Removal and Replacement

REMOVAL PROCEDURE

^ Tools Required
- J 28467-360 Engine Support Fixture





1. Disconnect the battery negative cable from the battery. Refer to Battery Disconnect Caution in Service Precautions.
2. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
3. Remove the upper filler panel.
4. Remove the air cleaner upper plenum and intake tube. Refer to Air Cleaner Assembly Replacement in Powertrain Management.
5. Remove the surge tank inlet pipe. Refer to Radiator Hose Replacement - Inlet in Cooling System.
6. Remove the surge tank outlet pipe. Refer to Surge Tank Pipe Replacement - Outlet in Cooling System.
7. Remove the oil cooler lines at the cooler and the oil sending line at the transmission. Install plugs in the inlet and the return hose to prevent fluid leakage or contamination.
8. Disconnect the shift cable from the shift linkage.





9. Remove the shift linkage assembly from the transmission.





10. Install the J 42504 Engine Lift Bracket to the engine.





11. Install the J 42478 Engine Support Fixture Adapters and J 28467-A Engine Support Fixture.





12. Remove the upper transmission to engine bolts (2).
13. Raise the left side of the powertrain (the transmission side) 25.4 mm (1.0 inch)above the powertrain resting position with the adjusting screws.
14. Raise the vehicle. Refer to Vehicle Lifting.
15. Support the vehicle with safety stands.
16. Remove both front tire and wheel assemblies.
17. Remove the wheel opening splash shields.
18. Remove both front suspension position sensors links from the lower control arms and position out of the way.





19. Remove both stabilizer links from the lower control arms. Allow the stabilizer shaft to sit loosely on the engine frame.





20. Remove both stabilizer shaft insulator brackets from the engine frame.
21. Remove both drive axle nuts and separate both drive axles from the hubs.
22. Remove both tie rod cotter pins and nuts and separate both tie rods from the steering knuckles.
23. Remove both lower ball joint cotter pins and nuts. Separate both ball joints from the steering knuckles.
24. Remove the lower closeout panel.
25. Remove both drive axles from the transmission.
26. Remove the Brake Pressure Modulator Valve (BPMV) and bracket from the engine frame and support with safety wire.





27. Remove the rear transmission mount bracket nut (2) and bolts (3).





28. Remove the rear transmission mount bolt (1) and nuts (3) from the left frame rail.





29. Remove the left engine mount nut from the engine frame.





30. Remove the right engine mount nuts from the engine frame.
31. Remove the steering rack bolts from the engine frame.
32. Remove the following electrical connectors.
^ The transmission connectors.
^ The Vehicle Speed Sensor (VSS) connector.
^ The ground junction block.

33. Remove the brake line and power steering line fasteners from the engine frame.
34. Remove the post oxygen sensor heat shield and disconnect the post oxygen sensor.





35. Disconnect the center exhaust hanger to allow easy movement of the exhaust in the rearward direction.





36. Remove the catalytic converter brace.





37. Lower the vehicle and support the engine frame using the J-35580 Engine Support Table.





38. Remove the six engine frame mount bolts (3) from the engine frame (2).
39. Fully separate the tie rod ends and lower ball joints from the steering knuckles.
40. Raise the vehicle slowly away from the engine frame.
41. Remove the engine frame and support table from under the vehicle.
42. Remove the steering rack heat shield from the rack.
43. Disconnect the power steering lines from the steering rack.





44. Remove the right rear engine to transmission bracket upper bolt (1), nuts (3), and bracket (2).





45. Remove the right transmission mount bracket lower bolts (2) and bracket (1) from the transmission. It will be necessary to support the steering rack in a position that allows access to the bracket bolts.
46. Remove the steering rack from the vehicle.





47. Remove the right front engine to transmission brace bolt (1), nut (2), brace (3) and heatshield.





48. Remove the right front engine to transmission bracket.
49. Remove the engine oil pan to transmission bracket.
50. Remove the torque converter cover brace.
51. Remove the torque converter cover.
52. Remove the flywheel to converter bolts.

IMPORTANT: Mark the flywheel to converter position so that they can be assembled in the same position.

53. Disconnect all transmission electrical connectors.
54. Remove the engine to transmission heat shield and the bracket.
55. Support the transmission with a transmission jack.





56. Remove the engine to transmission bolts.
57. Separate the transmission from the engine.
58. Lower the transmission.

INSTALLATION PROCEDURE





1. Install the rear transmission mount bracket (1) onto its stud before the transmission is fully up into the vehicle.





2. Loosely attach the rear transmission mount (2) to the left frame rail with its nuts (3) and bolt (1).
3. Raise the transmission on the transmission jack.
3.1. Guide the rear mount bracket and the rear mount together as the transmission is raised into the vehicle.
3.2. Align the transmission with the engine and position the transmission onto the engine dowels.





4. Install the engine to transmission bolts.
^ Tighten the bolts to 75 Nm (55 ft. lbs.).

NOTICE: Refer to Fastener Notice in Service Precautions.

5. Remove the transmission jack.





6. Install the right front engine to transmission heat shield and brace.
^ Tighten the bolts to 50 Nm (37 ft. lbs.).





7. Install the right front engine to transmission bracket.
^ Tighten the bolts to 50 Nm (37 ft. lbs.).





8. Install the right transmission mount bracket (1) and the lower bolts (2) to the transmission.
^ Tighten the bolts (2) to 110 Nm (81 ft. lbs.).

9. Loosely position the steering rack into the vehicle and insert the tie rod ends into the steering knuckles.





10. Install the right rear engine to transmission bracket (2).
^ Tighten the bolt (1) to 110 Nm (81 ft. lbs.) and the nuts (3) to 50 Nm (37 ft. lbs.).

11. Connect the power steering lines to the power steering rack.
^ Tighten the lines to 27 Nm (20 ft. lbs.).

12. Install the power steering rack heat shield.
13. Install the flywheel to converter bolts.
^ Tighten the bolts to 60 Nm (44 ft. lbs.).

IMPORTANT: Line up the flywheel and converter using the alignment marks made at disassembly.

14. Install the torque converter cover.
15. Install the following electrical connectors:
^ The transmission connectors.
^ The Vehicle Speed Sensor (VSS) connector.
^ The ground junction block.

16. Install both drive axles into the hubs and both drive axle nuts.
^ Tighten the nuts to 145 Nm (110 ft. lbs.).

17. Position the engine frame on to the J 35580 Engine Support Table.
18. Position the stabilizer bar onto the engine frame in its approximate position.
19. Lower the vehicle to the engine frame while locating all the mounting points.
20. Install the engine frame mounting bolts finger tight.
21. Raise the vehicle away from the engine support table.
22. Tighten the engine frame bolts.
^ Tighten the engine frame bolts to 192 Nm (142 ft. lbs.).

23. Install the steering intermediate shaft to the steering gear and install the clamp bolt.
^ Tighten the clamp bolt to 50 Nm (37 ft. lbs.).

24. Install the steering gear bolts.
^ Tighten the bolts to 105 Nm (77 ft. lbs.).

25. Install the left and right transmission mount nuts and the right engine mount nuts at the frame.
^ Tighten the nuts to 50 Nm (37 ft. lbs.).

IMPORTANT: When tightening the ball joint nut, a minimum torque of 50 Nm (37 ft. lbs.) must be obtained. If 50 Nm (37 ft. lbs.) is not obtained, inspect for stripped threads. If threads are satisfactory, replace the ball joint and knuckle. If required, turn the nut up to an additional 60 degrees to allow for installation of the cotter pin.

26. Install both lower ball joints into the steering knuckles and both ball joint nuts and cotter pins.
^ Tighten the ball joint nut to 10 Nm (84 inch lbs.).

27. Tighten the ball joint nut an additional 120 degrees.

IMPORTANT: When tightening the tie rod end nut, a minimum torque of 45 Nm (33 ft. lbs.) must be obtained. If 45 Nm (33 ft. lbs.) is not obtained, inspect for stripped threads. If the threads are satisfactory, replace the tie rod end and knuckle.

28. Tighten the tie rod end nut to 10 Nm (7.5 ft. lbs.) then an additional 1/3 turn (2 flats). After tightening the castellated nut to specification, align the slot in the nut to the cotter pin hole by tightening only. Do not loosen the nut for cotter pin installation. Tighten the tie rod end nut to 100 Nm (74 ft. lbs.) then an additional 1/3 turn (2 flats).
29. Install the brake and power steering line retainers to the engine frame.
30. Install the brake pressure modulator valve and bracket to the engine frame.
31. Install the sway bar insulators onto the sway bar.
32. Install both stabilizer links to the control arms.
^ Tighten the nuts to 65 Nm (49 ft. lbs.).

33. Install both front suspension position sensors to the lower control arms.
34. Install lower close out panel.





35. Install the catalytic converter brace.





36. Connect the center exhaust hanger.
37. Connect the post oxygen sensor and install the heat shield.
38. Install both wheel opening splash shields.
39. Install both front tire and wheel assemblies. Refer to Wheel Installation in Tires and Wheels.
40. Lower the vehicle.





41. Remove the J 42478 Engine Support Fixture Adapters and J 28467-A Engine Support Fixture.





42. Remove the J 42504 Engine Lift Bracket to the engine.





43. Install the upper bell housing bolts.
44. Remove the oil cooler line plugs from the lines.
45. Install the transmission cooler pipe fittings at the transmission.
^ Tighten the cooler pipe fittings at transmission to 22 Nm (16 ft. lbs.).

46. Install the transmission oil sending pipe to the transmission.





47. Install the shift linkage assembly to the transmission.





48. Install the right rear engine to transmission bracket (2).
^ Tighten the bolt (1) to 110 Nm (81 ft. lbs.) and the nuts (3) to 50 Nm (37 ft. lbs.).

49. Connect surge tank outlet hose. Refer to Radiator Hose Replacement - Inlet in Cooling System.
50. Connect the surge tank inlet hose. Refer to Surge Tank Pipe Replacement - Outlet in Cooling System.
51. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Powertrain Management.
52. Install the upper filler panel.
53. Connect the negative battery cable. Refer to Battery Disconnect Caution in Service Precautions.
54. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
55. Bleed the power steering system. Refer to Bleeding Power Steering System in Steering.
56. Add Dexron(R)-III transmission fluid as required. Refer to Fluid Capacity in Specifications.
57. Check the front suspension alignment. Refer to Wheel Alignment Specifications in Suspension.
58. Reset the transmission adapts.