Transmission/Transaxle Replacement

AUTOMATIC TRANSMISSION UNIT COMPONENTS





COMPONENTS

REMOVAL
1. REMOVE BATTERY
2. REMOVE AIR CLEANER CAP DRIVE BELT, FAN AND FLUID COUPLING ASSEMBLY, FAN SHROUD AND RADIATOR RESERVOIR





3. REMOVE OIL FILLER PIPE UPPER SIDE MOUNTING BOLT
a. Remove the level gauge.
b. Remove the upper side mounting bolt.

Torque: 11.5 Nm (120 kgf-cm, 8 ft. lbs.)

c. Disconnect the 2 bleeder hoses.
4. REMOVE TRANSFER SHIFT LEVER BOOT
a. Remove the transfer shift lever knob.
b. Remove upper console panel.





c. Remove the 4 bolts and transfer shift lever boot.

Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)

5. REMOVE ENGINE NO.1 AND NO.2 UNDER COVERS
6. REMOVE LH AND RH FRONT EXHAUST PIPES
7. REMOVE FRONT AND REAR PROPELLER SHAFTS





8. REMOVE OIL FILLER PIPE
a. Remove the bolt and filler pipe.

Torque: 11.5 Nm (120 kgf-cm, 8 ft. lbs.)

b. Remove the O-ring from the filler pipe.

HINT: At the time of installation, please refer to the following item. Replace the used O-ring with a new one.

9. REMOVE TRANSMISSION SHIFT CONTROL ROD
Remove the nut, plate washer and disconnect the transmission control rod.

Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)





10. DISCONNECT TRANSFER SHIFT LEVER Remove the clip, plate washer and collar, and disconnect the transfer shift lever rod assembly.
11. DISCONNECT CONNECTORS
a. Disconnect the No.1 vehicle speed sensor connector.
b. Disconnect the No.2 vehicle speed sensor connector.
c. Disconnect the O/D direct clutch speed sensor connector.
d. Disconnect the solenoid connector.
e. Disconnect the ATF temperature sensor connector.
f. Disconnect the park/neutral position switch connector.
g. Disconnect the center differential lock indicator switch connector.
h. Disconnect the motor actuator connector
i. Disconnect the L4 position switch connector.
j. Disconnect the neutral position switch connector.
k. Disconnect 5 clamps.





12. REMOVE TORQUE CONVERTER CLUTCH MOUNTING BOLT
a. Remove the 2 bolts and hole plug.

Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)





b. Turn the crankshaft to gain access to each bolt.
c. Hold the crankshaft pulley nut with a wrench and remove the 6 bolts.

Torque: 48 Nm (490 kgf-cm, 35 ft. lbs.)

HINT: At the time of installation, please refer to the following item. First install green colored bolt and then 5 other bolts.





13. REMOVE OIL COOLER PIPE UNION NUT
a. Loosen the 2 oil cooler pipe union nuts.
b. Remove the oil cooler pipe mounting bolt.

Torque: 11.5 Nm (115 kgf-cm, 8 ft. lbs.)

c. Remove the 2 oil cooler pipe union nuts.

Torque: 69 Nm (700 kgf-cm, 51 ft. lbs.)

14. REMOVE CROSSMEMBER
a. Support the transmission with a jack.





b. Remove the 8 bolts and 2 nuts, and then remove the crossmember.

Torque:
Bolt: 50 Nm (510 kgf-cm, 37 ft. lbs.)
Nut: 74 Nm (750 kgf-cm, 54 ft. lbs.)

15. REMOVE TRANSMISSION
a. Lower the rear end of the transmission.
b. Remove the transmission wire clamp bolt.





c. Remove the 10 bolts and transmission.

Torque: 72 Nm (730 kgf-cm, 53 ft. lbs.)

INSTALLATION





1. CHECK TORQUE CONVERTER CLUTCH INSTALLATION
Using calipers and a straight edge, measure the distance from the installed surface of the transmission housing to the installed surface of the torque converter clutch.

Correct distance: More than 17.1 mm (0.673 inch)

2. TRANSMISSION INSTALLATION
Installation is in the reverse order of removal.

HINT:
- Transmission control rod and park/neutral position switch
- ATF level
- Conduct the road test of the vehicle