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TRANSAXLE INSTALLATIONTOOLS REQUIRED
- 87-92-335 Shift Linkage Lock Pin
- SA9 105E Engine Support Bar Assembly
- SA91112T Axle Seal Protector
1. Securely place transaxle on transmission jack. Place transaxle in any gear.
2. Raise transaxle into vehicle and align transaxle input shaft to center of clutch disc. Guide transaxle into position, rotate back and forth to align input shaft splines to clutch disc.
NOTICE: Make sure input shaft splines line up with the clutch disc splines before tightening transaxle-to-engine mounting bolts. Do not use bolts to pull transaxle up to engine.
3. Install lower transaxle-to-engine mounting bolts.
Torque:
Transaxle-to-Engine Bolts: 65 Nm (48 ft. lbs.)
4. Remove transmission jack.
5. Install control shaft lever assembly pivot pin bracket onto transaxle case.
Torque:
Control Shaft Lever Pivot Pin Bracket-to-Transaxle Bolts: 24 Nm (18 ft. lbs.)
6. Using Axle Seal Protector SA91112T, insert axle shafts into transaxle. After splines clear seal protector but before snapping axle into place, remove sea] protector.
7. Ensure transaxle drain plug is installed in transaxle case. If it is not installed, clean and apply sealant (P/N 21485278) to threads and install plug.
Torque:
Transaxle Drain Plug: 50 Nm (37 ft. lbs.)
8. Lower vehicle.
9. Remove transaxle fill plug from top of transaxle. Fill transaxle with two quarts of manual transaxle lubricant (P/N 21018899).
10. Clean and apply sealant (P/N 21485278) to threads and reinstall transaxle fill plug.
Torque:
Exhaust Manifold Pipe-to-Exhaust Manifold Nuts: 50 Nm (37 ft. lbs.)
11. Install left transaxle mount bracket onto transaxle. (Automatic shown, Manual similar)
Torque:
Left Transaxle Mount Bracket-to-Transaxle Bolts: 55 Nm (41 ft. lbs.)
12. Raise left side of powertrain to correct height using Engine Support Bar Assembly SA9105E.
13. Raise vehicle.
14. Reposition A/C line against body and install A/C line retaining clips.
15. Install rear transaxle mount onto transaxle.
Torque:
Rear Transaxle Mount-to-Transaxle: 55 Nm (41 ft. lbs.)
16. Install front transaxle mount onto transaxle.
Torque:
Front Transaxle Mount-to-Transaxle: 55 Nm (41 ft. lbs.)
IMPORTANT: Be sure the frame alignment tool fully engages in all gauge holes.
17. Install new cage nuts into the body as torque retention of old nuts may not be sufficient.
18. Raise frame assembly to body.
IMPORTANT: Do not tighten Fasteners at this time.
19. Install four new frame-to-body bolts.
20. Install new cage nuts into body for suspension supports. Torque retention of old nuts may not be sufficient.
21. Install suspension supports using new bolts and tighten all frame bolts.
Torque:
Frame-to-Body Bolts: 90 Nm (60 ft. lbs.) + 45° to 60°
22. Install ball stud into steering knuckle.
Torque:
Ball Stud into Steering Knuckle: 100 Nm (75 ft. lbs.)
23. Install frame-to-shifter link pivot pin clip.
24. Install steering gear-to-frame-using new bolts and nuts (Automatic shown, manual similar).
Torque:
Steering Gear-To-Frame: 45 Nm (35 ft. lbs.) + 90°
NOTICE: Hold ball stud from turning when tightening nut. The boot can become torn and damaged if the ball stud turns.
25. Install stabilizer bar links-to-strut assemblies using new nuts
Torque:
Stabilizer Bar Links-to-Strut Assemblies: 65 Nm (50 ft. lbs.)