Automatic Transaxle Replacement

AUTOMATIC TRANSAXLE ASSEMBLY (U250E)





COMPONENTS

REPLACEMENT
1. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
2. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH
3. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH
SST 09520-01010, 09520-24010 (09520-32040)





4. REMOVE TRANSMISSION CONTROL CABLE BRACKET NO.2
a. Remove the bolt and transmission control cable bracket No.2.





5. REMOVE WIRE HARNESS CLAMP
a. Disconnect the wire harnesses from the 2 clamps.
b. Remove the 2 bolts and 2 clamps.





6. DISCONNECT WIRE HARNESS
a. Remove the bolt and disconnect the wire harness.





7. REMOVE STARTER ASSEMBLY
a. Remove the nut and disconnect the starter wire.
b. Disconnect the connector.
c. Remove the 2 bolts and starter assembly.





8. DISCONNECT CONNECTOR
a. Disconnect the transmission wire connector.
b. Disconnect the park/neutral position switch connector.
c. Disconnect the 2 speed sensor connectors.
d. Disconnect the speedometer driven gear connector.





9. REMOVE TRANSMISSION CONTROL CABLE BRACKET NO.1
a. Remove the bolt and oil cooler tube clamp.
b. Remove the 2 bolts and transmission control cable bracket No.1.





10. REMOVE TRANSMISSION OIL FILLER TUBE SUB-ASSEMBLY
a. Remove the ATF level gauge.
b. Remove the breather hose from the automatic transaxle.
c. Remove the bolt and transmission oil filler tube sub-assembly.
d. Remove the O-ring from the oil filler tube.





11. REMOVE OIL COOLER INLET TUBE NO.1
a. Remove the oil cooler inlet tube No.1.
12. REMOVE OIL COOLER OUTLET TUBE NO.1
a. Remove the oil cooler outlet tube No.1.





13. REMOVE ENGINE MOUNTING BRACKET FR
a. Remove the 3 bolts and engine mounting bracket FR.





14. REMOVE FLYWHEEL HOUSING UNDER COVER
a. Remove the flywheel housing under cover.





15. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY
a. Turn the crankshaft to gain access and remove the 6 bolts while holding the crankshaft pulley bolt with a wrench.

HINT: There will be one green colored bolt.





b. Remove the 8 bolts.
c. Separate and remove the automatic transaxle.
16. REMOVE TORQUE CONVERTER CLUTCH ASSEMBLY
17. INSPECT TORQUE CONVERTER CLUTCH ASSEMBLY
SST 09350-32014 (09351-32010, 09351-32020)





18. REMOVE TRANSAXLE CASE COVER UPPER
a. Remove the 3 bolts and transmission case cover upper.





19. INSTALL TRANSAXLE CASE COVER UPPER
a. Install the transmission case cover upper with the 3 bolts.
Torque: 12 Nm (122 kgf-cm, 9 ft. lbs.)





20. INSTALL TORQUE CONVERTER CLUTCH ASSEMBLY
a. Using vernier calipers and a straight edge, measure the dimension A between the transaxle fitting part of the engine and the converter fitting part of the drive plate.





b. Set the key of the front oil pump drive gear to the top and put a mark on the housing.





c. Put a mark on the torque converter clutch so that its groove can be clearly indicated.





d. Match the 2 marks on the transaxle case and the torque converter clutch and fit the splined part of the input shaft to the spline part of the turbine runner.





e. Rotating the torque converter clutch, fit the spline part of the stator shaft with the spline part of the stator.

HINT: Rotate it about 180 degrees.





f. Rotating the torque converter clutch, match the 2 marks on the case and the torque converter clutch again and fit the key of the oil pump drive gear into the key way of the torque converter clutch.

NOTICE: When rotating the torque converter clutch, do not push it by excessive force.





g. Using vernier calipers and a straight edge, measure the dimension B shown in the illustration and check that B is greater than A measured in step (a).
Standard: A + 1 mm (0.04 inch) or more





21. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY
a. Install the automatic transaxle to the engine with the 8 bolts.
Torque:
Bolt A: 64 Nm (653 kgf-cm, 47 ft. lbs.)
Bolt B: 44 Nm (449 kgf-cm, 32 ft. lbs.)
Bolt C: 46 Nm (470 kgf-cm, 34 ft. lbs.)
b. Apply a few drops of adhesive to 2 threads on the tip of the 6 torque converter clutch mounting bolts. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent





c. Install the 6 torque converter clutch mounting bolts.
Torque: 41 Nm (418 kgf-cm, 30 ft. lbs.)

NOTICE: First install the green colored bolt and then the remaining 5 bolts.





22. INSTALL FLYWHEEL HOUSING UNDER COVER
a. Install the flywheel housing under cover.





23. INSTALL ENGINE MOUNTING BRACKET FR
a. Install the engine mounting bracket FR with the 3 bolts to the automatic transaxle.
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)





24. INSTALL TRANSMISSION OIL FILLER TUBE SUB-ASSEMBLY
a. Coat a new O-ring with ATF, and install it to the oil filler tube.
b. Install the oil filler tube to the automatic transaxle with the bolt.
Torque: 5.5 Nm (56 kgf-cm, 49 inch lbs.)





c. Install the breather hose to the automatic transaxle.
d. Install the ATF level gauge.





25. INSTALL TRANSMISSION CONTROL CABLE BRACKET NO.1
a. Install the control cable bracket No.1 with the 2 bolts.
Torque: 12 Nm (122 kgf-cm, 9 ft. lbs.)
26. INSTALL OIL COOLER INLET TUBE NO.1
a. Temporarily install the oil cooler outlet tube No.1.
b. Temporarily install the oil cooler inlet tube No.1.





c. Install the oil cooler tube clamp with the bolt.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)

HINT: Install them so that the oil cooler tube cushion is positioned as shown in the illustration.





d. Torque the oil cooler inlet tube No.1.
Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.)
27. INSTALL OIL COOLER OUTLET TUBE NO.1
a. Torque the oil cooler outlet tube No.1.
Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.)





28. CONNECT CONNECTOR
a. Connect the transmission wire connector.
b. Connect the park/neutral position switch connector.
c. Connect the 2 speed sensor connectors.
d. Connect the speedometer driven gear connector.





29. INSTALL STARTER ASSEMBLY
a. Install the starter assembly with the 2 bolts.
Torque: 37 Nm (377 kgf-cm, 27 ft. lbs.)
b. Connect the connector.
c. Connect the starter wire with the nut.
Torque: 9.8 Nm (100 kgf-cm, 87 inch lbs.)





30. CONNECT WIRE HARNESS
a. Connect the wire harness with the bolt.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)





31. INSTALL WIRE HARNESS CLAMP
a. Install the 2 clamps with the 2 bolts.
Torque: 8.4 Nm (86 kgf-cm, 74 inch lbs.)
b. Connect the wire harnesses to the clamps.





32. INSTALL TRANSMISSION CONTROL CABLE BRACKET NO.2
a. Install the transmission control cable bracket No.2 with the bolt.
Torque: 12 Nm (122 kgf-cm, 9 ft. lbs.)
33. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
34. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH
35. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
36. RESET MEMORY

NOTICE: Perform the RESET MEMORY (AT initialization) when replacing the automatic transmission assembly, engine assembly or ECM.

HINT: RESET MEMORY can not be completed by only disconnecting the battery terminal.