Transmission Replacement (1.6L LDE)
Special Tools
• |
CH-49290
Engine Support Tool |
• |
DT-47648
Transmission Holder |
• |
EN-47649
Engine Support Fixture |
For equivalent regional tools, refer to
Special Tools .
Removal Procedure
|
Note: Do NOT
disconnect engine coolant hoses.
|
2. |
Remove radiator surge tank
clip (2). |
3. |
Remove radiator surge tank (1)
and lay aside. |
4. |
Remove shift lever and
selector lever cable (2) from transmission control housing
(3). |
5. |
Remove shift lever and
selector lever cable from shift lever and selector lever cable
bracket (1). |
6. |
Disconnect backup lamp switch
electrical connector. |
|
Note: Before
disconnecting the clutch actuator cylinder front pipe, remove the
clutch/brake fluid from the reservoir tank. Place basin
underneath.
|
7. |
Disconnect clutch actuator
cylinder front pipe (1) from clutch master cylinder. |
8. |
Open retaining clip
(arrow). |
9. |
Disconnect clutch actuator
cylinder front pipe (1) from clutch actuator cylinder pipe
elbow. |
10. |
Remove 3 upper transmission
bolts (1). |
|
Note: The SPX
installation manual is supplied with the special tool and is also
available online from SPX directly. Go to www.spxtools-shop.com
|
12. |
Assemble the CH-49290
support tool (1) according to the details provided in the
SPX installation manual. |
13. |
Support the CH-904
base frame on a jack. |
14. |
Support the CH-49290
support tool on the CH-904 base frame
. |
|
Note: The SPX
installation manual is supplied with the special tool and is also
available online from SPX directly. Go to www.spxtools-shop.com
|
15. |
Install the CH-49290
support tool (1) according to the details provided in the
SPX installation manual. |
17. |
Remove the transmission front
mount bolts (1) and the transmission front mount (2). |
18. |
Remove the transmission mount
bracket - rear bolts (1) and the transmission mount bracket - rear
(2). |
|
Note: In order to
drain transmission fluid the clutch and differential housing cover
must be removed.
|
25. |
Remove and DISCARD the
transmission mount bolts - left side (1) from transmission mount
bracket - left side. |
26. |
Lower the engine and the
transmission on the left hand side with the EN-47649
engine support fixture . |
27. |
Remove transmission mount
bracket bolts - left side (1) from transmission (2). |
29. |
Remove 3 transmission lower
bolts (1, 3) |
30. |
Remove transmission lower bolt
(2) and nut (4) |
31. |
Place DT-47648
transmission holder on CH-904 base frame and
preinstall the supports as shown in the illustration. |
32. |
Preinstall DT-47648-2
clutch housing support (4) to position 2 on the base
plate. |
33. |
Preinstall DT-47648-4
transmission housing support (2) to position 14 on the base
plate. |
34. |
Preinstall DT-47648-5
left support with rear transmission swivel arm (1) to
position A on the base plate. |
35. |
Preinstall DT-47648-5
right support with front transmission swivel arm (3) to
position F on the base plate. |
|
Note: Before placing
in position slacken all bolt connections of the swivel arms and
supports as far as the base plate. Adjust the supports for the
converter housing and transmission housing using the spindles until
they are as low as possible.
|
36. |
Attach the DT-47648
holder to the transmission. |
37. |
Align DT-47648
holder under transmission. |
38. |
Attach swivel arms (1, 2) to
transmission. |
|
Note: Align the
swivel arms so that as little leverage as possible is created.
|
39. |
Tighten the bolt connections
of the swivel arms, starting from the transmission and going as far
as the base plate. |
40. |
Position supports for clutch
housing and transmission housing to transmission by twist up the
spindles. |
41. |
Tighten bolt connections of
the supports. |
42. |
Remove last lower transmission
bolt (1). |
43. |
Separate the transmission from
the engine. |
44. |
Lower the transmission with
the transmission jack and DT-47648 holder far
enough to remove the transmission. |
Installation Procedure
1. |
Raise the transmission with
the transmission jack and DT-47648 holder and
position the transmission to the engine. |
2. |
Install lower transmission
bolt (1) and tighten to 60 N·m (44 lb ft)
. |
3. |
Remove the transmission jack
with the DT-47648 holder . |
4. |
Install 3 transmission lower
bolts (3) and tighten to 40 N·m (32 lb ft)
. |
5. |
Install transmission bolt (1)
and tighten to 60 N·m (44 lb ft) .
|
6. |
Install transmission lower
bolt (2) and nut (4) and tighten to 40 N·m (32 lb
ft) . |
8. |
Install transmission mount
bracket bolts - left side (1) to transmission (2) and tighten to
100 N·m (74 lb ft) . |
9. |
Raise the engine and the
transmission on the left hand side with the EN-47649
engine support fixture . |
10. |
Install the NEW transmission
mount - left side bolts (1) but do not tighten yet. |
14. |
Install the transmission mount
bracket - rear (2) and tighten the bolts (1) to 100
N·m (74 lb ft) . |
15. |
Install the transmission front
mount (2) and tighten the bolts (1) to 100 N·m (74
lb ft) . |
19. |
Tighten the NEW transmission
mount bolts left side (1) a first pass to 50 N·m (37
lb ft) . |
20. |
Tighten the NEW transmission
mount bolts left side (1) a final pass to an additional 60
- 75 degrees , using the EN-45059 meter
. |
22. |
Lower the CH-49290
support tool (1) with the CH-904 base frame
and a jack. |
23. |
Remove the CH-49290
support tool from the CH-904 base frame
. |
|
Note: The SPX
installation manual is supplied with the special tool and is also
available online from SPX directly. Go to www.spxtools-shop.com
|
24. |
Disassemble the
CH-49290 support tool (1) according to the details
provided in the SPX installation manual. |
25. |
Install the upper transmission
bolts (1) and tighten to 60 N·m (44 lb ft)
. |
26. |
Connect clutch actuator
cylinder front pipe (1) to clutch actuator cylinder pipe
elbow. |
27. |
Close retaining clip
(arrow). |
28. |
Connect the electrical
connector to the backup lamp switch. |
29. |
Install shift lever and
selector lever cable (2) to shift lever and selector lever cable
bracket (1). |
30. |
Install shift lever and
selector lever cable to transmission control housing (3).
|
34. |
Install radiator surge tank
(1). |
35. |
Install radiator surge tank
clip (2). |
37. |
Road test the vehicle.
|
|