Automatic Transmission Servicing: Removal & Installation Pontiac Aztek I

REMOVAL & INSTALLATION

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.

Note. Some removal and installation procedures may require the removal of engine and/or transaxle mounts. For procedures related to these components, see appropriate REMOVAL & INSTALLATION article.

Removal

1. Raise and support the vehicle. Remove the oil pan. Remove the filter. See «DRAINING & REFILLING»(ref-153939-S24508323162003042900000) under LUBRICATION.
2. Remove the accumulator bolts. Remove the manual 2-1 band servo cover bolts. (Scheme 193)
3. Use a large flat-blade tool in order to gently pry the lube oil pipe retainer from the case. (Scheme 194) Remove the lube oil pipe from the front differential carrier internal gear lube hole. (Scheme 195)
4. Remove the accumulator. Remove the manual 2-1 band servo cover. Remove the manual 2-1 band servo. Remove the manual 2-1 band servo cover gasket. (Scheme 196)
5. To disassemble, inspect and service the accumulator and 2-1 manual servo, see appropriate OVERHAUL article.

Scheme 193

Scheme 194

Scheme 195

Scheme 196

Installation

1. Install the manual 2-1 band servo cover gasket into the case. Lubricate the manual 2-1 band servo cover gasket with automatic transmission fluid. Install the manual 2-1 band servo. (Scheme 196) Install the manual 2-1 band servo cover. (Scheme 195)
2. Install the manual 2-1 band servo cover bolts. (Scheme 193) Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-153939-S13545750352003042900000). Install the accumulator. Install the lube oil pipe into the case at the lube hole for the front differential carrier internal gear.
3. Use a flat-blade tool in order to lock the lube oil pipe retainer into the case. Tighten the accumulator attaching bolts to specification. See «TORQUE SPECIFICATIONS»(ref-153939-S13545750352003042900000).
4. If removed, install the new filter seal. Install the filter. Install the oil pan. See «DRAINING & REFILLING»(ref-153939-S24508323162003042900000) under LUBRICATION. Lower the vehicle.
5. Fill transaxle with appropriate fluid to proper level. See «LUBRICATION»(ref-153939-S42043472612003042900000).

1. Raise and support the vehicle. Disconnect the right drive axle from the transaxle. See appropriate AXLE SHAFTS article in DRIVELINE/AXLES. Remove the transaxle brace. See «TRANSAXLE BRACE»(ref-153939-S42513718942003042900000).
2. Remove the vehicle speed sensor. See «VEHICLE SPEED SENSOR»(ref-153939-S31113209592003042900000). Remove the case extension housing bolts. (Scheme 197)
3. Remove the case extension housing with axle seal and the "O" ring. Inspect the case extension for the following conditions: Damaged or porous sealing surface for the case extension seal. Damaged or porous sealing surface for the vehicle speed sensor. Damaged or porous sealing surface for the right drive axle oil seal. Damaged or porous sealing surface for the case extension housing. Damaged or worn differential carrier bushing or output shaft bearing. Damaged bolt holes. Inspect the drive axle seal and replace if necessary.

Scheme 197

1. Perform differential carrier end play inspection. See appropriate OVERHAUL article. If removed, install the drive axle seal. Install the case extension housing with the axle seal and the "O" ring. (Scheme 197)
2. Install the case extension housing bolts. Tighten the case extension housing bolts to specification. See «TORQUE SPECIFICATIONS»(ref-153939-S13545750352003042900000). Install the vehicle speed sensor. See «VEHICLE SPEED SENSOR»(ref-153939-S31113209592003042900000).
3. Install the transaxle brace. See «TRANSAXLE BRACE»(ref-153939-S42513718942003042900000). Connect the right drive axle to the transaxle. See appropriate AXLE SHAFTS article in DRIVELINE/AXLES. Lower the vehicle.
4. Fill transaxle with appropriate fluid to proper level. See «LUBRICATION»(ref-153939-S42043472612003042900000). Inspect for completion of the repairs. Inspect for fluid leaks. WARNING: DO NOT overfill the transaxle. Overfilling of the transaxle causes foaming, loss of fluid, shift complaints, and possible damage to the transaxle.

1. Disconnect the negative battery cable. Remove the throttle body air inlet duct. Install the engine support fixture. See appropriate REMOVAL & INSTALLATION article. Remove the engine mount struts. Raise and support the vehicle.
2. Remove the left front tire and wheel. Remove the left engine splash shield. Remove the stabilizer shaft links from the lower control arms. See appropriate FRONT article in SUSPENSION. Remove the left tie rod end from the steering knuckle. See appropriate FRONT article in SUSPENSION.
3. Remove the wheel speed sensor harness connector. Remove the left lower ball joint from the left steering knuckle. See appropriate FRONT article in SUSPENSION. Disconnect the left drive axle from the transaxle. See appropriate AXLE SHAFTS article in DRIVELINE/AXLES. Reposition and secure the drive axle.
4. Remove the intermediate shaft from the steering gear. See appropriate POWER RACK & PINION article in STEERING. Disconnect the catalytic converter pipe from the right (rear) exhaust manifold. Support the right side of the frame with a utility stand. CAUTION: Failure to disconnect the intermediate shaft from the rack and pinion stub shaft can result in damage to the steering gear and/or damage to the intermediate shaft. This damage may cause loss of steering control which could result in personal injury.
5. Support the left side of the frame with a utility stand. Remove the transaxle mount and bracket. See «TRANSAXLE MOUNT & BRACKET»(ref-153939-S29166516012003042900000).
6. Loosen the engine mount lower nuts. See appropriate REMOVAL & INSTALLATION article. Loosen the right side frame bolts. Remove the left side frame bolts. Use the utility stand in order to lower left side of the frame.
7. Position the drain pan under the transaxle. Remove the wiring harness connectors. Remove the case side cover bolts. (Scheme 198) Remove the case side cover pan (53). (Scheme 199) Remove the case side cover gasket (54). Remove the case side cover inner gasket (59).
8. Inspect the case side cover (53) for the following conditions: Damaged or porous gasket sealing surfaces. Damaged or porous casting surfaces. Damaged or stripped bolt holes.
9. Inspect the case side cover gasket (54) and case side cover inner gasket (59) for damage. The gaskets are reusable if they are NOT damaged. Clean the case side cover. Clean the case side cover gasket surfaces.

Scheme 198

Scheme 199

1. Apply Transjel(tm) Lubricant (J-36850) to the case side cover "O" ring (59). (Scheme 199) Install the "O" ring (59) to the case side cover. Install the case side cover gasket (54).
2. Install the case side cover (53). Install the case side cover bolts. (Scheme 198) Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-153939-S13545750352003042900000). Remove the drain pan from under the transaxle.
3. Install the wiring harness connectors. Use the utility stand in order to raise the left side of the frame. Install the NEW left side frame bolts. Install the NEW right side frame bolts. Install the engine mount lower nuts.
4. Install the transaxle mount and bracket. See «TRANSAXLE MOUNT & BRACKET»(ref-153939-S29166516012003042900000). Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-153939-S13545750352003042900000). Lower the vehicle.
5. Remove the utility stand support from the right side of the frame. Remove the utility stand support from the left side of the frame. Connect the catalytic converter pipe to the right (rear) exhaust manifold.
6. Install the intermediate shaft to the steering gear. See appropriate POWER RACK & PINION article in STEERING. CAUTION: When installing the intermediate shaft make sure that the shaft is seated prior to pinch bolt installation. If the pinch bolt is inserted into the coupling before shaft installation, the two mating shafts may disengage. Disengagement of the two mating shafts will cause loss of steering control which could result in personal injury.
7. Install the left drive axle to the transaxle. See appropriate AXLE SHAFTS article in DRIVELINE/AXLES. Install the left lower ball joint to the left steering knuckle. See appropriate FRONT article in SUSPENSION.
8. Install the wheel speed sensor harness connector. Install the left tie rod end to the steering knuckle. Install the stabilizer shaft links to the lower control arms. See appropriate FRONT article in SUSPENSION.
9. Install the left engine splash shield. Install the left front tire and wheel. Lower the vehicle. Install the engine mount struts. See appropriate REMOVAL & INSTALLATION article.
10. Remove the engine support fixture. Remove the throttle body air inlet duct. Connect the negative battery cable.
11. Fill transaxle with appropriate fluid to proper level. See «LUBRICATION»(ref-153939-S42043472612003042900000). Inspect for fluid leaks. Inspect for proper completion of the repairs. Inspect for fluid leaks. CAUTION: DO NOT overfill the transaxle. Overfilling will result in foaming, loss of fluid, and possible damage to the transaxle.

1. Remove the case side cover. See «CASE SIDE COVER»(ref-153939-S11113648082003042900000). Remove the oil pump. See «OIL PUMP»(ref-153939-S14620624772003042900000). Remove the valve body bolts (374-381 and 384). (Scheme 200)
2. Remove the valve body (300) while keeping the spacer plate (370) with the transaxle. (Scheme 201) Remove the ball check valves (372 and 373) from the valve body. (Scheme 202) CAUTION: Carefully remove the valve body or the ball check valves will fall out.
3. Remove the spacer plate (370) and gasket. (Scheme 203) Remove the ball check valves (372) from the case cover. (Scheme 204) Inspect each check valve seat in the spacer plate (370) for excessive peening. (Scheme 205)
4. Place a ball check valve (372) on each seat and use a flashlight in order to look for visible light between the valve and the seat. Inspect all components removed from the transaxle. See appropriate OVERHAUL article.

Scheme 200

Scheme 201

Scheme 202

Scheme 203

Scheme 204

Scheme 205

1. Install the ball check valves (372) into the case cover. (Scheme 204) Use the Transjel(tm) lubricant to retain the ball check valves in their proper locations. Install the gasket and the spacer plate (370). (Scheme 203)
2. Install the ball check valves (372 and 373) into the valve body. (Scheme 202) Use the Transjel(tm) lubricant to retain the ball check valves in their proper locations.
3. Install the gasket (371) and the valve body (300). (Scheme 201) Install the valve body bolts (374-381 and 384). (Scheme 200) Tighten the valve body bolts to specification. See «TORQUE SPECIFICATIONS»(ref-153939-S13545750352003042900000). CAUTION: DO NOT use impact type tools on the valve body or on the oil pump.
4. DO NOT use impact type tools on the valve body or on the oil pump. Install the oil pump. See «OIL PUMP»(ref-153939-S14620624772003042900000). Install the case side cover. See «CASE SIDE COVER»(ref-153939-S11113648082003042900000).

Remove the oil indicator from the filler tube. Remove the air cleaner assembly. Remove the retaining nut from the EGR at the top of the filler tube. (Scheme 206) Remove the lower retaining bolt at the base of the filler tube. Remove the fluid filler tube.

Scheme 206

Install the fluid filler tube seal in the transaxle. (Scheme 207) Position the fluid filler tube into the transaxle. Install the fluid filler tube bracket bolt through the fluid filler tube bracket. (Scheme 206) Tighten the fluid filler tube bracket bolt to specification. See TORQUE SPECIFICATIONS. At the top of the filler tube, install the retaining nut to the filler tube the EGR at the top of the filler tube. Install the air cleaner assembly. Fill transaxle with appropriate fluid to proper level. See LUBRICATION. Inspect for fluid leaks.

Scheme 207

Note. This procedure is for FWD vehicles ONLY. The forward servo for AWD vehicles is serviced with the transfer case removed, which MUST be serviced with the transaxle removed from the vehicle. For transfer case replacement, see appropriate REMOVAL & INSTALLATION article.

1. Install the engine support fixture. See appropriate REMOVAL & INSTALLATION article. Raise and support the vehicle. Remove the stabilizer shaft. Remove the power steering gear heat shield. Remove the power steering gear from the frame. See appropriate POWER RACK & PINION article in STEERING.
2. Use a strap in order to secure the power steering gear to the exhaust manifold. See appropriate POWER RACK & PINION article in STEERING. Remove the power steering cooler line clamps from the frame. Use wire in order to secure the power steering cooler line to an engine component.
3. Remove the engine mount nuts. See appropriate REMOVAL & INSTALLATION article. Remove the transaxle mount nuts. Use a utility stand in order to support the frame front. Use a utility stand in order to support the frame rear.
4. Remove the frame bolts. Use the utility stand in order to lower the frame rear for access to the forward servo cover. Position a drain pan under the forward servo cover.
5. Remove the forward band servo cover bolts. Remove the forward servo cover. Remove the forward servo cover "O" ring. Remove the servo piston assembly. Remove the servo spring. (Scheme 208)

Scheme 208

1. Install the servo spring. Install the servo piston assembly. Install the forward servo cover "O" ring. Install the forward servo cover. (Scheme 208)
2. Install the 3 forward servo cover attaching bolts. Tighten the forward servo cover attaching bolts to specification. See «TORQUE SPECIFICATIONS»(ref-153939-S13545750352003042900000).
3. Remove the drain pan from under the forward servo cover. Use the utility stand in order to raise the frame rear. Install the NEW frame bolts. Install the powertrain mounts to the frame. Install the transaxle mount nuts. Install the engine mount nuts. See appropriate REMOVAL & INSTALLATION article.
4. Install the power steering gear to the frame. See appropriate POWER RACK & PINION article in STEERING. Install the power steering gear heat shield. Install the stabilizer shaft.
5. Lower the vehicle. Remove the engine support fixture. Fill transaxle with appropriate fluid to proper level. See «LUBRICATION»(ref-153939-S42043472612003042900000).

1. Remove the transaxle assembly. See appropriate OVERHAUL article.
2. Remove the transfer case from the transmission. See appropriate OVERHAUL article.
3. Remove the forward band servo cover bolts. (Scheme 208)
4. Remove the forward servo cover.
5. Remove the forward servo cover "O" ring.
6. Remove the servo piston assembly.
7. Remove the servo spring.

1. Install the servo spring. (Scheme 208)
2. Install the servo piston assembly.
3. Install the forward servo cover "O" ring.
4. Install the forward servo cover.
5. Install the transfer case. See appropriate OVERHAUL article.
6. Install the transaxle. See appropriate OVERHAUL article.

1. Remove the case side cover. See «CASE SIDE COVER»(ref-153939-S11113648082003042900000).
2. Disconnect the transaxle wiring harness. Remove the input speed sensor clip (441) from the case cover. (Scheme 209)
3. Remove the input speed sensor (440) from the case cover. Inspect the input speed sensor (440) for the following conditions: Damaged or missing magnet. Damaged housing. Bent or missing electrical terminals. Damaged speed sensor clip (441).

Scheme 209

1. Install the input speed sensor (440) into the case cover. (Scheme 209)
2. Install the input speed sensor clip (441) into the case cover.
3. Connect the transaxle wiring harness.
4. Install the case side cover. See «CASE SIDE COVER»(ref-153939-S11113648082003042900000).

1. Disconnect the transaxle oil cooler (TOC) outlet hose from top side of the radiator as follows: Disengage the plastic cap from the quick connect fitting. Pull the plastic cap back along the pipe. (Scheme 210) Hold one leg of the retaining clip. Using a small pick-type tool or bent screwdriver, gently disengage the other end of the retaining clip from the quick connect fitting. Rotate the retaining clip out of the quick connect fitting. Remove the retaining clip completely. Disconnect the cooler line from the quick connect fitting.
2. Raise and support the vehicle.
3. Remove the TOC hose retainer bolt. (Scheme 211)
4. Position a drain pan below the oil cooler hoses.
5. Disconnect the TOC outlet hose from the transaxle. (Scheme 212) Perform steps A - E.
6. Disconnect the TOC inlet hose from the transaxle. (Scheme 212) Perform steps A - E.
7. Disconnect the TOC inlet hose from the radiator. (Scheme 213) Perform steps A - E.
8. Disconnect the TOC hoses from the radiator support retainer.
9. Remove the TOC hoses from the vehicle.

Scheme 210

Scheme 211

Scheme 212

Scheme 213

Note. Allow sufficient clearance around the transaxle oil cooler pipes and around the hoses to prevent damage or wear which may cause fluid loss.

1. Install the TOC hoses to the vehicle. (Scheme 213)
2. Connect the TOC hoses to the radiator support retainer.
3. Connect the TOC inlet hose to the radiator as follows: Install the retaining clip into the quick connect fitting by using your thumb and forefinger. Insert the retaining clip into one of the three fitting recesses. Ensure that the retaining clip is engaged in all 3 slots. (Scheme 214) With one end of the retaining clip engaged in the connector fitting slot, use your thumb in order to rotate the retaining clip around the connector fitting, until the retaining clip snaps into place. Ensure that the 3 retaining clip ears are seen from inside the fitting and that the retaining clip moves freely in the fitting slots. NOTE: A distinct snap should be heard when assembling the cooler line to the quick connect fitting. To ensure the cooler line is fully inserted into the quick connect fitting, give the cooler line a gentle pull. DO NOT use the plastic cap in order to install the cooler line into the fitting. Install the cooler line straight into the quick connect fitting until a click is either heard or felt. Pull back gently on the cooler line in order to ensure that the cooler line is installed in the quick connect fitting. NOTE: Ensure the cooler line being installed has a plastic cap on the end that connects to the quick connect fitting. If no plastic cap exists, or the plastic cap is damaged, obtain a new cap. Install the cap on to the cooler line prior to cooler line installation. DO NOT manually depress the retaining clip when installing the plastic cap. Snap the plastic cap onto the quick connect fitting. Ensure that the plastic cap is fully seated against the fitting. Ensure that no gap is present between the cap and the fitting. Run the engine. Inspect the transmission oil cooling system for leaks. Inspect the fluid levels. Add fluid if necessary.
4. Connect the TOC inlet hose to the transaxle. (Scheme 212) Perform steps A - J.
5. Connect the TOC outlet hose to the transaxle. (Scheme 212) Perform steps A - J.
6. Install the TOC hose retainer and the bolt. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-153939-S13545750352003042900000).
7. Lower the vehicle.
8. Connect the TOC outlet hose to the top side of the radiator. Perform steps A - J.
9. Adjust the fluid level. See «LUBRICATION»(ref-153939-S42043472612003042900000).

Scheme 214

Remove the throttle body air inlet duct. Remove the pressure test hole plug (38). (Scheme 215)

Scheme 215

Apply sealant to the pressure test hole plug. Install the pressure test hole plug (38). (Scheme 215) Tighten the line pressure pipe plug to specification. See TORQUE SPECIFICATIONS. Install the throttle body air inlet duct.

Note. DO NOT remove the 3 bolts which hold the pump together.

Remove the case side cover. See CASE SIDE COVER. Remove the oil pump bolts (205, 206 and 207). (Scheme 216) Remove the oil pump from the valve body. (Scheme 217) Clean and inspect the oil pump. See appropriate OVERHAUL article.

Scheme 216

Scheme 217

Install the oil pump to the valve body. (Scheme 217) Install the oil pump bolts (205, 206 and 207). (Scheme 216) Tighten the oil pump bolts to specification. See TORQUE SPECIFICATIONS. Install the case side cover. See CASE SIDE COVER.

1. Disconnect the left and right drive axles from the transaxle. See appropriate AXLE SHAFTS article in DRIVELINE/AXLES. Remove the case extension housing. See «CASE EXTENSION HOUSING»(ref-153939-S28214241202003042900000). Rotate the differential carrier until the end of the output shaft can be seen and the differential pinion shaft is in a horizontal position. (Scheme 218)
2. Place the Axle Removal Wedge (J-42562) between the end of the output shaft and the differential pinion shaft. Using a hammer, hit the end of the axle removal wedge in order to compress the output shaft compression ring and push the output shaft through the differential side gear.
3. Remove the differential carrier. Using snap ring pliers remove the compression ring from the output shaft. (Scheme 219) Be careful not to damage the bearing on the output shaft. (Scheme 221)
4. Remove the output shaft through the left wheel opening. (Scheme 220) Inspect the output shaft and the bearing for the following: A cracked or deformed bearing cage. Damaged bushing journals. Stripped splines. A damaged retainer ring groove.

Scheme 218

Scheme 219

Scheme 220

Scheme 221

1. Install the drive axle retaining ring and the output shaft differential inboard snap ring onto the output shaft. (Scheme 221) Install the fourth clutch bearing onto the output shaft. (Scheme 221)
2. Hold the front differential carrier in place and carefully install the output shaft into the transaxle through the left wheel opening. (Scheme 220)
3. Extend the output shaft through the differential side gear. Install the case extension housing. See «CASE EXTENSION HOUSING»(ref-153939-S28214241202003042900000).

Remove the case side cover. See CASE SIDE COVER. Disconnect the transaxle wiring harness. Remove the pressure control solenoid (322). (Scheme 222)

Scheme 222

Install the pressure control solenoid (322). (Scheme 222) Connect the transaxle wiring harness. Install the case side cover. See CASE SIDE COVER.

1. Remove the throttle body air inlet duct. Use a large flat-blade tool in order to depress the reverse servo cover. (Scheme 223)
2. Use a small flat-blade tool in order to remove the retaining ring. (Scheme 224) Use a small flat-blade tool in order to pull the "O" ring seal out through the slot in the case. Use side cutting pliers in order to cut the servo cover "O" ring seal.
3. Depress the reverse servo cover, grasp one end of the cut seal and pull the seal out of the servo cover.
4. Use a large flat-blade tool in order to depress the reverse servo cover, grasp one end of the cut seal and pull the seal out of the servo cover.
5. Remove the reverse servo cover. (Scheme 224) Remove the servo assembly. Remove the servo spring.

Scheme 223

Scheme 224

1. Raise the driver (left) side of the vehicle until it is higher than the passenger (right) differential side. This ensures the reverse band is in the proper location. NOTE: Failure to perform the following step may result in no reverse gear due to the servo pin not aligning with the reverse band.
2. Install the servo spring. (Scheme 224) Install the servo assembly.
3. Install the reverse servo cover with new "O" ring seal. (Scheme 223) Install the snap ring. Install the throttle body air inlet duct.

1. Remove the throttle body air inlet duct. Use a flat-blade tool in order to remove the retaining clip from the shift cable at the shift cable bracket. (Scheme 225)
2. Use a large flat-blade tool in order to remove the shift cable from the manual control lever. (Scheme 226) Use pliers in order to depress the cable retainers.
3. Remove the shift cable from the shift cable bracket. Remove the knee bolster.
4. If the vehicle is equipped with a console shift, perform the following steps: Remove the console trim plate. See appropriate SHIFT INTERLOCK SYSTEMS article. Remove the transaxle shift cable from the floor shift control. (Scheme 227)
5. If the vehicle is equipped with a column shift, perform the following steps: Remove the retaining clip from the shift cable at steering column. (Scheme 228) Use a flat-blade tool in order to remove the automatic transaxle range selector cable from the column control lever. Remove the shift cable from the column control lever.
6. Remove the shift cable through the hole in the cowl. (Scheme 229)

Scheme 225

Scheme 226

Scheme 227

Scheme 228

Scheme 229

1. Properly route the shift cable through the engine compartment. (Scheme 230) Install the shift cable through the cowl. (Scheme 229)
2. If the vehicle is equipped with a column shift, perform the following steps: Install the shift cable to the steering column bracket. Install the retaining clip to the shift cable. (Scheme 228) Install the shift cable to the column control lever.
3. If the vehicle is equipped with a console shift, perform the following steps: Install the transaxle shift cable to the floor shift control. (Scheme 227) Install the console trim plate. See appropriate SHIFT INTERLOCK SYSTEMS article.
4. Install the knee bolster. Install the shift cable to the shift cable bracket. Install the shift cable to the PNP switch lever. Install the retaining clip to the shift cable. (Scheme 226)
5. Adjust the shift cable. See «SHIFT CABLE»(ref-153939-S25197173392003042900000) under ADJUSTMENTS. Install the throttle body air inlet duct.

Scheme 230

1. Remove the case side cover. See «CASE SIDE COVER»(ref-153939-S11113648082003042900000). Disconnect the transaxle wiring harness.
2. Remove the TCC pulse width modulation solenoid (334). (Scheme 231)

Scheme 231

1. Install the TCC PWM solenoid (334). (Scheme 231) Connect the transaxle wiring harness.
2. Install the case side cover. See «CASE SIDE COVER»(ref-153939-S11113648082003042900000).

1. Remove the case side cover. See «CASE SIDE COVER»(ref-153939-S11113648082003042900000). Disconnect the transaxle wiring harness.
2. Remove the control valve body bolts (375, 379 and 381) that mount the fluid pressure manual valve position switch to the control valve body (300). (Scheme 232)
3. Carefully remove the fluid pressure manual valve position switch. Handle the switch carefully, the fluid pressure manual valve position switch is very delicate. Inspect the fluid pressure manual valve position switch (395) for the following conditions: Damaged electrical connector terminals. Damaged seals. Damaged switch membranes. Debris on the switch membranes. NOTE: When removing the TFP switch handle the switch carefully, the fluid pressure manual valve position switch is very delicate.

Scheme 232

1. Carefully install the fluid pressure manual valve position switch. Handle the switch carefully, the fluid pressure manual valve position switch is very delicate. (Scheme 232)
2. Install the control valve body bolts (375, 379 and 381) that mount the fluid pressure manual valve position switch to the control valve body (300). Tighten the control valve body bolts (375, 379 and 381) to specification. See «TORQUE SPECIFICATIONS»(ref-153939-S13545750352003042900000).
3. Connect the transaxle wiring harness. Install the case side cover. See «CASE SIDE COVER»(ref-153939-S11113648082003042900000).

1. Remove the oil pan. See «DRAINING & REFILLING»(ref-153939-S24508323162003042900000) under LUBRICATION.
2. Remove the thermo element pins and washers (120 and 123). (Scheme 233)
3. Remove the thermo element (121) and the thermo element plate (122).

Scheme 233

1. Use the Thermo Element Height Gage (J-34094-A) to set the middle thermo pin (123). (Scheme 234) Install the new thermo element plate (122). Install the pin and washer (120).
2. Use the thermo element height gage to set the height of the pin and washer (120) furthest from the accumulator. Use the thermo element height gage to set the height of the second pin and washer (120).
3. Carefully install the thermo element (121) between the 2 pin and washers (120). The "V" in the thermo element (121) must contact the thermo element plate (122). Install the oil pan. See «DRAINING & REFILLING»(ref-153939-S24508323162003042900000) under LUBRICATION. Fill transaxle with appropriate fluid to proper level. See «LUBRICATION»(ref-153939-S42043472612003042900000).

Scheme 234

Disconnect the negative battery cable. Raise and support the vehicle. Remove the right front tire and wheel. Remove the right engine splash shield. Remove the transaxle brace bolts. (Scheme 235) Remove the transaxle brace.

Scheme 235

Position the transaxle brace to transaxle and engine. Hand start the bolts to the engine. Hand start the bolts to the transaxle. Install the transaxle brace bolts to the engine. Install the transaxle brace bolts to the transaxle. (Scheme 235) Tighten the transaxle brace bolts to the transaxle to specification. See TORQUE SPECIFICATIONS. Tighten the transaxle brace bolts to the engine to specification. Install the right engine splash shield. Install the right front tire and wheel. Lower the vehicle. Connect the negative battery cable.

1. Raise and support the vehicle. Remove the left front tire and wheel. Remove the left inner splash shield.
2. Use a utility stand with a block of wood in order to support the transaxle. Remove the transaxle mount upper nuts. (Scheme 236)
3. Remove the transaxle bracket to transaxle mount upper nuts. (Scheme 236) Remove the transaxle mount bracket bolts. Remove the transaxle mount bracket. (Scheme 237)
4. Remove the transaxle mount lower nuts to the transaxle mount frame bracket. Remove the transaxle mount from the transaxle mount frame bracket.

Scheme 236

Scheme 237

1. Install the transaxle mount to the transaxle mount frame bracket. Install the transaxle mount lower nuts to the transaxle mount frame bracket. Tighten transaxle mount lower nuts to specification. See «TORQUE SPECIFICATIONS»(ref-153939-S13545750352003042900000).
2. Position the transaxle mount to the frame. Install the transaxle mount bracket bolts. (Scheme 237) Start with the forward lower bolt and work clockwise to tighten the transaxle bracket bolts to specification. See «TORQUE SPECIFICATIONS»(ref-153939-S13545750352003042900000).
3. Remove the utility stand. Install the transaxle mount upper nuts. (Scheme 236) Tighten the transaxle mount upper nuts to specification. See «TORQUE SPECIFICATIONS»(ref-153939-S13545750352003042900000).
4. Install the left engine splash shield. Install the left front tire and wheel. Lower the vehicle.

Remove the throttle body air inlet duct. Use a hammer and a chisel in order to raise the transaxle vent seat off of the transaxle. (Scheme 238) Use a flat-blade tool in order to pry the transaxle vent (37) out of the transaxle.

Scheme 238

Use a small hammer and a flat-blade tool and tap down on the transaxle vent seat in order to install the transaxle vent (37). (Scheme 238) Install the air cleaner intake duct.

Note. Handle the vehicle speed sensor (10) carefully.

Raise and support the vehicle. Remove the right front tire and wheel assembly. Remove the right engine splash shield. Remove the vehicle speed sensor wiring harness connector. Remove the vehicle speed sensor bolt (9). (Scheme 239) Remove the vehicle speed sensor (10) from the extension case. Remove the "O" ring (11) from the vehicle speed sensor (10). (Scheme 240) Inspect the vehicle speed sensor and "O" ring seal for the following

1. Damaged connector.
2. Cracked housing.
3. Signs of rotor damage.
4. Cuts or nicks on the "O" ring seal (11).

Scheme 239

Scheme 240

Install the "O" ring (11) to the vehicle speed sensor (10). (Scheme 240) Install the vehicle speed sensor (10) to the extension case. Install the vehicle speed sensor bolt (9). (Scheme 239) Tighten the vehicle speed sensor bolt (9) to specification. See TORQUE SPECIFICATIONS. Install the vehicle speed sensor wiring harness connector. Install the right front tire and wheel assembly. Lower the vehicle.

Remove the case side cover. See CASE SIDE COVER. Use a small flat-blade tool in order to remove the wiring harness from the solenoid valve(s), TFP manual valve position switch and/or the temperature sensor. (Scheme 241) Remove the wiring harness. Remove the clips retaining the solenoid(s).

Scheme 241

Connect the wiring harness. (Scheme 241) Install the wiring harness to the solenoid valve(s), TFP manual valve position switch and/or the temperature sensor. Install the case side cover. See CASE SIDE COVER.

Remove the case side cover. See CASE SIDE COVER. Disconnect the transaxle wiring harness. Remove the 1-2 shift solenoid (315A). (Scheme 242)

Scheme 242

Install the 1-2 shift solenoid (315A). (Scheme 242) Connect the transaxle wiring harness. Install the case side cover. See CASE SIDE COVER.

Remove the case side cover. See CASE SIDE COVER. Disconnect the transaxle wiring harness. Using a small screwdriver or pick, remove the 2-3 shift solenoid valve retainer (314C) from the control valve body (301). (Scheme 243) Remove the 2-3 shift solenoid (315B). Remove the "O" ring seal (316) from the 2-3 shift solenoid valve (315B) ONLY if it is damaged.

Scheme 243

Install a new "O" ring seal (316) onto the 2-3 shift solenoid valve (315B) if the "O" ring was removed. Install the 2-3 shift solenoid (315B). (Scheme 243) Install the 2-3 shift solenoid valve retainer (314C) into the control valve body (301). Connect the transaxle wiring harness. Install the case side cover. See CASE SIDE COVER.