14. Transaxle Installation
TRANSAXLE INSTALLATION^ TOOLS REQUIRED
- J 41239 Cooler Line Seal Remover
- J 44015 Tie Rod Installer
- SA91112T Axle Seal Protector
1. For all-wheel drive (AWD) transaxle, install stub shaft into transaxle.
2. For all-wheel drive (AWD) transaxle, install power take-off unit (PTU) and PTU bolts to transaxle.
Torque: Power Take-Off Unit Bolts: 60 N.m (44 ft. lbs.)
3. With transaxle supported, carefully raise transaxle. Meanwhile, it may be helpful to lower the vehicle down around the transaxle. Pay close attention to any interference with the coolant lines during installation.
4. Assemble engine to transaxle.
5. Install lower transaxle-to-engine bolts.
Torque: Transaxle-to-Engine Bolts: 75 N.m (55 ft. lbs.)
6. For AWD transaxles, install PTU-to-engine bracket assembly.
Torque: Power Take-Off Bracket Bolts: 60 N.m (44 ft. lbs.)
7. Rotate crank and align net hole of flexplate through starter opening.
8. Install torque converter-to- flexplate bolts through starter hole.
Torque: Torque Converter-to-Flexplate Bolts: 60 N.m (44 ft. lbs.)
9. Install starter and starter bolts.
Torque: Starter Bolts: 40 N.m (30 ft. lbs.)
10. Install starter wiring harness.
Torque: B+ Cable to Starter Nut: 10 N.m (89 inch lbs.)
Torque: S Terminal Nut: 5 N.m (35 inch lbs.)
11. For front wheel drive (FWD) transaxle, perform the following:
11.1. Install Axle Sea] Protector SA91112T inside seal.
11.2. Position bracket to engine, hand start all bolts, then tighten.
Torque: Bracket-to-Engine Bolts: 35 N.m (26 ft. lbs.)
NOTICE: When installing shaft into transaxle, use caution not to contact axle seal with shaft splines. Damage may occur to seals.
11.3. Install intermediate drive shaft into transaxle.
11.4. Remove seal protector tool after splines clear the seal protector, but before intermediate drive shaft is fully installed.
11.5. Push intermediate drive shaft all the way into transaxle.
11.6. Install new retaining ring to intermediate drive shaft.
11.7. Install right axle shaft to intermediate drive shaft.
12. For all-wheel drive (AWD) transaxle, install new axle shaft O-ring and install right axle shaft to PTU shaft.
13. Install new retaining ring on left axle shaft.
14. Install Axle Seal Protector SA91112T inside seal.
NOTICE: Lubricate axle with Saturn Transaxle fluid (P/N 2688912) then use caution when inserting axle into transaxle. Be sure not to damage seal.
15. Install left axle shaft into transaxle.
16. Remove seal protector tool after splines clear the seal protector, but before axle shaft is fully installed.
17. Push left axle shaft all the way into transaxle.
18. Support cradle with cradle support.
19. Install cradle and cradle bolts.
Torque: Cradle Bolts: 200 N.m (148 ft. lbs.)
20. Remove support table.
21. Install rear pitch restrictor through-bolt.
Torque: Cradle Bolts: 110 N.m (81 ft. lbs.)
22. Install front pitch restrictor bolts and front pitch restrictor.
Torque: Front Pitch Restrictor Bolts: 50 N.m (37 ft. lbs.)
Torque: Through Bolt: 110 N.m (81 ft. lbs.)
23. Install outer tie rod-to-knuckle using Tie Rod Installer J44015.
Torque: Tie Rod-to-Knuckle: 40 N.m (30 ft. lbs.)
24. Install outer tie rod-to-knuckle nut.
Torque: Tie Rod-to-Knuckle Nut: 50 N.m (37 ft. lbs.)
25. Install lower control arm ball stud-to-knuckle.
26. Install nut and new cotter pin.
Torque: Lower Control Arm Nut: 10 N.m (89 inch lbs.) +150°
^ Tighten nut one additional flat to align cotter pin hole if necessary.
27. Install rack and pinion bolts to cradle.
Torque: Rack and Pinion Bolts: 110 N.m (81 ft. lbs.)
28. Install lower stabilizer nut to cradle on both sides of vehicle.
Torque: Lower Stabilizer Nut: 65 N.m (48 ft. lbs.)
29. For all-wheel drive (AWD) transaxles, install drive shaft to PTU.
Torque: Drive Shaft Fasteners: 100 N.m (74 ft. lbs.)
30. For all-wheel drive (AWD) VT25-E, connect drive shaft to PTU.
NOTICE: Avoid spinning seal in the case bore. Damage to case bore may result.
31. If transaxle being installed is not new, then transaxle oil cooler line seals must be removed and replaced.
31.1. Use a long chisel with 6.35 mm. (1/4 inch) blade (or equivalent tool) to partially collapse the seal in one place only.
31.2. Using Cooler Line Seal Remover J41239, remove seals and discard.
31.3. Clean case bores for the cooler line seals.
31.4. Using Cooler Line Sea] Installer J41239, install new cooler line seals.
32. Install transaxle cooler lines to transaxle.
Torque: Transaxle Oil Cooler Line Assembly: 8 N.m (71 inch lbs.)
33. Install front air dam deflector-to-cradle pushpins.
34. Install left-hand and right-hand inner splash shield.3
35. Install left-hand and right-hand wheel and tire assembly.
Torque: Wheel Nuts: 125 N.m (92 ft. lbs.)
Torque: Front Axle Shaft Hub Nut: 205 N.m (151 ft. lbs.)
36. Lower vehicle.
37. Install upper left-hand transaxle mount bolts.
Torque: Upper Left-Hand Transaxle Mount Bolts: 50 N.m (37 ft. lbs.)
38. Install one upper transaxle-to-engine bolt.
Torque: Upper Transaxle-to-Engine Bolts: 75 N.m (55 ft. lbs.)
39. Remove engine support tool.
40. Remove tie straps from radiator.
41. Connect transaxle range switch harness to switch.
42. Connect transaxle harness connector to valve body.
43. Connect shifter cable to shifter cable bracket.
44. Connect shifter cable to transaxle range switch lever.
45. Install air induction resonator bracket.
46. Install air induction resonator.
47. Install battery tray bracket.
47.1. Position battery tray bracket and tighten screws.
Torque: Battery Tray Bracket Screws: 16 N.m (12 ft. lbs.)
48. Install battery cooling box.
49. Install battery.
49.1. Insert battery and tighten battery hold-down screw.
Torque: Battery Hold-Down Screw: 15 N.m (11 ft. lbs.)
49.2. Connect positive battery cable to battery.
Torque: Battery Terminal Bolts: 17 N.m (13 ft. lbs.)
49.3. Connect negative battery cable to battery.
Torque: Battery Terminal Bolts: 17 N.m (13 ft. lbs.)
49.4. Install battery cooling box cover and tighten screws.
Torque: Battery Cooling Box Cover Screws: 2 N.m (18 inch lbs.)
49.5. Reprogram radio stations.
50. Fill transaxle to proper level using Saturn Transaxle fluid (P/N 2688912). Verify fluid level using the "Transaxle Fluid Replacement".
51. Perform wheel alignment.