Removal and Replacement
REMOVAL1. Remove battery and battery carrier.
2. Disconnect main fuse block and distributor lead.
3. Disconnect air flow meter connector, then remove air cleaner assembly.
4. Remove resonance chamber, then the resonance chamber bracket.
5. On models with electro-mechanical instrument cluster, disconnect speedometer cable from transaxle.
6. On models with electronic instrument 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, then the range selector cable from transaxle case.
9. Disconnect kickdown cable from throttle cam.
10. Raise and support vehicle, then remove front wheel and tire assemblies.
11. Remove splash shields, then drain transaxle fluid.
12. Disconnect oil cooler inlet and outlet hoses. Plug hoses to prevent fluid leakage.
13. Remove both stabilizer link assemblies.
14. Remove tie rod nuts and cotter pins, then disconnect both tie rod ends.
15. Remove bolts and nuts from both lower arm ball joints.
16. Pull lower arms down to separate from knuckles.
17. Remove righthand joint shaft bracket.
18. Remove halfshafts from transaxle by prying with a bar inserted between shaft and transaxle case. Support halfshafts in vehicle with wire.
19. Install two transaxle plugs tool No. T88C-7025-AH or equivalent, into differential side gears.
CAUTION: Failure to install transaxle plugs may allow differential side gears to become improperly positioned.
20. Remove gusset plate to transaxle bolts.
21. Remove torque converter cover, then the torque converter nuts.
22. Remove starter motor and access brackets.
23. Install engine support bar tool No. D79P-6000-A or equivalent, and attach to engine hanger.
24. Remove center transaxle mount and bracket, then the lefthand transaxle mount.
25. Remove nut and bolt attaching righthand transaxle mount to frame.
26. Remove crossmember and the lefthand lower arm as an assembly.
27. Position transaxle jack under transaxle, then secure transaxle to jack.
28. Remove six engine to transaxle attaching bolts.
29. Insert screwdriver between flex plate and converter, then carefully disengage studs.
NOTE: Before transaxle can be lowered out of vehicle, torque converter studs must be clear of flex plate.
30. Lower transaxle from vehicle.
INSTALLATION
NOTE: The following procedure has been revised by a Technical Service Bulletin.
A pin is used to hold the throttle valve in a fixed position on new or remanufactured service replacement transaxle assemblies.
The pin is used during the assembling process to make installation of the control valve easier. When installing a new or remanufactured transaxle, ensure to remove the pin and install a new retaining bolt. 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 transaxle 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 bolts. Torque bolts to 66-86 ft lbs.
4. Install center transaxle mount and bracket. Torque bolts to 27-40 ft lbs and nuts to 47-66 ft lbs.
5. Install lefthand transaxle mount. Torque transaxle to mount nut to 63-86 ft lbs, then the mount to bracket nut and bolt to 49-69 ft lbs.
6. Install crossmember and lefthand lower arm as an assembly. Torque bolts to 27-40 ft lbs, then the nuts to 35-69 ft lbs.
7. Install righthand transaxle mount bolt and nut. Torque bolt and nut to 63-86 ft lbs.
8. Install starter motor and access brackets.
9. Install torque converter to flex plate nuts. Torque nuts to 32-45 ft lbs.
10. Install torque converter cover. Torque bolts to 69-95 in lbs.
11. Install gusset plate to transaxle bolts. Torque to 27-38 ft lbs.
12. Replace circlips on end of each halfshaft, then remove transaxle plugs and install halfshafts to transaxle.
13. Attach lower arm ball joints to knuckles.
14. Install tie rod ends. Torque nuts to 22-33 ft lbs.
15. Install new cotter pins to tie rod ends.
16. Install lower arm ball joint bolts and nuts. Torque bolts and nuts to 32-40 ft lbs.
17. Install stabilizer link assemblies, noting the following:
a. Torque nuts on each assembly until one inch (25.4 mm) of bolt thread can be measured from upper nut.
b. Secure upper nut and back off lower nut to reach torque of 12-17 ft lbs.
18. Connect oil cooler inlet and outlet hoses, then install splash shields.
19. Install front wheel and tire assemblies. Torque lug nuts to 65-87 ft lbs.
20. Lower vehicle.
21. Connect kickdown cable, then the range selector cable. Torque selector cable to transaxle bolt to 22-29 ft lbs.
22. Connect two ground wires to transaxle case, then torque to 69-95 in lbs.
23. Attach five transaxle electrical connectors to transaxle case, then the transaxle wiring harness to transaxle clips.
24. On models with electro-mechanical instrument cluster, connect speedometer cable.
25. On models with electronic instrument cluster, connect speed sensor harness connector.
26. On all models, install resonance chamber and bracket. Torque to 69-95 in lbs.
27. Install air cleaner assembly. Torque bolt to 23-30 ft lbs, then the nuts to 69-95 in lbs.
28. Connect air flow meter electrical connector and distributor lead.
29. Connect main fuse block. Torque to 69-95 in lbs.
30. Install battery carrier and battery, then connect battery cables.
31. Remove engine support bracket.
32. Add proper transaxle fluid, then check for leaks and fluid level.
33. Adjust kickdown cable.