Case: Service and Repair

Case Side Cover Replacement

^ Tools Required
- J 41102 Axle Seal Protector
- J 41545 Transaxle Range Switch Alignment Tool
- J 43405 Engine Support Fixture Adapter
- SA9105E Engine Support Bar Assembly

Removal Procedure





1. Caution: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.

Position the vehicle on a hoist.
2. Remove the battery.
1. Disconnect the negative battery cable.
2. Disconnect the positive battery cable.
3. Move the fan control module. Leave the wiring connected, lift the module up and away from the bracket, and position out of the way.
4. Remove the battery hold-down bracket.
5. Remove the battery.





3. Disconnect the battery feed to the underhood fuse block.
4. Disconnect the coolant hose from the underhood fuse block.
5. Release the retaining tabs on the underhood fuse block cover and remove.
6. Release the retaining tabs (2) on the underhood fuse block and roll the fuse block (1) back to access the electrical connectors.





7. Remove the following connectors from the underhood fuse block:
^ Engine 68-way (1)
^ Forward Lamp 68-way (2)
^ I/P 68 way (3)





8. Remove the following connectors from the underhood fuse block.
^ Forward Lamp 2-way (White) (4)
^ I/P 2-way (Black) (5)
^ I/P 2-way (Green) (6)
^ I/P 2-way (Brown) (7)
9. Lift the fuse block off the case.





10. Important: There are 2 tabs that hold the hard shell grommets in place at the bottom of the grommet. Disengage the tabs to remove the grommet from the case.

Remove the harnesses from the underhood fuse block case by releasing the retaining tabs on the bottom of the hard shell grommets.
^ Engine (A)
^ Forward Lamp (B)
^ Instrument Panel (I/P) (C)
11. Remove the underhood fuse block case fastener and the case from the battery tray.





12. Remove the battery tray fasteners and the battery tray.
13. Remove the wire harness from the transaxle case side cover.





14. Remove the hose clip, holding the 2 power steering lines together.





15. Apply the parking brake and place the control assembly in NEUTRAL. The transaxle manual shaft must be in NEUTRAL position prior to installing the range switch.
16. Remove the shift control cable from the transaxle range switch lever.
17. Disconnect the electrical connectors from the transaxle range switch.





18. Remove the transaxle range switch lever nut and lever.





19. Remove the transaxle range switch bolts and remove the switch.





20. Remove the upper transaxle case side cover fasteners.





21. Install the SA9105E with the J 43405 as shown. L61 (L4) is shown.





22. Install the SA9105E with the J 43405 as shown. L81 (V6) is shown.





23. Mark the position of and remove the left transaxle mount bolts.
24. Remove the left transaxle mount from the engine compartment rail.
25. Remove the frame assembly.





26. Notice: To prevent damage to CV Joint boots, be careful not to allow them to contact other parts during the removal/installation process. Also, never pull on the shaft assembly.

Remove the left drive axle from the transaxle using a pry bar. Remove the axle retaining ring from the output shaft of the transaxle and discard. The axle can be left in the steering knuckle. Tie the axle up and out of the way.





27. Remove the power steering lines from left transaxle mount bracket. Remove the transaxle mount bracket fasteners and remove the bracket.





28. Important: Pry on the side cover near locating dowel pins to prevent damage to the sealing surfaces.

Remove the remaining transaxle case side cover bolts and remove the case side cover.





29. Remove the 2 case side cover gaskets and side cover to driven support thrust washer, if they did not remain with the side cover assembly when it was removed.

Installation Procedure





1. Inspect the case side cover for cracks or damage to the seal grooves and the mounting bosses.
2. Inspect the side cover seals for damage. The side cover seals are reusable if not damaged.
3. Thoroughly clean the side cover and side cover seals. Clean and dry the seal grooves and axle seal bore.
4. Install the case side cover gaskets into grooves on the side cover. Retain seals with petroleum jelly.
5. Install the side cover to driven sprocket thrust washer onto the side cover. Retain with petroleum jelly.





6. Notice: J41102 must be used on the output shaft of the transaxle to protect the axle seal from damage when installing the case side cover. If J41102 is not used, damage to the seal may result.

Install the J 41102 on the output shaft of transaxle, and install the side cover assembly onto the transaxle case.

7. Notice: Install and hand start the lower side cover-to-transaxle case bolts and tighten.

^ Tighten the side cover-to-transaxle case bolt to 20 Nm (15 ft. lbs.).





8. Install the left transaxle mount bracket to transaxle.
^ Tighten the left transaxle mount bracket-to-transaxle bolts to 90 Nm (66 ft. lbs.).
9. Install the power steering lines to the left transaxle mount bracket.
^ Tighten power steering lines-to-left transaxle mount bracket to 10 Nm (89 inch lbs.).

10. Notice: In order to prevent damage to shaft splines during vehicle operation, add grease P/N 7847638 to the splines on the stub shaft.

Install a new axle retaining clip on the output shaft of transaxle. Untie the left axle shaft and install the axle shaft into the transaxle.
11. Install the frame assembly.





12. Install the left transaxle mount to the engine compartment rail.
^ Tighten the transaxle mount (left)-to-engine compartment rail bolts to 20 Nm (15 ft. lbs.).





13. Notice: If the powertrain mount is not reinstalled in its original position, it could lead to premature mount wear.

Reference the alignment marks made during disassembly and install the left transaxle mount bolts.
^ Tighten the transaxle mount (left)-to-transaxle mount bracket bolts to 55 Nm (41 ft. lbs.).
14. Remove the engine support bar assembly.





15. Install the upper transaxle side cover fasteners.
^ Tighten the side cover-to-transaxle case bolts to 20 Nm (15 ft. lbs.).
16. Install the wire harness to the transaxle case side cover.
^ Tighten wiring harness attachment fasteners to 20 Nm (15 ft. lbs.).





17. Make sure the transaxle manual shaft is in the NEUTRAL (N) position.
18. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch.
19. Loosely install the transaxle range switch bolts.





20. Insert the J 41545 as shown and rotate the switch until the tool drops into position.
21. Tighten the transaxle range switch bolts.
^ Tighten transaxle range switch bolts to 20 Nm (15 ft. lbs.).
22. Remove the alignment tool.





23. Install the transaxle range switch lever and nut.
^ Tighten the transaxle range switch lever nut to 35 Nm (26 ft. lbs.).





24. Important: After adjusting the switch, verify the engine only starts in PARK or NEUTRAL. If the engine starts in any other position, readjust the switch.

Connect the transaxle range switch electrical connectors.
25. Install the shift control cable to the transaxle range switch lever and verify proper operation.





26. Install the battery tray and the battery tray fasteners.
^ Tighten the battery bolts to 15 Nm (11 ft. lbs.).





27. Install the underhood fuse block case to the battery tray and install the bolt.
^ Tighten the underhood fuse block case bolt to 9 Nm (80 inch lbs.).





28. Install the wire harnesses to the fuse block case. The wire harness grommets have retaining tabs that lock into the case (3) when the harnesses are fully installed.
^ Engine (A)
^ Forward Lamp (B)
^ Instrument Panel (I/P) (C)
29. Snap the fuse block onto the fuse block case hinges.
30. Install the following connectors to the underhood fuse block:
^ Engine 68-way (1)
^ Forward Lamp 68-way (2)
^ I/P 68-way (3)





31. Install the following connectors to the underhood fuse block:
^ Forward Lamp 2-way (White) (4)
^ I/P 2-way (Black) (5)
^ I/P 2-way (Green) (6)
^ I/P 2-way (Brown) (7)
32. Secure the underhood fuse block to the fuse block case by rotating down and snapping into place.
33. Install the underhood fuse block cover.
34. Secure the coolant hose into place on the fuse block cover.
35. Install the battery feed cable to the underhood fuse block.
^ Tighten the battery feed cable-to-underhood fuse block bolt to 16 Nm (12 ft. lbs.).





36. Install the battery.
1. Install the battery into the battery tray.
2. Install the battery hold-down bracket.
^ Tighten the battery hold down bracket bolt to 20 Nm (15 inch lbs.).

3. Important: The positive battery terminal must be connected first to prevent arcing.

Install the fan control module by sliding down onto the battery hold-down bracket.
4. Install the positive battery cables first and then the negative battery cable.
^ Tighten the battery cables-to-battery to 17 Nm (13 ft. lbs.).
37. Start the engine, warm up the transaxle, and check for fluid leaks.
38. Check for proper fluid level.