ION, L-Series, S-Series 1999-2005

Transaxle Removal & Installation

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  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Disconnect the air inlet duct hose from the intake plenum.
  6.  
  7. Disconnect the transaxle wiring harness from the transaxle and the PNP switch.
  8.  
  9. Remove the upper transmission to engine bolts and stud.
  10.  
  11. Install an engine support fixture.
  12.  
  13. Remove the front wheel assemblies.
  14.  
  15. Remove the both front fender liners.
  16.  
  17. Remove the steering gear mounting bolts and secure the steering gear with mechanics wire.
  18.  
  19. Disconnect the wheel speed sensor wires from the both front wheels and unclip from the frame.
  20.  
  21. Separate the ball joints from the steering knuckles.
  22.  
  23. Remove the frame as follows:
    1. Secure the radiator and condenser assembly to the radiator support.
    2.  
    3. Remove the front transaxle mount to cradle through bolt.
    4.  
    5. Remove the rear transaxle mount to frame bolts.
    6.  
    7. Remove both stabilizer link to stabilizer shaft nuts.
    8.  
    9. Remove both tie rod to steering knuckle nuts.
    10.  
    11. Separate the outer tie rods from the steering knuckles.
    12.  
    13. 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.

    14.  
    15. Disconnect the intermediate steering shaft from the steering gear.
    16.  
    17. 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.

    18.  
    19. Lower the lower control arms in order to disengage the steering knuckle. . If necessary, use ball joint removal tool J 43631.
    20.  
    21. Mark the frame to body position with a paint pen or permanent marker.
    22.  
    23. Lower the vehicle to about 3 feet off the ground in order to place a hydraulic lift table under the frame.
    24.  
    25. Use two 2 x 4 pieces of wood between the lift table and the frame and lift the table to the frame.
    26.  
    27. Slowly remove the frame bolts using the following sequence:

      Front frame bolts
       
      Rear frame bolts
       

    28.  
    29. Slowly lower the lift table to the floor.
    30.  

  24.  
  25. Remove the 2 bolts from the transmission brace.
  26.  
  27. Disconnect the shift cable from the shift linkage.
  28.  
  29. Disconnect the cable from the bracket.
  30.  
  31. Remove the flywheel inspection cover.
  32.  
  33. Remove the starter
  34.  
  35. Mark the relationship of the flywheel to the torque converter for reassembly.
  36.  
  37. Use the flywheel holding tool to prevent the crankshaft from rotating.
  38.  
  39. Remove the torque converter to flywheel bolts.
  40.  
  41. Remove the transmission cooler lines by removing the nut holding the bracket to the transaxle case.
  42.  
  43. Disconnect the VSS wiring harness from the sensor.
  44.  
  45. Disconnect the wheel drive shafts from the transaxle.
  46.  
  47. Remove the body to transmission mount bolts.
  48.  
  49. Lower the transmission with the engine support fixture enough to remove the transmission.
  50.  
  51. Raise the vehicle.
  52.  
  53. Remove the oil pan to drain the transmission.
  54.  
  55. Support the transmission with a suitable jack.
  56.  
  57. Remove the transaxle to engine nut.
  58.  
  59. Separate the engine and the transaxle.
  60.  
  61. Remove the transaxle from the vehicle.
  62.  

To install:

  1. Position the transaxle in the vehicle.
    NOTE
    Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  2.  
  3. Install the lower transmission to engine bolts and nuts. Tighten to 66 ft. lbs. (90 Nm).
  4.  
  5. Connect the transaxle cooler pipes to the transaxle. Tighten to 71 inch lbs. (8 Nm).
  6.  
  7. Use a flywheel holding tool to prevent the crankshaft from rotating.
  8.  
  9. Install the torque converter to flywheel bolts. Tighten to 46 ft. lbs. (62 Nm).
  10.  
  11. Install the wheel drive shafts to the transaxle.
  12.  
  13. Connect the wiring harness to the VSS.
  14.  
  15. Install the starter.
  16.  
  17. Install the flywheel inspection cover bolts.
  18.  
  19. Use the engine support fixture to raise the engine and transmission assembly.
  20.  
  21. Install the transaxle mount to body bolts. Tighten to 66 ft. lbs. (90 Nm).
  22.  
  23. 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.  

  24.  
  25. 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.  

  26.  
  27. Route and clip the wheel speed sensor wiring into the proper position on both sides.
  28.  
  29. Install the steering gear to the front suspension crossmember.
  30.  
  31. Install the steering gear bolts to the front suspension crossmember. Tighten to 81 ft. lbs. (100 Nm).
  32.  
  33. Install the transmission to engine brace bolts. Tighten to 53 ft. lbs. (72 Nm).
  34.  
  35. Install the upper transmission to engine bolts and stud. Tighten to 66 ft. lbs. (90 Nm).
  36.  
  37. Install the engine wiring harness grounds to the transaxle to engine mount stud and nut.
  38.  
  39. Remove the engine support fixture
  40.  
  41. Install the shift linkage to the transmission.
  42.  
  43. Connect the electrical connectors to the PNP switch and transaxle.
  44.  
  45. Connect the air duct hose to the intake plenum.
  46.  
  47. Connect the negative battery cable.
  48.  
  49. Fill the transmission to the proper level.
  50.  

1.9L Engines



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

    Both battery cables
     
    Air cleaner assembly
     
    Battery and tray
     
    Powertrain Control Module (PCM) J2 (black 28-way) harness connector. Do not disconnect the J1 (80-way) connector.
     
    PCM attaching bolts and move aside
     
    Transaxle strut to midrail bracket fastener and loosen the strut to transaxle fastener and move the strut aside
     
    Transaxle solenoid harness connector
     
    Vehicle speed and input sensor harness connectors
     
    Transaxle fluid temperature sensor connector
     
    Range switch harness connector
     
    Ground terminals from the converter housing
     
    Ground wire from the range switch
     
    Spark plug wires from the coil towers
     
    Electronic ignition module electrical connectors
     
    Electronic ignition module
     

  6.  
  7. Wire the radiator to the upper support.
  8.  
  9. Install an engine support bar and place the feet on the outer edge of the shock tower.
  10.  
  11. Connect the bar hooks to the engine support bracket.
  12.  
  13. Position the stabilizer foot on the engine to the right of the dipstick tube.
  14.  
  15. Adjust the hooks and stabilizer to remove any looseness.
  16.  
  17. Remove or disconnect the following:

    Both front wheels and inner splash shields
     
    Engine splash shield
     
    Engine strut cradle bracket fasteners
     
    Transaxle mount to cradle fasteners
     
    Front exhaust pipe to manifold and catalytic converter fasteners
     
    Front exhaust pipe
     
    Steering gear to cradle fasteners
     
    Brake pipe bracket push pin
     
    Engine-to-transaxle stiffening brace
     
    Dust cover
     
    Torque converter-to-flywheel bolts
     
    Ball joint from the lower control arm
     
    Separate the left axle from the transaxle and install an axle seal protector
     
    Separate the right axle from the intermediate shaft
     
    Intake bracket-to-intake manifold bolt (on DOHC engines)
     
    Intake bracket-to-intermediate shaft support bolt
     
    Support bracket
     
    Intermediate shaft from the transaxle
     
    Transaxle cooler lines
     
    4 cradle-to-body bolts and lower the cradle on a support dolly
     
    Lower torque converter bolts
     
    Separate the transaxle from the engine
     
    Shifter cable from the converter housing
     
    Transaxle from the vehicle

    Click image to see an enlarged view

    Fig. Remove the intake-to-intermediate shaft support bracket and the intermediate shaft-1.9L engines

     

  18.  

To install:

  1. Flush the transaxle oil cooler lines.
  2.  
  3. Place the transaxle assembly securely onto a jack and position under the vehicle. Install axle seal protectors into seals on both sides.
  4.  
  5. Raise the transaxle high enough to connect the shifter cable.
  6.  
  7. Install or connect the following:

    Shifter cable to the transaxle gear selector lever and insert it in the converter housing
     
    2 lower converter housing-to-engine bolts and torque them to 96 ft. lbs. (130 Nm)
     
    Axle Seal Protector tool to the inside seal and remove the transaxle jack
     
    Left side axle to the transaxle. When the splines clear the seal protector, remove the tool.
     
    Intermediate shaft to the transaxle
     
    Intermediate shaft and torque the bolts to 40 ft. lbs. (54 Nm)
     
    Intake manifold support bracket (on DOHC) and torque the bolts to 22 ft. lbs. (30 Nm)
     
    Intake bracket to the intermediate shaft support and torque the bolt to 40 ft. lbs. (54 Nm)
     
    Right side axle to the intermediate shaft
     
    Cooler lines to the transaxle
     

  8.  
  9. Raise the cradle up on a support dolly and place the ball joints into the knuckles. Verify the correct positioning of the lower control arm bar studs to the knuckles, the cooling module support bushings, the engine strut bracket and the transaxle mount.
  10.  
  11. Insert 9 / 16 in. round steel rods into the cradle-to-body alignment holes near the front cradle to body fastener holes. Guide the cradle into position making sure all mount studs are properly guided into their holes.
  12.  
  13. Be sure the washers are in place, then install the 2 rear cradle to body bolts. Verify proper cradle positioning and install the 2 front cradle bolts, then torque the 4 cradle bolts to 155 ft. lbs. (210 Nm).
  14.  
  15. Remove the support dolly and lower the vehicle sufficiently for underhood access. Remove the engine support bar assembly.
  16.  
  17. Install or connect the following:
    NOTE
    Proper orientation of the ignition module is critical to the operation of the module and the on board diagnostic system. The proper sequence is 4-1-2-3 from left to right.



    Transaxle strut-to-cradle bracket through-bolt and nut and torque them to 40 ft. lbs. (54 Nm)
     
    Strut midrail bracket and torque the bolt to 52 ft. lbs. (70 Nm)
     
    Ignition module and torque the bolts to 71 inch lbs. (8 Nm)
     
    Ignition module wire connector
     
    Spark plug wires to the coil towers
     



    Click image to see an enlarged view

    Fig. Electronic ignition module wire sequence 4-1-2-3-1.9L engines



    2 top converter housing-to-engine studs and torque them to 74 ft. lbs. (100 Nm)
     
    Transaxle solenoid harness connector and torque the fastener to 22 inch lbs. (2.5 Nm)
     
    Vehicle speed and input sensor connectors
     
    Transaxle fluid temperature sensor connectors
     
    Transaxle range switch harness connectors
     
    Ground terminals to the top 2 converter housing bolts and torque the bolts to 19 ft. lbs. (25 Nm)
     
    Ground wire to the neutral selector switch
     
    Adjust the control cable
     
    Air cleaner assembly
     
    Battery tray and torque the bolts to 89 inch lbs. (10 Nm)
     
    PCM and torque the bolts to 53 inch lbs. (6 Nm)
     
    Connect the PCM J2 (28-way) harness
     
    Battery and hold down retainer and torque the fastener to 80 inch lbs. (9 Nm)
     
    Transaxle lower mount to cradle fastener and torque it to 37 ft. lbs. (50 Nm)
     
    2 engine strut cradle bracket-to-cradle fasteners and torque them to 37 ft. lbs. (50 Nm)
     
    Steering gear to cradle fasteners and torque them to 37 ft. lbs. (50 Nm)
     
    Brake pipe to cradle retainer
     
    Torque converter to flexplate and torque the bolts to 52 ft. lbs. (70 Nm)
     
    Dust cover and torque the bolts to 8 ft. lbs. (11 Nm)
     
    Engine to transaxle stiffening brace and torque the bolts to 40 ft. lbs. (54 Nm)
     
    Exhaust manifold pipe and torque the bolts to 23 ft. lbs. (31 Nm)
     
    Intermediate exhaust pipe to the catalytic converter and torque the bolts to 18 ft. lbs. (25 Nm)
     
    Front exhaust pipe support to the stiffening bracket and torque the fasteners to 23 ft. lbs. (31 Nm)
     
    Lower ball joint and torque the nut to 55 ft. lbs. (75 Nm)
     
    New cotter pins
     
    Splash shields
     
    Both front wheels
     
    Both battery cables
     

  18.  
  19. Fill the transaxle to the proper level.
  20.  
  21. Warm the engine and check the transaxle fluid. Check and adjust vehicle alignment, as necessary.
  22.  

2.3L & 3.0L Engines



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

    Both battery cables
     
    Move the fan control module up and out of the way
     
    Battery feed to the underhood fuse block
     
    Coolant hose from the underhood fuse block
     
    Release the retaining tabs on the fuse block cover and remove it
     
    Engine 68-way electrical connector
     
    Forward lamp 68-way connector
     
    Forward lamp 2-way (white) connector
     
    Black, green and brown instrument panel 2-way connectors
     
    Fuse block from the case
     
    Engine, forward lamp and instrument panel harness from the fuse block case
     
    Case from the battery tray
     
    Battery tray and battery
     
    Control cable from the range switch lever
     
    Control cable bracket from the rear powertrain mount
     
    Transaxle electrical connector and ground wire
     
    Remaining wire harness connectors from the transaxle
     
    Transaxle range switch electrical connector
     
    Upper engine to transaxle bolts
     
    Drive belt from the alternator, for 3.0L engine
     
    Drive belt tensioner, for 3.0L engine
     
    Alternator, for 3.0L engine
     
    Output speed sensor electrical connector
     

  6.  
  7. Install an Engine Support Fixture.
    NOTE
    The wire harness mounting bracket on the rear of the engine must be removed on the 3.0L.



    Frame
     
    Axle shafts from the transaxle
     
    Engine to transaxle bracket
     
    Starter solenoid electrical connector
     
    Starter motor
     



    Torque converter-to-flexplate bolts through the starter opening
     
    Transaxle oil cooler lines
     
    2 lower engine to transaxle bolts
     
    Left side transaxle mount bolts
     

  8.  
  9. Slide a hydraulic lifting table under the transaxle and remove the remaining mounting bolts.
  10.  
  11. Separate the transaxle from the engine.

    Click image to see an enlarged view

    Fig. Lifting table mounting points-2.2L and 3.0L engines

  12.  

To install:

  1. With the transaxle on a hydraulic lift, raise the transaxle to the engine.
  2.  
  3. Install or connect the following:

    Rear wire harness bracket, for 3.0L engine
     
    Engine to transaxle mounting bolts and torque them to 48 ft. lbs. (60 Nm)
     
    Left side transaxle mount bolts and torque them to 41 ft. lbs. (55 Nm)
     
    Bottom 2 engine to transaxle mounting bolts and torque them to 48 ft. lbs. (65 Nm)
     
    Transaxle oil cooler lines after lubricating them with automatic transaxle fluid and torque the fasteners to 71 inch lbs. (8 Nm)
     
    Loosely install the flex plate-to-torque converter bolts. When aligned properly, torque the bolts to 33 ft. lbs. (45 Nm).
     
    Starter motor and torque the bolts to 30 ft. lbs. (40 Nm)
     
    Starter solenoid electrical connectors
     
    Engine to transaxle bracket and torque the bolts to 26 ft. lbs. (35 Nm)
     
    New axle shaft retaining rings on the end of the output shafts and install the axle shafts to the transaxle
     
    Frame assembly
     
    Output speed sensor electrical connector and secure it to the mounting stud
     
    Alternator and torque the bolts to 30 ft. lbs. (40 Nm), for 3.0L engine
     
    Drive belt tensioner and torque the bolts to 30 ft. lbs. (40 Nm), for 3.0L engine
     
    Drive belt, for 3.0L engine
     
    Remaining transaxle to engine mounting bolts and torque them to 48 ft. lbs. (65 Nm)
     
    Transaxle electrical connector and ground wire and torque the fasteners to 18 ft. lbs. (25 Nm)
     
    Wire harness attachments to the transaxle side cover and torque the fasteners to 15 ft. lbs. (20 Nm)
     
    Control cable mounting bracket and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Control cable to the range switch lever
     
    Battery tray and torque the fasteners to 11 ft. lbs. (15 Nm)
     
    Underhood fuse block case to the battery tray. Torque the bolt to 80 inch lbs. (9 Nm) and snap the block onto the hinges.
     
    Engine 68-way connectors
     
    Forward lamp 68-way connectors
     
    Instrument panel 68-way connectors
     
    Forward 2-way (white) connector
     
    Black, green and brown 2-way connectors
     
    Snap the fuse block to the case
     
    Coolant hose to the fuse block
     
    Battery feed to the fuse block and torque the fastener to 12 inch lbs. (16 Nm)
     
    Battery tray and hold-down bracket and torque the fastener to 15 ft. lbs. (20 Nm)
     
    Battery
     
    Fan control module to the battery hold down bracket
     
    Both battery cables
     

  4.  
  5. Fill the transaxle to the proper level.
  6.  
  7. Warm the engine and check the transaxle fluid. Check and adjust vehicle alignment, as necessary.
  8.  

5-Speed Continuously Variable Transmission



  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
     
    Electronic Control Module (ECM)
     
    Transmission Control Module (TCM) connections noting their locations to aid during installation
     
    TCM by releasing the tab on the junction block bracket, lift it half way, then turn it clockwise to remove
     
    Positive battery post from the underhood junction block
     
    Positive cables from the underhood junction block
     
    Surge tank inlet hose from the surge tank
     
    Underhood junction block bracket nuts and bolt
     
    Front wiring harness from the junction block bracket
     
    Move the junction block aside
     
    Park/Neutral switch connector
     

  6.  
  7. Install an engine support fixture.
  8.  
  9. Secure the cooling module to the upper body
  10.  
  11. Remove or disconnect the following:

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

  12.  
  13. 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.  

  14.  
  15. Remove or disconnect the following:

    Cooler lines from the transmission
     
    Drive shafts from the transmission and support with wire
     
    Starter
     
    Torque converter-to-flywheel bolts
     
    Shift cable from the transmission as follows:
     

    1. Remove the shift cable retaining nut near the exhaust heat shield.
    2.  
    3. Remove the shift cable from the transmission cable bracket.
    4.  
    5. Disconnect the shift cable from the park/neutral switch.
    6.  

  16.  
  17. Use the engine support fixture to lower the powertrain assembly 2-to-3 inches 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



    Shift cable to the transmission as follows:
     

    1. Connect the shift cable from the park/neutral switch.
    2.  
    3. Connect the shift cable to the transmission cable bracket.
    4.  
    5. Install the shift cable retaining nut near the exhaust heat shield and tighten to 89 inch lbs. (10 Nm).
    6.  

  2.  
  3. Install or connect the following:

    Torque converter-to-flywheel bolts and tighten to 48 ft. lbs. (65 Nm)
     
    Starter
     
    Drive shafts
     
    Transmission cooler lines to the transmission. Lubricate the cooler pipe seals with transmission fluid prior to connecting the lines.
     

  4.  
  5. Use the engine support fixture to raise the powertrain assembly into position.
    1. Place the mount in position and tighten the mount-to-rail bolts to 25 ft. lbs. (34 Nm).
    2.  
    3. Use a jack raise the engine back into position and to align the mount when it is in position.
    4.  
    5. 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).
    6.  

  6.  
  7. 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.  

  8.  
  9. Install or connect the following:

    Top engine-to-transmission bolt and tighten to 55 ft. lbs. (75 Nm)
     
    Park/neutral switch connector
     
    Cooling module
     

  10.  
  11. Remove the engine support fixture.

    Underhood 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)
     
    TCM and ECM
     
    Negative battery cable
     

  12.  
  13. Fill the transaxle to the proper level.
  14.  
  15. Adjust the shift cable as follows:
    1. Place the transmission in Neutral .
    2.  
    3. Use fascia retainer remover tool J 36346 to disconnect the shift control cable from the transaxle range switch lever.
    4.  
    5. Disconnect the cable from the cable bracket by depressing the cable clip tabs and pulling up.
    6.  
    7. Release the cable assemble adjustment lock by sliding the black tab.
    8.  
    9. Insert a screw driver into the slot under the white tab and pull the tab out.
    10.  
    11. Attach the cable to the cable bracket. The clamp will be secure when an audible click is heard.
    12.  
    13. Attach the cable end fitting into the ball stud of the transaxle range switch selector. The clamp will be secure when an audible click is heard.
    14.  
    15. Attach the cable to the cable bracket. The clamp will be secure when an audible click is heard.
    16.  
    17. Lock the adjustment in place by pushing down on the white tab, slide the black tab up to lock the white tab in place and verify cable operation.
    18.  

  16.  
  17. Warm the engine and check the transaxle fluid. Check and adjust vehicle alignment, as necessary.
  18.  

5-Speed



  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
     
    Transmission Control Module (TCM) connections noting their locations to aid during installation
     
    TCM by releasing the tab on the junction block bracket
     
    Positive battery post from the underhood junction block
     
    Positive cables from the underhood junction block
     
    Surge tank inlet hose from the surge tank
     
    Underhood junction block bracket nuts and bolt
     
    Front wiring harness from the junction block bracket
     
    Move the junction block aside
     
    Park/Neutral switch connector
     
    Main transmission harness connector
     

  6.  
  7. Install an engine support fixture.
  8.  
  9. Remove or disconnect the following:

    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:

    Cooler lines from the transmission
     
    Drive shafts from the transmission and support with wire
     
    Starter
     
    Torque converter-to-flywheel bolts
     
    Shift cable from the transmission as follows:
     

    1. Remove the shift cable retaining nut near the exhaust heat shield.
    2.  
    3. Remove the shift cable from the transmission cable bracket.
    4.  
    5. Disconnect the shift cable from the park/neutral switch.
    6.  

  14.  
  15. Use the engine support fixture to lower the powertrain assembly to allow clearance between the side rail and powertrain.
  16.  
  17. Attach a transmission jack and remove the transmission-to-engine bolts.
  18.  
  19. Remove the transmission.
  20.  

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



    Shift cable to the transmission as follows:
     

    1. Connect the shift cable from the park/neutral switch.
    2.  
    3. Connect the shift cable to the transmission cable bracket.
    4.  
    5. Install the shift cable retaining nut near the exhaust heat shield and tighten to 89 inch lbs. (10 Nm).
    6.  

  2.  
  3. Install or connect the following:

    Torque converter-to-flywheel bolts and tighten to 48 ft. lbs. (65 Nm)
     
    Starter
     
    Drive shafts
     
    Transmission cooler lines to the transmission. Lubricate the cooler pipe seals with transmission fluid prior to connecting the lines.
     

  4.  
  5. Use the engine support fixture to raise the powertrain assembly into position.
  6.  
  7. 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.  

  8.  
  9. 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.  

  10.  
  11. 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.  

  12.  
  13. Remove the engine support fixture.
  14.  
  15. Install or connect the following:

    Top engine-to-transmission bolt and tighten to 55 ft. lbs. (75 Nm)
     
    Main transmission harness connector
     
    Park/neutral switch connector
     
    Underhood 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)
     
    TCM
     
    Negative battery cable
     

  16.  
  17. Fill the transaxle to the proper level.
  18.  
  19. Adjust the shift cable as follows:
    1. Place the transmission in Neutral .
    2.  
    3. Use fascia retainer remover tool J 36346 to disconnect the shift control cable from the transaxle range switch lever.
    4.  
    5. Disconnect the cable from the cable bracket by depressing the cable clip tabs and pulling up.
    6.  
    7. Release the cable assemble adjustment lock by sliding the black tab.
    8.  
    9. Insert a screw driver into the slot under the white tab and pull the tab out.
    10.  
    11. Attach the cable to the cable bracket. The clamp will be secure when an audible click is heard.
    12.  
    13. Attach the cable end fitting into the ball stud of the transaxle range switch selector. The clamp will be secure when an audible click is heard.
    14.  
    15. Attach the cable to the cable bracket. The clamp will be secure when an audible click is heard.
    16.  
    17. Lock the adjustment in place by pushing down on the white tab, slide the black tab up to lock the white tab in place and verify cable operation.
    18.  

  20.  
  21. Warm the engine and check the transaxle fluid. Check and adjust vehicle alignment, as necessary.
  22.  

 
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