Transmission Replacement
Transmission Replacement
Special Tools
EN-48536 - Frame Support Tool (Engine Lower 65 mm Kit)
Removal Procedure
1. Place the transmission in the Park position.
Warning: Refer to Battery Disconnect Warning Battery Disconnect Warning.
2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Primary) Battery Negative Cable Disconnection and Connection (Primary)Battery Negative Cable Disconnection and Connection (Auxiliary) Battery Negative Cable Disconnection and Connection (Auxiliary).
3. Remove the air cleaner outlet duct from the engine. Refer to Air Cleaner Outlet Duct Replacement Air Cleaner Outlet Duct Replacement.
4. Remove the radiator support brackets (2) from top of radiator by raising the securing lock (3) 10 mm and then sliding the bracket off the radiator slide pin (1). Carry out same procedure for other bracket.
5. Disconnect the evaporative emission (EVAP) canister purge pipe. Refer to Evaporative Emission Canister Purge Pipe Replacement Evaporative Emission Canister Purge Pipe Replacement.
Danger:
To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.
6. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.
7. Remove the exhaust system. Refer to Exhaust System Replacement Service and Repair.
8. Remove the propeller shaft. Refer to Propeller Shaft Replacement (Except 4L60) Propeller Shaft Replacement (Except 4L60).
9. Remove the front air deflector. Refer to Front Air Deflector Replacement .
10. Remove the engine splash shield. Refer to Engine Splash Shield Replacement .
11. Remove the transmission manual shift shaft nut (3).
12. Disconnect the shift linkage (1) from the transmission shift shaft (2).
13. Remove the starter motor. Refer to Starter Replacement Service and Repair.
14. Remove the right flex plate inspection cover.
15. Remove the left flex plate inspection cover.
16. Rotate the harmonic balancer centre bolt clockwise ONLY, in order to align the torque converter bolt with the starter motor opening in the engine block.
17. Mark the torque converter to flex plate orientation to make sure of correct realignment.
Note: NEW torque converter bolts will be required each time the torque converter bolts are removed.
18. Remove the torque converter bolt.
Discard the bolt.
19. Repeat Steps 16 and 18 for the remaining torque converter bolts.
20. Through the starter motor opening, push the torque converter back towards the transmission pump.
21. Remove the automatic transmission cooler pipe clamp to generator retaining nut (1).
22. Remove the automatic transmission cooler pipe retaining bolt (3) from the transmission assembly (2).
Note: Make sure that the O-rings remain with the cooler pipes.
23. Position the automatic transmission cooler pipes (1) aside.
Note:
* LHD shown, RHD similar.
* The front wheels of the vehicle must be maintained in the straight ahead position and the steering column must be in the LOCK position before disconnecting the steering column or intermediate shaft. If these procedures are not followed, incorrect alignment of some components during installation will result and damage to the SIR coil assembly will occur.
* Observing the orientation of the intermediate steering shaft (1) with reference to the pinion shaft (3) will minimize the potential of incorrect steering column assembly alignment.
24. Mark the intermediate steering shaft (1) in relation to the pinion shaft (3).
Note: Bolts with micro-encapsulated thread sealant must be discarded after removal.
25. Remove the intermediate shaft to pinion shaft retaining bolt (2).
Discard the bolt.
26. Disconnect the intermediate shaft (2) from the pinion shaft (3).
Note: Step 29 to 42 detail how to use the engine and transmission 65 mm drop tool. If this procedure is known, go to Step 43.
27. Using special tool EN-48536 - Frame Support Tool lower the engine and transmission assembly 65 mm.
Note: The engine mounts must NOT bend or deflect from the vertical position, damage to the mount will occur.
28. Support the power train with a suitable jack or table.
29. Remove the transmission support to body retaining bolts (1).
30. Remove the front and rear sub frame to front chassis rail retaining bolts (1).
Note: Do not tighten the bolts at this stage.
31. Replace the front and rear sub frame to body retaining bolts with four (M16 x 2.0) 160 mm bolts from special tool kit EN-48536 - Frame Support Tool.
32. Install the bolts until 2 mm of the thread remains visible below the sub frame.
Note: Do not tighten the bolts at this stage.
33. Replace the transmission support to body retaining bolts with the two (M10 x 1.5) 115 mm bolts (2) from special tool kit EN-48536 - Frame Support Tool adjacent to each other, e.g. left hand front and right hand rear.
34. Install the bolts until 65 mm of bolt remains visible (A) between the bolt heads (2) and the transmission mount (1).
35. Remove the centre sub frame to body retaining bolts (1).
36. Lower the power train slowly until the sub frame and transmission assembly is resting on the bolt heads.
37. Insert the 65 mm spacer blocks (1) between the sub frame (2) and chassis rails (3).
Caution: Refer to Fastener Caution Fastener Caution.
38. Tighten the front and rear sub frame retaining bolts to 95 Nm (70 lb ft).
39. Install the remaining two (M16 x 2.0) 115 mm centre sub frame to body retaining bolts from special tool kit EN-48536 - Frame Support Tool to the front sub frame and tighten to 95 Nm (70 lb ft).
40. Position the engine support plate (1) to the front sub frame.
41. Install the four (M8 x 1.25) 28 mm engine support plate to front sub frame retaining bolts (2) from special tool kit EN-48536 - Frame Support Tool and tighten to 10 Nm (89 lb in).
42. Support the transmission with a suitable jack or table.
43. Disconnect the transmission vent hose (1) from the transmission.
44. Disconnect the transmission wiring harness connector (1) from the transmission by rotating the locking latch (2) counter-clockwise.
45. Remove the wiring harness retaining bolts (2) from the transmission.
46. Disconnect the wiring harness clips (1) from the transmission, and position the wiring harness aside.
47. Remove the transmission support to transmission mount retaining nuts (1).
48. Remove the two (M10 x 1.5) 115 mm special tool kit EN-48536 - Frame Support Tool transmission support to body retaining bolts (1).
49. Remove the transmission mount. Refer to Transmission Mount Replacement Service and Repair.
50. Remove the transmission to engine assembly retaining bolts.
51. Pull the transmission free from the engine dowels.
Note: Ensure clearance is maintained between the transmission and the following:
* The catalytic converters
* The wiring harnesses
* The transmission cooler pipes
* The transmission shift linkage
* The transmission vent hose
52. Carefully lower the transmission from the vehicle.
53. Flush the transmission oil cooler. Refer to Transmission Fluid Cooler Flushing and Flow Test Transmission Fluid Cooler Flushing and Flow Test.
Installation Procedure
Note:
* The engine mounts must NOT bend or deflect from the vertical position, damage to the mount will occur.
* Ensure clearance is maintained between the transmission and the following:
- The catalytic converters
- The wiring harnesses
- The transmission cooler pipes
- The transmission shift linkage
- The transmission vent hose
1. Rotate the harmonic balancer centre bolt clockwise ONLY to align the torque converter bolt hole that has the flex plate to torque converter alignment mark with the starter motor opening.
2. Prepare the transmission for installation by rotating the torque converter clockwise ONLY to align the torque converter bolt hole that has the alignment mark with the starter motor opening.
3. Using a suitable transmission jack, carefully raise the transmission to the vehicle.
4. Align the transmission with the engine dowels.
5. Install the transmission to engine retaining bolts and tighten to 59 Nm (43 lb ft).
6. Install the transmission mount. Refer to Transmission Mount Replacement Service and Repair.
7. Install the two (M10 x 1.5) 115 mm bolts from special tool kit EN-48536 - Frame Support Tool adjacent to each other, e.g. left hand front and right hand rear.
8. Install the bolts (1) until 65 mm of bolt remains visible between the upper surface of the transmission mount and the vehicle body.
9. Install the transmission support to transmission mount retaining nuts (1) and tighten to 58 Nm (43 lb ft).
10. Position the transmission wiring harness to the transmission and connect the wiring harness clips (1) to the transmission.
11. Install the wiring harness retaining bolts (2) to the transmission and tighten to 12 Nm (106 lb in).
12. Connect the transmission wiring harness connector (1) to the transmission by rotating the locking latch (2) clockwise.
13. Connect the transmission vent hose (1) to the transmission.
14. Remove the four (M8 x 1.25) 28 mm engine support plate to front sub frame retaining bolts (2).
15. Remove the engine support plate (1) from the front sub frame.
16. Loosen the six sub frame to front chassis rail retaining bolts (1 and 2) by one turn each.
17. Remove the 65 mm spacer blocks from between the sub frame and chassis rails.
18. Raise the power train slowly until the sub frame and transmission mount are lifted off the bolt heads and the power train is positioned back up into the engine bay.
19. Remove the six sub frame to front chassis rail retaining bolts (1 and 2).
20. Install the original front and centre sub frame to front chassis rail retaining bolts (1) and tighten to 160 Nm (118 lb ft).
21. Install the original rear sub frame to front chassis rail retaining bolts (1) and tighten to 240 Nm (177 lb ft).
22. Remove the two (M10 x 1.5) 115 mm special tool kit EN-48536 - Frame Support Tool transmission support to body retaining bolts (1).
23. Install the four original transmission support to lower sub frame retaining bolts (1) and tighten to 58 Nm (43 lb ft).
24. Remove the support from under the power train.
Note: LHD shown, RHD similar.
Note: The intermediate steering shaft and pinion shaft splines must be installed in the position recorded during removal and aligned with the marks previously made.
25. Connect the intermediate steering shaft (1) to the pinion shaft (3).
26. Install a NEW intermediate steering shaft to pinion shaft retaining bolt (2) and tighten to 25 Nm (18 lb ft).
Note: Replace the O-rings if cracked, cut, or distorted.
27. Lubricate the O-rings with automatic transmission fluid.
28. Install the O-rings onto the cooler pipes prior to inserting the cooler pipes into the transmission.
29. Insert the transmission fluid cooler pipes (1) into the transmission (2).
30. Install the automatic transmission cooler pipe retaining bolt (3) and tighten to 20 Nm (15 lb ft).
31. Install the automatic transmission cooler pipe to generator retaining nut (1) and tighten to 22 Nm(17 lb ft).
32. Align the torque converter to flex plate orientation marks made during the removal procedure.
Note: Torque converter bolts are self locking and must be replaced with NEW torque converter bolts every time the bolts are removed.
33. Repeat the following steps for all 3 torque converter bolts:
1. Rotate the harmonic balancer centre bolt clockwise ONLY, in order to align the torque converter bolt holes in the flex plate with the starter motor opening in the engine block.
2. To aid in alignment of the torque converter to the flex plate. Install all 3 NEW torque converter bolts before fully tightening to 63 Nm (46 lb ft).
34. Install the left flex plate inspection cover and tighten the retaining bolt to 10 Nm (89 lb in).
35. Install the right flex plate inspection cover and tighten the retaining bolt to 10 Nm (89 lb in).
36. Install the starter motor. Refer to Starter Replacement Service and Repair.
37. Place the transmission in the park position by rotating the shift shaft fully counter clockwise.
38. Connect the shift linkage (1) to the transmission manual shift shaft (2).
39. Install the transmission manual shift shaft nut (3) and tighten to 15 Nm (11 lb ft).
40. Adjust the shift control linkage. Refer to Range Selector Lever Link Adjustment Adjustments.
41. Install the engine splash shield. Refer to Engine Splash Shield Replacement .
42. Install the front air deflector. Refer to Front Air Deflector Replacement .
43. Install the propeller shaft. Refer to Propeller Shaft Replacement (Except 4L60) Propeller Shaft Replacement (Except 4L60).
44. Install the exhaust system. Refer to Exhaust System Replacement Service and Repair.
45. Lower the vehicle.
46. Connect the EVAP canister purge pipe. Refer to Evaporative Emission Canister Purge Pipe Replacement Evaporative Emission Canister Purge Pipe Replacement.
47. Install the radiator retaining brackets (2) onto the radiator slide pin (1).
48. Secure the retaining brackets by pushing the securing lock (3) downwards until the lock reaches the bottom of the radiator bracket. Carry out the same procedure for the other bracket.
49. Install the air cleaner outlet duct to the engine. Refer to Air Cleaner Outlet Duct Replacement Air Cleaner Outlet Duct Replacement.
50. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Primary) Battery Negative Cable Disconnection and Connection (Primary)Battery Negative Cable Disconnection and Connection (Auxiliary) Battery Negative Cable Disconnection and Connection (Auxiliary).
51. The transmission control module must be programmed with the proper software/calibrations. Refer to Service Programming System (SPS) Service Programming System (SPS).
Final Test and Inspection
Complete the following procedure after the transmission is installed in the vehicle:
1. Disable the ignition and fuel system:
* Remove the fuel pump fuse from the under hood body electrical centre.
* Remove the ignition relay from the under hood body electrical centre.
2. Crank the engine several times. Listen for any unusual noises or evidence that any parts are binding.
3. Enable the ignition and fuel system:
* Install the fuel pump fuse to the under hood body electrical centre.
* Install the ignition relay to the under hood body electrical centre.
4. Start the engine and listen for abnormal conditions.
5. While the engine continues to idle raise and support the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.
6. Inspect for fluid leaks while the engine is idling.
7. Check the transmission fluid level (fill if necessary). Refer to Transmission Fluid Level and Condition Check Transmission Fluid Level and Condition Check.
8. Lower the vehicle.
9. Road test the vehicle.