Removal and Replacement

REMOVAL
1. Disconnect battery cables, then remove battery and battery carrier.
2. Disconnect main fuse block and distributor lead.
3. Disconnect air flow meter connector and remove air cleaner assembly.
4. Remove resonance chamber, then the resonance chamber bracket.
5. On models with electro-mechanical dash cluster, disconnect speedometer cable from transaxle.
6. On models with electronic dash cluster, disconnect speed sensor harness connector from transaxle.
7. On all models, disconnect five transaxle electrical connectors, then separate transaxle wiring harness from transaxle clips.
8. Disconnect two ground wires from transaxle case.
9. Disconnect range selector cable front transaxle case.
10. Disconnect kickdown cable front throttle cam.
11. Raise and support vehicle, then remove front wheel and tire assemblies.
12. Remove splash shields, then drain transaxle fluid.
13. Disconnect oil cooler inlet and outlet hoses. Insert plugs to prevent fluid leakage.
14. Remove tie rod nuts and cotter pins then disconnect both tie rod ends.
15. Remove both stabilizer link assembly.
16. Remove bolts and nuts from both lower arm ball joints.
17. Pull lower arms down to separate from knuckles.
18. Remove righthand joint shaft bracket.
19. Remove halfshafts from transaxle by prying with a bar inserted between shaft and transaxle case. Support halfshafts in vehicle with wire.
20. Install two transaxle plug tools No. T88C-7025-AH or equivalent, into differential side gears.

CAUTION: Failure to install transaxle plugs may allow differential side gears to become incorrectly positioned.

21. Remove gusset plate-to-transaxle bolt.
22. Remove torque converter cover, then the torque converter nuts.
23. Remove starter motor and access brackets.
24. Install engine support bar tool No. D79P-6000-B or equivalent and attach to engine hanger.
25. Remove center transaxle mount and bracket, then the left transaxle mount.
26. Remove nut and bolt attaching right transaxle mount to frame.
27. Remove crossmember and the left lower arm as an assembly.
28. Position a transmission jack under transaxle and secure transaxle to jack.
29. Remove six engine-to-transaxle attaching bolts.
30. Before transaxle can be lowered out of vehicle, torque converter studs must be clear of flex late. Insert a screwdriver between flexplate and converter, then carefully disengage studs.
31. Lower transaxle out of vehicle.

INSTALLATION

NOTE: The following procedure has been revised by a Technical Service Bulletin.
a. A pin is used to hold the throttle valve in a fixed position on new or remanufactured service replacement transaxle assemblies.
b. The pin is used during the assembly process to make installation of the control valve easier. When installing a new or remanufactured 4EAT transaxle, ensure to remove the pin and install a new retaining bolt.

CAUTION: Failure to remove pin from the throttle cam will hold the transaxle throttle lever in a fixed position resulting in a shift concern.

1. Place transaxle on transmission jack and secure.
2. Raise transaxle to proper height and mount transaxle to engine. Align torque converter studs and flex plate holes.
3. Install six engine-to-transaxle attaching bolts and torque.
4. Install center transaxle mount and bracket. Torque bolts and nuts.
5. Install left transaxle mount. Torque transaxle-to-mount nut and mount-to-bracket nut and bolt.
6. Install crossmember and left lower arm as an assembly. Torque bolts and nuts.
7. Install right transaxle mount bolt and nut and torque.
8. Install starter motor and access brackets.
9. Install torque converter-to-flex plate nuts and torque.
10. Install torque converter cover. Torque attaching bolts.
11. Install gusset plate-to-transaxle bolts and torque.
12. Replace circlips on end of each halfshaft, remove transaxle plugs, then install halfshafts in transaxle.
13. Attach lower arm ball joints to knuckles.
14. Install tie rod ends and torque nuts to 22-33 ft lbs. Install new cotter pins.
15. Install lower arm ball joint bolts and nuts, torquing to 32-40 ft lbs.
16. Install stabilizer link assemblies. Tighten nuts on each assembly until one inch (25.4 mm) of bolt thread can be measured from upper nut, then secure upper nut and back off lower nut until a torque of 12-17 ft lbs is reached.
17. Connect oil cooler inlet and outlet hoses, then install splash shields.
18. Install front wheel and tire assemblies. Torque lug nuts to 65-87 ft lbs.
19. Connect kickdown cable, then the range selector cable. Torque selector cable-to-transaxle bolt to 22-29 ft lbs.
20. Connect two ground wires to transaxle case and torque to 69-95 in lbs.
21. Attach five transaxle electrical connectors, then attach transaxle wiring harness to transaxle clips.
22. Connect speedometer cable or speed sensor harness connector.
23. Install resonance chamber and bracket, torquing to 69-95 in lbs.
24. Install air cleaner assembly. Torque bolt to 23-30 ft lbs, nuts to 69-95 in lbs.
25. Connect air flow meter electrical connector and distributor lead.
26. Connect main fuse block and torque to 69-95 in lbs.
27. Install battery carrier and battery, then connect battery cables.
28. Remove engine support bracket.
29. Add specified transaxle fluid, check for leaks, and check fluid level.
30. Adjust kickdown cable.