Case: Service and Repair

Case Side Cover Replacement

Removal Procedure

1. Important: Lock steering wheel in centered position with wheels straight ahead.

Remove the air cleaner intake duct.
2. Remove the engine mount struts.
3. Install the engine support fixture.





4. Disconnect the range selector cable from the cable bracket and range selector lever.
5. Remove the top bolt from the transaxle side cover.





6. Disconnect the transmission wiring harness connector (2).
7. Remove the wire harness (3) from the wire harness retainer (1).
8. Raise and support the vehicle. Refer to Vehicle Lifting.
9. Remove the left front tire and wheel assembly.





10. Remove the wheel speed sensor harness (1) from the 4 retainers (2) at the frame.





11. Remove the transmission mount to frame nuts only. .
12. Remove the engine splash shield.





13. Remove the stabilizer bolts and reposition the stabilizer.
14. Remove the steering gear frame bolts and support the gear before lowering the frame.





15. Separate the left ball joint (3) from the steering knuckle.
16. Position the drain pan under the transaxle.





17. Remove the left drive shaft (1) from the transaxle.
18. Secure the drive axle to the steering knuckle/strut.
19. Support the left side of the frame with a jackstand.





20. Loosen the engine mount lower nuts.
21. Loosen the right center frame bolt only. Do NOT loosen the right front or right rear frame bolts.
22. Remove the left frame bolts.
23. Adjust the jackstand to lower the left side of the frame until the frame hangs free. Remove the jack stand.
24. Lower vehicle to access engine support fixture.
25. Lower the engine/transmission assembly with the engine support fixture to gain access to the remaining side cover bolts.
26. Raise the vehicle to access the side cover bolts.





27. Remove the case side cover bolts (56-58).





28. Remove the case side cover pan (53).
29. Remove the case side cover gasket (54).
30. Clean the case.
31. Clean the side cover gasket mating surfaces.

Installation Procedure





1. Install the case side cover gasket (54).
2. Install the case side cover pan (53).





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

Install the case side cover bolts (56-58) except for the top bolt.
Tighten the bolts to 25 Nm (18 ft. lbs.).
4. Use a jackstand to raise the left side of the frame and engine assembly into position.
5. Install the left side frame bolts and tighten the right center frame bolt.





6. Install the engine mount lower nuts.





7. Install the transaxle mount to frame nuts. .
8. Remove the jackstands from the frame.





9. Install the left drive shaft (1) to the transaxle.
10. Remove the drain pan from under the transaxle.





11. Install the ball joint nut (2) and the cotter pin (1).
12. Install the steering gear frame bolts.





13. Reposition the stabilizer and install the stabilizer bolts.
14. Install the engine splash shield.





15. Install the wheel speed sensor harness (1) to the 4 retainers (2) at the frame.
16. Install the left front tire and wheel assembly.
17. Lower the vehicle.





18. Connect the transaxle wiring harness connector (2).
19. Install the wire harness (3) to the wire harness retainer (1).
20. Install the transaxle top side cover bolt.





21. Connect the range selector cable to the cable bracket and range selector.
22. Remove the engine support fixture.
23. Install the engine mount struts.
24. Install the throttle body air inlet duct.

25. Notice: Refer to Transmission Overfill Notice in Service Precautions.

Inspect the fluid level and fill the transaxle as necessary.
26. Inspect for fluid leaks.