ION 2006-2007

Transaxle Removal & Installation

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Getrag Transaxle



  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Drain the transaxle fluid.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Positive battery post from the under right hand hood junction block
     
    Positive cables from the under right hand hood junction block
     
    Surge tank inlet hose from the surge tank
     
    Under right hand hood junction block bracket nuts and bolt
     
    Front wiring harness from the junction block bracket
     
    Move the junction block aside
     
    Clutch hose from the actuator cylinder
     

  6.  
  7. Install an engine support fixture.
  8.  
  9. Secure the cooling module to the upper body structure.

    Upper transmission-to-mount bolts
     
    Upper transmission-to-engine bolt
     

  10.  
  11. Remove the front frame as follows:
    1. Mark the frame-to-body position.
    2.  
    3. Lower the vehicle until it is 3 feet off the ground so that a lift table may be placed in position. As necessary, use blocks of wood between the frame and table to support the assembly.
    4.  
    5. Slowly remove the front frame bolts, the partially unscrew the bolts until 1 1 / 2 inch of the bolt shank is exposed.
    6.  
    7. Slowly lower the table to the floor
    8.  

  12.  
  13. Remove or disconnect the following:

    Drive shafts from the transmission and support with wire
     
    Starter
     
    Shift cable from the transmission as follows:
     

    1. Apply the parking brake.
    2.  
    3. Shift the transmission to Neutral .
    4.  
    5. Remove the console.
    6.  
    7. Lift up the cable retainers.
    8.  
    9. Disconnect the cable ends from the shifter assembly.
    10.  
    11. Disconnect the cable ends from the transmission shift levers, make sure to mark the cable locations prior to removal, this will aid during assembly.
    12.  

  14.  
  15. Remove or disconnect the following:

    Back-up lamp switch and Vehicle Speed Sensor connections
     

  16.  
  17. Use the engine support fixture to lower the powertrain assembly to allow clearance between the side rail and powertrain.
  18.  
  19. Attach a transmission jack and remove the transmission-to-engine bolts.
  20.  
  21. Remove the transmission.
  22.  

To install:


NOTE
The number 3 bolt position does not require a bolt. Refer to the accompanying illustration for bolt locations.

  1. Use the transmission jack to align the transmission, install the transmission-to-engine bolts and torque to 55 ft. lbs. (75 Nm).

    Click image to see an enlarged view

    Fig. The number 3 bolt position does not require a bolt-ION

  2.  
  3. Install or connect the following:

    Back-up lamp switch and Vehicle Speed Sensor connections
     

  4.  
  5. Connect the shift cable to the transmission as follows:
    1. Connect the cable ends to the transmission shift levers as noted during removal.
    2.  
    3. Connect the cable ends to the shifter assembly.
    4.  
    5. Push the shifter neutral lock clip. Move the shifter slightly to center the clip and make sure the transmission is in Neutral .
    6.  
    7. Press down on the locking tabs.
    8.  
    9. Pull the shifter neutral lock into its original position.
    10.  
    11. Install the console.
    12.  

  6.  
  7. Install or connect the following:

    Starter
     
    Drive shafts
     

  8.  
  9. Use the engine support fixture to raise the powertrain assembly into position.
  10.  
  11. Install the side transmission mount as follows:
    1. Place the mount in position and tighten the mount-to-rail bolts to 25 ft. lbs. (34 Nm).
    2.  

  12.  
  13. Use a jack to align the mount when it is in position.
    1. Install and hand tighten the mount-to-transmission bolts. Do not pry the transmission or mount to align the holes. Hand start the bolts in the following sequence; rear bolt, middle and then front bolt. Using the same sequence, tighten the bolts to 33 ft. lbs. (45 Nm).
    2.  

  14.  
  15. Install or connect the following:

    Under right hand hood fuse block
     
    Surge tank inlet hose
     
    Front wiring harness to the junction block
     
    Positive battery cables to the junction block bracket
     
    Positive battery post to the junction block bracket
     
    Junction block bracket bolt and tighten to 18 ft. lbs. (25 Nm) and the nuts to 89 inch lbs. (10 Nm)
     

  16.  
  17. Install the front frame as follows:
    1. Slowly raise the table to the into position and align the frame to the marks made during removal.
    2.  
    3. Hand tighten the frame bolts
    4.  
    5. Tighten the frame bolts to 74 ft. lbs. (100 Nm) plus an additional torque of 180 degrees using a torque angle meter.
    6.  

  18.  
  19. Remove the engine support fixture.
  20.  
  21. Install or connect the following:

    Top engine-to-transmission bolt and tighten to 55 ft. lbs. (75 Nm)
     
    Clutch hose to the actuator cylinder and bleed the hydraulic clutch system.
     
    Cooling module
     
    Negative battery cable.
     

  22.  
  23. Fill the transmission to the proper level.
  24.  
  25. Warm the engine and check the transmission fluid. Check and adjust vehicle alignment, as necessary.
  26.  

Mu3 Transaxle



  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the cover from the under right hand hood electrical center.
  6.  
  7. Release the forward lamp harness retainer from the ABS modulator bracket, or the proportioning valve bracket, to allow the under right hand hood electrical center to be repositioned adequately.
  8.  
  9. Remove the under right hand hood electrical center bracket from the vehicle and reposition the electrical center to access the bracket .
  10.  
  11. Release the wiring harness retainers above the brake booster, to allow the electrical center to be repositioned adequately.
  12.  
  13. Disconnect the hydraulic clutch hose from the clutch actuator cylinder and the clutch master cylinder.
  14.  
  15. Install an engine support fixture.
  16.  
  17. Secure the cooling module to the upper body structure.
  18.  
  19. Remove the upper transmission to mount bolts.
  20.  
  21. Disconnect the wiring harness retainer from the transmission stud.
  22.  
  23. Remove the upper transmission to engine stud and bolt.
  24.  
  25. Remove the frame as follows:
    1. Secure the radiator and condenser assembly to the radiator support.
    2.  
    3. Remove the front wheels from the vehicle.
    4.  
    5. Remove the splash shields.
    6.  
    7. Remove the front transaxle mount to cradle through bolt.
    8.  
    9. Remove the rear transaxle mount to frame bolts.
    10.  
    11. Remove both stabilizer link to stabilizer shaft nuts.
    12.  
    13. Remove both tie rod to steering knuckle nuts.
    14.  
    15. Separate the outer tie rods from the steering knuckles.
    16.  
    17. Remove the intermediate steering shaft to steering gear pinch bolt and discard.
      NOTE
      DO NOT rotate the intermediate shaft once separated from the gear. Possible damage or a malfunction could occur.

    18.  
    19. Disconnect the intermediate steering shaft from the steering gear.
    20.  
    21. Remove both lower control arm ball stud to steering knuckle pinch bolts.
      NOTE
      Do not free the ball stud by using a pickle fork or a wedge-type tool. Damage to the seal or bushing may result.

    22.  
    23. Lower the lower control arms in order to disengage the steering knuckle. If necessary, use ball joint removal tool J 43631.
    24.  
    25. Mark the frame to body position with a paint pen or permanent marker.
    26.  
    27. Lower the vehicle to about 3 feet off the ground in order to place a hydraulic lift table under the frame.
    28.  
    29. Use two 2 x 4 pieces of wood between the lift table and the frame and lift the table to the frame.
    30.  
    31. Slowly remove the frame bolts using the following sequence:

      Front frame bolts
       
      Rear frame bolts
       

    32.  
    33. Slowly lower the lift table to the floor.
    34.  

  26.  
  27. Drain the transaxle fluid.
  28.  
  29. Disconnect the drive axle and intermediate shaft from the transmission and secure out of the way.
  30.  
  31. Remove the starter.
  32.  
  33. Disconnect the shift cables from the transmission.
  34.  
  35. Disconnect the backup lamp switch harness connector.
  36.  
  37. Use the engine support fixture rear hook to lower the powertrain enough to allow clearance between the side rail and powertrain.
  38.  
  39. Use a transmission jack to secure the transmission, and remove the transmission to engine bolts.
  40.  
  41. Remove the transmission from the vehicle.
  42.  

To install:

  1. Use a transmission jack to position the transmission to the vehicle.
  2.  
  3. Secure the transmission to the engine. Tighten the bolts to 55 ft. lbs. (75 Nm).
  4.  
  5. Connect the backup lamp switch harness connector.
  6.  
  7. Connect the shift cable to the transmission.
  8.  
  9. Install the starter.
  10.  
  11. Connect the drive axle and intermediate shaft to the transmission.
  12.  
  13. Use the engine support fixture in order to raise the powertrain assembly.
  14.  
  15. Install the left transmission mount. Tighten the bolts to 20 ft. lbs. (27 Nm).
  16.  
  17. Install the frame as follows:
    1. With the frame on the lift table, raise the frame to the vehicle.
    2.  
    3. Hand start all the frame bolts while aligning the frame to the paint marks.
    4.  
    5. Tighten the frame bolts. Tighten the bolts 74 ft. lbs. (100 Nm) plus and additional 180.
    6.  

  18.  
  19. Lower and remove the hydraulic table.
    1. Connect the lower control arm to the steering knuckle.
      NOTE
      The torque sequence must be followed in the order that is listed.

    2.  
    3. Install the ball joint pinch bolt and nut. Tighten the nut to 37 ft. lbs. (50 Nm), back of the nut 3 / 4 turn then retighten the nut to 37 ft. lbs. (50 Nm) plus an additional 30 degree turn.
      NOTE
      The front and rear transmission mounts must be allowed to settle with the through bolts loosened.

    4.  
    5. Hand start the front transaxle mount through bolt.
    6.  
    7. Loosen the rear transmission mount through bolt.
    8.  
    9. Tighten the rear transaxle mount to frame bolts to 37 ft. lbs. (50 Nm)
    10.  
    11. Tighten the rear transaxle mount through bolts to 74 ft. lbs. (100 Nm), then tighten the front transaxle mount through bolts to 74 ft. lbs. (100 Nm).
    12.  
    13. Install the outer tie rods to the steering knuckles. Install new outer tie rod to the knuckle nuts and tighten to 15 ft. lbs. (20 Nm) plus an additional 180 degree turn.
    14.  
    15. Connect the stabilizer links to the stabilizer shaft. Tighten to 81 ft. lbs. (100 Nm).
    16.  
    17. Connect the intermediate shaft to the steering gear. Install a new intermediate shaft pinch bolt and tighten to 25 ft. lbs. (34 Nm).
    18.  
    19. Install the splash shields.
    20.  
    21. Install the front wheels.
    22.  

  20.  
  21. Remove the engine support fixture.
  22.  
  23. Install the top engine to transmission bolt. Tighten the bolts to 55 ft. lbs. (75 Nm).
  24.  
  25. Install the top engine to transmission stud. Tighten to 55 ft. lbs. (75 Nm).
  26.  
  27. Connect the wiring harness retainer to the transmission stud.
  28.  
  29. Connect the hydraulic clutch hose to the clutch actuator cylinder.
  30.  
  31. Bleed the clutch hydraulic system.
  32.  
  33. Install the under right hand hood electrical center bracket to the vehicle and install the electrical center (1) into position on the bracket .
  34.  
  35. Secure the forward lamp harness retainer to the ABS modulator bracket, or the proportioning valve bracket .
  36.  
  37. Connect the electrical connector to the brake fluid level sensor, then press forward on the Connector Position Assurance (CPA) tab of the connector to secure.
  38.  
  39. Install the cover to the under right hand hood electrical center.
  40.  
  41. Release the cooling module from the upper body structure.
  42.  
  43. Connect the negative battery cable.
  44.  
  45. Fill the transmission to the proper level.
  46.  

 
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