Toyota RAV4 2000-05

Transaxle Removal & Installation

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2wd





Click image to see an enlarged view

Fig. Transaxle exploded view-2001-03 with 2WD

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

    Negative battery cable
     
    Throttle cable
     
    Engine coolant reservoir tank
     
    Air cleaner assembly
     
    Ground cable from the transaxle
     
    Set nut of the engine wire clamp
     

  4.  
  5. Remove the starter, as follows:

    Connector and nut from the starter
     
    2 bolts and the engine wire
     
    Starter
     

  6.  
  7. Remove the 3 upper side transaxle mounting bolts.
  8.  
  9. Install an engine support fixture.
  10.  
  11. Remove or disconnect the following:

    2 bolts and 2 nuts from the left engine mount
     
    Engine undercovers
     

  12.  
  13. Drain the fluid from the transaxle.
  14.  
  15. Remove the left and right halfshafts.
  16.  
  17. Remove the front exhaust pipe, as follows:

    2 front exhaust pipe-to-center exhaust pipe bolts and gasket
     
    3 front exhaust pipe-to-exhaust manifold nuts and gasket
     
    Exhaust manifold
     

  18.  
  19. Disconnect the shift control cable from the transaxle and frame, as follows:

    Control shaft lever nut
     
    Clip and the control cable from the transaxle
     
    2 shift control cable-to-centermember bolts
     
    Crossmember
     

  20.  
  21. Detach the following connectors:

    Shift solenoid valve connector
     
    Park/Neutral Position (PNP) switch connector
     
    Vehicle Speed Sensor (VSS) connector
     

  22.  
  23. Remove or disconnect the following:

    Oil cooler hoses from the transaxle
     
    Rack and pinion from the crossmember by removing both nuts/ bolts
     

  24.  
  25. Support the rack and pinion.
  26.  
  27. Support the suspension crossmember with a floor jack.
  28.  
  29. Remove or disconnect the following:

    Crossmember-to-centermember fasteners
     
    Crossmember with the sway bar
     
    Stiffener plate by removing the 3 bolts
     
    Rear endplate by removing the 4 bolts
     
    6 torque converter bolts
     
    Both rear side transaxle mounting bolts
     
    Transaxle
     

  30.  

To install:

  1. Install or connect the following:

    Transaxle
     
    Both rear side transaxle mounting bolts. Tighten the top bolt to 18 ft. lbs. (25 Nm) and the lower bolt to 34 ft. lbs. (46 Nm).
     
    Torque converter bolts. Tighten the bolts to 20 ft. lbs. (27 Nm).
     

  2.  


NOTE
First install the gray bolt; then, install the 5 black bolts.



Rear endplate. Tighten the engine bolts to 78 inch lbs. (9.0 Nm) and the transaxle bolts to 14 ft. lbs. (19 Nm).
 
Stiffener plate. Tighten the 3 bolts to 27 ft. lbs. (37 Nm).
 

  1. Install the front suspension crossmember and centermember with the sway bar. Tighten the nuts/bolts, as follows:

    Bolt A: 152 ft. lbs. (206 Nm)
     
    Bolt B: 101 ft. lbs. (137 Nm)
     
    Bolt C: 26 ft. lbs. (35 Nm)
     
    Bolt D: 53 ft. lbs. (72 Nm)
     
    Nut: 54 ft. lbs. (73 Nm)
     

  2.  
  3. Install or connect the following:

    Rack and pinion to the crossmember. Tighten the nuts to 83 ft. lbs. (113 Nm).
     
    Oil cooler hoses with both clips
     

  4.  
  5. Connect the following connectors:

    Shift solenoid valve connector
     
    PNP switch connector
     
    VSS connector
     

  6.  
  7. Install or connect the following:

    Shift control cable to the transaxle. Tighten the nut to 10 ft. lbs. (13 Nm).
     

  8.  
  9. Install the front exhaust pipe, as follows:

    Front exhaust pipe, using new gaskets
     
    Front exhaust pipe to the exhaust manifold. Tighten the 3 nuts to 46 ft. lbs. (62 Nm).
     
    Front exhaust pipe to the center exhaust pipe. Tighten both bolts to 35 ft. lbs. (48 Nm).
     

  10.  
  11. Install or connect the following:

    Left and right halfshafts
     
    Engine undercovers
     
    Left engine mount. Tighten the both nuts/bolts to 47 ft. lbs. (64 Nm).
     

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

    Upper side transaxle mount. Tighten the 3 bolts to 47 ft. lbs. (64 Nm).
     
    Starter. Tighten both bolts to 29 ft. lbs. (39 Nm).
     
    Engine wire
     
    Starter wire with the nut
     
    Engine wire clamp set nut
     
    Ground cable to the transaxle. Tighten the bolt to 14 ft. lbs. (19 Nm).
     
    Air cleaner assembly
     
    Engine coolant reservoir tank
     
    Throttle cable
     
    Negative battery cable
     

  16.  
  17. Check all fluids.
  18.  



Click image to see an enlarged view

Fig. Automatic transaxle and related parts-2004 with 2WD

  1. Remove the hood.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Remove the coolant reservoir.
  6.  
  7. Remove the control cables from the transmission.
  8.  
  9. Remove the wiring from the speed sensor and back-up light switch.
  10.  
  11. Remove the ground cable from the transaxle.
  12.  
  13. Remove the starter.
  14.  
  15. Remove the clutch release cylinder.
  16.  
  17. Remove the 3 upper transaxle-to-engine bolts.
  18.  
  19. Attach an engine support fixture, such as 12281-28010, or equivalent.
  20.  
  21. Disconnect the left engine mount from the transaxle.
  22.  
  23. Remove the engine under-covers.
  24.  
  25. Drain the transaxle.
  26.  
  27. Remove the front exhaust pipe.
  28.  
  29. Remove the halfshafts.
  30.  
  31. Remove the stabilizer bar.
  32.  
  33. Disconnect the oil cooler lines.
  34.  
  35. Remove the power steering gear mounting bolts. Support the gear.
  36.  
  37. Remove the front suspension crossmember.
  38.  
  39. Using a transmission jack, slightly raise the transaxle.
  40.  
  41. Remove the 4 lower transaxle-to-engine bolts.
  42.  
  43. Remove the front side mounting bolt, the 2 rear side mounting bolts and the transaxle.
  44.  
  45. Installation is the reverse of removal. Observe the following torques:

    Lower transaxle-to-engine bolts: 32 ft. lbs. (44 Nm)
     
    Front side mounting bolt, the 2 rear side mounting bolts: 34 ft. lbs. (46 Nm)
     
    Torque converter bolts: 32 ft. lbs. (41 Nm). Torque the green bolt first.
     


    Click image to see an enlarged view

    Fig. Crossmember bolt identification-2004 with 2WD

    Front suspension crossmember (see the illustration): bolt A 28 ft. lbs. (39 Nm); bolt B 59 ft. lbs. (80 Nm); bolts C 80 ft. lbs. (113 Nm); bolt D 85 ft. lbs. (115 Nm); bolt E 115 ft. lbs. (157 Nm); nuts 85 ft. lbs. (115 Nm)
     
    Power steering gear bolts: 101 ft. lbs. (137 Nm)
     
    Stabilizer bar links: 32 ft. lbs. (44 Nm)
     
    Exhaust pipe-to-manifold: 32 ft. lbs. (43 Nm)
     
    Exhaust pipe-to-pipe: 14 ft. lbs. (19 Nm)
     
    Left engine mount through-bolt: 41 ft. lbs. (56 Nm)
     
    Upper transaxle-to-engine bolts: 47 ft. lbs. (64 Nm)
     
    Starter: 28 ft. lbs. (37 Nm)
     
    Hood: 10 ft. lbs. (13 Nm)
     

  46.  



Click image to see an enlarged view

Fig. Transaxle exploded view-2WD RAV4

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

    Negative battery cable
     
    Throttle cable
     
    Engine coolant reservoir tank
     
    Air cleaner assembly
     
    Ground cable from the transaxle
     
    Set nut of the engine wire clamp
     

  4.  
  5. Remove the starter, as follows:

    Connector and nut from the starter
     
    2 bolts and the engine wire
     
    Starter
     

  6.  
  7. Remove the 3 upper side transaxle mounting bolts.
  8.  
  9. Install an engine support fixture.
  10.  
  11. Remove or disconnect the following:

    2 bolts and 2 nuts from the left engine mount
     
    Engine undercovers
     

  12.  
  13. Drain the fluid from the transaxle.
  14.  
  15. Remove the left and right halfshafts.
  16.  
  17. Remove the front exhaust pipe, as follows:

    2 front exhaust pipe-to-center exhaust pipe bolts and gasket
     
    3 front exhaust pipe-to-exhaust manifold nuts and gasket
     
    Exhaust manifold
     

  18.  
  19. Disconnect the shift control cable from the transaxle and frame, as follows:

    Control shaft lever nut
     
    Clip and the control cable from the transaxle
     
    2 shift control cable-to-centermember bolts
     
    Crossmember
     

  20.  
  21. Detach the following connectors:

    Shift solenoid valve connector
     
    Park/Neutral Position (PNP) switch connector
     
    Vehicle Speed Sensor (VSS) connector
     

  22.  
  23. Remove or disconnect the following:

    Oil cooler hoses from the transaxle
     
    Rack and pinion from the crossmember by removing both nuts/ bolts
     

  24.  
  25. Support the rack and pinion.
  26.  
  27. Support the suspension crossmember with a floor jack.
  28.  
  29. Remove or disconnect the following:

    Crossmember-to-centermember fasteners
     
    Crossmember with the sway bar
     
    Stiffener plate by removing the 3 bolts
     
    Rear endplate by removing the 4 bolts
     
    6 torque converter bolts
     
    Both rear side transaxle mounting bolts
     
    Transaxle
     

  30.  

To install:

  1. Install or connect the following:
    NOTE
    First install the gray bolt; then, install the 5 black bolts.



    Transaxle
     
    Both rear side transaxle mounting bolts. Tighten the top bolt to 18 ft. lbs. (25 Nm) and the lower bolt to 34 ft. lbs. (46 Nm).
     
    Torque converter bolts. Tighten the bolts to 20 ft. lbs. (27 Nm).
     



    Rear endplate. Tighten the engine bolts to 78 inch lbs. (9.0 Nm) and the transaxle bolts to 14 ft. lbs. (19 Nm).
     
    Stiffener plate. Tighten the 3 bolts to 27 ft. lbs. (37 Nm).
     

  2.  
  3. Install the front suspension crossmember and centermember with the sway bar. Tighten the nuts/bolts, as follows:

    Bolt A: 152 ft. lbs. (206 Nm)
     
    Bolt B: 101 ft. lbs. (137 Nm)
     
    Bolt C: 26 ft. lbs. (35 Nm)
     
    Bolt D: 53 ft. lbs. (72 Nm)
     
    Nut: 54 ft. lbs. (73 Nm)
     

  4.  
  5. Install or connect the following:

    Rack and pinion to the crossmember. Tighten the nuts to 83 ft. lbs. (113 Nm).
     
    Oil cooler hoses with both clips
     

  6.  
  7. Connect the following connectors:

    Shift solenoid valve connector
     
    PNP switch connector
     
    VSS connector
     

  8.  
  9. Install or connect the following:

    Shift control cable to the transaxle. Tighten the nut to 10 ft. lbs. (13 Nm).
     

  10.  
  11. Install the front exhaust pipe, as follows:

    Front exhaust pipe, using new gaskets
     
    Front exhaust pipe to the exhaust manifold. Tighten the 3 nuts to 46 ft. lbs. (62 Nm).
     
    Front exhaust pipe to the center exhaust pipe. Tighten both bolts to 35 ft. lbs. (48 Nm).
     

  12.  
  13. Install or connect the following:

    Left and right halfshafts
     
    Engine undercovers
     
    Left engine mount. Tighten the both nuts/bolts to 47 ft. lbs. (64 Nm).
     

  14.  
  15. Remove the engine fixture.
  16.  
  17. Install or connect the following:

    Upper side transaxle mount. Tighten the 3 bolts to 47 ft. lbs. (64 Nm).
     
    Starter. Tighten both bolts to 29 ft. lbs. (39 Nm).
     
    Engine wire
     
    Starter wire with the nut
     
    Engine wire clamp set nut
     
    Ground cable to the transaxle. Tighten the bolt to 14 ft. lbs. (19 Nm).
     
    Air cleaner assembly
     
    Engine coolant reservoir tank
     
    Throttle cable
     
    Negative battery cable
     

  18.  
  19. Check all fluids.
  20.  



Click image to see an enlarged view

Fig. Automatic transaxle and related components-2000-2003 2WD

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

    Negative battery cable
     
    Throttle cable
     
    Engine coolant reservoir tank
     
    Air cleaner assembly
     
    Ground cable from the transaxle
     
    Set nut of the engine wire clamp
     

  4.  
  5. Remove the starter, as follows:

    Connector and nut from the starter
     
    2 bolts and the engine wire
     
    Starter
     

  6.  
  7. Remove the 3 upper side transaxle mounting bolts.
  8.  
  9. Install an engine support fixture.
  10.  
  11. Remove or disconnect the following:

    2 bolts and 2 nuts from the left engine mount
     
    Engine undercovers
     

  12.  
  13. Drain the fluid from the transaxle.
  14.  
  15. Remove the left and right halfshafts.
  16.  
  17. Remove the front exhaust pipe, as follows:

    2 front exhaust pipe-to-center exhaust pipe bolts and gasket
     
    3 front exhaust pipe-to-exhaust manifold nuts and gasket
     
    Exhaust manifold
     

  18.  
  19. Disconnect the shift control cable from the transaxle and frame, as follows:

    Control shaft lever nut
     
    Clip and the control cable from the transaxle
     
    2 shift control cable-to-centermember bolts
     
    Crossmember
     

  20.  
  21. Detach the following connectors:

    Shift solenoid valve connector
     
    Park/Neutral Position (PNP) switch connector
     
    Vehicle Speed Sensor (VSS) connector
     

  22.  
  23. Remove or disconnect the following:

    Oil cooler hoses from the transaxle
     
    Rack and pinion from the crossmember by removing both nuts/ bolts
     

  24.  
  25. Support the rack and pinion.
  26.  
  27. Support the suspension crossmember with a floor jack.
  28.  
  29. Remove or disconnect the following:

    Crossmember-to-centermember fasteners
     
    Crossmember with the sway bar
     
    Stiffener plate by removing the 3 bolts
     
    Rear endplate by removing the 4 bolts
     
    6 torque converter bolts
     
    Both rear side transaxle mounting bolts
     
    Transaxle
     

  30.  

To install:

  1. Install or connect the following:
    NOTE
    First install the gray bolt; then, install the 5 black bolts.



    Transaxle
     
    Both rear side transaxle mounting bolts. Tighten the top bolt to 18 ft. lbs. (25 Nm) and the lower bolt to 34 ft. lbs. (46 Nm).
     
    Torque converter bolts. Tighten the bolts to 20 ft. lbs. (27 Nm).
     



    Rear endplate. Tighten the engine bolts to 78 inch lbs. (9.0 Nm) and the transaxle bolts to 14 ft. lbs. (19 Nm).
     
    Stiffener plate. Tighten the 3 bolts to 27 ft. lbs. (37 Nm).
     

  2.  
  3. Install the front suspension crossmember and centermember with the sway bar. Tighten the nuts/bolts, as follows:

    Bolt A: 152 ft. lbs. (206 Nm)
     
    Bolt B: 101 ft. lbs. (137 Nm)
     
    Bolt C: 26 ft. lbs. (35 Nm)
     
    Bolt D: 53 ft. lbs. (72 Nm)
     
    Nut: 54 ft. lbs. (73 Nm)
     

  4.  
  5. Install or connect the following:

    Rack and pinion to the crossmember. Tighten the nuts to 83 ft. lbs. (113 Nm).
     
    Oil cooler hoses with both clips
     

  6.  
  7. Connect the following connectors:

    Shift solenoid valve connector
     
    PNP switch connector
     
    VSS connector
     

  8.  
  9. Install or connect the following:

    Shift control cable to the transaxle. Tighten the nut to 10 ft. lbs. (13 Nm).
     

  10.  
  11. Install the front exhaust pipe, as follows:

    Front exhaust pipe, using new gaskets
     
    Front exhaust pipe to the exhaust manifold. Tighten the 3 nuts to 46 ft. lbs. (62 Nm).
     
    Front exhaust pipe to the center exhaust pipe. Tighten both bolts to 35 ft. lbs. (48 Nm).
     

  12.  
  13. Install or connect the following:

    Left and right halfshafts
     
    Engine undercovers
     
    Left engine mount. Tighten the both nuts/bolts to 47 ft. lbs. (64 Nm).
     

  14.  
  15. Remove the engine fixture.
  16.  
  17. Install or connect the following:

    Upper side transaxle mount. Tighten the 3 bolts to 47 ft. lbs. (64 Nm).
     
    Starter. Tighten both bolts to 29 ft. lbs. (39 Nm).
     
    Engine wire
     
    Starter wire with the nut
     
    Engine wire clamp set nut
     
    Ground cable to the transaxle. Tighten the bolt to 14 ft. lbs. (19 Nm).
     
    Air cleaner assembly
     
    Engine coolant reservoir tank
     
    Throttle cable
     
    Negative battery cable
     

  18.  
  19. Check all fluids.
  20.  



Click image to see an enlarged view

Fig. Automatic transaxle and related components-2004-2005 2WD

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the hood.
  4.  
  5. Remove the air cleaner assembly.
  6.  
  7. Remove the coolant reservoir.
  8.  
  9. Remove the control cables from the transaxle.
  10.  
  11. Remove the wiring from the speed sensor and back-up light switch.
  12.  
  13. Remove the ground cable from the transaxle.
  14.  
  15. Remove the starter.
  16.  
  17. Remove the clutch release cylinder.
  18.  
  19. Remove the 3 upper transaxle-to-engine bolts.
  20.  
  21. Attach an engine support fixture, such as 12281-28010, or equivalent.
  22.  
  23. Disconnect the left engine mount from the transaxle.
  24.  
  25. Remove the engine under-covers.
  26.  
  27. Drain the transaxle.
  28.  
  29. Remove the front exhaust pipe.
  30.  
  31. Remove the halfshafts.
  32.  
  33. Remove the stabilizer bar.
  34.  
  35. Disconnect the oil cooler lines.
  36.  
  37. Remove the power steering gear mounting bolts. Support the gear.
  38.  
  39. Remove the front suspension crossmember.
  40.  
  41. Using a transmission jack, slightly raise the transaxle.
  42.  
  43. Remove the 4 lower transaxle-to-engine bolts.
  44.  
  45. Remove the front side mounting bolt, the 2 rear side mounting bolts and the transaxle.
  46.  

To install:

  1. Installation is the reverse of removal. Observe the following torques:

    Lower transaxle-to-engine bolts: 32 ft. lbs. (44 Nm)
     
    Front side mounting bolt, the 2 rear side mounting bolts: 34 ft. lbs. (46 Nm)
     
    Torque converter bolts: 32 ft. lbs. (41 Nm). Torque the green bolt first.

    Click image to see an enlarged view

    Fig. Crossmember bolt identification-2004 with 2WD

     
    Front suspension crossmember (see the illustration): bolt A 28 ft. lbs. (39 Nm); bolt B 59 ft. lbs. (80 Nm); bolts C 80 ft. lbs. (113 Nm); bolt D 85 ft. lbs. (115 Nm); bolt E 115 ft. lbs. (157 Nm); nuts 85 ft. lbs. (115 Nm)
     
    Power steering gear bolts: 101 ft. lbs. (137 Nm)
     
    Stabilizer bar links: 32 ft. lbs. (44 Nm)
     
    Exhaust pipe-to-manifold: 32 ft. lbs. (43 Nm)
     
    Exhaust pipe-to-pipe: 14 ft. lbs. (19 Nm)
     
    Left engine mount through-bolt: 41 ft. lbs. (56 Nm)
     
    Upper transaxle-to-engine bolts: 47 ft. lbs. (64 Nm)
     
    Starter: 28 ft. lbs. (37 Nm)
     
    Hood: 10 ft. lbs. (13 Nm)
     

  2.  

4wd





Click image to see an enlarged view

Fig. Automatic transaxle exploded view-2001-03 with 4WD

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

    Negative battery cable
     
    Engine/transaxle assembly
     
    Starter
     
    Stiffener plate, by removing the 3 bolts
     
    Rear endplate, by removing the 4 bolts
     
    6 torque converter clutch mounting bolts
     
    Connectors and wiring harness, from the transaxle
     
    Center stiffener plate, by removing the 4 bolts
     

  4.  
  5. Remove the transaxle with the transfer assembly, as follows:

    2 bolts
     
    5 transaxle mounting bolts
     
    Transaxle from the engine
     

  6.  

To install:

  1. Install the transaxle. Tighten the 14mm head bolts to 47 ft. lbs. (64 Nm) and the 12mm head bolts to 34 ft. lbs. (46 Nm).
  2.  
  3. Install or connect the following:

    Tighten both bolts to 27 ft. lbs. (37 Nm).
     
    Center stiffener plate. Tighten the 4 bolts to 27 ft. lbs. (37 Nm).
     
    Connectors and the wiring harness to the transaxle
     
    Torque converter clutch mounting bolts. Tighten each bolt to 20 ft. lbs. (27 Nm).
     

  4.  


NOTE
Coat the threads of the bolts with an approved locking compound.



Rear endplate. Tighten the 4 bolts to 80 inch lbs. (9.0 Nm).
 
Stiffener plate. Tighten the 3 bolts to 27 ft. lbs. (37 Nm).
 
Starter. Tighten both bolts to 29 ft. lbs. (39 Nm).
 
Engine/transaxle assembly
 
Negative battery cable
 



Click image to see an enlarged view

Fig. Automatic transaxle and related parts-2004 with 4WD

  1. Remove the engine and transaxle as a unit. See -Engine Removal and Installation-, above.
  2.  
  3. Remove the starter.
  4.  
  5. Remove the engine-to-transaxle wiring.
  6.  
  7. Remove the stiffener plate.
  8.  
  9. Remove the access plate and remove the 6 torque converter bolts.
  10.  
  11. Remove lower bolts and separate the transaxle from the engine.
  12.  
  13. Installation is the reverse of removal. Observe the following torques:

    Transaxle-to-engine lower bolts: 32 ft. lbs. (44 Nm)
     
    Stiffener plate: 25 ft. lbs. (34 Nm)
     
    Starter: 27 ft. lbs. (37 Nm)
     
    Torque converter bolts: 30 ft. lbs. (41 Nm). Install the green colored bolt first.
     

  14.  



Click image to see an enlarged view

Fig. Automatic transaxle exploded view-4WD RAV4

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

    Negative battery cable
     
    Engine/transaxle assembly
     
    Starter
     
    Stiffener plate, by removing the 3 bolts
     
    Rear endplate, by removing the 4 bolts
     
    6 torque converter clutch mounting bolts
     
    Connectors and wiring harness, from the transaxle
     
    Center stiffener plate, by removing the 4 bolts
     

  4.  
  5. Remove the transaxle with the transfer assembly, as follows:

    2 bolts
     
    5 transaxle mounting bolts
     
    Transaxle from the engine
     

  6.  

To install:

  1. Install the transaxle. Tighten the 14mm head bolts to 47 ft. lbs. (64 Nm) and the 12mm head bolts to 34 ft. lbs. (46 Nm).
  2.  
  3. Install or connect the following:
    NOTE
    Coat the threads of the bolts with an approved locking compound.



    Tighten both bolts to 27 ft. lbs. (37 Nm).
     
    Center stiffener plate. Tighten the 4 bolts to 27 ft. lbs. (37 Nm).
     
    Connectors and the wiring harness to the transaxle
     
    Torque converter clutch mounting bolts. Tighten each bolt to 20 ft. lbs. (27 Nm).
     



    Rear endplate. Tighten the 4 bolts to 80 inch lbs. (9.0 Nm).
     
    Stiffener plate. Tighten the 3 bolts to 27 ft. lbs. (37 Nm).
     
    Starter. Tighten both bolts to 29 ft. lbs. (39 Nm).
     
    Engine/transaxle assembly
     
    Negative battery cable
     

  4.  



Click image to see an enlarged view

Fig. Automatic transaxle and related components-2000-2003 4WD

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

    Negative battery cable
     
    Engine/transaxle assembly
     
    Starter
     
    Stiffener plate, by removing the 3 bolts
     
    Rear endplate, by removing the 4 bolts
     
    6 torque converter clutch mounting bolts
     
    Connectors and wiring harness, from the transaxle
     
    Center stiffener plate, by removing the 4 bolts
     

  4.  
  5. Remove the transaxle with the transfer assembly, as follows:

    2 bolts
     
    5 transaxle mounting bolts
     
    Transaxle from the engine
     

  6.  

To install:

  1. Install the transaxle. Tighten the 14mm head bolts to 47 ft. lbs. (64 Nm) and the 12mm head bolts to 34 ft. lbs. (46 Nm).
  2.  
  3. Install or connect the following:
    NOTE
    Coat the threads of the bolts with an approved locking compound.



    Tighten both bolts to 27 ft. lbs. (37 Nm).
     
    Center stiffener plate. Tighten the 4 bolts to 27 ft. lbs. (37 Nm).
     
    Connectors and the wiring harness to the transaxle
     
    Torque converter clutch mounting bolts. Tighten each bolt to 20 ft. lbs. (27 Nm).
     



    Rear endplate. Tighten the 4 bolts to 80 inch lbs. (9.0 Nm).
     
    Stiffener plate. Tighten the 3 bolts to 27 ft. lbs. (37 Nm).
     
    Starter. Tighten both bolts to 29 ft. lbs. (39 Nm).
     
    Engine/transaxle assembly
     
    Negative battery cable
     

  4.  



Click image to see an enlarged view

Fig. Automatic transaxle and related components-2004-2005 4WD

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the engine and transaxle as a unit. Position it in a suitable holding fixture.
  4.  
  5. Remove the starter.
  6.  
  7. Remove the engine-to-transaxle wiring.
  8.  
  9. Remove the stiffener plate.
  10.  
  11. Remove the access plate and remove the 6 torque converter bolts.
  12.  
  13. Remove lower bolts and separate the transaxle from the engine.
  14.  

To install:

  1. Installation is the reverse of removal. Observe the following torques:

    Transaxle-to-engine lower bolts: 32 ft. lbs. (44 Nm)
     
    Stiffener plate: 25 ft. lbs. (34 Nm)
     
    Starter: 27 ft. lbs. (37 Nm)
     
    Torque converter bolts: 30 ft. lbs. (41 Nm). Install the green colored bolt first.
     

  2.  

 
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