eight bolts and two nuts, and then remove the crossmember.
Torque:
Bolt: 61 Nm (45 ft. lbs.).
Nut: 74 Nm (54 ft.lbs).
17. Remove transmission, as follows:
a. Lower the rear end of the transmission.

NOTICE: Be careful not to damage the cooling fan, brake booster and brake line.

b. Separate the wire harness from the transmission and transfer.





c. Remove the oil cooler pipe mounting bolts from the torque converter clutch housing, and then disconnect the two oil cooler pipes from the elbows.





d. Remove the 10 bolts and transmission.
Torque: 72 Nm (53 ft. lbs.).

INSTALLATION
1. Check torque converter clutch installation.





Using calipers and a straight edge, measure from the installed surface of the transmission housing.
Correct distance: More than 15.7 mm (0.618 inch).
2. Install transmission.
Installation is in the reverse order of removal.

NOTE:
^ After installation, adjust the shift lever position and throttle cable.
^ Fill and check fluid level.