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MAINTENANCE AND REPAIR

ON-VEHICLE SERVICE



T3B15AS6
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Transaxle Fluid Level Checking Procedure

    Notice : Check the fluid level when the transaxle temperature is 70°C~80°C (158°F~176°F).

    Notice : During the fluid level check, the selector lever must be in position P.

    Notice : When adding fluid or making a complete fluid change, always use ISU DEXRON III or ESSO JWS 3309. Failure to use the proper fluid will cause hose and seal damage and fluid leaks.



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  1. Make sure the vehicle is level.
  2. Shift into all range from "P" to "1" and return to "P" with engine idling.
  3. Remove the transaxle fluid dipstick and check the transaxle fluid level.
  4. The correct fluid level must be between the HOT MIN and the HOT MAX notches on the dipstick.
  5. If the fluid level is below the MIN notch, add transaxle fluid through the fluid filler tube and check for leaks in the transaxle.
  6. If the fluid above the MAX notch, the transaxle is overfilled. Drain some of the fluid through the fluid pan drain plug. Check the transaxle fluid level.


T3B15AS8
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Fluid Drain Procedure

Draining Procedure

  1. Raise and support the vehicle. Refer to "Vehicle Lifting Procedures," Section 0B, General Information.
  2. Place a suitable fluid drainage container under the transaxle.
  3. Remove the fluid drain plug. allow the fluid to drain completely.
  4. Clean the drain plug threads.
  5. Install the fluid drain plug.
  6. Tighten
    Torque the fluid drain plug to 17 N•m (13 Ib-ft).



T3B15AS7
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Filling Procedure

  1. Remove the drainage container and lower the vehicle.
  2. Add three-fourths of the recommended amount of ISU DEXRON III or ESSO JWS 3309.
  3. Start the engine and allow it to reach normal operating temperature.
  4. Shift the gear selector through all positions.
  5. Check the fluid level and add fluid until the dipstick indicates a safe level.

Locating Fluid Leaks

General Method

  1. Verify that the material leaking is transaxle fluid.
  2. Thoroughly clean the suspected leak area.
  3. Allow the transaxle to reach the normal operating temperature of 176-194°F (80-90°C).
  4. Park the vehicle over a clean paper or a clean cardboard.
  5. Turn the engine OFF and look for fluid spots on the paper.
  6. Make the necessary repairs to correct that leak.

Powder Method

  1. Thoroughly clean the suspected leak area.
  2. Apply an aerosol type powder, such as foot powder, to the suspected leak area.
  3. Allow the transaxle to reach the normal operating temperature of 176-194°F (80-90°C).
  4. Turn the engine OFF.
  5. Inspect the suspected leak area and trace the leak path through the powder to find the source of the leak.
  6. Make the necessary repairs to correct the leak.
  7. Once the leak point is found, the source of the leak must be determined and repaired.

Case Porsity Repair

  1. Determine the leak area. Refer to "Locating Fluid Leaks" in this section.
  2. Clean the leak area with the solvent. Air dry.
  3. Caution : Epoxy cement may cause skin irritations and eye damage. Read and follow all information on the container label as provided by the manufacturer.

  4. Mix a sufficient amount of epoxy cement following the manufacturer's recommendations.
  5. While the transaxle case is hot, apply epoxy cement with a clean, dry soldering acid brush.
  6. Allow the epoxy cement to dry for 3 hours before starting the engine.

Fluid Cooler Flushing

Flushing Procedure

  1. Drain the fluid from the transaxle and refill the transaxle with new transaxle fluid. Refer to "Fluid Drain Procedure" in this section.
  2. Let the engine idle for 5 minutes.
  3. Drain the fluid from the transaxle and refill the transaxle with new transaxle fluid. Refer to "Fluid Drain Procedure" in this section.


T3B15AS9
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Control Cable Adjustment

Adjustment Procedure

    The various shift control cable positions must match at the shift control lever in the vehicle and at the selector lever on the transaxle to provide proper transaxle shifting.
    Place the shift control lever in the PARK position and check the selector lever connection to verify that it is in the forward most position. If it is not, the following adjustment must be performed:
  1. Disconnect the negative battery cable.
  2. Remove the floor console. Refer to Section 9G, Interior Trim.
  3. Place the shift control lever in the PARK position.


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  5. Loosen the control cable adjusting nut.


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  7. Move the Transmission Range (TR) switch lever counterclockwise until stopping the lever.


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  9. Pull the shift control cable until it is tight and tighten the control cable adjusting nut.
  10. Tighten
    Tighten the control cable adjusting nut to 8 N•m (71 Ib-in).

  11. Install the floor console. Refer to Section 9G, Interior Trim.
  12. Connect the negative battery cable.


J3B15A50
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Shift Control Lever Assembly

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Remove the floor console. Refer to Section 9G, Interior Trim.
  3. Disconnect the wiring harness connectors from the shift control lever.


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  5. Loosen the control cable adjusting nut.
  6. Disconnect the control cable from the shift control lever assembly.


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  8. Remove the shift control lever assembly mounting bolts and nuts.
  9. Remove the shift control lever assembly.


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Installation Procedure

  1. Install the shift control lever assembly and mounting bolts and nuts.
  2. Tighten
    Tighten the shift control lever assembly mounting bolts and nuts to 8 N•m (71 Ib-in).



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  3. Connect the control cable to the shift control lever assembly.
  4. Tighten the control cable adjusting nut.
  5. Tighten
    Tighten the control cable adjusting nut to 8 N•m (71 Ib-in).



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  6. Connect the harness connector.
  7. Adjust the control cable. Refer to "Control Cable Adjustment" in this section.
  8. Install the floor console. Refer to Section 9G, Interior Trim.
  9. Connect the negative battery cable.


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Transmission Range (TR) Switch

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Disconnect the Transmission Range (TR) switch electrical connector from the wiring harness.


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  4. Remove the E-ring.
  5. Disconnect the shift control cable from the TR switch lever.


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  7. Remove the retaining nut and then remove the washer and the control lever.
  8. Using a driver, unstake the lock washer and remove the nut.


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Installation Procedure

  1. Install the Transmission Range (TR) switch onto the manual valve lever shaft and temporarily install the 2 adjusting bolts.
  2. Install the new lock washer and nuts.
  3. Tighten
    Tighten the nuts to 12 N•m (106 Ib-in).



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  4. Temporarily install the control lever.
  5. Turn the lever counterclockwise until it stops, then turn it clockwise 2 notches.
  6. Remove the control lever.


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  8. Aligh the groove with the neutral basic line, then install the 2 bolts.
  9. Tighten
    Tighten the 2 bolts to 5.4 N•m (48 Ib-in).



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  10. Using a screw driver, stake the nut with the lock washer.


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  12. Install the control lever, washer and nut.
  13. Tighten
    Tighten the nut to 12 N•m (106 Ib-in).



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  14. Connect the control cable to TR switch.
  15. Connect the TR switch electrical connector.
  16. Adjust the control cable. Refer to "Control Cable Adjustment" in this section.
  17. Install the control cable adjusting nut.
  18. Tighten
    Tighten the control cable adjusting nut to 8 N•m (71 Ib-in).

  19. Connect the negative battery cable.


J3B15A19
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Shift Control Cable

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Remove the floor console. Refer to Section 9G, Interior Trim.
  3. Remove the cable adjusting nut.
  4. Disconnect the shift control cable from the shift control lever assembly.


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  6. Remove the shift control cable retaining E-ring.
  7. Disconnect the shift control cable from the TR switch.


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  9. Remove the E-ring from the shift control cable bracket and disconnect the shift control cable.
  10. Disconnect the shift control cable from the shift control cable fastener.
  11. Remove the shift control cable from the vehicle.


J3B15A51
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Installation Procedure

  1. Install the shift control cable to the vehicle.
  2. Connect the shift control cable to the shift control cable fastener.
  3. Install the E-ring to the shift control cable bracket and connect the shift control cable.


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  5. Connect the shift control cable to the TR switch.
  6. Install the shift control cable retaining E-ring.


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  8. Connect the shift control cable to the shift control lever assembly.
  9. Install the cable adjusting nut.
  10. Tighten
    Tighten the cable adjusting nut to 8 N•m (71 Ib-in).

  11. Install the trim panel to the floor console. Refer to Section 9G, Interior Trim.
  12. Connect the negative battery cable.


T3B15AU2
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Shift Select Cover

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Remove the floor console. Refer to Section 9G, Interior Trim.
  3. Remove the shift select lever knob.


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  5. Disconnect the connectors.
  6. Remove the shift select cover from the shift select housing.


J3B15A50
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Installation Procedure

  1. Connect the connectors to the shift select cover.
  2. Install the shift select cover to the housing.


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  4. Install the shift select lever knob.
  5. Install the floor console. Refer to Section 9G, Interior Trim.
  6. Connect the negative battery cable.


T3B15AU5
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Input Shaft Speed (ISS) Sensor

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Disconnect the input shaft speed (ISS) sensor electrical connector.


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  4. Remove the ISS sensor retaining bolt.
  5. Remove the ISS sensor from the transaxle.


T3B15AU6
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Installation Procedure

    Notice : Lubricate the O-ring with ISU DEXRON III or ESSO JWS 3309.

  1. Install a new O-ring on the ISS sensor.
  2. Install the ISS sensor and retaining bolt into the transaxle case.
  3. Tighten
    Tighten the ISS sensor retaining bolt to 5.4 N•m (48 Ib-in).



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  4. Connect the ISS sensor electrical connector.
  5. Connect the negative battery cable.


T3B15AU8
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Output Shaft Speed (OSS) Sensor

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Disconnect the output shaft speed (OSS) sensor electrical connector.


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  4. Remove the OSS sensor retaining bolt.
  5. Remove the OSS sensor from the transaxle.


T3B15AV1
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Installation Procedure

    Notice : Lubricate the O-ring with ISU DEXRON III or ESSO JWS 3309.

  1. Install a new O-ring on the output shaft speed (OSS) sensor.
  2. Install the OSS sensor and retaining bolt into the transaxle.
  3. Tighten
    Tighten the OSS sensor retaining bolt to 7.4 N•m (65 Ib-in).



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  4. Connect the OSS sensor electrical connector.
  5. Connect the negative battery cable.


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Transmission Control Module (TCM)

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Disconnect the transmission control module (TCM) electrical connector.


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  4. Remove the TCM retaining bolts.
  5. Remove the TCM.


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Installation Procedure

  1. Connect the negative battery cable.
  2. Install the TCM and retaining bolts.
  3. Tighten
    Tighten the TCM retaining bolts to 5 N•m (44 Ib-in).



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  4. Connect the TCM electrical connector.
  5. Connect the negative battery cable.


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Fluid Cooler Inlet Pipes and Hoses

Removal Procedure

  1. Raise and support the vehicle.
  2. Drain the transaxle fluid.
  3. Remove the clip from the hose, then disconnect the hose from the fluid cooler inlet pipe.
  4. Remove the inlet pipe union bolt from the radiator.


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  6. Remove the fluid cooler inlet pipe bolt from the transaxle.
  7. Remove the inlet pipe fitting nut from the transaxle.
  8. Remove the fluid cooler inlet pipe and hoses.


T3B15AV6
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Installation Procedure

  1. Install the fluid cooler inlet pipe fitting nut into the transaxle.
  2. Tighten
    Tighten the fluid cooler inlet pipe fitting nut to 35 N•m (26 Ib-ft).

  3. Install the fluid cooler inlet pipe bolt into the transaxle.
  4. Tighten
    Tighten the fluid cooler inlet pipe bolt to 9 N•m (80 Ib-in).



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  5. Install the inlet pipe union bolt into the radiator.
  6. Tighten
    Tighten the inlet pipe union bolt to 35 N•m (26 Ib-ft).

  7. Connect the hose to inlet pipe and install the clip into the hose.
  8. Lower the vehicle.
  9. Fill the transaxle with the fluid.


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Fluid Cooler Outlet Pipe and Hoses

Removal Procedure

  1. Drain the transaxle fluid.
  2. Remove the front outlet pipe union bolt from the radiator.
  3. Remove the clip from the hose.


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  5. Remove the rear outlet pipe clip bolt from the transaxle.
  6. Remove the rear outlet pipe fitting nut from the transaxle.
  7. Remove the fluid cooler outlet pipe and hoses.


J3B15A57
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Installation Procedure

  1. Install the fluid cooler rear outlet pipe fitting nut.
  2. Tighten
    Tighten the fluid cooler rear outlet pipe fitting nut to 35 N•m (26 Ib-ft).

  3. Install the fluid cooler rear outlet pipe clip bolt.
  4. Tighten
    Tighten the fluid cooler rear outlet pipe clip bolt to 9 N•m (80 Ib-in).



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  5. Install the front outlet pipe union bolt into the radiator.
  6. Tighten
    Tighten the front outlet pipe union bolt to 35 N•m (26 Ib-ft).

  7. Install the clip into the hose.
  8. Fill the transaxle with the fluid.


T3B15AV6
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Transaxle Assembly

Tools Required

DW110-060 Engine Support Fixture
DW260-012 Transaxle Support Fixture (81-40 LE)

Removal Procedure

  1. Remove the battery and battery tray. Refer to Section 1E, Engine Electrical.
  2. Drain the transaxle fluid. Refer to "Fluid Drain Procedure" in this section.
  3. Remove the left and right drive axle assemblies. Refer to Section 3A, Automatic Transaxle Drive Axle.
  4. Disconnect the fluid cooler inlet and outlet pipes and hoses from the transaxle. Refer to "Fluid Cooler Inlet or Outlet Pipe and Hoses" in this section.


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  6. Disconnect the shift control cable from the transaxle. Refer to "Shift Control Cable" in this section.
  7. Install engine support fixture DW110-060 to support the engine.


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  9. Disconnect the input shaft speed (ISS) sensor electrical connector.
  10. Disconnect the output shaft speed (OSS) sensor electrical connector.
  11. Disconnect the Transmission Range (TR) Switch electrical connector.
  12. Disconnect the transaxle electrical connector.


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  14. Remove the service hall cover.
  15. Remove the three torque converter bolts.


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  17. Remove the damping block connection nut and bolt.
  18. Remove the rear mounting bracket bolts and rear mounting bracket.


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  20. Remove the three upper transaxle mounting bracket bolts.


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  22. Remove the three upper transaxle-to-engine mounting bolts.


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  24. Secure the transaxle to a transaxle jack and transaxle support fixture DW260-013.


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  26. Remove the seven lower transaxle-to-engine retaining bolts.


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  28. Carefully remove the transaxle from the vehicle.


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Installation Procedure

  1. Secure the transaxle to the transaxle jack, then carefully position in the vehicle.


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  3. Install the seven lower transaxle-to-engine retaining bolts.
  4. Tighten
    Tighten the bolts(a) to 73 N•m (54 Ib-ft).

    Tighten
    Tighten the bolts(b) to 31 N•m (23 Ib-ft).

    Tighten
    Tighten the bolts(c) to 21 N•m (15 Ib-ft).



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  5. Install the three upper transaxle-to-engine mounting bolts.
  6. Tighten
    Tighten the three upper transaxle-to-engine mounting bolts to 73 N•m (54 Ib-ft).



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  7. Install the three upper transaxle mounting bracket bolts and the bracket.
  8. Tighten
    Tighten the three upper transaxle mounting bracket bolts to 60 N•m (44 Ib-ft).



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  9. Install the rear mounting bracket bolts and the bracket.
  10. Tighten
    Tighten the rear mounting bracket bolts to 60 N•m (44 Ib-ft).

  11. Install the damping block connection nut and bolt.
  12. Tighten
    Tighten the damping block connection nut and bolt to 80 N•m (59 Ib-ft).



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  13. Install the torque converter bolts.
  14. Tighten
    Tighten the torque converter bolts to 45 N•m (33 Ib-ft).

  15. Install the service hall cover.


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  17. Connect the transaxle electrical connector.
  18. Connect the TR switch electrical connector.
  19. Connect the OSS sensor electrical connector.
  20. Connect the ISS sensor electrical connector.


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  22. Remove engine support fixture DW110-060.
  23. Connect the shift control cable into the transaxle. Refer to "Shift Control Cable" in this section.


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  25. Connect the fluid cooler inlet and outlet pipe and hose into the transaxle. Refer to "Fluid Cooler Inlet or Outlet Pipe and Hoses" in this section.
  26. Install the left and right drive axle assemblies. Refer to Section 3A, Automatic Transaxle Drive Axle.
  27. Install the battery and battery tray. Refer to Section 1E, Engine Electrical.
  28. Fill the transaxle with fluid. Refer to "Fluid Drain Procedure" in this section.
  29. Check the fluid level. Refer to "Transaxle Fluid Level Checking Procedure" in this section.


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