Case: Service and Repair

Case Side Cover Replacement

Removal Procedure
1. Remove the throttle body air inlet duct.
2. Install the engine support fixture.





3. Remove the engine mount struts.
4. Raise and support the vehicle. Refer to Vehicle Lifting.
5. Remove the left front tire and wheel.
6. Remove the left engine splash shield.
7. Remove the stabilizer shaft links from the lower control arms.
8. Remove the left tie rod end from the steering knuckle.
9. Remove the wheel speed sensor harness connector (2).
10. Remove the left lower ball joint from the left steering knuckle.
11. Disconnect the left drive axle from the transaxle.
12. Reposition and secure the drive axle.





Caution: Failure to disconnect the intermediate shaft from the rack and pinion stub shaft can result in damage to the steering gear and/or damage to the intermediate shaft. This damage may cause loss of steering control which could result in personal injury.

13. Remove the intermediate shaft from the steering gear.
14. Disconnect the catalytic converter pipe from the right (rear) exhaust manifold.
15. Support the right side of the frame with a utility stand.
16. Support the left side of the frame with a utility stand.
17. Remove the transaxle mount bracket.
18. Remove the transaxle mount.
19. Loosen the engine mount lower nuts.
20. Loosen the right side frame bolts.
21. Remove the left side frame bolts.
22. Use the utility stand in order to lower left side of the frame.
23. Position the drain pan under the transaxle.





24. Disconnect the wiring harness connectors.





25. Remove the case side cover bolts (56-58).





26. Remove the case side cover pan (53).
27. Remove the case side cover gasket (54).
28. Remove the case side cover inner gasket (59).





29. Inspect the case side cover (53) for the following conditions:
^ Damaged or porous gasket sealing surfaces
^ Damaged or porous casting surfaces
^ Damaged or stripped bolt holes

30. Inspect the case side cover gasket (54) and case side cover inner gasket (59) for damage The gaskets are reusable if they are NOT damaged.
31. Clean the case side cover
32. Clean the case side cover gasket surfaced.

Installation Procedure





1. Install the case side cover inner gasket (59).
2. Install the case side cover gasket (54).
3. Install the case side cover pan (53).

Notice: Refer to Fastener Notice in Service Precautions.





4. Install the case side cover bolts (56-58).
Tighten the case side cover bolts (56-58) to 25 Nm (18 ft. lbs.).
5. Remove the drain pan from under the transaxle.





6. Connect the wiring harness connectors.
7. Use the utility stand in order to raise the left side of the frame.
8. Install the NEW left side frame bolts.
9. Install the NEW right side frame bolts.
10. Install the engine mount lower nuts.
11. Install the transaxle mount.
12. Install the transaxle mount bracket.
13. Remove the utility stand support from the right side of the frame.
14. Remove the utility stand support from the left side of the frame.
15. Connect the catalytic converter pipe to the right (rear) exhaust manifold.





Caution: When installing the intermediate shaft make sure that the shaft is seated prior to pinch bolt installation. If the pinch bolt is inserted into the coupling before shaft installation, the two mating shafts may disengage. Disengagement of the two mating shafts will cause loss of steering control which could result in personal injury.

16. Install the intermediate shaft to the steering gear.
17. Install the left drive axle to the transaxle.
18. Install the left lower ball joint to the left steering knuckle.




19. Install the wheel speed sensor harness connector (2).
20. Install the left tie rod end to the steering knuckle.
21. Install the stabilizer shaft links to the lower control arms.
22. Install the left engine splash shield.
23. Install the left front tire and wheel.
24. Lower the vehicle.
25. Install the engine mount struts.

26. Remove the engine support fixture.
27. Remove the throttle body air inlet duct.

Notice: Do NOT overfill the transaxle. The overfilling of the transaxle causes foaming, loss of fluid shift complaints, and possible damage to the transaxle.

28. Adjust the fluid level.

29. Inspect for proper completion of the repairs.
30. inspect for fluid leaks.