With KF400 Transmission
KF4OO TRANSAXLE REMOVAL AND INSTALLATIONTools Required:
^ J 28467-A Universal Support Fixture
^ J 28467-125 Engine Support Adapters
REMOVE OR DISCONNECT
1. Negative (-) battery cable.
2. Positive (+) battery cable.
3. One nut, one bolt and battery hold down bracket from battery.
4. Battery from vehicle.
5. Park/neutral position (PNP) switch and kickdown solenoid electrical connectors (underneath right side of battery tray).
6. Engine wiring harness and ignition coil ground wire connector from top of transaxle.
7. Intake air duct from air cleaner (ACL).
8. Air breather tube from ACL. Separate ACL halves.
9. Shift select cable adjustment nut from damper pin and shift select cable from transaxle shift lever.
10. One C-clip and shift select cable from shift select cable bracket.
11. Vacuum hose from vacuum modulator supply pipe at rear of transaxle.
12. Speedometer cable from speedometer driven gear case.
13. Vacuum hose governor vacuum hose connection at top of transaxle.
^ Install a J 28467-A with the J 28467-125.
14. Four upper transaxle to engine bolts from transaxle.
^ Raise and suitably support vehicle.
15. Six screws and left splash shield from vehicle.
16. Six screws and right splash shield from vehicle.
17. One through bolt and nut from left transaxle mount.
18. Two front tire and wheel assemblies.
^ Unstake both drive axle nuts.
19. Two drive axle nuts from drive axles.
^ Place a drain pan or suitable container underneath transaxle.
NOTICE: This transaxle is not equipped with a fluid pan drain plug. Transaxle fluid will begin to drain out immediately after fluid pan seal is loosened. Make sure a drain pan or suitable container has been placed underneath the transaxle fluid pan.
NOTICE: When removing the transaxle fluid pan, use caution in order not to damage the transaxle case-to-fluid pan mating surfaces. If the fluid pan is frozen to the transaxle case, use a rubber mallet and a wood block to lightly tap the fluid pan free. DO NOT attempt to pry the fluid pan away from the case with metal tools; damage to the case or fluid pan flange could result.
20. Sixteen transaxle fluid pan bolts, fluid pan, fluid pan gasket and drain transaxle fluid.
^ Install transaxle fluid pan and fluid pan gasket onto transaxle to support transaxle assembly on hydraulic jack; secure with sixteen bolts.
Tighten
^ Transaxle fluid pan bolts to 7 N.m (62 lb.in.).
21. Left drive axle from vehicle.
22. Right drive axle from vehicle.
23. One through bolt and nut from front engine mounting strut.
24. One bolt, one nut and center crossmember strut from center crossmember and front suspension crossmember.
25. One through bolt from rear transaxle mount.
26. Four bolts from center crossmember at core support and front suspension crossmember and center crossmember from vehicle.
27. Two bolts from front exhaust pipe at three way catalytic converter (TWC).
28. Three nuts from front exhaust pipe at exhaust manifold.
29. Two bolts from front exhaust pipe bracket at rear of engine and front exhaust pipe from vehicle.
30. One nut from front engine mounting strut stud.
31. Two bolts and front engine mounting strut bracket with front engine mounting strut from engine.
^ Lower vehicle.
^ Lower engine slightly using the J 28467-A.
^ Raise and suitably support vehicle.
^ Support transaxle with a suitable hydraulic jack.
32. Three bolts and rear engine mounting bracket from engine and transaxle.
33. One bolt and rear transaxle mount from transaxle.
34. Five bolts and flywheel cover from vehicle.
35. Six flywheel-to-torque converter bolts from flywheel.
36. One clamp and fluid cooler inlet hose from fluid cooler pipe (Figure 55).
37. One clamp and fluid cooler outlet hose from transaxle.
38. Transaxle from engine by carefully moving transaxle away from engine toward the left side of the engine compartment and very slowly lowering the transmission jack making sure no obstructions exist.
INSPECT
^ For automatic transaxle disassembly and inspection procedures, refer to Overhaul.
NOTICE: Transaxle fluid cooler flushing must be performed when a transaxle is removed for service. The flushing procedure should be performed after the installation of the overhauled or replacement assembly. Failure to flush the system may cause damage to the system and its components.
IMPORTANT
^ Before installing the transaxle assembly, these steps and precautions must be followed:
A. Apply grease around the pilot at the center of the torque converter. This will ensure ease of assembly.
B. Measure the distance between the outside edge of the torque converter housing and the torque converter lug. The distance should be within 11.7 to 12.5 mm (0.460 to 0.492-inch). If it is less than 11.7 mm (0.460-inch), the torque converter is improperly installed. Remove the torque converter and properly seat it on the input shaft.
INSTALL OR CONNECT
Tools Required:
^ J 28467-A Universal Support Fixture
^ J 28467-1 25 Engine Support Adapters
1. Transaxle to engine by carefully raising the transaxle using a suitable hydraulic jack and making sure no obstructions exist.
2. Fluid cooler outlet hose to transaxle; secure with one clamp.
3. Fluid cooler inlet hose from fluid cooler pipe, secure with one clamp.
4. Six flywheel-to-torque converter bolts to flywheel.
Tighten
^ Flywheel-to-torque converter bolts to 42 N.m (31 lb.ft.).
5. Flywheel cover to transaxle; secure with five bolts.
Tighten
^ Flywheel cover bolts to 10 N.m (89 lb.in.).
6. Rear transaxle mount to transaxle; secure with one bolt.
Tighten
^ Rear transaxle mount bolt to 39 N.m (29 lb. ft.).
7. Rear engine mounting bracket to engine and transaxle: secure with three bolts.
Tighten
^ Rear engine mounting bracket bolts to 39 N.m (29 lb.ft.).
^ Remove hydraulic jack from underneath transaxle.
^ Lower vehicle.
^ Raise engine slightly using the J 28467-A.
^ Raise and suitably support vehicle.
8. Front engine mounting strut bracket and front engine mounting strut to engine; secure with two bolts.
Tighten
^ Front engine mounting strut bracket bolts to 61 N.m (45 lb.ft.).
9. One nut to front engine mounting strut stud.
Tighten
^ Front engine mounting strut stud nut to 61 N.m (45 lb.ft.).
10. Front exhaust pipe to vehicle; secure with two bolts at front exhaust pipe bracket at rear of engine.
Tighten
^ Front exhaust pipe bracket bolts to 43 N.m (32 lb.ft.).
11. Front exhaust pipe to exhaust manifold; secure with three nuts.
Tighten
^ Front exhaust pipe-to-exhaust manifold nuts to 62 N.m (46 lb.ft.).
12. Front exhaust pipe to TWC; secure with two bolts.
Tighten
^ Front exhaust pipe-to-TWC bolts to 43 N.m (32 lb.ft.).
13. Center crossmember to vehicle; secure with four bolts at front suspension crossmember and core support.
Tighten
^ Center crossmember bolts to 61 N.m (45 lb.ft.).
14. One through bolt into rear transaxle mount.
Tighten
^ Rear transaxle mount through bolt to 87 N.m (64 lb.ft.).
15. Center crossmember strut to center crossmember and front suspension crossmember; secure with one nut and one bolt.
Tighten
^ Center crossmember strut nut and bolt to 50 N.m (37 lb.ft.).
16. One through bolt and nut into front engine mounting strut.
Tighten
^ Front engine mounting strut through bolt and nut to 87 N.m (64 lb.ft.).
17. Right drive axle to vehicle.
18. Left drive axle to vehicle.
^ Remove the sixteen transaxle fluid pan bolts (Figure 32).
CLEAN
^ Transaxle fluid pan mating surfaces.
19. New transaxle fluid pan gasket and transaxle fluid pan to transaxle; secure with sixteen bolts.
Tighten
^ Transaxle fluid pan bolts to 7 N.m (62 lb.in.).
20. Two drive axle nuts to drive axles.
Tighten
^ Drive axle nuts to 186 Nm (137 lb.ft.).
^ Stake both drive axle nuts.
21. Two front tires and wheel assemblies.
22. One through bolt and nut to left transaxle mount.
Tighten
^ Left transaxle through bolt and nut to 87 N.m (64 lb.ft.).
23. Right splash shield to vehicle; secure with six screws.
24. Left splash shield to vehicle; secure with six screws.
^ Lower vehicle.
25. Four upper transaxle to engine bolts to transaxle.
Tighten
^ Upper transaxle-to-engine bolts to 42 N.m (31 lb.ft.).
^ Remove the J 28467-A and the J 28467-125.
26. Vacuum hose to governor vacuum hose connection at top of transaxle.
27. Speedometer cable to speedometer driven gear case.
28. Vacuum hose to vacuum modulator pipe at rear of transaxle.
29. Shift select cable into shift select cable bracket; secure with One C-clip.
30. Damper pin and shift select cable into transaxle shift lever; secure with one nut.
ADJUST
^ Shift select cable.
Tighten
^ Shift select cable adjustment nut to 57 N.m (42 lb.ft.).
^ Assemble ACL halves.
31. Air breather tube to ACL.
32. Intake air duct to ACL.
33. Engine wiring harness and ignition coil ground wire connector to top of transaxle.
34. PNP switch and kickdown solenoid electrical connectors (underneath right side of battery tray).
35. Battery into vehicle.
36. Battery hold down bracket onto battery; secure with one bolt and one nut.
Tighten
^ Battery hold down bracket bolt to 5 N.m (44 lb.in.).
^ Battery hold down bracket nut to 8 N.m (71 lb.in.).
37. Positive (+) battery cable.
Tighten
^ Positive (+) battery cable-to-positive (+) battery terminal retainer to 15 N.m (11 lb.ft.).
38. Negative (-) battery cable.
Tighten
^ Negative (-) battery cable-to-negative (-) battery terminal retainer to 15 N.m (11 lb.ft.).
Refill transaxle as necessary:
A. Place vehicle on a level surface.
B. Remove fluid level indicator.
C. Add approximately 4.1 liters (4.4 qts.) of Dexron II GM P/N 1051855 automatic transmission fluid, or equivalent into fluid filler tube.
D. Install fluid level indicator into fluid filler tube.
E. Apply parking brake and block vehicle wheels.
F. With selector lever in "P" (park) position, start engine. DO NOT race engine.
G. Run engine at idle and move selector lever through each range and return to the "P" (park) position.
H. With engine running at idle. remove fluid level indicator from filler tube and wipe indicator off.
I. Reinsert fluid level indicator into filler tube making sure it is seated in its original position.
J. Remove the indicator and check the fluid level. The level should be between the full hot and low hot marks. If the level is below the low hot mark. add fluid to bring the level to the full hot mark. Bringing the fluid level from the low hot mark to the full hot mark requires 0.3 liters (0.3 qts.) of fluid. Use Dexron II GM P/N 1051855 automatic transmission fluid, or equivalent.