Case: Service and Repair

Case Side Cover Replacement

Removal Procedure

1. Remove the throttle body air inlet duct.
2. Remove the engine mount struts.
3. Remove the wiper module cover.




4. Disconnect the 20-way electrical connector at the transaxle.
5. Remove the shift cable bracket from the transaxle.
6. Install the engine support fixture and support the engine/transaxle assembly.
7. Raise and support the vehicle. Refer to Vehicle Lifting.
8. Remove the left front tire and wheel.




9. Disconnect the left wheel speed sensor harness connector (1).
10. Remove the left engine splash shield.
11. Remove both stabilizer shaft links from the lower control arms.
12. Remove the wheel speed sensor harness from the control arm (1).
13. Remove the left lower ball joint from the left steering knuckle.
14. Remove the left drive axle from the transaxle.
15. Reposition and secure the drive axle.
16. Remove the heat shield bolts from the frame.
17. Remove the steering gear-to-frame bolts and secure the steering gear.
18. Support the left side of the frame with a utility stand.
19. Remove the transaxle mount lower nuts only.
20. Loosen the engine mount lower nuts. Refer to Engine Mount Replacement.
21. Remove the air deflector.
22. Remove only the left side frame bolts. DO NOT LOOSEN the right side frame-to-body bolts.
23. Use the utility stand in order to lower the left side of the frame.
24. Position a drain pan under the transaxle.
25. Remove the utility stand and lower the vehicle.
26. Loosen the right engine support bolts.
27. Raise the vehicle.
28. Remove the transaxle mount bracket.
29. Remove the transaxle wiring harness connectors.




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




31. Remove the case side cover pan (53).
32. Remove the case side cover gasket (54).
33. Remove the case side cover inner gasket (59).




34. Inspect the case side cover (53) for the following conditions:

* Damaged or porous gasket sealing surfaces
* Damaged or porous casting surfaces
* Damaged or stripped bolt holes

35. Inspect the case side cover gasket (54) and case side cover inner gasket (59) for damage. The gaskets are reusable if they are NOT damaged.
36. Clean the case side cover.
37. Clean the case side cover gasket surfaces.

Installation Procedure




1. Install the case side cover inner gasket (59).
2. Install the case side cover gasket (54).
3. Install the case side cover pan (53).





Notice: Refer to Fastener Notice.

4. Install the case side cover bolts (56-58).

Tighten the bolts (56-58) to 25 N.m (18 lb ft).

5. Install the transaxle mount bracket.

Torque to 95 N.m (70 lb ft).

6. Remove the drain pan from under the transaxle.




7. Install the wiring harness connectors.
8. Use the utility stand in order to raise the left side of the frame.
9. Install the left side frame bolts.

Tighten the bolts to 165 N.m (122 lb ft).

10. Install the transaxle mount.
11. Remove the utility stand support from the left side of the frame.
12. Install the air deflector.
13. Install the left drive axle to the transaxle.
14. Install the left lower ball joint to the left steering knuckle.

Important: This is a prevailing torque type fastener. This fastener may be reused ONLY if:

* The fastener and its counterpart are clean and free from rust.

* The fastener develops 2 N.m (18 lb in) of torque/drag against its counterpart prior to the fastener seating.

If the fastener does not meet these criteria, REPLACE the fastener.

Install two steering gear bolts.

Tighten the bolts to 80 N.m (59 lb ft).

15. Install the heat shield.
16. Install the lower ball joint nut and tighten.




17. Install and connect the wheel speed sensor harness (1).
18. Tighten the engine mount lower nuts. Refer to Engine Mount Replacement.
19. Install the stabilizer shaft links to the lower control arms.

Tighten to 23 N.m (17 lb ft).

20. Install the left engine splash shield.
21. Install the left front tire and wheel.
22. Lower the vehicle.
23. Remove the engine support fixture from the engine/transaxle assembly.
24. Install the shift cable bracket.
25. Connect the 20-way transmission electrical connector.
26. Install the engine mount struts.
27. Install the throttle body air inlet duct.
28. Install the wiper module cover.

Notice: Do NOT overfill the transaxle. The overfilling of the transaxle causes foaming, loss of fluid, shift complaints, and possible damage to the transaxle.

29. Adjust the fluid level. Refer to the following information.

* Line Pressure Check
* Fluid and Lubricant Recommendations
* Approximate Fluid Capacities

30. Inspect for proper completion of the repairs.
31. Inspect for fluid leaks.