Aura, Outlook 2007

Transaxle Removal & Installation

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4T45-E



2.4L Engine
  1. Remove the battery tray.
  2.  
  3. Disconnect the air cleaner outlet duct.
  4.  
  5. Disconnect the transaxle wiring harness from the transaxle and the Park Neutral Position (PNP) switch.
  6.  
  7. Remove the radiator outlet pipe.
  8.  
  9. Disconnect the transaxle shift control cable terminal from the transaxle manual shift lever pin.
  10.  
  11. Remove the retainer from the transaxle shift control cable.
  12.  
  13. Press the locking tabs inward in order to release the transaxle shift control cable from the cable bracket.
  14.  
  15. Remove the shift cable bracket.
  16.  
  17. Remove the transaxle wiring harness from the retainer on the transaxle.
  18.  
  19. Remove the upper transaxle to engine studs and bolts.
  20.  
  21. Install the engine support fixture.
  22.  
  23. Remove the left transmission mount.
  24.  
  25. Secure the radiator and condenser to the vehicle structure and the engine in order to prepare for frame removal.
  26.  
  27. Raise the vehicle.
  28.  
  29. Remove the front wheels and tires.
  30.  
  31. Remove the bolts from the transaxle brace.
  32.  
  33. Remove the transaxle brace.
  34.  
  35. Remove the starter.
  36.  
  37. Mark the relationship of the flywheel to the torque converter for reassembly.
  38.  
  39. Use the flywheel holding tool to prevent the crankshaft from rotating.
  40.  
  41. Remove the torque converter to flywheel bolts.
  42.  
  43. Remove the nut holding the transaxle cooler line retainer to the transaxle.
  44.  
  45. Disconnect the transaxle cooler lines from the transaxle.
  46.  
  47. Disconnect the Vehicle Speed Sensor (VSS) wiring harness from the sensor.
  48.  
  49. Remove the intermediate shaft to steering gear pinch bolt. Discard the bolt.
  50.  
  51. Disconnect the intermediate shaft from the steering gear.
  52.  
  53. Disconnect the tie rods from the steering knuckle.
  54.  
  55. Disconnect the stabilizer shaft links from the stabilizer shaft.
  56.  
  57. Disconnect the ball joints from the steering knuckles.
  58.  
  59. Remove the frame as follows;
    1. Install the engine support fixture.
    2.  
    3. Support the radiator and condenser from above using the condenser tabs on each side.
    4.  
    5. Remove the front fender liner.
    6.  
    7. Remove the engine splash shield.
    8.  
    9. Remove the lower ball joints from the steering knuckles.
    10.  
    11. Remove the tie rod ends from the steering knuckles.
    12.  
    13. Remove both stabilizer links from the stabilizer bar.
    14.  
    15. Separate the steering gear from the intermediate shaft.
    16.  
    17. Remove the front transmission mount bolt from the frame.
    18.  
    19. Remove the rear transmission mount bracket fasteners from the frame.
    20.  
    21. Lower the vehicle until the frame contacts the engine support stand.
    22.  
    23. Remove the reinforcement bolts.
    24.  
    25. Remove the front frame bolts.
    26.  
    27. Remove the rear frame bolts.
    28.  
    29. Remove the frame reinforcements.
    30.  
    31. Raise the vehicle off of the frame.
    32.  

  60.  
  61. Disconnect the wheel drive shafts from the transaxle. Secure the wheel drive shafts out of the way.
  62.  
  63. Support the transaxle with a suitable jack.

    Click image to see an enlarged view

    Fig. Transaxle to engine bolt locations-2.4L engine

  64.  
  65. Remove the lower transaxle to engine bolts.
  66.  
  67. Separate the engine and the transaxle.
  68.  
  69. Remove the transaxle from the vehicle.
  70.  

To install:

  1. Position the transaxle in the vehicle.
  2.  
  3. Install the lower transaxle to engine bolts and tighten to 55 ft. lbs. (75 Nm).
  4.  
  5. Install the wheel drive shafts to the transaxle.
  6.  
  7. Lubricate the transaxle cooler pipes before inserting into seals.
  8.  
  9. Connect the transaxle cooler pipes to the transaxle.
  10.  
  11. Install the transaxle cooler pipes retainer nut and tighten to 62 in. lbs. (7 Nm).
  12.  
  13. Install the torque converter to flywheel bolts and tighten to 44 ft. lbs. (60 Nm).
  14.  
  15. Install the starter.
  16.  
  17. Install the frame as follows:
    1. Lower the vehicle on to the frame.
    2.  
    3. Install the frame reinforcements.
    4.  
    5. Install the front frame bolts and hand tighten only.
    6.  
    7. Install the reinforcement bolts and hand tighten only.
    8.  
    9. Install the rear frame bolts. Tighten to 74 ft. lbs. (100 Nm) , plus an additional 180 degrees.
    10.  

  18.  
  19. Tighten the front frame bolts. Tighten to 74 ft. lbs. (100 Nm) , plus an additional 180 degrees.
  20.  
  21. Install the reinforcement bolts. Tighten to 74 ft. lbs. (100 Nm).
    1. Raise the vehicle.
    2.  
    3. Install the rear transmission mount bracket fasteners. Tighten the transaxle mount to transmission bolts to 66 ft. lbs. (90 Nm) and the transaxle to mount bracket through bolt to 66 ft. lbs. (90 Nm).
    4.  
    5. Install the front transmission mount bracket bolt. Tighten the transaxle mount to transmission bolts to 66 ft. lbs. (90 Nm) and the transaxle to mount bracket through bolt to 66 ft. lbs. (90 Nm).
    6.  
    7. Install the power steering gear mounting bolts.
    8.  
    9. Connect the steering gear to the intermediate shaft.
    10.  
    11. Install both stabilizer links to the stabilizer bar. Tighten the stabilizer link nut to 48 ft. lbs. (65 Nm).
    12.  
    13. Install the tie rod ends to the steering knuckles.
    14.  
    15. Install the lower ball joints to the steering knuckles. Tighten the ball stud to steering knuckle pinch nut to 37 ft. lbs. (50 Nm). Reverse the nut  3 / 4 of a turn. Tighten to 37 ft. lbs. (50 Nm) plus an additional 60 degrees.
    16.  
    17. Install the front fender liner.
    18.  
    19. Install the engine splash shield.
    20.  
    21. Remove the engine support fixture.
    22.  

  22.  
  23. Connect the intermediate shaft to the steering gear shaft.
  24.  
  25. Install the new steering gear pinch bolt to the intermediate shaft.
  26.  
  27. Tighten the torque converter bolts to 37 ft. lbs. (50 Nm)
  28.  
  29. Connect the ball joints to the steering knuckles.
  30.  
  31. Connect the stabilizer shaft links to the stabilizer shaft.
  32.  
  33. Connect the tie rods to the steering knuckle.
  34.  
  35. Connect the wiring harness to the VSS.
  36.  
  37. Install the transaxle brace.
  38.  
  39. Install the transaxle brace bolts. Tighten to 37 ft. lbs. (50 Nm)
  40.  
  41. Install the front splash shields.
  42.  
  43. Install the catalytic converters.
  44.  
  45. Install the front wheel and tire assemblies.
  46.  
  47. Lower the vehicle.
  48.  
  49. Install the left transaxle mount.
  50.  
  51. Install the upper transaxle to engine bolts and studs. Tighten to 55 ft. lbs. (75 Nm)
  52.  
  53. Untie the radiator, air conditioning condenser, and fan module assembly.
  54.  
  55. Remove the engine support fixture.
  56.  
  57. Install the radiator outlet pipe.
  58.  
  59. Connect the transaxle wiring harness to the main transaxle electrical connector, and the PNP switch.
  60.  
  61. Install the shift cable bracket.
  62.  
  63. Install the transaxle shift control cable to the cable bracket. Install the retainer to the transaxle shift control cable.
  64.  
  65. Connect the transaxle shift control cable terminal to the transaxle manual shift lever pin.
  66.  
  67. Install the battery tray.
  68.  
  69. Connect the air cleaner outlet duct.
  70.  
  71. Add automatic transmission fluid (ATF) and verify the proper fluid level of the transaxle.
  72.  
  73. Prime the auxiliary fluid pump.
  74.  
  75. Road test the vehicle.
  76.  

3.5L Engine
  1. Remove the air cleaner outlet duct.
  2.  
  3. Disconnect the negative battery cable. Refer
  4.  
  5. Disconnect the transaxle wiring harness from the transaxle and the Park Neutral Position (PNP) switch.
  6.  
  7. Remove the shift cable bracket front bolt and shift cable from the lever.
  8.  
  9. Remove the transmission wiring harness from the retainer on the transmission.
  10.  
  11. Disconnect bank 2, Heated Oxygen Sensor (HO2S) sensor 1 electrical connector.
  12.  
  13. Remove the left exhaust manifold heat shield.
  14.  
  15. Remove the exhaust manifold heat shield.
  16.  
  17. Remove the front exhaust pipe nuts.
  18.  
  19. Remove the upper transmission to engine bolts and stud.
  20.  
  21. Install the engine support fixture.
  22.  
  23. Support the radiator and condenser from above using the condenser tabs on each side.
  24.  
  25. Raise the vehicle.
  26.  
  27. Remove the front wheels and tires.
  28.  
  29. Disconnect the bank 2, HO2S sensor 2 electrical connector.
  30.  
  31. Remove the left catalytic converter to right catalytic converter nuts.
  32.  
  33. Remove the left catalytic converter.
  34.  
  35. Remove the steering gear intermediate shaft.
    NOTE
    It is only necessary to remove the control arms from the frame if the frame is being replaced.

  36.  
  37. Remove the frame as follows:
    1. Support the radiator and condenser from above.
    2.  
    3. Raise the vehicle on a hoist. Remove the front fender liner.
    4.  
    5. Remove the engine splash shield.
    6.  
    7. Remove the lower ball joints from the steering knuckles.
    8.  
    9. Remove the tie rod ends from the steering knuckles.
    10.  
    11. Remove both stabilizer links from the stabilizer bar.
    12.  
    13. Remove the power steering gear mounting bolts and secure the gear out of the way using mechanic's wire, being sure not to overextend the intermediate shaft.
    14.  
    15. Remove the engine mount fasteners from the frame.
    16.  
    17. Remove the front transmission mount bolt from the frame.
    18.  
    19. Remove the left transmission mount fasteners from the frame.
    20.  
    21. Remove the rear transmission mount bracket fasteners from the frame.
    22.  
    23. Remove the brake lines from the retainers on the frame.
    24.  
    25. Remove the power steering outlet pipe/hose from the frame. .
    26.  
    27. Remove the rear catalytic converter.

      Click image to see an enlarged view

      Fig. Lower the vehicle until the frame contacts the engine support stand-3.5L engine

    28.  
    29. Lower the vehicle until the frame contacts the engine support stand.
    30.  
    31. Remove the reinforcement bolts.
    32.  
    33. Remove the front frame bolts.
    34.  
    35. Remove the rear frame bolts.
    36.  
    37. Remove the frame reinforcements.
    38.  
    39. Raise the vehicle off of the frame.
    40.  

  38.  
  39. Disconnect the wheel drive shafts from the transaxle.
  40.  
  41. Remove the 3 bolts from the transmission brace near the right axle shaft.
  42.  
  43. Remove the oil pan to bellhousing bolts and bracket.
  44.  
  45. Remove the flywheel inspection cover.
  46.  
  47. Remove the starter.
  48.  
  49. Mark the relationship of the flywheel to the torque converter for reassembly.
  50.  
  51. Remove the torque converter to flywheel bolts.
  52.  
  53. Remove the transmission oil cooler lines by removing the nut holding the bracket to the transaxle case.
  54.  
  55. Disconnect the Vehicle Speed Sensor (VSS) wiring harness from the sensor.
  56.  
  57. Disconnect the rear Heated Oxygen Sensor (HO2S) harness from the rear transmission mount.
  58.  
  59. Remove the remaining (rear) bolt from the shift cable bracket.
  60.  
  61. Remove the front transmission mount bracket from the transmission.
  62.  
  63. Use a transmission jack in order to support the transmission.
  64.  
  65. Remove the remaining bellhousing bolts and separate the transmission from the engine.
  66.  
  67. Lower the transmission with the transmission jack far enough to remove the transmission.
  68.  

To install:

  1. Position the transaxle in the vehicle.
  2.  
  3. Install the lower transmission to engine bolts and tighten to 66 ft. lbs. (90 Nm).
  4.  
  5. Install the front transmission mount bracket to the transmission.
  6.  
  7. Install the wheel drive shafts to the transaxle.
  8.  
  9. Connect the wiring harness to the VSS.
  10.  
  11. Install the torque converter to flywheel bolts and tighten to 46 ft. lbs. (62 Nm).
  12.  
  13. Install the starter.
  14.  
  15. Install the flywheel inspection cover bolts.
  16.  
  17. Connect the transaxle oil cooler pipes to the transaxle.
  18.  
  19. Install the oil pan to bellhousing bracket and bolts. Tighten the bolts to 53 ft. lbs. (72 Nm).
  20.  
  21. Install the 3 bolts to the transmission brace at the final drive area and tighten.
  22.  
  23. Remove the transmission jack.
  24.  
  25. Install the frame as follows:
    1. Lower the vehicle on to the frame.
    2.  
    3. Install the frame reinforcements.
    4.  
    5. Install the front frame bolts and hand tighten only.
    6.  
    7. Install the reinforcement bolts and hand tighten only.
    8.  
    9. Tighten the rear frame bolts. Tighten to 74 ft. lbs. (100 Nm) , plus an additional 180 degrees.
    10.  
    11. Tighten the front frame bolts. Tighten to 74 ft. lbs. (100 Nm) , plus an additional 180 degrees.
    12.  
    13. Install the reinforcement bolts. Tighten to 74 ft. lbs. (100 Nm).
    14.  
    15. Raise the vehicle.
    16.  
    17. Install the power steering outlet pipe/hose to the frame. Install the brake lines to the retainers on the frame.
    18.  
    19. Install the rear transmission mount bracket fasteners. Tighten the transaxle mount to transmission bolts to 37 ft. lbs. (50 Nm) and the transaxle to mount bracket through bolt to 66 ft. lbs. (90 Nm).
    20.  
    21. Install the left transmission mount fasteners to the frame. Tighten the transaxle mount to transmission bolts to 66 ft. lbs. (90 Nm) and the transaxle to mount bracket through bolt to 66 ft. lbs. (90 Nm).
    22.  
    23. Install the front transmission mount bracket bolt. Tighten the transaxle mount to transmission bolts to 66 ft. lbs. (90 Nm) and the transaxle to mount bracket through bolt to 66 ft. lbs. (90 Nm).
    24.  
    25. Install the engine mount fasteners to the frame. Tighten the nuts/bolts to 37 ft. lbs. (50 Nm).
    26.  
    27. Install the power steering gear mounting fasteners.
    28.  
    29. Install both stabilizer links to the stabilizer bar. Tighten to 48 ft. lbs. (65 Nm) plus an additional 180 degrees.
    30.  
    31. Install the tie rod ends to the steering knuckles.
    32.  
    33. Install the lower ball joints to the steering knuckles. Tighten the ball stud to steering knuckle pinch nut to 37 ft. lbs. (50 Nm). Reverse the nut  3 / 4 of a turn. Tighten to 37 ft. lbs. (50 Nm) plus an additional 60 degrees.
    34.  
    35. Install the rear catalytic converter.
    36.  
    37. Install the front fender liner.
    38.  
    39. Install the engine splash shield.
    40.  
    41. Lower the vehicle.
    42.  
    43. Remove the temporary radiator and condenser support.
    44.  
    45. Remove the engine support fixture.
    46.  

  26.  
  27. Install the engine splash shields.
  28.  
  29. Install the front wheels and tires.
  30.  
  31. Lower the vehicle.
  32.  
  33. Remove the radiator and condenser support and the engine support fixture.
  34.  
  35. Install the upper transmission to engine bolts and stud and tighten to 66 ft. lbs. (90 Nm).
  36.  
  37. Install the shift cable bracket and shift cable to the lever.
  38.  
  39. Install the remaining components in the reverse order of removal.
  40.  
  41. Connect bank 2, O2 sensor 2 electrical connector.
  42.  
  43. Add automatic transmission fluid (ATF) and verify the proper fluid level of the transaxle.
  44.  
  45. Road test the vehicle.
  46.  

6T70/6T75



3.6L Engine
  1. Remove the battery tray.
  2.  
  3. Remove the transmission range select lever cable and bracket.
  4.  
  5. Drain the transmission fluid.
  6.  
  7. Remove the wire harness retainer from the control valve body cover stud.
  8.  
  9. Disconnect the control valve body Transmission Control Module (TCM) electrical connector.
  10.  
  11. Remove the transmission fluid cooler pipe retainer nut.
  12.  
  13. Remove the transmission fluid cooler inlet hose and seal from the transmission.
  14.  
  15. Plug and/or cap the hose and transmission to prevent contamination.
  16.  
  17. Remove the transmission fluid cooler pipe retainer nut.
  18.  
  19. Remove the transmission fluid cooler outlet hose and seal from the transmission.
  20.  
  21. Plug and/or cap the hose and transmission to prevent contamination.
  22.  
  23. Remove the upper transmission to engine bolts.
  24.  
  25. Remove the frame as follows:
    1. Install the engine support fixture.
    2.  
    3. Support the radiator and condenser from above.
    4.  
    5. Raise the vehicle on a hoist.
    6.  
    7. Remove the tire and wheel assemblies.
    8.  
    9. Remove the front fender liner.
    10.  
    11. Remove the engine splash shield.
    12.  
    13. Remove the lower ball joints from the steering knuckles.
    14.  
    15. Remove the tie rod ends from the steering knuckles.
    16.  
    17. Remove both stabilizer links from the stabilizer bar.
    18.  
    19. Remove the power steering gear mounting bolts and secure the gear out of the way using mechanic's wire or equivalent, being sure not to overextend the intermediate shaft.
    20.  
    21. Remove the engine mount fasteners from the frame.
    22.  
    23. Remove the front transmission mount bolt from the frame.
    24.  
    25. Remove the left transmission mount fasteners from the frame.
    26.  
    27. Remove the rear transmission mount bracket fasteners from the frame.
    28.  
    29. Remove the brake lines from the retainers on the frame.
    30.  
    31. Remove the power steering outlet pipe/hose from the frame.
    32.  
    33. Remove the rear catalytic converter.
    34.  
    35. Lower the vehicle until the frame contacts the engine support fixture.
    36.  
    37. Remove the reinforcement bolts.
    38.  
    39. Remove the front frame bolts.
    40.  
    41. Remove the rear frame bolts.
    42.  
    43. Remove the frame reinforcements.
    44.  
    45. Raise the vehicle off of the frame.
    46.  

  26.  
  27. Disconnect the wheel drive shafts from the transmission.
  28.  
  29. Remove the intermediate drive shaft.
  30.  
  31. Remove the transmission brace bolts.
  32.  
  33. Remove the transmission brace.
  34.  
  35. Remove the rear transmission mount from the transmission.
  36.  
  37. Remove the front transmission mount from the transmission.
  38.  
  39. Remove the starter.
  40.  
  41. Mark the relationship of the flywheel to the torque converter for reassembly.
  42.  
  43. Remove the torque converter to flywheel bolts.
  44.  
  45. Use a transmission jack in order to support the transmission.
  46.  
  47. Remove the flywheel inspection cover bolts.
  48.  
  49. Remove the flywheel inspection cover.
  50.  
  51. Remove the remaining transmission bolts.
    NOTE
    Ensure the torque converter remains securely in place on the transmission input shaft while separating and removing the transmission.

  52.  
  53. Separate the transmission from the engine.
  54.  
  55. Lower the transmission with the transmission jack far enough to remove the transmission.
  56.  

To install:

  1. Raise the transmission with the transmission jack and position the transmission to the engine. Tighten the bolts to 55 ft. lbs. (75 Nm).
  2.  
  3. Install the flywheel inspection cover and bolts. Tighten the bolts to 55 ft. lbs. (75 Nm).
  4.  
  5. Remove the transmission jack.
  6.  
  7. Install the torque converter to flywheel bolts. Tighten the bolts to 46 ft. lbs. (62 Nm).
  8.  
  9. Install the starter.
  10.  
  11. Install the front transmission mount to the transmission. Tighten the nut to 66 ft. lbs. (90 Nm) and the bolts to 37 ft. lbs. (50 Nm).
  12.  
  13. Install the rear transmission mount to the transmission. Tighten the transaxle mount to transmission bolts to 37 ft. lbs. (50 Nm) and the transaxle to mount bracket through bolt to 66 ft. lbs. (90 Nm).
  14.  
  15. Install the transmission brace.
  16.  
  17. Install the transmission brace bolts. Tighten the bolts to 37 ft. lbs. (50 Nm)
  18.  
  19. Install the intermediate drive shaft.
  20.  
  21. Install the wheel drive shafts to the transmission. Install the frame as follows:
  22.  
  23. Install the frame as follows:
    1. Lower the vehicle on to the frame.
    2.  
    3. Install the frame reinforcements.
    4.  
    5. Install the front frame bolts and hand tighten only.
    6.  
    7. Install the reinforcement bolts and hand tighten only.
    8.  
    9. Tighten the rear frame bolts. Tighten to 74 ft. lbs. (100 Nm) , plus an additional 180 degrees.
    10.  
    11. Tighten the front frame bolts. Tighten to 74 ft. lbs. (100 Nm) , plus an additional 180 degrees.
    12.  
    13. Install the reinforcement bolts. Tighten to 74 ft. lbs. (100 Nm).
    14.  
    15. Raise the vehicle.
    16.  
    17. Install the power steering outlet pipe/hose to the frame. Install the brake lines to the retainers on the frame.
    18.  
    19. Install the rear transmission mount bracket fasteners. Tighten the transaxle mount to transmission bolts to 37 ft. lbs. (50 Nm) and the transaxle to mount bracket through bolt to 66 ft. lbs. (90 Nm).
    20.  
    21. Install the left transmission mount fasteners to the frame. Tighten the transaxle mount to transmission bolts to 66 ft. lbs. (90 Nm) and the transaxle to mount bracket through bolt to 66 ft. lbs. (90 Nm).
    22.  
    23. Install the front transmission mount bracket bolt. Tighten the transaxle mount to transmission bolts to 66 ft. lbs. (90 Nm) and the transaxle to mount bracket through bolt to 66 ft. lbs. (90 Nm).
    24.  
    25. Install the engine mount fasteners to the frame. Tighten the nuts/bolts to 37 ft. lbs. (50 Nm).
    26.  
    27. Install the power steering gear mounting fasteners.
    28.  
    29. Install both stabilizer links to the stabilizer bar. Tighten to 48 ft. lbs. (65 Nm) plus an additional 180 degrees.
    30.  
    31. Install the tie rod ends to the steering knuckles.
    32.  
    33. Install the lower ball joints to the steering knuckles. Tighten the ball stud to steering knuckle pinch nut to 37 ft. lbs. (50 Nm). Reverse the nut  3 / 4 of a turn. Tighten to 37 ft. lbs. (50 Nm) plus an additional 60 degrees.
    34.  
    35. Install the rear catalytic converter.
    36.  
    37. Install the front fender liner.
    38.  
    39. Install the engine splash shield.
    40.  
    41. Lower the vehicle.
    42.  
    43. Remove the temporary radiator and condenser support.
    44.  
    45. Remove the engine support fixture.
    46.  

  24.  
  25. Install the upper transmission to engine bolt. Tighten the bolts to 55 ft. lbs. (75 Nm).
  26.  
  27. Install the transmission fluid cooler outlet and inlet hoses and seal to the transmission.
  28.  
  29. Install the transmission fluid cooler pipe retainer nut. Tighten to 16 ft. lbs. (22 Nm).
  30.  
  31. Install the remaining components in the reverse order of removal.
  32.  
  33. Fill the transmission with fluid.
  34.  
  35. Road test the vehicle.
  36.  

 
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