Automatic Transaxle Replacement

REMOVAL
1. REMOVE BATTERY
2. REMOVE SUSPENSION UPPER BRACE
3. REMOVE AIR CLEANER ASSEMBLY





4. REMOVE THROTTLE CABLE FROM THROTTLE BODY





5. REMOVE CRUISE CONTROL ACTUATOR
a. Disconnect the connector.
b. Remove the 3 bolts and disconnect cruise control actuator with the bracket.





6. DISCONNECT GROUND CABLE
7. DISCONNECT VEHICLE SPEED SENSOR CONNECTOR
8. DISCONNECT DIRECT CLUTCH SPEED SENSOR CONNECTOR
9. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR
10. DISCONNECT SOLENOID CONNECTOR





11. DISCONNECT SHIFT CONTROL CABLE
a. Remove the nut and disconnect the shift control cable from the park/neutral position switch.
b. Remove the clip and disconnect the shift control cable.





12. REMOVE 2 ENGINE MOUNTING ABSORBER BOLTS





13. REMOVE 2 FRONT SIDE ENGINE MOUNTING BOLTS





14. REMOVE STARTER AND A/T SHIFT CABLE CLAMP
a. Disconnect the connector and remove the nut.
b. Remove the 2 bolts, starter and A/T shift cable clamp.





15. REMOVE EXHAUST MANIFOLD BRACKET MOUNTING BOLT





16. REMOVE 5 TRANSAXLE-TO-ENGINE BOLTS AND DISCONNECT GROUND TERMINAL
17. REMOVE ENGINE HOOD
a. Disconnect the washer pipe.
b. Remove the 4 bolts and engine hood.
18. RAISE AND SUPPORT VEHICLE SECURELY
19. REMOVE FRONT WHEELS
20. REMOVE DIFFERENTIAL FLUID DRAIN PLUG AND GASKET
21. DRAIN DIFFERENTIAL FLUID
22. REMOVE LH AND RH ENGINE SIDE COVERS
23. REMOVE LH AND RH FRONT DRIVE SHAFTS. Refer to Steering and Suspension.
24. REMOVE ENGINE UNDER FRONT COVER AND NO.4 CENTER ENGINE UNDER COVER
25. REMOVE FRONT EXHAUST PIPE





a. Remove the 2 bolts and exhaust pipe support stay.
b. Remove the 4 nuts and 2 gaskets from the exhaust manifold.
c. Remove the 2 bolts, nuts and gasket.
d. Remove the 2 set bolts of the No.1 exhaust pipe support bracket.
e. Remove the front exhaust pipe.





f. Remove the 2 nuts, 2 bolts, exhaust front pipe support bracket and hole cover.





26. REMOVE FRONT SIDE ENGINE MOUNTING INSULATOR BOLT





27. DISCONNECT 2 OIL COOLER HOSES





28. REMOVE REAR SIDE ENGINE MOUNTING NUT
a. Remove the 2 grommets.
b. Remove the 4 nuts.





29. REMOVE LEFT SIDE TRANSAXLE MOUNTING NUT
a. Remove the 2 grommets.
b. Remove the 2 nuts.





30. REMOVE STEERING GEAR HOUSING
a. Remove the 4 bolts, LH and RH stabilizer bar brackets and bushings.
b. Remove the front stabilizer bar.
c. Remove the 2 steering gear housing mounting bolts and nuts.





31. SUPPORT STEERING GEAR HOUSING, AS SHOWN





32. ATTACH ENGINE SLING DEVICE TO ENGINE HANGERS
a. Install the No.2 engine hanger in the correct direction.
Part No.:
No.2 engine hanger: 12282-20020
Bolt: 91621-60822
Torque: 20 Nm (200 kgf-cm, 14 ft. lbs.)
b. Attach the engine chain hoist to the engine hangers.

CAUTION: Do not attempt to hang the engine by hooking the chain to any other part.

33. REMOVE FRONT FRAME ASSEMBLY





a. Remove the 2 bolts and PS reservoir pipe mounting brackets.





b. Remove the 4 screws and turn over the front side of the LH and RH fender liners.





c. Remove the 4 screws and turn over the rear side of LH and RH fender liners.





d. Remove the 6 bolts and 4 nuts.
e. Remove the front frame assembly.
34. SUPPORT TRANSAXLE WITH A TRANSMISSION JACK





35. REMOVE TORQUE CONVERTER CLUTCH MOUNTING BOLTS
Turn the crankshaft to gain access to each bolt, remove the 6 bolts with holding the crankshaft pulley bolt by a wrench.

HINT: At the time of installation, please refer to the item. First install black colored bolt and then the 5 other bolts.





36. REMOVE EXHAUST MANIFOLD PLATE
Remove the bolt, nut and exhaust manifold plate.





37. REMOVE 3 LOWER TRANSAXLE-TO-ENGINE BOLTS
38. REMOVE TRANSAXLE ASSEMBLY
Separate the transaxle and engine, and lower the transaxle.

INSTALLATION





1. CHECK TORQUE CONVERTER CLUTCH INSTALLATION
Using a scale and a straight edge, measure from the installed surface to the transaxle housing.
Correct distance: 13.7 mm (0.539 inch) or more
2. INSTALL TRANSAXLE ASSEMBLY
a. Using a jack, lift up the transaxle.
b. Install the transaxle to engine.





3. TEMPORARILY INSTALL 3 LOWER TRANSAXLE-TO-ENGINE BOLTS





4. INSTALL EXHAUST MANIFOLD PLATE
Install the bolt, nut and exhaust manifold plate.
Torque:
Except California: 20 Nm (200 kgf-cm, 15 ft. lbs.)
California: 34 Nm (350 kgf-cm, 25 ft. lbs.)





5. INSTALL TORQUE CONVERTER CLUTCH MOUNTING BOLTS
Turn the crankshaft to gain access to each bolt, install the 6 bolts with holding the crankshaft pulley bolt by a wrench.
Torque: 41 Nm (420 kgf-cm, 30 ft. lbs.)

HINT: At the time of installation, please refer to the item. First install black colored bolt and then the 5 other bolts.

6. TIGHTEN 3 LOWER TRANSAXLE-TO-ENGINE BOLTS
Torque: 48 Nm (490 kgf-cm, 35 ft. lbs.)
7. INSTALL FRONT FRAME ASSEMBLY
a. Install the front frame assembly.





b. Install the 6 bolts and 4 nuts.
Torque:
19 mm head bolt: 181 Nm (1,850 kgf-cm, 134 ft. lbs.)
14 mm head bolt: 32 Nm (330 kgf-cm, 24 ft. lbs.)
Nut: 36 Nm (370 kgf-cm, 27 ft. lbs.)





c. Install the 4 screws and turn over the rear side of LH and fender liners.





d. Install the 4 screws and turn over the front side of the LH and RH fender liners.





e. Install the 2 bolts and PS reservoir pipe mounting brackets.
Torque: 10 Nm (100 kgf-cm, 7 ft. lbs.)
8. REMOVE ENGINE SLING DEVICE FROM ENGINE HANGERS





9. INSTALL STEERING GEAR HOUSING
a. Install the 2 steering gear housing mounting bolts and nuts.
Torque: 181 Nm (1,850 kgf-cm, 134 ft. lbs.)
b. Install the front stabilizer bar.
c. Install the 4 bolts, LH and RH stabilizer bar brackets and bushings.
Torque: 19 Nm (195 kgf-cm, 14 ft. lbs.)





10. INSTALL LEFT SIDE TRANSAXLE MOUNTING NUT
a. Install the 2 nuts.
Torque: 80 Nm (820 kgf-cm, 59 ft. lbs.)
b. Install the 2 grommets.





11. INSTALL REAR SIDE ENGINE MOUNTING NUT
a. Install the 4 nuts.
Torque: 80 Nm (820 kgf-cm, 59 ft. lbs.)
b. Install the 2 grommets.





12. CONNECT 2 OIL COOLER HOSES





13. INSTALL FRONT SIDE ENGINE MOUNTING INSULATOR BOLT
Torque:
Green color bolt: 66 Nm (670 kgf-cm, 48 ft. lbs.)
Silver color bolt: 44 Nm (440 kgf-cm, 32 ft. lbs.)





14. INSTALL EXHAUST FRONT PIPE
Install the 2 nuts, 2 bolts, exhaust front pipe support bracket and hole cover.
Torque:
Exhaust front pipe support bracket mounting nut: 21 Nm (210 kgf-cm, 15 ft. lbs.)
Hole plug mounting bolt: 20 Nm (200 kgf-cm, 15 ft. lbs.)





15. INSTALL FRONT EXHAUST PIPE
a. Install the front exhaust pipe, then install the No.1 exhaust pipe support bracket and 2 set bolts.
Torque: 33 Nm (330 kgf-cm, 24 ft. lbs.)
b. Install the gasket, 2 bolts and nuts.
Torque: 56 Nm (570 kgf-cm, 41 ft. lbs.)
c. Install the 2 gaskets and 4 nuts to the exhaust manifold.
Torque: 62 Nm (630 kgf-cm, 46 ft. lbs.)
d. Install the exhaust pipe support stay and the 2 bolts.
Torque: 33 Nm (330 kgf-cm, 24 ft. lbs.)
16. INSTALL ENGINE UNDER COVER AND CENTER ENGINE UNDER COVER
17. INSTALL LH AND RH FRONT DRIVE SHAFTS. Refer to Steering and Suspension.
18. INSTALL LH AND RH FENDER APRON SEALS
19. INSTALL DIFFERENTIAL FLUID DRAIN PLUG AND A NEW GASKET
20. FILL DIFFERENTIAL FLUID
21. INSTALL FRONT WHEELS
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
22. DOWN VEHICLE
23. INSTALL ENGINE HOOD
a. Install the 4 bolts and engine hood.
b. Connect the washer pipe.





24. INSTALL 5 TRANSAXLE-TO-ENGINE BOLTS AND DISCONNECT GROUND TERMINAL
Torque: 66 Nm (670 kgf-cm, 48 ft. lbs.)





25. INSTALL EXHAUST MANIFOLD BRACKET MOUNTING BOLT
Torque:
Except California: 20 Nm (200 kgf-cm, 15 ft. lbs.)
California: 34 Nm (350 kgf-cm, 25 ft. lbs.)





26. INSTALL STARTER AND A/T SHIFT CABLE CLAMP
a. Install the 2 bolts, starter and A/T shift cable clamp.
Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.)
b. Connect the connector and install the nut.





27. INSTALL 2 FRONT SIDE ENGINE MOUNTING BOLTS
Torque:
Green color bolt: 66 Nm (670 kgf-cm, 48 ft. lbs.)
Silver color bolt: 44 Nm (440 kgf-cm, 32 ft. lbs.)





28. INSTALL 2 ENGINE MOUNTING ABSORBER BOLTS
Torque: 48 Nm (490 kgf-cm, 35 ft. lbs.)





29. CONNECT SHIFT CONTROL CABLE
a. Install the clip and connect the shift control cable.
b. Install the nut and connect the shift control cable from the park/neutral position switch.
Torque: 15 Nm (150 kgf-cm, 11 ft. lbs.)
30. CONNECT SOLENOID CONNECTOR
31. CONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR
32. CONNECT DIRECT CLUTCH SPEED SENSOR CONNECTOR
33. CONNECT VEHICLE SPEED SENSOR CONNECTOR





34. CONNECT GROUND CABLE





35. INSTALL CRUISE CONTROL ACTUATOR
a. Install the 3 bolts and connect cruise control actuator with the bracket.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
b. Connect the connector.





36. INSTALL THROTTLE CABLE TO THROTTLE BODY
Torque: 15 Nm (150 kgf-cm, 11 ft. lbs.)
37. INSTALL AIR CLEANER ASSEMBLY
38. INSTALL SUSPENSION UPPER BRACE
Torque: 80 Nm (820 kgf-cm, 59 ft. lbs.)
39. INSTALL BATTERY
40. CHECK AND ADJUST TRANSMISSION CONTROL ROD AND PARK/NEUTRAL POSITION SWITCH. Refer to Transmission Position Switch/Sensor; Service and Repair.
41. CHECK ATF LEVEL.
42. CONDUCT ROAD TEST OF VEHICLE