REMOVAL & INSTALLATION
| WARNING | Vehicle is equipped with Supplemental Inflatable Restraint (SIR) system. When servicing vehicle, use care to avoid accidental air bag deployment. SIR system-related components are located in various locations throughout interior and exterior of vehicle, depending on application. Do not use electrical test equipment on or near these circuits. If necessary, deactivate SIR system before servicing components. See AIR BAG DEACTIVATION PROCEDURES article in GENERAL INFORMATION. |
| CAUTION | When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery. |
Remove the front bumper cover. See FRONT BUMPER COVER . Disconnect the cooler tubes. See OIL COOLER TUBES . Remove the bolts and the auxiliary transaxle fluid cooler. To install, reverse the removal procedure. Fill the transaxle to the specified level. Fill the transaxle with appropriate fluid to proper level and check for correct transaxle operation. See LUBRICATION .
Removal
- Disconnect negative battery cable. Disconnect positive battery cable and remove battery from vehicle. Position power distribution box aside, and remove battery tray. Remove air cleaner assembly.
- Disconnect the breather tube and Mass Air Flow (MAF) sensor. Remove the intake tube and air cleaner cover. Disconnect the transaxle wiring harness connector, and Transmission Range (TR) sensor harness connector. (Scheme 1)
- Disconnect the shift cable. Remove the shift cable and bracket, and position out of the way. (Scheme 2) Remove the vent tube hose. Raise and support the vehicle. Remove the left front wheel and remove the splash shield.
- Remove the main control cover bolts and remove cover. (Scheme 3) Remove the main control cover gasket. Remove the main control valve body bolts. (Scheme 4)
- Lift the main control valve body while disconnecting the manual valve link. (Scheme 5) Depress the retaining tabs and push the solenoid valve body harness connector down through the transaxle case. (Scheme 6)
- Make sure the manual valve control lever does not fall out of the main control valve body while removing the main control valve body from the vehicle. (Scheme 7)
Scheme 1
Scheme 2
Scheme 3
Scheme 4
Scheme 5
Scheme 6
Scheme 7
Installation
- Push the solenoid valve body harness connector up through the transaxle case. Install NEW O-ring on valve body harness connector receptacle. Install receptacle in transaxle case. (Scheme 6)
- Insert "Z" link into end of manual valve. (Scheme 5) Place valve body in position on transaxle case and install 12 valve body bolts. Tighten bolts in sequence to specification. (Scheme 4) See «TORQUE SPECIFICATIONS»(ref-149586-S34766213352002101500000). Loosen nut on ball stud of manual valve detent lever actuating rod assembly. (Scheme 9)
- Remove manual detent lever bolt and lever assembly. Using Shifter Shaft Alignment Tool (T94P-77000-H), move manual control lever shaft to Drive position. (Scheme 8) Install pin to hold the shifter shaft alignment tool in position. Move manual valve detent lever assembly to Drive position.
- Snug nut on ball stud. Remove shifter pin. Rotate shifter shaft alignment tool until socket can be installed on nut. Tighten nut on ball stud to specification. See «TORQUE SPECIFICATIONS»(ref-149586-S34766213352002101500000). Rotate lever back to Drive position and recheck adjustment. Remove pin and alignment tool.
- Install manual detent lever assembly. Tighten bolt to specification. Install main control cover (side cover) with NEW gasket. Tighten bolts in sequence to specification. (Scheme 3) See «TORQUE SPECIFICATIONS»(ref-149586-S34766213352002101500000).
- To complete installation, reverse removal procedures. Install transaxle drain plug and tighten to specification. (Scheme 3) See «TORQUE SPECIFICATIONS»(ref-149586-S34766213352002101500000). Install splash shield. Lower the vehicle.
- Connect the transaxle harness connector, and the TR sensor connector. (Scheme 1) Install the intake tube and air cleaner cover. Connect the breather tube and MAF sensor.
- Install battery tray, battery and connect the battery cables. Fill the transaxle with appropriate fluid to proper level and check for correct transaxle operation. See «LUBRICATION»(ref-149586-S00583741212002101500000).
Scheme 8
Scheme 9
Remove the 6 pin-type retainers (3 on each side). Remove the 4 front bumper cover bolts (2 on each side). Remove the 2 front bumper cover-to-front fender pin-type retainers (one on each side). If equipped, disconnect the fog lamp harness connectors. Remove the lower front bumper cover bolts. Remove the pin-type retainers. Remove the 2 upper bolts (one on each side) and the front bumper cover.
To install, reverse the removal procedure. When installing, be sure to position the front bumper cover into the bumper slides. Transfer components as necessary.
- Assemble the Servo Cover Remover/Installer (307-295). (Scheme 10) Remove the splash shield. Remove the transaxle oil cooler line bracket and bolt, and position the bracket out of the way. (Scheme 11) Using the servo cover remover/installer (1), compress the servo (2) and remove the retaining ring (3). (Scheme 12)
- Remove the servo cover remover/installer (1). Remove the servo cover assembly. Remove the intermediate and overdrive servo piston and return spring. Wipe the servo piston and the servo cover cap with a lint-free cloth.
- Inspect the servo piston for cracks on its pressure surfaces and in the sealing area. Look for damage near the point where the servo piston is attached to the servo rod. Squeeze the servo piston lip for flexibility. If the lip feels brittle, install a new piston. Inspect the servo retainer spring for cracks, breaks or deformation.
Scheme 10
Scheme 11
Scheme 12
| WARNING | Servo return spring force is very high. Failure to follow these instructions may result in personal injury. |
| CAUTION | Do not use a screwdriver to install the retaining ring or damage to the case may occur. Use only snap ring pliers to install the retaining ring. |
Note. If the servo cover will not seat deep enough in the bore to install the servo cover retaining ring, use a blunt punch or small hammer and gently tap the cover around the outer edge until the servo cover retaining ring can be installed.
- Install the servo cover remover/installer. (Scheme 12) Tighten the bolt on the servo cover remover/installer. Install the servo cover retaining ring. If the case is stamped "WG", install a wide-groove snap ring, or the servo will be damaged.
- Loosen the servo cover remover/installer bolt. When the spring tension is released, remove the servo cover remover/installer. Install the transmission fluid cooler line. (Scheme 11) Install the splash shield. Lower the vehicle.
- Start the vehicle. Place gearshift lever in each gear and allow to engage. Check for leaks. Fill the transaxle with appropriate fluid to proper level and check for correct transaxle operation. See «LUBRICATION»(ref-149586-S00583741212002101500000).
- Remove the front bumper cover. See «FRONT BUMPER COVER»(ref-149586-S34893976592002101600000). Disconnect the front oil cooler tube. (Scheme 13) Disconnect and remove the front cooler tube. (Scheme 14)
- Disconnect the rear cooler tube. (Scheme 15) Remove the rear transaxle cooler tube bracket bolt and the cooler tube. (Scheme 11)
- Lower the vehicle. Disconnect and remove the integral-to-auxiliary cooler tube. (Scheme 16) To install, reverse the removal procedure.
Scheme 13
Scheme 14
Scheme 15
Scheme 16
- Remove the driveshaft. Using the Drive Pinion Flange Holding Fixture (205-126) and a torque wrench, remove the pinion nut and record torque. (Scheme 17) Mark the companion flange relative to the pinion spline. Using the Steering Wheel Remover (211-014), remove the companion flange. (Scheme 18)
- Install the companion flange to engage the spline as previously marked. Using the special tool, install the companion flange. Install the pinion nut and tighten to the rotational torque previously recorded when removing the pinion nut. Install the driveshaft.
Scheme 17
Scheme 18
Remove the power take off unit rear output shaft flange. See POWER TAKE OFF UNIT REAR OUTPUT SHAFT FLANGE . Remove the companion flange dust shield. Using the special tool, install the companion flange dust shield.
Using the special tool (308-432), install the companion flange dust shield. (Scheme 19) Install the power take off unit rear output shaft flange. See POWER TAKE OFF UNIT REAR OUTPUT SHAFT FLANGE. Fill the transfer case with appropriate fluid to proper level and check for correct operation. See LUBRICATION.
Scheme 19
- Place the vehicle in Neutral. Disconnect the battery cables. Remove the battery and tray. Disconnect the breather tube and Mass Air Flow (MAF) sensor. see scheme 11 Remove the intake tube and air cleaner cover. (Scheme 20)
- Remove the air cleaner assembly. If necessary, remove the thermostat housing. see scheme 12 Remove the Transmission Range (TR) sensor.
- Disconnect the TR sensor harness connector (1). see scheme 13 Remove the bolts (2). Remove the TR sensor (3). Ensure the transaxle is in the Neutral position. Install the TR sensor and loosely install the bolts.
- Using the TR sensor alignment tool (307-351), align the TR sensor and tighten the bolts. see scheme 14 Connect the harness connector. Install the thermostat housing. Install the air cleaner assembly. Install the intake tube and air cleaner cover.
- Connect the breather tube and mass air flow (MAF) sensor. Before installing the battery tray check the vent tube hose for any obstructions, kinks, or incorrect routing position.
- Install the battery and tray. Connect the battery cables. Check the correct operation with parking brake control engaged. The engine should start only in Park or Neutral. Back-up lights should be active only in the Reverse position.
Scheme 20
Raise and support vehicle. Remove left front fender splash shield. Disconnect Turbine Shaft Speed (TSS) sensor harness connector. (Scheme 21) Unbolt and remove TSS sensor. To install, reverse removal procedure. Replace O-ring as needed. Tighten bolt to specification. See TORQUE SPECIFICATIONS.
Scheme 21
Disconnect negative battery cable. Raise and support vehicle. Disconnect Vehicle Speed Sensor (VSS) harness connector. Disconnect speedometer cable. Unbolt and remove VSS. (Scheme 22) To install, reverse removal procedure. Replace O-ring as needed. Tighten bolt to specification. See TORQUE SPECIFICATIONS.
