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Unread 05-18-2011, 04:21 PM   #1
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Clutch Job - Gas Engine

This thread will have several "referals" that are noted in the top of the posts.

Clutch Job

FIG 1
Raise hood, remove the resonator, remove engine cover, remove air cleaner assembly, disconnect negative battery cable, unplug the speed sensor connector (if equipped), disconnect back-up lamp switch connector (2).

FIG 2
Remove shift cable-to-bracket clips (1).

FIG 3
Disconnect shift selector and crossover cable (1) from levers. Remove cables and secure out of the way.
Remove the slave cylinder hose at bracket.

FIG 4
Remove the air inlet tube (1) by loosing the screw (2) at the throttle body (3).

FIG 5
Remove the throttle body support bracket bolts (1).
Remove the throttle body support bracket (2).
Remove upper bell housing bolts.
Remove the starter bolts and slide the starter back. (Refer to STARTER in this section)

1.jpg   2.jpg   3.jpg   4.jpg   5.jpg  

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Unread 05-18-2011, 04:23 PM   #2
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CLUTCH JOB cont.

FIG 6
Support transmission and loosen the left/upper transmission mount through bolt (1).
Remove the transmission mount bolts (2)
Raise vehicle on hoist.

FIG 7
Remove the splash shields (refer to SPLASH SHIELDS in this section)
Remove transaxle oil drain plug (2) and drain oil into a suitable container.
[I]Reinstall drain plug and tighten to 14 N·m (120 in. lbs.).
Remove both axle halfshafts (Refer to HALF SHAFTS – Front in this section)

Remove Power Transfer Unit (PTU) if equipped. (refer to Power Transfer Unit 4X4 in this section)

FIG 8
Support the engine with a screw jack (1) and the transmission with a transmission jack.
Remove bell housing dust cover (3).

FIG 9
Remove four modular clutch-to-drive plate bolts (1). While removing bolts, one tight-tolerance (slotted) drive plate hole will be encountered. When this bolt is removed, mark drive plate and modular clutch assembly at this location, and be sure to align marks upon reassembly.

FIG 10
Remove the front transmission mount through bolt (4). [FONT=Times New Roman]Remove the transmission crossmember mounting bolts (2, 3).
Remove the transmission crossmember (1).
6.jpg   7.jpg   8.jpg   9.jpg   10.jpg  

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Unread 05-18-2011, 04:24 PM   #3
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CLUTCH JOB cont.

FIG 11
Remove the rear transmission through bolt (4).
Remove the rear transmission mount bolts (3) and mount (1) from the frame. Remove the rear transmission mount bracket bolts and bracket from transmission.

FIG 12
Remove the remaining transmission bell housing bolts (1).
Carefully lower engine and transaxle on screw jack and transmission jack until proper removal clearance is obtained.
Obtain a helper to assist in holding transaxle while removing transaxle-to-engine mounting bolts.
Remove transaxle from vehicle.

FIG 13
Remove clutch module from transaxle input shaft (1).
11.jpg   12.jpg   13.jpg  
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Unread 05-18-2011, 04:25 PM   #4
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DRIVE SHAFT

FIG 1
Raise the vehicle on the hoist and mark (2) driveshaft and differential (3) for proper installation.

FIG 2
Remove rear driveshaft to rear axle retaining nuts (2).

FIG 3
Remove the three bolts (3) from the center support heat shield (2).

CAUTION: Propeller shaft removal. Never allow propeller shaft to hang while connected to Power Transfer Unit (PTU), rear driveline module flanges or center bearings. If propeller shaft section is hung unsupported, damage may occur to joint, boot and/or center bearing from over-angulation. This may result in vibration/balance issues. A helper may be needed.

FIG 4
Remove the heat shield (2) and remove the two center support mounting bolts (3).

FIG 5
Remove the drive shaft (1).
1.jpg   2.jpg   3.jpg   4.jpg   5.jpg  

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Unread 05-18-2011, 04:27 PM   #5
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HALF SHAFTS - Front

CAUTION: Boot sealing is vital to retain special lubricants and to prevent foreign contaminants from entering the CV joint. Mishandling, such as allowing the assemblies to dangle unsupported, or pulling or pushing the ends can cut boots or damage CV joints. During removal and installation procedures, always support both ends of the halfshaft to prevent damage.

CAUTION: The halfshaft, when installed, acts as a bolt and secures the front hub/bearing assembly. If vehicle is to be supported or moved on its wheels with a halfshaft removed, install a PROPER–SIZED BOLT AND NUT through front hub. Tighten bolt and nut to 244 N·m (180 ft. lbs.). This will ensure that the hub bearing cannot loosen.

FIG 1
Disconnect battery negative cable, place transaxle in gated park (1st gear?), raise vehicle on hoist, remove wheel and tire assembly (1).


Halfshaft Retaining Hardware
FIG 2a
Remove the cotter pin (1), nut lock (5), spring washer (4), and hub nut (3) from the end of the outer C/V joint stub axle.

Fig 2b
If equipped with ABS, disconnect the front wheel speed sensor and secure harness out of the way.
Remove nut and bolt (1,2) retaining ball joint stud (3) into steering knuckle.

NOTE: Use caution when separating ball joint stud from steering knuckle, so ball joint seal does not get damaged.

FIG 3
Separate ball joint stud (4) from steering knuckle (1) by prying down on lower control arm (3).

NOTE: Care must be taken not to separate the inner CV joint during this operation. Do not allow halfshaft to hang by inner CV joint, halfshaft must be supported.

FIG 4
Remove halfshaft (2) from steering knuckle by pulling outward on knuckle while pressing in on halfshaft. Support outer end of halfshaft assembly. If difficulty in separating halfshaft from hub is encountered, do not strike shaft with hammer, instead use Puller to separate.
1.jpg   2a.jpg   2b.jpg   3.jpg   4.jpg  

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Unread 05-18-2011, 04:28 PM   #6
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HALF SHAFTS - Front cont.

FIG 5
Two wheel drive vehicles, remove halfshaft bracket (2) from engine lower mounting bolt (3).

FIG 6
Two wheel drive vehicles, remove halfshaft bracket from engine upper mounting bolts (2).
Support outer end of the halfshaft assembly.

NOTE: Removal of the inner tripod joints is made easier if you apply outward pressure on the joint as you strike the punch with a hammer. Do not pull on interconnecting shaft to remove, as the inner joint will become separated.

FIG 7
Remove the inner tripod joints (4) from the side gears of the transaxle using a punch (2) to dislodge the inner tripod joint retaining ring from the transaxle side gear. If removing the right side inner tripod joint, position the punch to the inner tripod joint extraction groove (5) (if equipped). Strike the punch sharply with a hammer to dislodge the right inner joint from the side gear. If removing the left side inner tripod joint, position the punch to the inner tripod joint extraction groove. Strike the punch sharply with a hammer to dislodge the left inner tripod joint from the side gear.


FIG 8
Hold inner tripod joint (1) and interconnecting shaft (6) of halfshaft assembly. Remove inner tripod joint from transaxle by pulling it straight out of transaxle side gear and transaxle oil seal (4). When removing tripod joint, do not let spline or snap ring drag across sealing lip of the transaxle to tripod joint oil seal. When tripod joint is removed from transaxle, some fluid will leak out.

CAUTION: The halfshaft, when installed, acts as a bolt and secures the front hub/bearing assembly. If vehicle is to be supported or moved on its wheels with a halfshaft removed, install a PROPER–SIZED BOLT AND NUT through front hub. Tighten bolt and nut to 244 N·m (180 ft. lbs.). This will ensure that the hub bearing cannot loosen.
5.jpg   6.jpg   7.jpg   8.jpg  
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Unread 05-18-2011, 04:29 PM   #7
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MUFFLER

WARNING: The normal operating temperature of the exhaust system is very high. Therefore, never work around or attempt to service any part of the exhaust system until it is cooled. Special care should be taken when working near the catalytic converter. The temperature of the converter rises to a high level after a short period of engine operating time.

NOTE: When replacement is required on any component of the exhaust system, you must use original equipment parts (or their equivalent). Sure

Raise vehicle on hoist and apply penetrating oil to band clamp nut and bolt of component being removed.

NOTE: Do not use petroleum-based lubricants when removing/installing muffler or exhaust pipe isolators (3) as it may compromise the life of the part. A suitable substitute is a mixture of liquid dish soap and water.

Remove exhaust system ground strap (1) at rear of I-Pipe/Muffler assembly (2).

Loosen band clamp and remove support isolators (3) at I-Pipe/Muffler assembly (2). Remove I-Pipe/Muffler assembly (2) from catalytic converter.

Clean ends of pipes and muffler to assure mating of all parts. Discard broken or worn isolators, rusted or overused clamps, supports, and attaching parts
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Unread 05-18-2011, 04:30 PM   #8
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POWER TRANSFER UNIT (PTU)

FIG 1
Disconnect negative battery cable (2), remove the engine trim cover, remove air cleaner assembly (1), remove Power Distribution Center (PDC) from bracket, raise the vehicle on the hoist, Remove front halfshafts (refer to HALFSHAFTS – Front

FIG 2
Remove drain plug (2) at PTU and allow fluid to drain, reinstall drain plug.

FIG 3
Mark (2) drive shaft and differential (3) for proper installation, remove the rear drive shaft (Refer to DRIVESHAFT)[/SIZE][/FONT]

FIG 4
Remove the two exhaust to maniverter (exhaust manifold w/catalytic converter) bolts (1).
Unplug the downstream O2 sensor connector.
Remove the exhaust system (Refer to MUFFLER)
Lower the vehicle on the hoist.
Unplug the upstream O2 sensor connector.

FIG 5
Remove upstream O2 sensor from the maniverter using O2s (Oxygen Sensor) Remover/Installer (2).
1.jpg   2.jpg   3.jpg   4.jpg   5.jpg  

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Unread 05-18-2011, 04:31 PM   #9
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PTU cont.

FIG 6
Remove the four maniverter heat shield bolts (1).

FIG 7
Remove the two retaining bolts (2) and one nut (1) from the maniverter side heat shield (3).

FIG 8
Remove the seven maniverter to head retaining bolts, slide the maniverter up and to the right, support the maniverter (1) with the help of a bungee cord.

FIG 9
Raise the vehicle on the hoist, remove the four (1) engine to maniverter bracket bolts.

FIG 10
Remove the rear engine mount through bolt (2) and remove the three front engine mount to frame bolts and the mount through bolt.
6.jpg   7.jpg   8.jpg   9.jpg   10.jpg  

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Unread 05-18-2011, 04:32 PM   #10
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PTU cont

FIG 11
Remove the six PTU mounting bolts (2), three on the bottom and three on the top.

FIG 12
Install a screw jack (2) on front engine mount bracket (1).

FIG 13
Raise the front of the engine until the rear mount has dropped (1, 2), Separate the PTU from the transaxle, remove and discard old O-ring between Transmission and PTU.

FIG 14
Roll the PTU (1) forward and down to remove.
11.jpg   12.jpg   13.jpg   14.jpg  
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Unread 05-18-2011, 04:33 PM   #11
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SPLASH SHIELDS

FIG 1
Remove the front fasteners (1).

FIG 2
Remove the remaining fasteners (3 - 5) and remove the splash shield (6).
1.jpg   2.jpg  
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Unread 05-18-2011, 04:34 PM   #12
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STARTER

FIG 1
Open hood, Remove air cleaner box and air tube, disconnect and isolate the battery negative cable, remove starter motor mounting bolt.

FIG 2
Disconnect the electrical connector at throttle body.

FIG 3
Remove Throttle body bolts and remove throttle body.

FIG 4
Push starter under intake manifold, tip starter nose toward cooling module, pull starter up and out.

FIG 5
Disconnect starter motor wiring, remove starter motor from vehicle.
1.jpg   2.jpg   3.jpg   4.jpg   5.jpg  

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