Rendezvous 2006-2007

Transaxle Removal & Installation

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NOTE
Transmission oil circulates between the transmission assembly and the transfer case. In situations where transmission related failures circulate debris into the transfer case, the transfer case must be disassembled, cleaned, and inspected for damage.

  1. Raise and support the vehicle.
  2.  
  3. Remove the transmission lower bell housing bolt located between the engine oil pan and the transmission oil pan.
  4.  
  5. Remove the powertrain (engine, transmission, frame) from the vehicle
  6.  
  7. Remove the fluid filler tube nut from the Exhaust Gas Recirculation (EGR) valve.
  8.  
  9. Remove the fluid filler tube bolt from the transaxle.
  10.  
  11. Remove the fluid filler tube.
  12.  
  13. Remove the transmission bell housing bolts.
  14.  
  15. Remove the transaxle brace bolts.
  16.  
  17. Remove the transaxle brace.
  18.  
  19. If the vehicle is equipped with AWD (M76), remove the transaxle brace bolts and nuts.
  20.  
  21. Remove the transaxle brace.
  22.  
  23. Remove the coolant inlet pipe.
  24.  
  25. Use a utility stand with a block of wood in order to support the transaxle.
  26.  
  27. Remove the transaxle mount upper nuts.
  28.  
  29. Remove the transaxle mount bracket bolts.
  30.  
  31. Remove the transaxle mount bracket.
  32.  
  33. If equipped with 3.5L, remove the starter motor bolts.
  34.  
  35. Remove the starter motor.
  36.  
  37. If equipped with 3.6L, remove the starter motor bolts.
  38.  
  39. Remove the starter motor.
  40.  
  41. Remove the torque converter bolts.
  42.  
  43. Remove the transmission upper brace nut located behind the power steering pump and above the transfer case.
  44.  
  45. Remove the transmission upper brace bolts.
  46.  
  47. Remove the transmission upper brace.
  48.  
  49. Remove the transmission bolt near the crank sensor and the engine coolant (block) heater.
  50.  
  51. Separate the transmission from the engine.
  52.  
  53. Install the transaxle to the transmission support fixture.
  54.  
  55. If the vehicle is equipped with AWD (M76), remove the transfer case.
  56.  
  57. Flush the transaxle oil cooler and the transaxle oil cooler hoses.
  58.  

To install:


NOTE
If you are replacing the transaxle, transfer case or any internal components, you must inspect the end play and adjust as needed.

  1. If the vehicle is equipped with AWD (M76), install the transfer case.
  2.  
  3. Remove the transmission support fixture.
  4.  
  5. Use the dowel locator pins in order to align and install the transmission to the engine.
    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.

  6.  
  7. Install the transmission bell housing bolts and tighten the bolts to 37 ft. lbs. (50 Nm).
  8.  
  9. Install the transmission bell housing bolt near the crank sensor and the engine coolant (block) heater and tighten the bolt to 37 ft. lbs. (50 Nm).
  10.  
  11. Install the transmission upper brace.
  12.  
  13. Install the transmission upper brace bolts:

    Tighten the transmission upper brace outboard bolts to 17 ft.lbs. (23 Nm).
     
    Tighten the transmission upper brace inboard bolts to 37 ft. lbs. (50 Nm).
     

  14.  
  15. Install the transmission upper brace nut located behind the power steering pump and above the transfer case and tighten the transmission upper brace nut to 37 ft. lbs. (50 Nm).
  16.  
  17. Install the torque converter bolts.
  18.  
  19. If equipped with 3.5L, install the starter motor.
  20.  
  21. Install the starter motor bolts and tighten the bolts to 30 ft. lbs. (40 Nm).
  22.  
  23. If equipped with 3.6L, install the starter motor.
  24.  
  25. Install the starter motor bolts and tighten the bolts to 37 ft. lbs. (50 Nm).
  26.  
  27. Position the transaxle mount bracket.
  28.  
  29. Install the transaxle mount bracket bolts. To tighten, start with the forward lower bolt and work clockwise to tighten the transaxle mount bracket bolts to 70 ft. lbs. (95 Nm).
  30.  
  31. Remove the utility stand.
  32.  
  33. Install the transaxle mount upper nuts and tighten the nuts to 35 ft. lbs. (47 Nm).
  34.  
  35. Install the coolant inlet pipe.
  36.  
  37. If the vehicle is equipped with AWD (M76), install the transfer case brace.
  38.  
  39. Install the transfer case brace bolts and nuts:

    Tighten the transfer case brace bolts to 37 ft. lbs. (50 Nm).
     
    Tighten the transfer case brace nuts to 37 ft. lbs. (50 Nm).
     

  40.  
  41. Install the transaxle brace.
  42.  
  43. Install the transaxle brace bolts and tighten the bolts to 32 ft. lbs. (43 Nm).
  44.  
  45. Use the dowel locator pins in order to align and install the transmission to the engine.
  46.  
  47. Install the bell housing bolts and tighten the bolts to 37 ft. lbs. (50 Nm).
    NOTE
    Do NOT place the fluid filler tube seal on the fluid filler tube when installing the tube or damage to the seal will result.

  48.  
  49. Install the fluid filler tube seal in the transaxle.
  50.  
  51. Install the filler tube.
  52.  
  53. Install the fluid filler tube bolt and tighten the bolt to 115 inch lbs. (13 Nm).
  54.  
  55. Install the fluid filler tube nut and tighten the nut to 115 inch lbs (13 Nm).
  56.  
  57. Install the powertrain (engine, transmission, frame) to the vehicle.
  58.  
  59. Install the transmission lower bell housing bolt located between the engine oil pan and the transmission oil pan and tighten the bolt to 37 ft. lbs. (50 Nm).
  60.  
  61. Lower the vehicle.
  62.  
  63. Inspect and adjust the transaxle fluid level as needed.
    NOTE
    It is recommended that Transmission Adaptive Pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned.

  64.  
  65. Reset the TAP values.
  66.  


NOTE
Transmission oil circulates between the transmission assembly and the transfer case. In situations where transmission related failures circulate debris into the transfer case, the transfer case must be disassembled, cleaned, and inspected for damage.

  1. Raise and support the vehicle.
  2.  
  3. Remove the transmission lower bell housing bolt located between the engine oil pan and the transmission oil pan.
  4.  
  5. Remove the powertrain (engine, transmission, and frame) from the vehicle.
  6.  
  7. Remove the filler tube.
  8.  
  9. Remove the transmission bell housing bolts.
  10.  
  11. Remove the coolant inlet pipe.
  12.  
  13. Remove the transmission mount with the transmission mount bracket.
  14.  
  15. Remove the starter motor.
  16.  
  17. Remove the torque converter bolts.
  18.  
  19. Remove the transmission lower brace.
  20.  
  21. Remove the transmission upper brace nut located behind the power steering pump and above the transfer case.
  22.  
  23. Remove the transmission bolt near the crank sensor and the engine coolant (block) heater.
  24.  
  25. Separate the transmission from the engine.
  26.  
  27. Flush the transaxle oil cooler and the transaxle oil cooler hoses.
  28.  

To install:

  1. Use the dowel locator pins in order to align and install the transmission to the engine.
    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 transmission bell housing bolts and tighten the bolts to 37 ft. lbs. (50 Nm).
  4.  
  5. Install the transmission bell housing bolt near the crank sensor and the engine coolant (block) heater and tighten the transmission bell housing bolt to 37 ft. lbs. (50 Nm).
  6.  
  7. Install the transmission upper brace nut located behind the power steering pump and above the transfer case and tighten the transmission upper brace nut to 37 ft. lbs. (50 Nm).
  8.  
  9. Install the transmission lower brace.
  10.  
  11. Install the torque converter bolts.
  12.  
  13. Install the starter motor.
  14.  
  15. Install the transmission mount with the transmission mount bracket.
  16.  
  17. Install the coolant inlet pipe.
  18.  
  19. Install the filler tube.
  20.  
  21. Install the powertrain (engine, transmission, and frame) to the vehicle.
  22.  
  23. Install the transmission lower bell housing bolt located between the engine oil pan and the transmission oil pan and tighten the transmission bell housing bolt to 37 ft. lbs (50 Nm).
  24.  
  25. Inspect and adjust the transaxle fluid level as needed.
    NOTE
    It is recommended that Transmission Adaptive Pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned.

  26.  
  27. Reset the TAP values.
  28.  

3.6L Engine



  1. Before servicing the vehicle, refer to the Precautions Section.
    NOTE
    Transmission oil circulates between the transmission assembly and the transfer case. In situations where transmission related failures circulate debris into the transfer case, the transfer case must be disassembled, cleaned, and inspected for damage.

  2.  
  3. Raise and support the vehicle.
  4.  
  5. Remove the transmission lower bell housing bolt located between the engine oil pan and the transmission oil pan.
  6.  
  7. Remove the powertrain (engine, transmission and frame) from the vehicle.
  8.  
  9. Remove the filler tube.
  10.  
  11. Remove the transmission bell housing bolts.
  12.  
  13. If the vehicle is equipped with all wheel drive (AWD), remove the transfer case brace.
  14.  
  15. Remove the coolant inlet pipe.
  16.  
  17. Remove the transmission mount with the transmission mount bracket.
  18.  
  19. Remove the starter motor.
  20.  
  21. Remove the torque converter bolts.
  22.  
  23. Remove the transmission lower brace.
  24.  
  25. Remove the transmission upper brace nut located behind the power steering pump and above the transfer case.
  26.  
  27. Remove the transmission bolt near the crank sensor and the engine coolant (block) heater.
  28.  
  29. Separate the transmission from the engine.
  30.  
  31. If the vehicle is equipped with AWD, remove the transfer case.
  32.  
  33. Flush the transaxle oil cooler and the transaxle oil cooler hoses.
  34.  

To install:


NOTE
If you are replacing the transaxle, transfer case or any internal components, you must inspect the end play and adjust as needed.

  1. If the vehicle is equipped with AWD, install the transfer case.
  2.  
  3. Use the dowel locator pins in order to align and install the transmission to the engine.
    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.

  4.  
  5. Install the transmission bell housing bolts. Tighten the transmission bell housing bolts to 37 ft. lbs. (50 Nm).
  6.  
  7. Install the transmission bell housing bolt near the crank sensor and the engine coolant (block) heater.
  8.  
  9. Tighten the transmission bell housing bolt to 37 ft. lbs. (50 Nm).
  10.  
  11. Install the transmission upper brace nut located behind the power steering pump and above the transfer case. Tighten the transmission upper brace nut to 37 ft. lbs. (50 Nm).
  12.  
  13. Install the transmission lower brace. Tighten the transmission upper brace nut to 37 ft. lbs. (50 Nm).
  14.  
  15. Install the torque converter bolts. Tighten the bolts to 47 ft. lbs. (63 Nm).
  16.  
  17. Install the starter motor.
  18.  
  19. Install the transmission mount with the transmission mount bracket. Start with the forward lower bolt and work clockwise to tighten the transaxle mount bracket bolts to 70 ft. lbs. (95 Nm).
  20.  
  21. Install the coolant inlet pipe.
  22.  
  23. If the vehicle is equipped with AWD, install the transfer case brace. Tighten the transfer case brace bolts to 37 ft. lbs. (50 Nm). Tighten the transfer case brace nuts to 37 ft. lbs. (50 Nm).
  24.  
  25. Install the filler tube.
  26.  
  27. Install the powertrain (engine, transmission and frame) to the vehicle.
  28.  
  29. Install the transmission lower bell housing bolt located between the engine oil pan and the transmission oil pan. Tighten the transmission bell housing bolt to 37 ft. lbs. (50 Nm).
  30.  
  31. Inspect and adjust the transaxle fluid level as needed.
    NOTE
    It is recommended that Transmission Adaptive Pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned.

  32.  
  33. Reset the TAP values.
  34.  

 
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