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Special Tool(s) Engine Lift Bar 303-F047 (014-00073) Heater Hose Disconnect Tool 5/8 Inch 412-042 (T85T-18539-AH) Removal 1. Evaluate the A/C system. For additional information, refer to Section 412-00. 2. Disconnect the battery ground cable (14301). For additional information, refer to Section 414-01. 3. Remove the hood (16612). 4. Remove the engine air cleaner. For additional information, refer to Section 303-12. 5. Remove the radiator. For additional information, refer to Section 303-03. 6. Disconnect the climate control vacuum feed connector. 7. Position aside the power steering reservoir. For additional information, refer to Section 211-02. 8. Remove the intake manifold. For additional information, refer to Intake Manifold—Variable Resonance Induction System in this section. 9. Remove the splash shield covering the engine main harness connectors. 10. Disconnect the two starter cable leads from the starter relay. 11. Disconnect the two 42-pin connectors and the single pin connector. 12. Disconnect the 16-pin connector and the single pin connector. 13. Remove the bolts and the junction block bracket. 14. Remove the heater water hoses from the heater core. 15. On 4.6L engines, disconnect the following electrical connectors. LH ignition coil connector (A). Camshaft position (CMP) sensor electrical connector (B). Radio capacitor electrical connector (C). 16. On 4.6L engines, disconnect the following electrical connectors. RH ignition coil connector (A). Radio capacitor electrical connector (B). 17. On 4.6L engines, remove the ignition coils and ignition coil mounting brackets. 1. Remove the RH bolts. 2. Remove the RH ignition coil and bracket. 3. Remove the LH bolt. 4. Remove the LH nuts. 5. remove the LH ignition coil and bracket. 18. Remove the lower radiator hose and retaining bracket from the engine. 19. Remove the transmission oil filler tube if equipped. For additional information, refer to Section 307-01A (4R70W), or Section 307-01B (4R100). 20. Raise and support the vehicle. For additional information, refer to Section 100-02. 21. Remove the drain plug and drain the engine oil. 22. Disconnect the A/C compressor electrical connection if equipped. 23. Disconnect the crankshaft position (CKP) sensor. 24. Remove the starter motor (11001). For additional information, refer to Section 303-06. 25. Remove the A/C compressor if equipped. For additional information, refer to Section 412-03A. 26. Remove the transmission fluid cooler hose (7B093) from the block-mounted clip, if equipped. 27. Position the shift cable and bracket aside. 1. Disconnect the shift cable. 2. Remove the fasteners and position the bracket and shift cable aside. 28. Remove the bolts and the flexplate inspection cover. 29. Remove the cylinder block opening cover. 30. Remove the torque converter-to-flexplate nuts. Discard the nuts. 31. NOTE: The upper two transmission-to-engine bolts will be removed later. Remove the lower five transmission-to-engine bolts. 32. On 4×4 vehicles, loosen the bolt and position the oil cooler aside.

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1. Thoroughly clean the transmission case and extension housing in solvent and blow dry with compressed air. 2. Inspect the transmission case for the following: 1. Stripped bolt hole threads. 2. Gasket and mating surfaces for burrs or nicks. 3. Obstructions to vent and fluid passages. Cracks or warpage. 3. Inspect the extension housing for cracks, burrs or warpage. 4. Inspect case bearing for damage. Replace as needed. 5. Remove the case bearing. 1. Install the Bearing Cup Puller with Slide Hammer into case bearing. 2. Remove the case bearing. Use an oil stone to remove any nicks or burrs in the bearing case bore. 6. Install a new case bearing. 1. Assemble and install the Drive Handle and Bearing Installer. 2. Position new case bearing onto bearing installer tool. 7. Tap case bearing into case bearing bore. 8. Install the A4LD Holding Fixure Adapter. 1. Position the A4LD Holding Fixture Adapter on the rear of the transmission case. 2. Install the A4LD Holding Fixture Adapter bolts. 9. Attach the fixture arm of the Bench Mounted Holding Fixture to the A4LD Holding Fixture Adapter. 10. Install transmission into Bench Mounted Holding Fixture. Rotate the transmission so that the fluid pan rail is facing up. -MOUNTED HOLDING FIXTURE IS SECURE. 11. Using Shift Lever Seal Replacer, install the manual control lever shaft seal. Lubricate the manual control lever shaft seal with petroleum jelly. 12. Assemble the manual valve inner lever and parking lever actuating rod as shown. 13. Install the manual control lever shaft. 14. NOTE: Align the manual control lever shaft alignment groove with the manual control lever shaft spring pin bore in the transmission case. Install the manual control lever shaft spring pin. Tap the manual control lever shaft spring pin into the transmission case. 15. Install the manual valve inner lever and parking lever actuating rod on to the manual control lever shaft. 16. Install the manual valve inner lever nut on the manual control lever shaft and tighten. 17. Install the output shaft thrust washer (No. 11). Coat the output shaft thrust washer with petroleum jelly. 18. Install the park gear.

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Temperature Blend Door Actuator Removal All vehicles 1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. For additional information, refer to Section 414-01. Vehicles equipped with floor console 2. Remove the floor console. For additional information, refer to Section 501-12. All vehicles 3. Remove the floor duct panel. Remove the pin-type retainers and release the expander clip. 4. Remove the RH instrument panel brake. 1. Remove the nut. 2. Remove the bolt. 3. Remove the brace. 5. Remove the LH instrument panel lower nut and position the brace aside. 6. Disconnect the restraints control module (RCM) electrical connector. 7. Remove the RCM and bracket assembly. 1. Remove the bracket retaining bolts. 2. Remove the RCM and bracket assembly. Vehicles equipped with rear airflow duct 8. Cut the rear seat airflow duct along both sides. Fold back carpet. Cut rear seat airflow duct. 9. Fold the air duct rearwards. All vehicles 10. Remove the floor duct. 1. Remove the two screws (one each side). 2. Remove the floor duct. 11. Remove the electronic blend door actuator. 1. Disconnect the connector. 2. Remove the screws. 3. Pull down to release the actuator shaft and remove the electronic blend door actuator. Installation All vehicles 1. Install the electronic blend door actuator. 1. Connect the actuator shaft. 2. Install the screws. 3. Connect the connector. 2. Install the floor duct. 1. Install the floor duct. 2. Install the two screws (one each side). Vehicles equipped with rear airflow duct 3. Zip-tie the rear airflow duct to floor duct. 4. Reposition the carpet. All vehicles WARNING: The tightening torque of the restraints control module (RCM) retaining bolts is critical for correct system operation. 5. Install the RCM and bracket assembly. 6. Connect the restraints control module (RCM) electrical connector.

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Removal 1. If equipped with power seats, move the seat fully rearward. 2. If equipped with adjustable pedal system, move the pedal to the full forward position. 3. If equipped with a manual transmission, place the transmission in second gear. 4. Remove the passenger air bag module. For additional information, refer to Section 501-20B. 5. Close the glove compartment. 6. Position the battery junction box (BJB) aside. Release the mounting tabs. 7. Remove the bulkhead electrical connectors from inside the engine compartment. 1. Loosen the bolts. 2. Disconnect the bulkhead electrical connectors. 8. Remove the bulkhead electrical connector insulator. 9. Unclip the bulkhead electrical connectors from the dash panel. 10. Remove the instrument panel steering column cover. For additional information, refer to Instrument Panel — Steering Column Cover in this section. 11. If equipped, remove the valance panel. Remove the two pin-type retainers and release the expander clip. 12. Disconnect the restraint control module (RCM) electrical connector. 1. Release the locking tab. 2. Disconnect the RCM electrical connector. Release the wiring harness locators. 13. Disconnect the electronic blend door actuator electrical connector. Release the wiring harness locators. 14. Disconnect the climate control head vacuum harness connector. 15. Remove the LH and RH front door scuff plates. 16. Position the LH and RH door weatherstrip seals aside. 17. Remove the LH and RH A-pillar lower trim panels. 18. If equipped, remove the alternative fuel control module (AFCM). 1. Disconnect the electrical connector. 2. NOTE: The AFCM is attached with Velcro®. Remove the AFCM from the vehicle by pulling gently down and to the right. 19. Remove the LH and RH A-pillar passenger assist handles. 1. Remove the four screw covers and four screws. 2. Remove the LH and RH A-pillar passenger assist handles. 20. Remove the LH and RH windshield side garnish mouldings. 21. Disconnect the brake pedal position (BPP) switch electrical connector. Release the wiring harness locators.

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Instrument Panel Removal CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. 1. Depower the supplemental restraint system (SRS). For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering in Section 501-20B. 2. Remove the LH front wheel and tire assembly. For additional information, refer to Section 204-04. 3. Position the LH fender splash shield away from the dash panel. 1. Remove the pin-type retainers. 2. Remove the screws. 3. Position the LH fender splash shield away from the dash panel. 4. Disconnect the bulkhead electrical connector from inside the fender opening. 1. Loosen the bolt. 2. Disconnect the bulkhead electrical connector. 5. Release the bulkhead electrical connector from the dash panel. 6. Install the LH front wheel and tire assembly. For additional information, refer to Section 204-04. 7. Remove the floor console. For additional information, refer to Floor Console in this section. 8. Remove the upper RH instrument panel support bolt. 9. Disconnect the antenna in-line connector. 10. Disconnect the climate control vacuum harness connector. 11. Close the glove compartment. 12. Remove the LH and RH scuff plates. 13. Remove the LH and RH A-pillar lower trim panels. 1. Remove the pin-type retainers. 2. Remove the A-pillar lower trim panels. 14. Remove the LH and RH windshield side garnish mouldings. If equipped with a convertible top, remove the pin-type retainers. 15. Position the LH and RH door weatherstrips aside. 16. Disconnect the RH main wiring harness electrical connectors. 17. Disconnect the climate control wiring harness connector. 18. Remove the instrument panel steering column cover. 1. Remove the screws. 2. Remove the instrument panel steering column cover. 19. Remove the instrument panel reinforcement. 1. Remove the screws. 2. Remove the instrument panel reinforcement. 20. Separate the intermediate shaft from the steering column shaft. 1. Remove the pinch bolt. 2. Separate the intermediate shaft from the steering column shaft. 21. NOTE: The corner of the carpet may have to be pulled back slightly to carry out this step. Disconnect the LH main wiring harness electrical connectors.