Pacifica 2006-2008

Transaxle Removal & Installation

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  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Battery cables
     
    Battery and tray
     
    Gearshift cable from the manual valve lever
     
    Oil cooler off of hose fitting connection.
     

  4.  
  5. Use a suitable cutting tool, cut the oil cooler hoses off flush at the fittings. A service splice kit will be required during installation. Cap the hoses.

    Ground cable from the transaxle case
     
    Input and output speed sensor connections
     
    Crankshaft Position Sensor (CKP)
     
    Transaxle range sensor and solenoid/pressure switch connections
     
    Transaxle harness from retainers and position aside
     
    Coolant bypass tube-to-engine and transaxle retainers
     
    Front brake lines from the Hydraulic Control Unit (HCU) and position aside
     
    Intermediate shaft extension from the steering gear using tool 6831A to remove the roll pin and then slide the shaft extension off the gear
     

  6.  
  7. Install a powertrain support fixture such as 8534B and adapter kit 8534-12.

    Oil dipstick tube-to-cylinder head bolt
     

  8.  
  9. Install lift support bracket 8534-8 and use the dipstick tube bolt to secure it.
  10.  
  11. Remove the Coolant Temperature Sensor (CTS) at the thermostat housing. Remove the engine harness-to-cylinder head bolt and position the harness aside.
  12.  
  13. Install lift support bracket 8534-7 and bolt.
  14.  
  15. Assemble mounting bracket/sleeve assemblies 8534-2 to support tube 8534-1 and install on the vehicle allowing the brackets to rest on the inner fender ledges.
  16.  
  17. Assemble cross bar 8534-3, clamp 8534-5 and support leg 8534-4 to support tube allowing the support leg to rest on the radiator upper support.
  18.  
  19. Tighten the cross bar-to-support tube clamp 8534-5 as well as mounting bracket/sleeve 8534-3.
  20.  
  21. Install lift bracket assemblies as shown in the accompanying illustration.

    Click image to see an enlarged view

    Fig. Assemble the torque thumb screw and pivot nut bracket assembly as shown



    Click image to see an enlarged view

    Fig. Assemble the T-handle, bracket and hook assembly at the rear lift bracket as illustrated



    Click image to see an enlarged view

    Fig. Assemble the T-handle, bracket and hook assembly at the front lift bracket as shown



    Click image to see an enlarged view

    Fig. The engine support system slack is taken up by using the T-handles

  22.  
  23. Raise the vehicle and remove the front wheels.
  24.  
  25. Remove or disconnect the following:

    ABS sensor connector and sensor brackets from the struts
     
    Sway bar links from struts
     
    Halfshafts
     
    Engine front and rear mount-to-cradle nuts
     
    Brake lines and brackets from the frame rails
     
    Power steering hydraulic line from the bracket at the cradle located on the passenger side
     
    Power steering oil cooler from the cradle
     
    Power steering pressure and return lines from the steering gear and cap the lines
     
    Transmission-to-cradle torque strut
     

  26.  
  27. Position drive line support table 8874 into position and lower the vehicle until the cradle and fixture engage as shown in the accompanying illustration.

    Click image to see an enlarged view

    Fig. Position drive line support table 8874 into position and lower the vehicle until the cradle and fixture engage

  28.  
  29. Scribe alignment marks to reference cradle-to-body alignment to help during installation, then remove the four cradle-to-body bolts.
  30.  
  31. Slowly raise the vehicle and separate the cradle from the vehicle. Check the overhead fixture is secure on the fenders and radiator support.
  32.  
  33. Have an assistant guide the brake and power steering lines through as they remain attached.
  34.  
  35. Remove or disconnect the following:

    Engine front mount/bracket
     
    Starter motor
     

  36.  
  37. On All Wheel Drive (AWD) models remove or disconnect the following:

    Propeller shaft
     
    Power Transfer Unit (PTU) rear mount bracket
     
    Oil pan-to-transaxle collar
     
    Heat shield
     
    PTU-to-transaxle upper bolts
     
    PTU-to-bracket lower bolts
     
    PTU
     

  38.  
  39. Remove or disconnect the following:

    Torque converter dust shield
     
    Four torque converter-to-flexplate bolts. Upon removing the bolts a tight tolerance (slotted) bolt will be found. Mark this location on the converter and flexplate to use as a reference during assembly.
     
    Four transaxle upper bellhousing bolts
     

  40.  
  41. Use the overhead fixture to lower the engine/transaxle assembly. and secure the transmission to a suitable jack.
  42.  
  43. Remove the two transaxle-to-engine lower bolts and remove the transaxle.
  44.  

To install:

  1. Install or connect the following:

    Transaxle
     
    Two transaxle-to-engine lower bolts and tighten to 70 ft. lbs. (95 Nm)
     

  2.  
  3. Remove the transmission jack.

    Four transaxle upper bellhousing bolts and tighten to 70 ft. lbs. (95 Nm)
     
    Four torque converter-to-flexplate bolts and tighten to 65 ft. lbs. (88 Nm)
     
    Torque converter dust shield
     

  4.  
  5. Loosely install the engine-to-transaxle collar.
  6.  
  7. On AWD models install or connect the following:

    PTU lower bracket and PTU
     
    PTU-to-bracket lower bolts and tighten to 21 ft. lbs. (28 Nm)
     
    PTU-to-transaxle upper bolts and tighten to 40 ft. lbs. (54 Nm)
     
    PTU rear mount bracket and tighten the bolts to 40 ft. lbs. (54 Nm)

    Click image to see an enlarged view

    Fig. Exploded view of the Power Transfer Unit mounting and related components

     
    Heat shield
     
    Propeller shaft
     

  8.  
  9. Install or connect the following:

    Starter motor
     
    Engine front mount/bracket and tighten the bolts to 50 ft. lbs. (67 Nm)
     

  10.  
  11. Align the scribe alignment marks made to reference cradle-to-body alignment during removal, then install the four cradle-to-body bolts and tighten to 120 ft. lbs. (162 Nm).
  12.  
  13. Route the brake and power steering lines.
  14.  
  15. Remove the overhead support fixture.
  16.  
  17. Install or connect the following:

    Engine front and rear mount-to-cradle nuts and tighten to 40 ft. lbs. (54 Nm)
     
    Steering shaft-to-gear coupler using tool 6831A
     
    Power steering pressure and return lines to the steering gear and tighten the fittings to 23 ft. lbs. (31 Nm)
     
    Power steering oil cooler and hose routing clip to the cradle
     
    Transmission-to-cradle torque strut and tighten to 40 ft. lbs. (54 Nm)
     
    Halfshafts
     
    Sway bar links to the struts and tighten the nuts to 65 ft. lbs. (88 Nm)
     
    ABS sensor brackets and electrical connectors
     
    Both wheels
     
    Front brake lines to the HCU
     
    Coolant bypass tube fasteners
     
    Solenoid/pressure switch and tighten the screw to 35 inch lbs. (4 Nm)
     
    Transaxle range sensor connection
     
    Input and output speed sensor connections
     
    Transaxle harness using the retainers
     
    CKP sensor
     
    Transaxle oil cooler splice kit using the kit instructions
     
    Gearshift cable to the manual valve lever
     
    Battery tray, battery and cables
     

  18.  
  19. Bleed the brakes.
  20.  
  21. Add power steering fluid.
  22.  
  23. Check and fill the transmission fluid to the proper level.
  24.  
  25. If equipped with AWD, remove the PTU fill plug, check the fluid level. The PTU should have 2.1 pints of 75W-90 gear and axle lubricant. After checking the fluid lever, install the fill plug and tighten to 26 ft. lbs. (35 Nm).
  26.  
  27. Check and adjust the wheel alignment.
  28.  

 
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