Honda Pilot - 2003-2005

Transaxle Removal & Installation

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  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Drain the transaxle.
  4.  
  5. Drain the power steering system.
  6.  
  7. Remove the engine appearance covers.
  8.  
  9. Remove the drivers side center console lower panel and pull back the cover to access steering joint cover.
  10.  
  11. Remove or disconnect the following:

    Steering joint bolt
     
    Steering joint from the steering gearbox pinion shaft
     



    Battery
     
    Battery tray
     
    Intake manifold cover
     
    Air intake assembly
     
    Power steering pump hose and the clamp bolt
     
    Splash shield
     
    Transmission breather tube
     
    Transaxle oil cooler lines
     
    Cooler hose from the clamp on the starter, if equipped
     
    Starter motor
     
    Shift control solenoid valve connectors
     
    Transaxle ground cable
     
    Connector from the bracket and the connector
     
    Harness clip from the brackets
     
    Clutch pressure switch connectors
     
    Joint connector and transmission range switch connector from the brackets
     
    Countershaft speed sensor connector
     
    Heated Oxygen (HO 2 S) sensor connectors
     
    Transmission housing mounting bolts
     
    Nut from the front mount and the ground cable from the engine
     
    Bulkhead cover, windshield wiper arms, cowl cover sealing and cover
     
    Install a support fixture to the engine lifting eyes.

    Click image to see an enlarged view

    Fig. Support the engine while removing the transaxle-Pilot

     
    Front sub-frame stiffener
     
    Primary HO 2 S sensor clamp bracket from the transmission and harness from the clamp
     
    Exhaust front pipe
     
    Lower control arms from the knuckle
     
    Stabilizer bar links
     
    Tie rod ends from the knuckle
     
    Left driveshaft from the differential
     
    Right driveshaft from the intermediate shaft
     
    Propeller shaft from the companion flange
     
    Shift cable cover and holder
     
    Shift control cable and lever
     

  12.  
  13. Install a 6 x 1 x 14mm bolt and nut on the cable cover, then reinstall the cable cover to the torque converter housing. If this is not done, the bolt head of the cable cover may prevent torque converter removal.

    Transfer assembly
     
    Engine-to-torque converter bolts
     
    Power steering pressure switch connection
     
    Power steering hose clamp, then the hose from the pipe at the sub-frame
     
    Transmission lower mount nuts
     

  14.  
  15. Matchmark the front subframe to the vehicle body.

    Rear mount bracket bolts
     




  16.  
  17. Support the sub-frame with a 4 x 4 x 50 inch piece of wood and a jack.

    Click image to see an enlarged view

    Fig. Support the sub-frame with a 4 x 4 x 50 inch piece of wood and a jack



    Sub-frame
     
    Transaxle lower mounts
     
    Driveshafts from the differential and intermediate shaft
     
    Intermediate shaft
     
    Transmission front mount bracket
     
    Transmission flange bolts
     
    Transmission
     

  18.  

To install:


NOTE
Use new circlips, split pins and self-locking nuts for assembly.

  1. Installation is the reverse of removal. Please note the following specifications:

    Transmission housing bolts and harness clamp bolts to 47 ft. lbs. (64 Nm)
     
    Transmission housing bolts to 40 ft. lbs. (54 Nm)
     
    Front mount bracket bolts to 28 ft. lbs. (38 Nm)
     
    Intermediate shaft bolts to 29 ft. lbs. (39 Nm)
     
    Transfer assembly bolts to 33 ft. lbs. (44 Nm)
     

  2.  
  3. Raise the subframe into position and align the matchmarks. Tighten the subframe bolts to 76 ft. lbs. (103 Nm). Tighten the front subframe bracket bolts to 54 ft. lbs. (74 Nm) and the rear bracket bolts to 86 ft. lbs. (117 Nm).

    Rear engine mount bolts to 28 ft. lbs. (38 Nm)
     
    Engine-to-torque converter bolts. Tighten the 6 x 1 mm bolts to 105 inch lbs. (12 Nm), 10 x 1.25mm bolt to 28 ft. lbs. (38 Nm).
     
    Front motor mount nut to 40 ft. lbs. (54 Nm)
     

  4.  
  5. Fill the transaxle to the correct level.
  6.  
  7. Start the engine and check for leaks.
  8.  
  9. Check the wheel alignment and adjust as necessary.
  10.  

 
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