Case: Service and Repair

Case Side Cover Replacement

Removal Procedure
1. Remove the air inlet duct.
2. If the vehicle is equipped with LY7, remove the master cylinder fluid level sensor in order to provide clearance for powertrain lowering.
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 left tie rod end from the steering knuckle.





8. Remove the left wheel speed sensor harness connector (2) and the harness (1) from the lower control arm.
9. Remove the left lower ball joint from the left steering knuckle.
10. Disconnect the left drive axle from the transaxle.
11. Reposition and secure the drive axle toward the rear of the vehicle.
12. Remove the trans mount nuts at the frame.





13. 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.

Remove the intermediate shaft (1) from the steering gear (2).
14. Disconnect the catalytic converter from the exhaust manifold (LA1) or crossover pipe (LY7).





15. Support the left side of the frame with a utility stand.
16. Remove the left side frame bolts.
17. Use the utility stand in order to lower the left side of the powertrain enough to gain access the case side cover bolts.





18. Support the transmission with a transmission jack.
19. Use the utility stand in order to lower the left side of the frame enough to access the case side cover lower bolts.
20. Position the drain pan under the transaxle.
21. Disconnect the transaxle wiring harness electrical connector(s).





22. Remove the case side cover bolts (5658).





23. Remove the case side cover pan (53).
24. Remove the case side cover gasket (54).
25. Remove the case side cover inner gasket (59).





26. 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
27. 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.
28. Clean the case side cover.
29. Clean the case side cover gasket surfaces.
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).





4. Notice: Refer to Fastener Notice in Service Precautions.

Install the case side cover bolts (5658).
Tighten the case side cover bolts (5658) to 25 Nm (18 ft. lbs.).
5. Remove the drain pan from under the transaxle.
6. Install the transaxle mount bracket.
7. Install the transaxle mount.
8. Connect the transaxle wiring harness connector(s).





9. Use the utility stand in order to raise the frame and powertrain until the frame insulators contact the chassis.
10. Remove the transmission jack.
11. Install the left side frame bolts.
12. Remove the utility stand support from the left side of the frame.
13. Connect the catalytic converter pipe to the exhaust manifold (LA1) or crossover pipe (LY7).





14. 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.

Install the intermediate shaft (1) to the steering gear (2).
15. Install the trans mount nuts at the frame.
16. Install the left drive axle to the transaxle.
17. Install the left lower ball joint to the left steering knuckle.





18. Install the wheel speed sensor harness connector (2) and harness (1) to the lower control arm.
19. Install the left tie rod end to the steering knuckle.
20. Install the left engine splash shield.
21. Install the left front tire and wheel.
22. Lower the vehicle.
23. Install the engine mount struts.
24. If the vehicle is equipped with LY7, install the master cylinder fluid level sensor.
25. Install the air inlet duct.

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

Adjust the fluid level. Refer to the following procedures:
^ Transmission Fluid Checking Procedure in Automatic Transaxle4T65-E.
^ Fluid and Lubricant Recommendations in Maintenance and Lubrication
^ Capacities - Approximate Fluid in Maintenance and Lubrication
27. Inspect for fluid leaks.