Removal and Replacement
REMOVAL1. Remove battery and battery carrier, then disconnect main fuse block.
2. Disconnect air cleaner hose from air cleaner, then remove air cleaner assembly.
3. Remove speed control actuator mounting bolts and nuts, then position speed control actuator aside.
4. Disconnect vehicle speed sensor or speedometer cable from transaxle.
5. Disconnect transaxle fluid cooling lines from radiator assembly, then cap lines.
6. Disconnect electrical connectors from transaxle, then the wiring harness from routing brackets on transaxle.
7. Disconnect shift cable from transaxle by removing 21 mm retaining nut.
8. Remove horseshoe clip from shift cable and routing bracket, then disconnect cable from bracket.
9. Remove transaxle wiring harness bracket, then the two ground straps from transaxle assembly.
10. Loosen transaxle kickdown cable adjusting nuts at cable bracket, then disconnect cable from bracket.
11. Disconnect kickdown cable from throttle cam.
12. Install engine support bar tool No. D88L-6000-A with necessary hooks to support engine and transaxle.
13. Remove all accessible transaxle to engine retaining bolts from top of engine compartment.
14. Remove upper transaxle mounting nuts.
15. Raise and support vehicle, then remove front wheels.
16. Remove inner fender splash shields.
17. Drain transaxle fluid.
18. Remove stabilizer link assemblies from lower control arms.
19. Remove lower control arm ball joint to steering knuckle pinch bolts.
20. Separate ball joints from steering knuckle by prying downward on lower control arm while pushing inward on rotor.
21. Remove mounting bolts from righthand halfshaft dynamic damper.
22. Remove halfshaft from Transaxle by prying on bar inserted between shaft and transaxle case.
23. Install two transaxle plugs tool No. T88C-7025-AH or equivalent, to differential side gears.
CAUTION: Failure to install transaxle plugs may result in misalignment of differential side gears.
24. Remove starter motor and bracket, then the transaxle support bracket.
25. Remove inspection plate from transaxle, then the torque converter retaining nuts.
26. Position transaxle jack under transaxle for support.
27. Remove transaxle rear lower mount bolts.
28. Remove transaxle front lower mount through bolt.
29. Remove lefthand front crossmember and lower control arm assembly.
30. Remove remaining transaxle to engine bolts.
31. Insert screwdriver between flexplate and converter, then carefully disengage studs.
NOTE: Before transaxle can be lowered out of vehicle, torque converter studs must be clear of flexplate.
32. Lower transaxle assembly 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.
NOTE: Ensure transaxle is secure.
2. Raise transaxle to proper height, then mount transaxle to engine.
3. Align torque converter studs and flexplate holes, then install transaxle to engine lower bolts. Torque bolts to 66-86 ft lbs.
4. Install lefthand front crossmember and lower control arm assembly. Torque crossmember bolts to 27-40 ft lbs, then the crossmember nut to 55-69 ft lbs.
5. Install transaxle front lower mount through bolt. Torque to 66-86 ft lbs.
6. Install transaxle rear lower mount bolts. Torque bolts to 49-69 ft lbs.
7. Install torque converter nuts. Torque nuts to 32-45 ft lbs.
8. Install inspection plate, then the transaxle support bracket.
9. Install starter motor and bracket.
10. Install new circlips to end of each halfshaft.
11. Remove transaxle plugs, then install halfshafts.
12. Install mounting bolts to righthand halfshaft dynamic damper. Torque bolts to 31-46 ft lbs.
13. Install lower control arm ball joints in steering knuckles.
14. Install ball joint pinch bolts. Torque pinch bolts to 27-40 ft lbs.
15. 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.
16. Install right inner fender splash guard. (Installation of the lefthand splash guard will be done after the kickdown cable has been adjusted.)
17. Install front wheels. Torque wheel lug nuts to 65-87 ft lbs.
18. Lower vehicle, then Install transaxle upper mount nuts. Torque nuts to 47- 66 ft lbs.
19. Install remaining transaxle to engine retaining bolts. Torque bolts to 66-86 ft lbs.
20. Remove engine support bar, then connect transaxle kickdown cable to throttle cam.
21. Connect kickdown cable to cable bracket, then tighten adjusting nuts.
22. Connect two ground straps to transaxle, then install transaxle wiring harness bracket.
23. Connect shift cable to its routing bracket, then install horseshoe clip.
24. Connect shift cable to transaxle, then install retaining nut. Torque nut to 33-47 ft lbs.
CAUTION: Do not use any type of power wrench to tighten retaining nut. Damage to transaxle may result.
25. Connect transaxle electrical connectors, then connect wiring harness routing brackets to transaxle.
26. Unplug, then install transaxle cooling lines to radiator assembly.
27. Connect vehicle speed sensor or speedometer cable to transaxle.
28. Install speed control actuator, then the air cleaner assembly.
29. Connect air cleaner hose to air cleaner.
30. Connect main fuse block, then install battery tray and battery.
31. Add proper transaxle fluid, then check for leaks and fluid level.
32. Adjust kickdown cable.