Tools Required

J 42640 Steering Column Anti-Rotation Pin

Notice: The wheels of the vehicle must be straight ahead and the steering column in the LOCK position before disconnecting the steering column or intermediate shaft from the steering gear. Failure to do so will cause the SIR coil assembly to become uncentered, which may cause damage to the coil assembly.

1. Lock the steering column by installing J 42640 into the underside of the steering column.
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
3. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.8L.



4. Use a large flat-bladed tool in order to remove the range selector cable from the range selector lever.
5. Remove the range selector cable bracket bolts (1).
6. Remove the range selector cable bracket (2) from the transmission case and set aside.



7. Disconnect the transaxle electrical connector C100 (2).
8. Remove the wiring harness (3) from the wiring harness retainer (1) on the transaxle.



9. Remove the ground cable bolt (1) from the transaxle.
10. Install the engine support fixture. Refer to Engine Support Fixture in Engine Mechanical - 3.8L.



11. Remove the upper engine to transaxle case bolts (2-5).
12. Raise and Support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
13. Remove the front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.



14. Remove both of the front fascia extensions (3). Refer to Front Bumper Fascia Extension Replacement in Bumpers.
15. Remove the front air deflector. Refer to Front Air Deflector Replacement in Body Front End.




Caution: Failure to disconnect the intermediate shaft from the rack and pinion steering gear stub shaft can result in damage to the steering gear or to the intermediate shaft. This damage may cause loss of steering control, which could result in an accident and possible personal injury.

16. Remove the intermediate shaft lower pinch bolt.
17. Disconnect the intermediate shaft from the power steering gear.
18. Remove the power steering gear heat shield. Refer to Steering Gear Heat Shield Replacement in Power Steering System.



19. Remove the power steering gear mounting bolts.
20. Remove the power steering line retainers from the frame.
21. Secure the power steering gear to the exhaust manifold.



22. Loosen the two mounting nuts (2) in order to allow removal of the brake pressure modulator valve (1) from the bracket (3).
23. Remove the brake line retainers from the frame.
24. Remove the left transaxle mount. Refer to Transmission Mount Replacement - Left Side .
25. Remove the frame. Refer to Front Frame Replacement in Frame and Underbody.



26. Remove the front transaxle mount bracket with mount attached. Refer to Transmission Front Mount Bracket Replacement .
27. Remove the right and left drive axles from the transaxle. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.
28. Disconnect the transmission oil cooler hoses from the transaxle. Refer to Transmission Fluid Cooler Hose/Pipe Replacement .
29. Remove the transaxle fluid filler tube. Refer to Transmission Fluid Filler Tube and Seal Replacement .
30. Remove the torque converter cover. Refer to Torque Converter Cover Replacement .



31. Mark the flywheel to converter relationship to ensure proper reassembly. Remove the flywheel to torque converter bolts.



32. Support transaxle using an appropriate transaxle jack.
33. Disconnect vehicle speed sensor electrical connector.



34. Remove the torque strut bracket to transaxle bolts.



35. Remove the torque strut bracket to engine bolts.
36. Remove the torque strut bracket.



37. Remove the engine to transaxle case bolt (6) which is accessible through right wheel opening.
38. Remove the remaining transaxle to engine bolt (1).
39. Remove the transaxle from vehicle using an appropriate transaxle jack.



40. Remove the rear transaxle bracket (1) from the transaxle.



41. Remove the left transaxle bracket (1) from the transaxle.
42. Flush the transmission cooler and lines. Refer to Transmission Fluid Cooler Flushing and Flow Test .

1. Install the left transaxle bracket (1) to the transaxle.

Notice: Refer to Fastener Notice in the Preface section.

2. Install the left transaxle bracket bolts.

Tighten
Tighten the left transaxle bracket bolts to 110 N·m (81 lb ft).




3. Install the rear transaxle bracket (1) to the transaxle.
4. Install the rear transaxle bracket bolts.

Tighten
Tighten the rear transaxle bracket bolts to 63 N·m (46 lb ft).




5. Install the transaxle into the vehicle and align the engine alignment dowels (1 and 5).
6. Install the transaxle case to engine bolts (1and 6).

Tighten
Tighten the lower transaxle bolts to 75 N·m (55 lb ft).




7. Install the torque strut bracket.
8. Install the torque strut bracket to engine bolts.

Tighten
Tighten the torque strut bracket to engine bolts to 65 N·m (48 lb ft).




9. Install the torque strut bracket to transaxle bolts.

Tighten
Tighten the torque strut bracket to transaxle bolts to 36 N·m (26 lb ft).

10. Connect vehicle speed sensor electrical connector.
11. Remove the transaxle jack




Important: 

•	Align the mark made on the torque converter with the mark made on the flywheel made in the disassembly unless installing a new converter.

•	Tighten all the torque converter to flywheel bolts twice.

12. Install the flywheel to torque converter bolts.

Tighten
Tighten the flywheel to torque converter bolts to 63 N·m (47 lb ft).

13. Install the torque converter cover. Refer to Torque Converter Cover Replacement .
14. Install the transaxle fluid filler tube. Refer to Transmission Fluid Filler Tube and Seal Replacement .
15. Connect the transmission oil cooler hoses to the transaxle. Refer to Transmission Fluid Cooler Hose/Pipe Replacement .

Important: Use care when installing the right side drive axle into the transaxle case. The splined shaft of the drive axle can easily damage the seal.

16. Install the left and the right drive axle into the transaxle. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.



17. Install the front transaxle mount bracket with mount attached. Refer to Transmission Front Mount Bracket Replacement .
18. Install the frame. Refer to Front Frame Replacement in Frame and Underbody.
19. Install the left transaxle mount. Refer to Transmission Mount Replacement - Left Side .



20. Position the brake pressure modulator valve (1) into the bracket (3).

Tighten
Tighten the two nuts (2) to 10 N·m (89 lb in).

21. Install the brake line retainers onto the frame.



22. Install the power steering gear mounting bolts.

Tighten
Tighten the bolts to 75 N·m (55 lb ft).

23. Install the power steering line retainers onto the frame.
24. Install the power steering gear heat shield. Refer to Steering Gear Heat Shield Replacement in Power Steering System.




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.

25. Connect the intermediate shaft to the power steering gear.
26. Install the intermediate shaft lower pinch bolt.

Tighten
Tighten the bolt to 45 N·m (33 lb ft).




27. Install both of the front fascia extensions (3). Refer to Front Bumper Fascia Extension Replacement in Bumpers.
28. Install the front air deflector. Refer to Front Air Deflector Replacement in Body Front End.
29. Install the front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
30. Lower the vehicle.



31. Install the upper transaxle case to engine bolts (2-5).

Tighten
Tighten the transaxle bolts to 75 N·m (55 lb ft).

32. Remove the engine support fixture.



33. Install the range selector cable bracket (2) to the transmission case.
34. Install the range selector cable bracket bolts (1).

Tighten
Tighten the bolts to 25 N·m (18 lb ft).

35. Check adjustment of the range selector cable. Re-adjust as needed. Refer to Range Selector Lever Cable Adjustment .



36. Install ground cable and bolt (1) to transaxle.

Tighten
Tighten the ground cable bolt to 17 N·m (13 lb ft).




37. Connect the transaxle electrical connector C100 (2).
38. Install the wiring harness (3) into the wiring harness retainer (1) on the transaxle.
39. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.8L.
40. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.



41. Remove the J 42640 from the steering column.
42. Fill the transaxle to the proper level. Refer to Fluid Capacity Specifications .
43. Inspect the transaxle fluid level. Refer to Transmission Fluid Check .
44. Inspect for fluid leaks.
45. Clear transmission adaptive pressures (TAPS). Refer to Scan Tool Output Controls .
46. Check the front end alignment.
47. Road test the vehicle and check for transaxle leaks.