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    1996 Lexus ES300 3.0L SFI DOHC 6cyl

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    Mercury Cougar 2000-2002

    Transaxle Removal & Installation

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    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Secure the radiator and fan shroud to the radiator support.
    4.  
    5. Loosen the left and right upper strut mounting nuts 5 turns.
    6.  
    7. Attach an engine support fixture to the engine lifting eyes.
    8.  
    9. Drain the transaxle fluid.

      Click image to see an enlarged view

      Fig. Transaxle drain plug location

    10.  
    11. Remove or disconnect the following:

      Battery
       
      Air cleaner assembly and mounting bracket
       
      Shift cable and bracket
       
      Transaxle control wiring harness connector
       
      Transaxle range sensor
       
      Rear transaxle support insulator
       
      Oil dipstick tube and exhaust manifold heat shield (2.0L engine)
       
      Water pump pulley shield (2.5L engine)
       
      Steering column pinch bolt
       
      Front wheels
       
      Left, right and center splash shields
       
      Lower ball joints
       
      Outer tie rod ends
       
      Stabilizer bar links
       
      Left and right engine support insulators
       
      Power steering oil cooler hoses
       
      Bumper cover braces
       
      Radiator air deflector
       
      Lower radiator supports
       
      Exhaust system
       
      A/C accumulator mounting bolts
       
      Transaxle cooler lines and bracket
       
      Power steering hoses. Lower the sub-frame for access.
       
      Sub-frame
       
      Turbine Speed (TSS) sensor connector

      Click image to see an enlarged view

      Fig. TSS sensor location

       
      Halfshafts and intermediate shaft
       
      Vehicle Speed (VSS) sensor connector
       
      Torque converter nuts
       
      Starter
       
      Front engine support insulator bracket
       

    12.  
    13. Lower the powertrain until the transaxle is level with the left frame member.
    14.  
    15. Support the transaxle on a transmission jack.
    16.  
    17. Remove or disconnect the following:
      NOTE
      Use care when removing the transaxle to prevent the torque converter from falling out.



      Transaxle flange bolts
       
      Transaxle from the engine
       
      Transaxle
       

    18.  

    To install:

    Click image to see an enlarged view

    Fig. Be sure that the torque converter is properly seated in the transaxle


    NOTE
    Replace all snaprings, split pins and self-locking nuts.

    1. Install or connect the following:
      NOTE
      The left and right support insulators must be aligned in the middle of the support insulator brackets.



      Transaxle and tighten the flange bolts to 41-50 ft. lbs. (55-68 Nm)
       
      Torque converter and tighten the nuts to 23-39 ft. lbs. (31-53 Nm)
       
      TSS connector
       
      Sub-frame. Attach the power steering hoses before installing the sub-frame bolts.
       
      Special tool Sub-frame Alignment Pin Set T95P-2100-AH and the sub-frame bolts. Tighten the sub-frame bolts to 81-110 ft. lbs. (110-150 Nm). Remove the alignment pins.
       
      A/C accumulator bolts
       
      Power steering oil cooler lines
       
      Special tool Powertrain Alignment Gauge T94P-6000-AH in place of the left engine support insulator. Tighten the 2 retaining bolts to 20 ft. lbs. (27 Nm) and snug the through-bolt.
       



      Right engine support insulator. Tighten the 2 sub-frame retaining bolts to 30-41 ft. lbs. (41-55 Nm) and the through-bolt to 75-102 ft. lbs. (103-137 Nm).
       
      Rear engine support insulator and tighten the nuts to 61 ft. lbs. (83 Nm)
       
      Front engine support insulator and tighten the nuts to 61 ft. lbs. (83 Nm)
       

    2.  
    3. Remove the Powertrain Alignment Tool and install the left engine support insulator. Tighten the center bolt to 88 ft. lbs. (120 Nm), and the mounting bolts to 35 ft. lbs. (48 Nm).

      Transaxle oil cooler lines
       
      Starter and tighten the bolts to 43-58 ft. lbs. (59-79 Nm) for the 2.5L engine or 15-20 ft. lbs. (20-27 Nm) for the 2.0L engine
       
      VSS sensor connector
       
      Halfshafts and intermediate shaft
       
      Exhaust system
       
      Lower radiator supports
       
      Radiator air deflector
       
      Bumper cover braces
       
      Power steering oil cooler hoses
       
      Left and right engine support insulators
       
      Stabilizer bar links and tighten the nuts to 35-48 ft. lbs. (47-65 Nm)
       
      Outer tie rod ends and tighten the nuts to 23-35 ft. lbs. (31-47 Nm)
       
      Lower ball joints and tighten the pinch bolt to 61 ft. lbs. (83 Nm)
       
      Left, right and center splash shields
       
      Front wheels and tighten the lug nuts to 63 ft. lbs. (86 Nm)
       
      Steering column pinch bolt and tighten the bolt to 15-20 ft. lbs. (20-27 Nm)
       
      Water pump pulley shield (2.5L engine)
       
      Oil dipstick tube and exhaust manifold heat shield (2.0L engine)
       
      Transaxle range sensor
       
      Transaxle control wiring harness connector
       
      Shift cable and bracket
       
      Air cleaner assembly and mounting bracket
       
      Battery
       

    4.  
    5. Tighten the upper strut mount nuts to 34 ft. lbs. (46 Nm).
    6.  
    7. Fill the transaxle.
    8.  
    9. Check for leaks and proper operation.
      NOTE
      Whenever the vehicle sub-frame is removed or lowered, the wheel alignment should be checked.



      Click image to see an enlarged view

      Fig. To properly align the sub-frame, install Sub-frame Alignment Pin Set T95P-2100-AH-manual and automatic transaxles

    10.  

     
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