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307-02 Transmission-Transaxle Cooling > < Transaxle - 1.9L Diesel

Galaxy 2000.75 (04.2000-02.2006)

Automatic Transmission/Transaxle - Vehicles With: AG5 - Transaxle—2.8L Galaxy 2000.75 (04/2000-02/2006)
Installation

Special Tool(s)

Support Bar, Engine

303-290A (21-140A)

Adapter for 303-290A

303-290-02 (21-140-02)

Adapter for 303-290A

303-290-04A (21-140-04A)

Lifting Bracket, Engine

303-122 (21-068A)

Splined Bit Set (M12/M14)

303-702 (21-253)
General Equipment
Retaining straps
Transmission jack
Steel straight edge
Materials
Name
Specification
Automatic transmission fluid
N052990VX00 

Installation

  1. CAUTION:
    CAUTION:The torque converter must remain at the correct installation depth throughout the whole installation procedure.
    NOTE:
    NOTE:The torque converter studs must be aligned with the engine drive plate holes before any transaxle retaining bolts are installed.
    Install the torque converter.

  1. CAUTION:
    CAUTION:The torque converter hub must engage fully in the oil pump drive gear.
    Check the installation depth of the torque converter.
    • Using a suitable straight edge, check the installation depth between the transaxle flange and the drive plate studs.

  1. NOTE:
    NOTE:Secure the transaxle to the transmission jack with the retaining straps before raising the transaxle.
    Using a suitable transmission jack and wooden block, raise and position the transaxle.

  1. NOTE:
    NOTE:Do not fully tighten the transaxle retaining bolts at this stage.
    Install the transaxle retaining bolts.
    1. Install the M12 x 40 mm bolt.
    1. Install the M12 x 50 mm bolt.
    1. Install the M12 x 65 mm bolt.
    1. Install the M12 x 60 mm bolt.
    1. Install the M10 x 55 mm bolts.
    1. Install the M12 x 70 mm bolt.

  1. Tighten the transaxle right-hand retaining bolts.

  1. Using the special tool, tighten the transaxle left-hand retaining bolts (two bolts).
    • Install the transaxle ground connection.

  1. Using the special tool, tighten the transaxle right-hand retaining bolt.

  1. Using the special tool, tighten the transaxle lower retaining bolts.

  1. NOTE:
    NOTE:Install new torque converter retaining nuts.
    Install the torque converter retaining nuts.
    • Rotate the torque converter to gain access to the remaining nuts.
    • Install the plastic cover.
  1. Lower the vehicle.

  1. NOTE:
    NOTE:Install new transaxle rear mount retaining bolts.
    Install the engine and transaxle rear mount retaining bracket.
    • Tighten the bolts in two stages.
    • Stage 1: 60 Nm.
    • Stage 2: 90 degrees.

  1. Using the special tools, raise the engine and transaxle assembly.

  1. NOTE:
    NOTE:Install new engine and transaxle rear mount retaining nuts and bolts at position 2 and 3.
    Install the engine and transaxle rear mount retaining nut and bolts.
    1. Tighten the bolt.
    1. Tighten the bolts and nut in two stages

        2. 1. Stage 1: 90 Nm.

        2. Stage 2: 90 degrees.

    1. Tighten the nut in two stages

        2. 1. Stage 1: 50 Nm.

        2. Stage 2: 90 degrees.

  1. Remove the special tools.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. CAUTION:
    CAUTION:Support the halfshaft. The inner joint must not be bent more than 20 degrees. The outer joint must not be bent more than 50 degrees.
    Attach the left-hand halfshaft to the output shaft drive flange.

  1. CAUTION:
    CAUTION:Support the halfshaft. The inner joint must not be bent more than 20 degrees. The outer joint must not be bent more than 50 degrees.
    NOTE:
    NOTE:Install new center bearing locknuts.
    Attach the right-hand halfshaft and the intermediate shaft to the output shaft drive flange.
    1. Attach the intermediate shaft to the output shaft drive flange.
    1. Attach the center bearing to the bearing carrier (two bolts, one bolt shown).

  1. Attach the lower arms to the wheel knuckles.

  1. Install the engine support insulator.
    1. Tighten the bolt.
    1. Tighten the bolts in two stages.
    • Stage 1: 60 Nm.
    • Stage 1: 90 degrees.

  1. Connect the transaxle control electrical connector.
    • Rotate the locking lever clockwise.

  1. Attach the cable bracket to the transaxle fluid pan (three nuts).

  1. Attach the ground cable to the transaxle.

  1. Install the secondary air injection (AIR) pump.
    1. Connect the hose.
    1. Connect the electrical connector.
    1. Install the bolts.

  1. Install the AIR pump intake pipe and ball valve.

  1. NOTE:
    NOTE:Install a new exhaust flange gasket.
    Attach the exhaust pipe to the exhaust downpipe (three bolts).
  1. Lower the vehicle.

  1. Attach the radiator grille opening panel reinforcement to the fender on both sides.

  1. NOTE:
    NOTE:Install new transaxle fluid cooler O-ring seals
    NOTE:
    NOTE:Check the install position.
    Attach the transaxle fluid cooler to the transaxle case.

  1. Tighten the transaxle upper retaining bolt.

  1. Install the starter motor (two bolts).

  1. Connect the transmission range (TR) sensor electrical connector.

  1. Attach the selector lever cable to the transaxle.
    1. Attach the selector lever cable to the manual control lever.
    1. Attach the selector lever cable bracket to the transaxle.

  1. Attach the selector lever cable to the selector lever cable bracket.

  1. Connect the starter motor cables.
    • Connect the starter motor electrical connector.
    • Attach the battery cable to the starter motor solenoid.
    • Install the protective cap.

  1. Install the battery tray.

  1. Attach the engine wiring harness rail to the battery tray.

  1. Install the battery side cover.

  1. Connect the engine wiring harness electrical connectors.
    • Attach the wiring harness to the battery tray.

  1. Connect the engine coolant level indicator electrical connector.

  1. Install the bulkhead cover.
  1. Check that the selector lever position indicator corresponds with the transaxle operation.
  1. If the selector lever position does not correspond with the transaxle operation in all setting, adjust the selector lever cable. For additional information, refer to Section  307-05 Automatic Transmission/Transaxle External Controls.
  1. Install the air cleaner. For additional information, refer to Section  303-12 Intake Air Distribution and Filtering.
  1. Install the hood. For additional information, refer to Section  501-02 Front End Body Panels.
  1. Install the battery. For additional information, refer to Section  414-01 Battery, Mounting and Cables.
  1. Fill the transaxle with automatic transmission fluid.
    For additional information, refer to Transmission Fluid Drain and Refill in this section.
  1. Install the engine and battery upper cover.

307-02 Transmission-Transaxle Cooling > < Transaxle - 1.9L Diesel