SMU - Revised Case Side Cover Replacement Procedure

This bulletin is being issued to revise the Case Side Cover Replacement procedure in the Automatic Transaxle - 4T65-E sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information.

The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page.

Removal Procedure

Tools Required

J 36850 Transjel Lubricant

1. Remove the engine dress cover.
2. Remove the air induction bellows between the throttle body and air cleaner assembly.
3. Disconnect the accelerator and cruise cables at throttle valve and remove the accelerator controls cable bracket. Refer to Accelerator Controls Cable Bracket Replacement in Engine Controls - 3.4L or Accelerator Controls Cable Bracket Replacement in Engine Controls - 3.8L.



4. Remove the transaxle shift cable from lever and bracket from the transaxle.
5. Disconnect the transaxle wiring harness connector and disconnect the harness retainer from side cover stud.
6. Remove both engine supports from engine and radiator support.



7. Remove the top case side cover bolt (56,58).
8. Install the engine support fixture and support engine/transaxle assembly. Refer to Engine Support Fixture in Engine Mechanical - 3.4L or Engine Support Fixture in Engine Mechanical - 3.8L.
9. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
10. Remove the left front wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
11. Remove the inner fender splash shield.
12. Remove the wheel speed sensor harness from 4 retainers on the lower control arm.
13. Remove the transmission mount-to-frame nuts (2).
14. Remove both stabilizer links and reposition stabilizer to access steering gear- to-frame bolts.
15. Remove steering gear-to-frame bolts and support steering gear.
16. Remove the front splash shield. Refer to Splash Shield Replacement - Engine - Left and Splash Shield Replacement - Engine - Right in Body Front End.
17. Remove the positive battery cable center retainer at front frame rail.
18. Remove the left side ball joint and support the left frame rail with a jack stand.
19. Remove ONLY the left two frame-to-body bolts. DO NOT LOOSEN right side frame-to-body bolts.
20. Lower frame with a jackstand and remove jackstand.
21. Position the drain pan under the transaxle.
22. Remove the left drive axle from the transaxle. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.
23. Secure the drive axle to the strut assembly.
24. Lower the vehicle.
25. Using the engine support fixture lower the engine assembly to access the transaxle case side cover.
26. Raise the vehicle.



27. Remove the transaxle mount bracket bolts and the bracket from the transaxle.



28. Remove the remaining case side cover bolts (56,57,58).



29. Remove the case side cover (53).
30. Remove the case side cover gasket (54).
31. Remove the case side cover O-ring (59).
32. Clean the side cover gasket mating surfaces.

Installation Procedure

1. Install the J 36850 to the case side cover O-ring (59).
2. Install the O-ring (59) to the case side cover.
3. Install the case side cover gasket (54).
4. Install the case side cover (53), by first installing any 2 of the upper case side cover bolts (56, 58).




Notice: Refer to Fastener Notice in Cautions and Notices.

5. Install the case side cover bolts (56,57,58).

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




6. Install the transaxle mount bracket
7. Install the transaxle mount bracket bolts.

Tighten
Tighten the bolts to 95 N·m (70 lb ft)

8. Install a jackstand under the left frame rail and raise frame while aligning transaxle mount bolts with frame and ball joint with steering knuckle.
9. Install and tighten left side frame-to-body bolts (2).
10. Install the drive axle to the transaxle.
11. Remove the drain pan from under the transaxle.
12. Install transaxle mount nuts (2).
13. Install the ball joint nut and cotter pin.
14. Install steering gear-to-frame bolts.
15. Install the positive battery cable center retainer on the front frame rail.
16. Reposition the stabilizer bar and install bolts-to-lower control arms.
17. Install the front splash shield. Refer to Splash Shield Replacement -- engine -- Left and Splash Shield Replacement -- Engine -- Right in Body Front End.
18. Install the wheel speed sensor harness to 4 retainers on the lower control arm.
19. Install the inner fender splash shield.
20. Install the left front wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
21. Lower the vehicle.
22. Remove the engine support fixture.



23. Install the top case side cover bolt.

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




24. Install the shift cable to the shift lever and transaxle shift cable bracket bolts to shift cable bracket.

Tighten
Tighten bolts to 30 N·m (22 lb ft).

25. Connect the transaxle wiring harness connector, and harness retainer to side cover stud.
26. Install the engine mount struts. Refer to Engine Mount Strut Replacement -- Left and Engine Strut Mount Replacement -- Right in Engine Mechanical - 3.4L or Engine Strut Mount Replacement -- Left and Engine Strut Mount Replacement -- Right in Engine Mechanical - 3.8L.
27. Install the accelerator cable bracket with the accelerator and cruise control cables. Refer to Accelerator Controls Cable Bracket Replacement in Engine Controls - 3.4L or Accelerator Controls Cable Bracket Replacement in Engine Controls - 3.8L.
28. Install the air induction duct. Refer to Air Cleaner Intake Duct Replacement in Engine Controls - 3.4L or Air Cleaner Intake Duct Replacement in Engine Controls - 3.8L.
29. Install the engine dress cover.

Notice: Refer to Do Not Overfill the Transmission Notice in Cautions and Notices.

30. Check and fill the transaxle as necessary.
31. Inspect for fluid leaks.

Removal Procedure

Tools Required

J 36850 Transjel Lubricant

1. Remove the engine dress cover.
2. Disconnect the MAF sensor harness connector from the MAF and disconnect the air intake duct from throttle body.
3. Disconnect the EVAP emission hose from the EVAP valve.



4. Remove the transaxle shift cable from the shift lever.
5. Remove the transaxle shift cable bracket bolts and the bracket from the transaxle.
6. Disconnect the transaxle wiring harness connector.
7. Remove both engine supports from the engine and radiator support.



8. Remove top side cover bolt (56,58).
9. Install the engine support fixture. Refer to Engine Support Fixture in Engine Mechanical - 3.8L.
10. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
11. Remove the left front wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
12. Remove the inner fender splash shield.
13. Remove the wheel speed sensor harness from 4 retainers on lower control arm.
14. Remove the transmission mount-to-frame nuts (2).
15. Using side cutters, remove the plastic pencil-like support on the left side of the front splash shield, just below the left front frame bolt.
16. Remove the front cradle to radiator support brackets on each side.
17. Remove both stabilizer links from the stabilizer and reposition stabilizer to access steering gear- to-frame bolts.
18. Remove steering gear-to-frame bolts and support steering gear.
19. Remove the positive battery cable center retainer at front rail.
20. Remove the left side ball joint from the steering knuckle.
21. Support the left frame rail with a jack stand.
22. Remove only the left two frame-to-body bolts. DO NOT LOOSEN RIGHT SIDE FRAME-TO-BODY BOLTS.
23. Lower the frame with jack stand and remove jack stand.
24. Position the drain pan under transaxle side cover.
25. Remove the left drive axle from the transaxle. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.
26. Secure the drive axle to the strut assembly.
27. Lower the vehicle.
28. Using the engine support fixture lower the engine assembly to access the transaxle case side cover.
29. Raise the vehicle.



30. Remove the transaxle mount bracket bolts and the bracket from the transaxle.



31. Remove the remaining case side cover bolts (56,57,58).



32. Remove the case side cover (53).
33. Remove the case side cover gasket (54).
34. Remove the case side cover O-ring (59).
35. Clean the side cover gasket mating surfaces.

1. Install the J 36850 Transjel Lubricant to the case side cover O-ring (59).
2. Install the O-ring (59) to the case side cover.
3. Install the case side cover gasket (54).
4. Install the case side cover (53).




Notice: Refer to Fastener Notice in Cautions and Notices.

5. Install the case side cover bolts (56,57,58) except top bolt.

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




6. Install the transaxle mount bracket
7. Install the transaxle mount bracket bolts.

Tighten
Tighten the bolts to 95 N·m (70 lb ft)

8. Install a jack stand under the left frame rail and raise frame while aligning transaxle mount bolts with frame and ball joint with the steering knuckle.
9. Install and tighten the left side frame-to-body bolts (2).
10. Install front cradle to radiator support brackets and bolts to both sides.
11. Install drive axle to transaxle.
12. Install transaxle mount nuts (2).
13. Install the ball joint nut and cotter pin.
14. Install the steering gear-to-frame bolts.
15. Install the positive battery cable center retainer on front frame rail.
16. Reposition the stabilizer bar and install bolts to stabilizer.
17. Install the wheel speed sensor harness to four retainers on the lower control arm.
18. Install the inner fender splash shield.
19. Install the left front wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
20. Lower the vehicle and remove the engine support fixture.



21. Install the top case side cover bolt.

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




22. Install the transaxle shift cable bracket and shift cable bracket bolts.

Tighten
Tighten the bolts to 30 N·m (22 lb ft).

23. Install the transaxle shift cable to the shift lever.
24. Connect the transaxle wiring harness connector.
25. Install the engine mount struts. Refer to Engine Mount Strut Replacement - Right and Engine Mount Strut Replacement - Left in Engine Mechanical - 3.8L.
26. Install the air intake duct and connect the MAF sensor wiring harness.
27. Install the EVAP hose to EVAP valve.
28. Install the engine dress cover.

Notice: Refer to Do Not Overfill the Transmission Notice in Cautions and Notices.

29. Check and fill the transaxle as necessary.
30. Inspect for fluid leaks.

Removal Procedure

Important: Lock steering wheel in centered position with wheels straight ahead.

1. Remove the engine dress cover.
2. Remove the air cleaner intake duct. Refer to Air Cleaner Intake Duct Replacement in Engine Controls - 3.1L or Air Cleaner Intake Duct Replacement in Engine Controls - 3.8L.
3. Remove the engine mount struts. Refer to Engine Mount Strut Replacement in Engine Mechanical - 3.1L or Engine Mount Strut Replacement - Right and Engine Mount Strut Replacement - Left in Engine Mechanical - 3.8L.

Important: For supercharged engines, remove the throttle cable bracket.

4. Disconnect the shift cable bracket.
5. Remove the transaxle top side cover bolt.
6. Install the engine support fixture. Refer to Engine Support Fixture in Engine Mechanical - 3.1L or Engine Support Fixture in Engine Mechanical - 3.8L.
7. Disconnect the transmission wiring harness connector.
8. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
9. Remove the left front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
10. Remove the left inner splash shield 3 push pins.
11. Loosen the wheel speed sensor harness from the 5 retainers at the cradle.
12. Remove the transmission support to cradle nuts only. Refer to Automatic Transmission Mount Replacement.
13. Raise the vehicle.
14. Remove the front splash shield 5 bolts.
15. Loosen the engine mount lower nuts. Refer to Engine Mount Bracket Replacement in Engine Mechanical - 3.1L or Engine Mount and Bracket Replacement in Engine Mechanical - 3.8L.
16. Remove the stabilizer bolts and reposition the stabilizer.
17. Remove the steering gear cradle bolts, then support gear before lowering cradle.
18. Support the left side of the frame with a jackstand.
19. Remove the left side frame bolts. DO NOT loosen the right front or the right rear frame bolts. Refer to Frame Replacement in Frame and Underbody.
20. Remove the left ball joint from the steering knuckle.
21. Position the drain pan under the transaxle.
22. Remove the left drive axle from the transaxle. Refer to Wheel Drive Shaft Replacement in Drive Axle.
23. Secure the drive axle to the steering knuckle/strut.
24. Adjust the jackstand to lower the left side of the frame until it hangs free. Remove jack stand.
25. Lower vehicle to access engine support fixture.
26. Lower the engine/transmission assembly with the engine support fixture to gain access to remaining side cover bolts.
27. If replacing the side cover, remove 4 engine mount bracket bolts.
28. Remove the harness retainer.
29. Raise vehicle to access side cover bolts.



30. Remove the case side cover bolts (56-58).



31. Remove the case side cover pan (53).
32. Remove the case side cover gasket (54).
33. Clean the case.
34. Clean the side cover gasket mating surfaces.

1. Install the case side cover gasket (54).
2. Install the case side cover pan (53).




Notice: Refer to Fastener Notice in Cautions and Notices.

3. Install the case side cover bolts (56-58) except for the top bolt.

Tighten
Tighten bolts (56-58) to 25 N·m (18 lb ft).

4. Install the left drive axle to the transaxle. Refer to Wheel Drive Shaft Replacement in Drive Axle.
5. Raise the vehicle.
6. Use a jackstand to raise the left side of the cradle and engine assembly into position.
7. Install the left ball joint into knuckle.
8. Install the left side frame bolts .

Tighten
Tighten the bolts to 165 N·m (122 lb ft).

9. Install the engine mount lower nuts. Refer to Engine Mount Bracket Replacement in Engine Mechanical - 3.1L or Engine Mount and Bracket Replacement in Engine Mechanical - 3.8L.
10. Install the transaxle mount nuts.

Tighten
Tighten the nuts to 47 N·m (35 lb ft).

11. Remove the jackstands from the frame.
12. Remove the drain pan from under the transaxle.
13. Install the ball joint nut, and cotter pin.
14. Install the steering gear cradle bolts.

Tighten
Tighten the bolts to 80 N·m (59 lb ft).

15. Reposition the stabilizer and install the stabilizer bolts .

Tighten
Tighten the bolts to 23 N·m (17 lb ft).

16. Install the front splash shield 5 bolts.
17. Lower the vehicle.
18. Install two engine mount bolts.

Tighten
Tighten the bolts to 47 N·m (35 lb ft).

19. Install the wheel speed sensor harness to the 5 retainers at the cradle.
20. Install the left inner splash shield 3 push pins.
21. Install the left front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
22. Lower the vehicle.
23. Remove the engine support fixture.
24. Connect the shift cable bracket.
25. Install the transaxle top side cover bolt.
26. Connect the transaxle wiring harness connector.

Important: Install the throttle cable bracket, if previously removed (Supercharged) .

27. Install the engine mount struts. Refer to Engine Mount Strut Replacement in Engine Mechanical - 3.1L or Engine Mount Strut Replacement - Right and Engine Mount Strut Replacement - Left in Engine Mechanical - 3.8L.
28. Install the throttle body air inlet duct. Refer to Air Cleaner Intake Duct Replacement in Engine Controls - 3.1L or Air Cleaner Intake Duct Replacement in Engine Controls - 3.8L.
29. Install the engine dress cover.

Notice: Refer to Transmission Overfill Notice in Cautions and Notices.

30. Check and fill the transaxle as necessary.
31. Inspect for fluid leaks.