Mitsubishi Car 1999-05

Transaxle Removal & Installation

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  1. Properly disarm the SRS system (air bag). Refer to Section 6.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove the front wheels.
  6.  
  7. Remove the engine side cover and undercovers.
  8.  
  9. Drain the transaxle assembly into a suitable container.
  10.  
  11. If equipped, remove the front catalytic converter.
  12.  
  13. Remove the exhaust pipe, main muffler and catalytic converter.
  14.  
  15. Disconnect the tie rod end and ball joint from the steering knuckle.
  16.  
  17. Unbolt the support bearing for the left side halfshaft.
  18.  
  19. Remove the halfshafts by inserting a prybar between the transaxle case and the driveshaft and prying the shaft from the transaxle.
  20.  
  21. Remove the air cleaner assembly and adjoining duct work.
  22.  
  23. Detach the engine harness connection.
  24.  
  25. If the vehicle is equipped with Active Electronic Controlled Suspension (Active-ECS), remove the compressor assembly from the transaxle and suspend with wire. Do not allow the compressor to hang from the air hose.
  26.  
  27. If equipped, remove the roll stopper stay bracket.
  28.  
  29. Disconnect the speedometer cable from the transaxle.
  30.  
  31. Remove the clip that secures the shifter and disconnect the shifter control cable from the transaxle.
  32.  
  33. Disconnect and plug the oil cooler hoses from the transaxle.
  34.  
  35. Detach the following:
  36.  


    Park/neutral switch electrical harness
     
    Kickdown servo switch
     
    Pulse generator
     
    Oil temperature sensor electrical harness
     
    Shift control solenoid valve harness.
     

  37. Support the transaxle and remove the transaxle mounting bracket.
  38.  
  39. Remove the three upper transaxle-to-engine mounting bolts.
  40.  



Click image to see an enlarged view

Fig. Location of 4-wheel steering oil pump mounting bolts-Diamante with a F4A33 automatic transaxle

  1. For vehicles with 4WS, remove the heat shield for the 4WS oil pump and remove the pump. Do not allow the pump to hang from the oil hoses.
  2.  
  3. For vehicles equipped with Active-ECS, disconnect the height sensor rod from the lower control arm.
  4.  
  5. Remove the bolt that secures the Heated Oxygen (HO 2 S) sensor harness to the right side crossmember.
  6.  
  7. Remove the starter assembly.
  8.  
  9. Remove the mounting brackets for access to the bell housing cover.
  10.  
  11. Remove the bell housing/oil pan covers assembly.
  12.  
  13. Remove the bolts holding the flexplate to the torque converter.
  14.  
  15. Remove the lower transaxle to engine bolts and remove the transaxle assembly.
  16.  



Click image to see an enlarged view

Fig. Transaxle removal (1 of 2)-Diamante with F4A51 transaxle



Click image to see an enlarged view

Fig. Transaxle removal (2 of 2)-Diamante with F4A51 transaxle

To install:

  1. Install the transaxle assembly to the engine block, install the mounting bolts and tighten to 54 ft. lbs. (75 Nm).
  2.  
  3. Install the bolts that secure the torque converter to the driveplate. Tighten the bolts to 34-38 ft. lbs. (46-53 Nm).
  4.  
  5. Install the bell housing/oil pan covers.
  6.  
  7. Install the transaxle stay brackets that were removed for access to the bell housing cover.
  8.  
  9. Install the starter assembly and connect the wiring.
  10.  
  11. Install the bolt that secures the HO 2 S sensor harness to the right side crossmember and tighten the bolt to 7-9 ft. lbs. (10-12 Nm).
  12.  
  13. For vehicles equipped with Active-ECS, connect the height sensor rod from the lower control arm. Check the height sensor rod for a length (A) of 10.59-10.63 in. (269-270mm).
  14.  



Click image to see an enlarged view

Fig. Height sensor rod adjustment-Diamante with a F4A33 automatic transaxle

  1. If removed, install the 4WS oil pump and tighten the mounting bolts to 17 ft. lbs. (24 Nm).
  2.  
  3. If removed, install the 4WS oil pump heat shield and tighten the mounting bolts to 17 ft. lbs. (24 Nm).
  4.  
  5. Install the three upper transaxle-to-engine mounting bolts. Tighten the mounting bolts to 54 ft. lbs. (75 Nm).
  6.  


NOTE
One of the upper bolts has a grounding strap to secure under the bolt.

  1. Install and connect the transaxle mounting bracket. Tighten the mounting nut and bolts to 51 ft. lbs. (70 Nm).
  2.  
  3. Connect the shift control solenoid valve harness.
  4.  
  5. Connect the kickdown servo switch, pulse generator and oil temperature sensor electrical harness.
  6.  
  7. Connect the park/neutral switch electrical harness.
  8.  
  9. Using new hose clamps, install the oil cooler hoses to the transaxle.
  10.  
  11. Install shifter control cable to the transaxle and secure the cable with clip.
  12.  
  13. Connect the speedometer cable to the transaxle.
  14.  
  15. If removed, install the roll stopper stay bracket and tighten the one through nut and bolt to 36-43 ft. lbs. (50-60 Nm). Tighten the two mounting bolts to 16 ft. lbs. (22 Nm).
  16.  
  17. If removed, install the Active-ECS compressor assembly. Tighten the mounting bolts to 48 inch lbs. (5 Nm) and connect the electrical harness.
  18.  
  19. Attach the engine harness connection.
  20.  
  21. Install the air cleaner assembly and adjoining duct work.
  22.  
  23. Using new circlips, install the halfshafts and seat halfshafts into the transaxle. Install the bolt that secure the left side support bearing and tighten the bolts to 33 ft. lbs. (45 Nm).
  24.  
  25. Connect the ball joint and tie rod end to the steering knuckle. Using new nuts, tighten the ball joint castle nut to 43-52 ft. lbs. (60-72 Nm) and tighten the tie rod castle nut to 22 ft. lbs. (30 Nm). Install new cotter pins.
  26.  
  27. Using new gaskets, install the exhaust system.
  28.  
  29. If removed, install front catalytic converter.
  30.  
  31. Install the engine undercovers.
  32.  
  33. Connect the negative battery cable.
  34.  
  35. Fill the transaxle to the correct level.
  36.  
  37. Start the engine and check for leaks.
  38.  

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner and intake hoses.
  4.  
  5. Drain the transaxle into a suitable waste container.
  6.  
  7. Remove the nut securing the shifter lever to the transaxle. Remove the cable retaining clip and remove the cable from the transaxle.
  8.  
  9. Remove the shifter cable mounting bracket.
  10.  
  11. Tag and detach the electrical connectors for the speedometer, solenoid, neutral safety switch (inhibitor switch), the pulse generator, kickdown servo switch, and the oil temperature sensor.
  12.  
  13. Tag and disconnect the oil cooler lines at the transaxle.
  14.  
  15. Remove the bolt securing the fluid dipstick tube to the transaxle. Remove the dipstick and tube from the transaxle.
  16.  
  17. Remove the starter motor and position it aside.
  18.  
  19. Using special tool MZ203827 or equivalent, support the engine assembly.
  20.  
  21. Remove the rear roll stopper mounting bracket.
  22.  
  23. Remove the transaxle mount bracket.
  24.  
  25. Remove the upper transaxle mounting bolts.
  26.  
  27. Raise and safely support the vehicle.
  28.  
  29. Remove the front wheel assemblies.
  30.  
  31. Remove the right hand undercover.
  32.  
  33. Remove and discard the cotter pin, then disconnect the tie rod end from the steering knuckle.
  34.  
  35. Disconnect the stabilizer bar link from the damper fork.
  36.  
  37. Disconnect the damper fork from the lateral lower control arm.
  38.  
  39. Disconnect the lateral lower arm, and the compression arm lower ball joints from the steering knuckle.
  40.  
  41. Pry the halfshafts from the transaxle, and secure aside.
  42.  
  43. Remove the cover from the transaxle bellhousing.
  44.  
  45. Remove the engine front roll stopper through-bolt.
  46.  
  47. Remove the crossmember and the triangular right hand stay.
  48.  
  49. Remove the bolts holding the flexplate to the torque converter with a box wrench. Rotate the engine to bring the bolts into a position appropriate for removal, one at a time. After removing the bolts, push the torque converter toward the transaxle. This will prevent the converter from remaining intact with the engine, possibly damaging the converter.
  50.  
  51. Support the transaxle, using a transmission jack, and remove the transaxle lower coupling bolt.
  52.  


NOTE
The coupling bolt threads from the engine side, into the transaxle, and is located just above the halfshaft opening.

  1. Slide the transaxle rearward and carefully lower it from the vehicle.
  2.  

To install:

  1. After the torque converter has been mounted on the transaxle, install the transaxle assembly to the engine. Install the mounting bolts and tighten to 35 ft. lbs. (48 Nm).
  2.  
  3. Install the transaxle lower coupling bolt and tighten to 21-25 ft. lbs. (29-34 Nm).
  4.  
  5. Connect the torque converter to the flexplate and tighten the bolts to 33-38 ft. lbs. (45-52 Nm).
  6.  
  7. Install the cover to the transaxle bellhousing and tighten the mounting bolts to 7 ft. lbs. (9 Nm).
  8.  
  9. Install the crossmember and tighten the front mounting bolts to 65 ft. lbs. (88 Nm) and the rear bolt to 54 ft. lbs. (73 Nm). Install the front engine roll stopper through-bolt and lightly tighten. Once the full weight of the engine is on the mounts, tighten the bolt to 42 ft. lbs. (57 Nm).
  10.  
  11. Install the triangular stay bracket and tighten the mounting bolts to 65 ft. lbs. (88 Nm).
  12.  
  13. Install the halfshafts, using new circlips on the axle ends.
  14.  


WARNING
When installing the axleshaft, keep the inboard joint straight in relation to the axle, so as not to damage the oil seal lip of the transaxle with the serrated part of the halfshaft.

  1. Connect the tie rod and ball joints to the steering knuckle. Tighten the ball joint self-locking nuts to 48 ft. lbs. (65 Nm). Tighten the tie rod end nut to 21 ft. lbs. (28 Nm) and secure with a new cotter pin.
  2.  
  3. Connect the damper fork to the lower control arm and tighten the through-bolt to 65 ft. lbs. (88 Nm).
  4.  
  5. Connect the stabilizer link to the damper fork, and tighten the self-locking nut to 29 ft. lbs. (39 Nm).
  6.  
  7. Install the undercover.
  8.  
  9. Install the wheels and carefully lower the vehicle.
  10.  
  11. Install the transaxle mount bracket to the transaxle, and tighten the mounting nuts to 32 ft. lbs. (43 Nm).
  12.  
  13. Install the rear roll stopper mounting bracket.
  14.  
  15. Remove the engine support. Tighten the transaxle mount through-bolt to 51 ft. lbs. (69 Nm) and tighten the front engine roll stopper through-bolt.
  16.  
  17. Install the upper transaxle mounting bolts and tighten to 35 ft. lbs. (48 Nm).
  18.  
  19. Install the starter motor.
  20.  
  21. Install the dipstick tube and the dipstick.
  22.  
  23. Install the shifter cable mounting bracket.
  24.  
  25. Connect the shifter lever and tighten the retaining nut to 14 ft. lbs. (19 Nm).
  26.  
  27. Connect the oil cooler lines and secure with clamps.
  28.  
  29. Attach the electrical connectors for the speedometer, solenoid, neutral safety switch (inhibitor switch), the pulse generator, kickdown servo switch and oil temperature sensor.
  30.  
  31. Install the air cleaner and the air intake hose.
  32.  
  33. Connect the negative battery cable.
  34.  
  35. Make sure the vehicle is level, and refill the transaxle. Start the engine and allow to idle for 2 minutes. Apply parking brake and move selector through each gear position, ending in N . Recheck fluid level and add if necessary. Fluid level should be between the marks in the HOT range.
  36.  
  37. Check the transaxle for proper operation. Make sure the reverse lights come on when in reverse and the engine starts only in P or N .
  38.  


NOTE
If the vehicle is going to be rolled on its wheels while the halfshafts are out of the vehicle, obtain two outer CV-joints or proper equivalent tools and install to the hubs. If the vehicle is rolled without the proper torque applied to the front wheel bearings, the bearings will no longer be usable.

  1. Disconnect the negative battery cable then the positive battery cable.
  2.  
  3. Remove the battery and battery tray.
  4.  
  5. Remove the air hose and air cleaner assembly.
  6.  
  7. Raise the vehicle and support safely.
  8.  
  9. Remove the under guard pan.
  10.  
  11. Drain the transaxle oil into a suitable container.
  12.  
  13. If equipped with 1.6L engine, remove the tension rod.
  14.  
  15. Disconnect the control cable and cooler lines.
  16.  
  17. On 3-speed transaxles, disconnect the throttle control cable.
  18.  
  19. On 4-speed transaxles, perform the following:
  20.  

  1. Detach the shift control solenoid valve connector.
  2.  
  3. Disconnect the inhibitor switch and kickdown servo switch.
  4.  
  5. Disconnect the pulse generator and oil temperature sensor.
  6.  

  1. Disconnect the speedometer cable and remove the starter.
  2.  
  3. Remove the transaxle mounting bolts and bracket.
  4.  
  5. Disconnect the stabilizer bar from the lower control arm.
  6.  
  7. Disconnect the steering tie rod end and the ball joint from the steering arm.
  8.  
  9. Remove the halfshafts at the inboard side from the transaxle. Tie the joint assembly aside.
  10.  


NOTE
It is not necessary to disconnect the halfshafts from the wheel hubs.

  1. Support the engine and remove the center member.
  2.  
  3. Remove the bellhousing cover and remove the driveplate bolts.
  4.  
  5. Remove the transaxle assembly lower connecting bolt, located just over the halfshaft opening.
  6.  
  7. Properly support the transaxle assembly, then lower it, moving it to the right for clearance.
  8.  

To install:

  1. After the torque converter has been mounted on the transaxle, install the transaxle assembly on the engine. Install the mounting bolts and tighten to 31-40 ft. lbs. (43-55 Nm) on 1990-92 models and 35 ft. lbs. (48 Nm) on 1993-00 models.
  2.  
  3. Tighten the driveplate bolts to 33-38 ft. lbs. (46-53 Nm). Install the bellhousing cover.
  4.  
  5. Install the center member.
  6.  
  7. Replace the circlips and install the halfshafts to the transaxle.
  8.  
  9. Install the tie rods, ball joints and stabilizer links to the steering arm.
  10.  
  11. Install the transaxle mounting bracket and bolts.
  12.  
  13. Install the starter.
  14.  
  15. Connect the speedometer cable.
  16.  
  17. Connect the inhibitor switch, kickdown servo switch, the pulse generator and oil temperature sensor, if disconnected.
  18.  
  19. Connect the shift control solenoid valve connector.
  20.  
  21. Connect the control cables and oil cooler lines.
  22.  
  23. Install the tension rod, if removed.
  24.  
  25. Install the air cleaner assembly.
  26.  
  27. Install the battery tray and battery.
  28.  
  29. Connect the positive then the negative terminal.
  30.  
  31. Refill with Dexron® II, Mopar® ATF Plus type 7176 or equivalent, automatic transaxle fluid.
  32.  
  33. Start the engine and allow to idle for two minutes. Apply parking brake and move selector through each gear position, ending in N . Recheck fluid level and add if necessary. Fluid level should be between the marks in the HOT range.
  34.  

  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Properly disarm the Supplemental Restraint System (SRS) system.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Remove or disconnect the following:

    Front wheels
     
    Engine side cover and undercovers
     

  8.  
  9. Drain the transaxle assembly.
  10.  
  11. If equipped, remove the front catalytic converter.
  12.  
  13. Remove or disconnect the following:

    Exhaust pipe, main muffler and catalytic converter
     
    Tie rod end and ball joint from the steering knuckle
     
    Support bearing for the left side halfshaft
     
    Halfshafts by inserting a prybar between the transaxle case and the driveshaft and prying the shaft from the transaxle
     
    Air cleaner assembly and adjoining ductwork
     
    Engine harness connection
     
    Compressor assembly, if the vehicle is equipped with Active Electronic Controlled Suspension (Active-ECS)-suspend with wire-Do not allow the compressor to hang from the air hose.
     
    Roll stopper stay bracket, if equipped
     
    Speedometer cable from the transaxle
     
    The clip that secures the shifter
     
    Shifter control cable from the transaxle
     
    Plug the oil cooler hoses from the transaxle
     

  14.  
  15. Disconnect the following:

    Park/neutral switch electrical harness
     
    Kickdown servo switch
     
    Pulse generator
     
    Oil temperature sensor electrical harness
     
    Shift control solenoid valve harness.
     

  16.  
  17. Support the transaxle and remove the transaxle mounting bracket.
  18.  
  19. Remove the 3 upper transaxle-to-engine mounting bolts.
  20.  
  21. For vehicles equipped with Active-ECS, disconnect the height sensor rod from the lower control arm.
  22.  
  23. Remove or disconnect the following:

    Bolt that secures the Heated Oxygen (HO2S) sensor harness to the right side crossmember
     
    Starter assembly
     
    Mounting brackets for access to the bell housing cover
     
    Bell housing/oil pan covers assembly
     
    Bolts holding the flexplate to the torque converter
     
    Lower transaxle to engine bolts and remove the transaxle assembly
     

  24.  

To install:

  1. Install or connect the following:

    Transaxle assembly to the engine block and install the mounting bolts
     
    Bolts that secure the torque converter to the driveplate. Tighten the bolts to 34-38 ft. lbs. (46-53 Nm).
     
    Bell housing/oil pan covers
     
    Transaxle stay brackets that were removed for access to the bell housing cover
     
    Starter assembly and connect the wiring
     
    Bolt that secures the HO2S sensor harness to the right side crossmember and tighten the bolt to 84-108 inch lbs. (10-12 Nm)
     

  2.  
  3. For vehicles equipped with Active-ECS, connect the height sensor rod from the lower control arm. Check the height sensor rod for a length (A) of 10.59-10.63 in. (269-270mm).
  4.  
  5. Install the 3 upper transaxle-to-engine mounting bolts. Tighten the mounting bolts to 54 ft. lbs. (75 Nm).
  6.  


    Click image to see an enlarged view

    Fig. Height sensor rod adjustment-Diamante with a F4A33 automatic transaxle



NOTE
One of the upper bolts has a grounding strap to secure under the bolt.

  1. Install or connect the following:

    Transaxle mounting bracket. Tighten the mounting nut and bolts to 51 ft. lbs. (70 Nm).
     
    Shift control solenoid valve harness
     
    Kickdown servo switch, pulse generator and oil temperature sensor electrical harness
     
    Park/neutral switch electrical harness
     
    Oil cooler hoses to the transaxle, using new hose clamps
     
    Shifter control cable to the transaxle and secure the cable with clip
     
    Speedometer cable to the transaxle
     
    Roll stopper stay bracket and tighten the one through nut and bolt to 36-43 ft. lbs. (50-60 Nm), if removed. Tighten the 2 mounting bolts to 16 ft. lbs. (22 Nm).
     
    Active-ECS compressor assembly, if removed. Tighten the mounting bolts to 48 inch lbs. (5 Nm) and connect the electrical harness.
     
    Engine harness connection
     
    Air cleaner assembly and adjoining ductwork
     
    Halfshafts and seat halfshafts into the transaxle, using new circlips
     
    Bolt that secure the left side support bearing and tighten the bolts to 33 ft. lbs. (45 Nm)
     
    Ball joint and tie rod end to the steering knuckle. Using new nuts, tighten the ball joint castle nut to 43-52 ft. lbs. (60-72 Nm) and tighten the tie rod castle nut to 22 ft. lbs. (30 Nm). Install new cotter pins.
     
    Exhaust system, using new gaskets
     
    Front catalytic converter, if removed
     
    Engine undercovers
     
    Negative battery cable
     

  2.  
  3. Fill the transaxle to the correct level.
  4.  
  5. Start the engine and check for leaks.
  6.  


    Click image to see an enlarged view

    Fig. Transaxle removal-Diamante with F4A51 transaxle 1 of 2



    Click image to see an enlarged view

    Fig. Transaxle removal-Diamante with F4A51 transaxle 2 of 2


  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Battery and the air intake hoses
     
    Battery tray and support
     
    Auto-cruise actuator and bracket, if equipped with cruise control
     
    Charcoal canister and bracket
     
    Shift and select cables from the transaxle
     
    Back-up light switch and the vehicle speed sensor connectors
     
    Dipstick and tube assembly
     
    Starter assembly
     
    Park/neutral switch, oil temperature sensor, kick down servo switch, solenoid valve, pulse generator and speedometer connections
     

  4.  
  5. Attach an engine support fixture to the engine and remove the transaxle mounting bolts.
  6.  
  7. Remove or disconnect the following:

    Rear roll stopper bracket mounting bolts
     
    Transaxle mounting bracket mounting nuts
     

  8.  
  9. Raise the vehicle and remove the engine undercovers.
  10.  
  11. Remove or disconnect the following:

    Front exhaust pipe
     
    Transfer case assembly, if equipped with all wheel drive
     
    Axle shafts
     
    Slave cylinder from the bell housing without disconnecting the fluid line. Position it out of the way.
     
    Bell housing cover and the right-hand center member stay (support)
     
    Center member
     
    Drive plate connecting bolts
     

  12.  
  13. Place a transmission jack under the transaxle and remove the transaxle mounting bolt.
  14.  
  15. Lower the transaxle.
  16.  

To install:

  1. Raise the transaxle into position and install the transaxle mounting bracket. Torque the through-bolt to 51 ft. lbs. (69 Nm).
  2.  
  3. Install or connect the following:

    Transaxle assembly mounting bolt. Torque the bolt to 22-25 ft. lbs. (29-34 Nm).
     
    Drive plate connecting bolts. Torque the bolts to 33-38 ft. lbs. (45-52 Nm).
     
    Center member assembly and the right-hand stay
     
    Bell housing cover and the slave cylinder
     
    Axle shafts.
     
    Front exhaust pipe
     
    Transfer case assembly if removed
     
    Engine undercovers and lower the vehicle
     
    Transaxle mounting bracket mounting nuts
     
    Rear roll stopper bracket mounting bolts
     
    Transaxle assembly mounting bolts. Torque the bolts to 35 ft. lbs. (48 Nm).
     

  4.  
  5. Remove the engine support fixture.
  6.  
  7. Install or connect the following:

    Park/neutral switch, oil temperature sensor, kick down servo switch, solenoid valve, pulse generator and speedometer connections
     
    Starter assembly
     
    Dipstick and tube assembly
     
    Vehicle speed sensor and the back-up light connectors
     
    Cruise control actuator if removed
     
    Battery tray support and the tray
     
    Charcoal canister bracket and the canister
     
    Air duct and the air cleaner assembly
     

  8.  
  9. Refill the transaxle and the transfer case, if equipped, with the proper fluid.
  10.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disarm the air bag, if equipped. Remove the battery, battery tray and washer tank.
  4.  
  5. Remove the air cleaner assembly and adjoining duct work.
  6.  
  7. Disconnect the shifter control cable.
  8.  
  9. Disconnect and plug the oil cooler hoses.
  10.  
  11. Disconnect the following

    Inhibitor switch
     
    Kickdown servo switch
     
    Pulse generator
     
    Oil temperature sensor
     
    Shift control solenoid valve
     
    Ground cable.
     
    Speedometer cable.
     

  12.  
  13. Raise and safely support the vehicle. Remove the undercovers.
  14.  
  15. Support the weight of the transaxle and remove the mount bracket. Remove the upper bell housing bolts.
  16.  
  17. Disconnect the tie rod end and ball joint from the steering knuckle.
  18.  
  19. Remove the right frame member.
  20.  
  21. Remove the starter.
  22.  
  23. Remove the halfshafts by inserting a prybar between the transaxle case and the driveshaft and prying the shaft from the transaxle.
  24.  
  25. Remove the remaining mounting brackets.
  26.  
  27. Remove the bell housing cover plate.
  28.  
  29. Remove the bolts holding the flexplate to the torque converter.
  30.  
  31. Remove the lower transaxle to engine bolts and remove the transaxle assembly.
  32.  

To install:

  1. After the torque converter has been mounted on the transaxle, install the transaxle assembly on the engine. Tighten the driveplate bolts to 34-38 ft. lbs. (46-53 Nm). Install the bell housing cover.
  2.  
  3. Install the mounting brackets.
  4.  
  5. Replace the circlips and install the halfshafts to the transaxle.
  6.  
  7. Install the starter and frame member.
  8.  
  9. Install the tie rods and ball joint to the steering arm.
  10.  
  11. Install the upper bell housing bolts.
  12.  
  13. Install the transaxle mounting bracket.
  14.  
  15. Install the undercovers.
  16.  
  17. Connect the following

    Inhibitor switch
     
    Kickdown servo switch
     
    Pulse generator
     
    Oil temperature sensor
     
    Shift control solenoid valve
     
    Ground cable.
     
    Speedometer cable.
     

  18.  
  19. Connect the oil cooler hoses.
  20.  
  21. Connect the shifter control cable.
  22.  
  23. Install the air cleaner assembly and adjoining duct work.
  24.  
  25. Install the washer tank, battery tray and battery.
  26.  
  27. Start the engine and check for leaks.
  28.  

  1. Remove or disconnect the following:

    Battery and the air intake hoses
     
    Battery tray and support
     
    Auto-cruise actuator and bracket, if equipped with cruise control
     
    Charcoal canister and bracket
     
    Shift and select cables from the transaxle
     
    Back-up light switch and the vehicle speed sensor connectors
     
    Dipstick and tube assembly
     
    Starter assembly
     
    Park/neutral switch
     
    Oil temperature sensor
     
    Kick down servo switch
     
    Solenoid valve
     
    Pulse generator
     
    Speedometer connections
     

  2.  
  3. Attach an engine support fixture to the engine and remove the transaxle mounting bolts.
  4.  
  5. Remove or disconnect the following:

    Rear roll stopper bracket mounting bolts
     
    Transaxle mounting bracket mounting nuts
     

  6.  
  7. Raise the vehicle and remove the engine undercovers.
  8.  
  9. Remove or disconnect the following:

    Front exhaust pipe
     
    Axle shafts
     
    Bell housing cover and the right-hand center member stay (support)
     
    Center member
     
    Drive plate connecting bolts
     

  10.  
  11. Place a transmission jack under the transaxle and remove the transaxle mounting bolt.
  12.  
  13. Lower the transaxle.
  14.  

To install:

  1. Raise the transaxle into position and install the transaxle mounting bracket. Torque the through-bolt to 51 ft. lbs. (69 Nm).
  2.  
  3. Install or connect the following:

    Transaxle assembly mounting bolt. Torque the bolt to 22-25 ft. lbs. (29-34 Nm).
     
    Drive plate connecting bolts. Torque the bolts to 33-38 ft. lbs. (45-52 Nm).
     
    Center member assembly and the right-hand stay
     
    Bell housing cover and the slave cylinder
     
    Axle shafts.
     
    Front exhaust pipe
     
    Engine undercovers and lower the vehicle
     
    Transaxle mounting bracket mounting nuts
     
    Rear roll stopper bracket mounting bolts
     
    Transaxle assembly mounting bolts. Torque the bolts to 35 ft. lbs. (48 Nm).
     

  4.  
  5. Remove the engine support fixture.

    Park/neutral switch
     
    Oil temperature sensor
     
    Kick down servo switch
     
    Solenoid valve
     
    Pulse generator
     
    Speedometer connections
     
    Starter assembly
     
    Dipstick and tube assembly
     
    Vehicle speed sensor and the back-up light connectors
     
    Cruise control actuator if removed
     
    Battery tray support and the tray
     
    Charcoal canister bracket and the canister
     
    Air duct and the air cleaner assembly
     

  6.  
  7. Refill the transaxle and the transfer case, if equipped, with the proper fluid.
  8.  

  1. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner and intake hoses
     

  2.  
  3. Drain the transaxle into a suitable waste container.

    Nut securing the shifter lever to the transaxle
     
    Cable retaining clip and remove the cable from the transaxle
     
    Shifter cable mounting bracket
     
    Electrical connectors for the speedometer, neutral safety switch (inhibitor switch), the pulse generator, kickdown servo switch, and the oil temperature sensor
     
    Oil cooler lines, at the transaxle
     
    Dipstick and tube from the transaxle
     
    Starter motor and position it aside
     

  4.  
  5. Support the engine assembly.

    Rear roll stopper mounting bracket
     
    Transaxle mount bracket
     
    Upper transaxle mounting bolts
     

  6.  
  7. Raise and safely support the vehicle.
  8.  
  9. Remove or disconnect the following:

    Front wheel assemblies
     
    Right-hand undercover
     
    Tie rod end from the steering knuckle
     
    Stabilizer bar link from the damper fork
     
    Damper fork from the lateral lower control arm
     
    Later lower arm and the compression arm lower ball joints, from the steering knuckle
     
    Halfshafts from the transaxle and secure aside
     
    Cover from the transaxle bell housing
     
    Engine front roll stopper through-bolt
     
    Crossmember and the triangular right-hand stay
     
    Bolts holding the flexplate to the torque converter
     

  10.  
  11. Support the transaxle using a transmission jack, and remove the transaxle lower coupling bolt.
    NOTE
    The coupling bolt threads from the engine side into the transaxle and is located just above the halfshaft opening.

  12.  
  13. Slide the transaxle rearward and carefully lower it from the vehicle.
  14.  

To install:

  1. After the torque converter has been mounted on the transaxle, install the transaxle assembly to the engine. Install the mounting bolts and tighten to 35 ft. lbs. (48 Nm). Install the transaxle lower coupling bolt and tighten to 21-25 ft. lbs. (29-34 Nm).
  2.  
  3. Install or connect the following:

    Torque converter to the flexplate and tighten the bolts to 33-38 ft. lbs. (45-52 Nm)
     
    Cover to the transaxle bell housing and tighten the mounting bolts to 84 inch lbs. (9 Nm)
     
    Crossmember and tighten the front mounting bolts to 65 ft. lbs. (88 Nm) and the rear bolt to 54 ft. lbs. (73 Nm)
     
    Front engine roll stopper through-bolt and lightly tighten. Once the full weight of the engine is on the mounts, tighten the bolt to 42 ft. lbs. (57 Nm).
     
    Triangular stay bracket and tighten the mounting bolts to 65 ft. lbs. (88 Nm)
     
    Halfshafts, using new circlips on the axle ends
     
    Tie rod and ball joints to the steering knuckle. Tighten the ball joint self-locking nuts to 48 ft. lbs. (65 Nm). Tighten the tie rod end nut to 21 ft. lbs. (28 Nm) and secure with a new cotter pin.
     
    Damper fork to the lower control arm and tighten the through-bolt to 65 ft. lbs. (88 Nm)
     
    Stabilizer link to the damper fork, and tighten the self-locking nut to 29 ft. lbs. (39 Nm)
     
    Underpan
     
    Wheels and lower the vehicle
     
    Transaxle mount bracket to the transaxle, and tighten the mounting nuts to 32 ft. lbs. (43 Nm)
     
    Rear roll stopper mounting bracket
     
    Engine support. Tighten the transaxle mount through-bolt to 51 ft. lbs. (69 Nm) and tighten the front engine roll stopper through-bolt.
     
    Upper transaxle mounting bolts and tighten to 35 ft. lbs. (48 Nm)
     
    Starter motor
     
    Dipstick tube and the dipstick
     
    Shifter cable mounting bracket
     
    Shifter lever and tighten the retaining nut to 14 ft. lbs. (19 Nm)
     
    Oil cooler lines and secure with clamps
     
    Electrical connectors for the speedometer, neutral safety switch (inhibitor switch), pulse generator, kickdown servo switch and oil temperature sensor
     
    Air cleaner and the air intake hose
     
    Negative battery cable
     

  4.  
  5. Fill the transaxle to the correct level.
  6.  

  1. Remove or disconnect the following:

    Negative battery cable
     
    Battery and battery tray
     
    Air hose and air cleaner assembly
     
    Under guard pan
     

  2.  
  3. Drain the transaxle oil.

    Control cable and cooler lines
     
    Shift control solenoid valve connector
     
    Inhibitor switch, kickdown servo switch, the pulse generator and oil temperature sensor, if equipped
     
    Speedometer cable and remove the starter
     
    Transaxle mounting bolts and bracket
     
    Stabilizer bar from the lower control arm
     
    Steering tie rod end and the ball joint from the steering arm
     
    Halfshafts at the inboard side from the transaxle. Tie the joint assembly aside.
     

  4.  
  5. Support the engine and remove the center member.

    Bell housing cover and remove the driveplate bolts
     
    Transaxle assembly lower connecting bolt, located just over the halfshaft opening
     
    Transaxle
     

  6.  

To install:

  1. Install or connect the following:

    Transaxle assembly on the engine. Tighten the driveplate bolts to 33-38 ft. lbs. (46-53 Nm).
     
    Bell housing cover
     
    Center member
     
    Halfshafts to the transaxle, using new circlips
     
    Tie rods, ball joints and stabilizer links to the steering arm
     
    Transaxle mounting bracket and bolts
     
    Starter
     
    Speedometer cable
     
    Inhibitor switch, kickdown servo switch, the pulse generator and oil temperature sensor, if disconnected
     
    Shift control solenoid valve connector
     
    Control cables and oil cooler lines
     
    Air cleaner assembly
     
    Battery tray and battery. Connect the positive, then the negative terminal.
     

  2.  
  3. Fill the transaxle to the correct level.
  4.  
  5. Start the engine and check for leaks.
  6.  

4-Speed



  1. Disconnect the negative battery cable. Drain the engine coolant. Drain the transaxle fluid.
  2.  
  3. Remove the left side under cover. Remove the air cleaner assembly. Remove the front exhaust pipe.
  4.  
  5. Remove the PCM. Remove the battery and the battery tray.
  6.  
  7. Remove the transaxle control cable adjusting nut. Remove the transaxle control cable.
  8.  
  9. Disconnect the transaxle range switch connection. Disconnect the A/T control solenoid valve assembly connector. Disconnect the input shaft speed sensor connector.
  10.  
  11. Disconnect the output shaft speed sensor connector. Disconnect the output shaft speed sensor connector.
  12.  
  13. Remove the front tire and wheel assembly. Remove the cotter pin. Remove the locknut. Remove the wheel speed sensor, sensor bracket and brake hose clamp.
  14.  
  15. Remove the stabilizer link connection (strut side) Remove the tie rod end self locking nut. Separate the tie rod end from the steering knuckle.
  16.  
  17. Remove the self locking nut for the lower ball joint connection.
  18.  
  19. Using tools MB990242, MB990244, MB991354 and MB990767, remove the left side driveshaft, circlip, right side driveshaft and circlip.
  20.  
  21. Disconnect the transaxle cooler lines. Remove the starter.
  22.  
  23. Remove the transaxle upper retaining bolts. Remove the bell housing cover. Remove the torque converter and drive plate retaining bolts. Remove the center member assembly.
  24.  
  25. Remove the rear roll stopper bracket. Remove the transaxle mounting bracket assembly.
  26.  
  27. Remove the transaxle mounting stopper. Remove the transaxle mounting body side bracket.
  28.  
  29. Install engine support tool MB991895. Set the tool to the front fender rear mounting bolts and the upper radiator support insulator mounting bolts, which are located in the engine compartment.
  30.  
  31. Use tools MB991527 (engine lifting fixture) and tool MB991454 (chain) to hold the engine and transaxle assembly in place.
  32.  
  33. Remove the lower transaxle retaining bolts. Remove the transaxle assembly from the vehicle.
  34.  

To install:

  1. Engage the torque converter into the transaxle, securely. Raise the transaxle into position and install the lower transaxle retaining bolts. Install the transaxle mounting stopper.
  2.  
  3. Install the driveshaft. Be sure to properly install the driveshaft washer.
    NOTE
    Before securely tightening the driveshaft nuts, make sure there is no load on the wheel bearings. Otherwise the wheel bearing will be damaged. Using tool MB990767, to hold the assembly in place, torque the retaining bolt to 146-188 ft. lbs. (197-155 Nm).

  4.  
  5. Place the selector lever and the manual control lever in the neutral -N- position. Position the cable stud into the manual control lever slot and loosely install the nut. Gently push the transaxle control cable into the manual control lever slot until the cable is taut. Tighten the nut to 90-124 inch lbs. (10-14 Nm).
  6.  
  7. Continue the installation in the reverse order of the removal procedure.
  8.  
  9. Check and adjust fluid levels, as required.
  10.  
  11. Check and adjust the front alignment.
  12.  
  13. To initialize the PCM, turn the ignition switch ON then OFF and keep it in the OFF position for at least ten seconds.
  14.  

5-Speed



  1. Disconnect the negative battery cable. Drain the transaxle fluid.
  2.  
  3. Remove the side under cover. Remove the air cleaner assembly. Remove the engine cover assembly.
  4.  
  5. Remove the PCM. Remove the battery and the battery tray.
  6.  
  7. Disconnect the front exhaust pipe. Remove the starter.
  8.  
  9. Remove the transaxle control cable adjusting nut. Remove the transaxle control cable. Inhibitor switch sensor connector.
  10.  
  11. Disconnect the A/T control solenoid valve assembly connector. Disconnect the input shaft speed sensor connector. Disconnect the output shaft speed sensor connector.
  12.  
  13. Remove the front tire and wheel assembly. Remove the cotter pin. Remove the locknut. Remove the wheel speed sensor, sensor bracket and brake hose clamp.
  14.  
  15. Remove the stabilizer link connection (strut side) Remove the tie rod end self locking nut. Separate the tie rod end from the steering knuckle.
  16.  
  17. Remove the self locking nut for the lower ball joint connection. Remove the lower arm ball joint connection.
  18.  
  19. Using tools MB990242, MB990244, MB991354 and MB990767, remove the left side driveshaft, circlip, right side driveshaft and circlip.
  20.  
  21. Disconnect the transaxle cooler lines. Remove the starter.
  22.  
  23. Remove the transaxle upper retaining bolts. Remove the bell housing cover. Remove the torque converter and drive plate retaining bolts. Remove the center member assembly.
  24.  
  25. Remove the engine oil pan to transaxle retaining bolts.
  26.  
  27. Remove the rear roll stopper bracket. Remove the transaxle mounting bracket assembly.
  28.  
  29. Remove the transaxle mounting stopper. Remove the transaxle mounting body side bracket.
  30.  
  31. Remove the engine hanger. Remove the intake manifold rear plenum stay and engine hanger. Install special tool MB992012 and MB992013 to each cylinder head.
  32.  
  33. Install engine support tool MB991895, to hold the engine and transaxle in position. Set the tool to the front fender rear mounting bolts and the upper radiator support insulator mounting bolts, which are located in the engine compartment.
  34.  
  35. Use tool MB991454 to hold the engine and transaxle assembly in place.
  36.  
  37. Remove the lower transaxle retaining bolts. Remove the transaxle assembly from the vehicle.
  38.  

To install:

  1. Engage the torque converter into the transaxle, securely. Raise the transaxle into position and install the lower transaxle retaining bolts. Install the transaxle mounting stopper.
  2.  
  3. Install the driveshaft. Be sure to properly install the driveshaft washer.
    NOTE
    Before securely tightening the driveshaft nuts, make sure there is no load on the wheel bearings. Otherwise the wheel bearing will be damaged. Using tool MB990767, to hold the assembly in place, torque the retaining bolt to 146-188 ft. lbs. (197-155 Nm).

  4.  
  5. Place the selector lever and the manual control lever in the neutral -N- position. Position the cable stud into the manual control lever slot and loosely install the nut. Gently push the transaxle control cable into the manual control lever slot until the cable is taut. Tighten the nut to 90-124 inch lbs. (10-14 Nm).
  6.  
  7. Continue the installation in the reverse order of the removal procedure.
  8.  
  9. Check and adjust fluid levels, as required.
  10.  
  11. Check and adjust the front alignment.
  12.  
  13. To initialize the PCM, turn the ignition switch ON then OFF and keep it in the OFF position for at least ten seconds.
  14.  

 
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