AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION [AW6A-EL, AW6AX-EL]

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1.  Disconnect the negative battery cable.

2.  Remove the following parts.

(1)  Battery and battery tray (See BATTERY REMOVAL/INSTALLATION [L3 Turbo].)
(2)  Air cleaner component (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [L3 Turbo].)
(3)  Engine cover
(4)  Charge air cooler (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [L3 Turbo].)
(5)  Windshield wiper arm and blade (See WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION.)
(6)  Cowl grille (See COWL GRILLE REMOVAL/INSTALLATION.)
(7)  Front wheel
(8)  Splash shield
(9)  Under cover
(10)  Side cover
(11)  Propeller shaft (transfer side) (See PROPELLER SHAFT REMOVAL/INSTALLATION.)
(12)  Transfer oil cooler (See TRANSFER OIL COOLER REMOVAL/INSTALLATION [AW6AX-EL].)

3.  Drain the ATF. (See AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [AW6A-EL, AW6AX-EL].)

Warning
•  Improperly jacking a transaxle is dangerous. It can slip off the jack and may cause serious injury.
Caution
•  To prevent the torque converter and transaxle from separating, remove the transaxle without tilting it toward the torque converter.

4.  Remove in the order shown in the figure.

5.  Install in the reverse order of removal.

6.  Add ATF to the specified level. (See AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [AW6A-EL, AW6AX-EL].)

7.  Perform the mechanical system test. (See MECHANICAL SYSTEM TEST [AW6A-EL, AW6AX-EL].)

Service item

Test item

Line pressure test

Stall test

Time lag test

Time lag test
ATX replacement
X
 
 
 
ATX overhaul
X
X
X
X
Torque converter replacement
X
X
 
 
Oil pump replacement
X
 
 
 
Control valve body component
X
 
 
 
Clutch system replacement
X
 
X
X

X  :Test to be performed after the service work

R.H.D.

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L.H.D.

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1
TCM connector
2
Wiring harness bracket
3
Selector cable
(See Selector Cable Installation Note.)
4
Oil filler tube, dipstick, breather hose
5
Wiring harness bracket (A/F sensor)
6
Transaxle mounting bolt (Upper side)
7
Steering shaft
(See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)
8
Stabilizer control link
9
Tie-rod end ball joint
(See FRONT CROSSMEMBER REMOVAL/INSTALLATION [L.H.D.].)
(See FRONT CROSSMEMBER REMOVAL/INSTALLATION [R.H.D.].)
10
Lower arm ball joint
(See FRONT LOWER ARM REMOVAL/INSTALLATION.)
11
No.1 engine mount bracket
(See No.1 Engine Mount Installation Note.)
12
Crossmember bracket
13
Crossmember
(See FRONT CROSSMEMBER REMOVAL/INSTALLATION [L.H.D.].)
(See FRONT CROSSMEMBER REMOVAL/INSTALLATION [R.H.D.].)
14
Drive shaft
(See FRONT DRIVE SHAFT REMOVAL/INSTALLATION.)
15
Joint shaft (2WD)
(See JOINT SHAFT REMOVAL/INSTALLATION [2WD].)
16
Transfer bracket (4WD)
17
WU-TWC bracket (4WD)
18
Heat shield (4WD)
19
Oil hose
(See OIL COOLER REMOVAL/INSTALLATION [AW6A-EL, AW6AX-EL].)
20
Starter
(See STARTER REMOVAL/INSTALLATION [L3 Turbo].)
21
Endplate cover
22
Torque converter installation nuts
(See Torque Converter Nuts Removal Note.)
(See Torque Converter Nuts Installation Note.)
23
No.4 engine mount bracket
(See No.4 Engine Mount Bracket Removal Note.)
(See No.4 Engine Mount Bracket Installation Note.)
24
Resistor
25
Transaxle mounting bolt (lower side)
26
Transaxle (2WD)
(See Transaxle Removal Note.)
(See Transaxle Installation Note.)
Transaxle, transfer and Joint shaft (4WD)
(See Transaxle Removal Note.)
(See Transaxle Installation Note.)

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27
Joint shaft
(See JOINT SHAFT REMOVAL/INSTALLATION [4WD].)
28
Transfer
29
Cable bracket
30
Transaxle


Torque Converter Nuts Removal Note

1.  Align the holes by turning the torque converter.

2.  Insert a flathead screwdriver through the converter housing service hole, and lock the drive plate.

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3.  Remove the torque converter nuts.

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No.4 Engine Mount Bracket Removal Note

1.  Install the SST using the following procedure.

Caution
•  Refer to the SST instruction manual for the basic handing procedure.
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(1)  Install the right rear shaft of the SST to the bolt of the right shock absorber as shown in the figure.
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(2)  Install the left rear shaft of the SST to the bolt of the left shock absorber. (Identical position to the right side)
(3)  Temporarily tighten the air clear bracket installation bolt, and install the left/right front shaft of the SST with front foot No.2 to the bolt as shown in the figure.
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(4)  Adjust the positions of the SST side bars so that they are the same height (left and right) and horizontal.
(5)  Make sure each joint is securely tightened.

2.  Support the engine using the SST.

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3.  Remove the No.4 engine mount bracket.


Transaxle Removal Note

1.  Support the transaxle on a jack.

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2.  Remove the transaxle mounting bolts.

3.  Remove the transaxle.


Transaxle Installation Note

1.  Set the transaxle on a jack and lift it.

2.  Install the transaxle mounting bolts.

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Tightening torque
Bolt A: 37—52 N·m {3.8—5.3 kgf·m, 28—38 ft·lbf}
Bolt B: 25.5—34.5 N·m {2.61—3.51 kgf·m, 18.9—25.4 ft·lbf}


No.4 Engine Mount Bracket Installation Note

1.  Install the No.4 engine mount bracket to the transaxle and temporarily tighten nuts

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2.  Temporarily tighten bolt D.

3.  Temporarily tighten bolt A and nuts B, C.

4.  Tighten bolt A, nuts B and C in the order of B→A→C.

5.  Tighten bolt D.

Tightening torque
Bolt A, Nut B, C: 74.5—93.1 N·m {7.6—9.4 kgf·m, 55.0—68.6 ft·lbf}
Bolt D: 74.5—104.9 N·m {7.60—10.69 kgf·m, 55.0—77.3 ft·lbf}


No.1 Engine Mount Installation Note

1.  Install the No.1 engine mount bracket to the transaxle, then temporarily tighten bolts A and B.

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2.  Install the No.1 engine mount rubber to the bracket, then temporarily tighten bolt C.

3.  Tighten the No.1 engine mount bracket bolt A and B in order of A→B.

Tightening torque
Bolt A, B: 107.5—116.6 N·m {11.0—11.8 kgf·m, 79.3—85.9 ft·lbf}

4.   Fully tighten bolt C.

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Note
•   It may not be possible to tighten bolt C completely due to the narrow operation space. In this case, tighten nut C instead of bolt C.
•   There are two types of parts, bolt C and nut C, and each has a different tightening torque. The appearance of bolt C and nut C is same, however, the tightening torque can be determined by the bolt D size.
Bolt C tightening torque
For bolt D (M12): 85.3—116.6 N·m {8.7—11.8 kgf·m, 63.0—85.9 ft·lbf}
For bolt D (M14): 86.1—95.1 N·m {8.8—9.6 kgf·m, 63.5—70.1 ft·lbf}
Nut C tightening torque
For bolt D (M12): 85.3—116.6 N·m {8.7—11.8 kgf·m, 63.0—85.9 ft·lbf}
For bolt D (M14): 59.3—72.5 N·m {6.0—7.3 kgf·m, 43.7—53.4 ft·lbf}


Torque Converter Nuts Installation Note

1.  Align the holes by turning the torque converter.

2.  Insert a screwdriver through the converter housing service hole, and lock the drive plate.

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Caution
•  Loosely and equally tighten the torque converter nuts, then further tighten them to the specified tightening torque.

3.  Tighten the torque converter mounting nuts.

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Tightening torque
40.5—54.7 N·m {4.13—5.57 kgf·m, 29.9—40.3 ft·lbf}


Selector Cable Installation Note

1.  Install the selector lever to the manual shaft lever so that no load acts on the selector cable.

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Note
•  Install the selector lever to the manual shaft lever with the clip side of the selector cable end facing up.

2.  Confirm that the tip of the manual shaft lever projects out of the end of the selector cable.