Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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Removal 1. Disconnect the hood lamp harness. 1. Remove the hood insulator retainers and position the insulator away from the hood. 2. Disconnect the hood lamp harness retainers. 3. Disconnect the hood lamp electrical connector. 2. NOTE: Mark the hinge-to-hood placement to ease alignment when reinstalling the hood. Remove the hood. 1. Disconnect the windshield washer hose. 2. Remove the ground strap bolt. 3. Disconnect the hood struts. 4. Remove the four hinge-to-hood bolts and remove the hood. 3. Recover the air conditioning (A/C) system. For additional information, refer to Section 412-00. 4. Remove the lower intake manifold (9424). For additional information, refer to Intake Manifold—Lower in this section. 5. Remove the front air deflector. 1. Remove the jack handle. 2. Remove the screws. 3. Remove the air deflector. 6. Remove the radiator upper hose from the radiator. 7. Using the special tools, remove the fan blade and fan clutch. 8. Remove the fan shroud. 1. Remove the screws. 2. Lift and remove the fan shroud and fan blade, as a unit, out of the vehicle. 9. NOTE: To avoid disturbing the transmission oil cooler fittings, use a backup wrench. Disconnect the transmission fluid cooler fittings. 1. Disconnect the upper transmission fluid cooler fitting. 2. Disconnect the lower transmission fluid cooler fitting. 10. Disconnect the lower radiator hose from the radiator. 1. Pry the locking tab up and out of the slot. 2. Rotate the lower radiator hose. 3. Disconnect the lower radiator hose. 11. Disconnect the degas hose from the radiator. 1. Release the clamp. 2. Slide the hose off of the radiator fitting. 12. Remove the radiator. 1. Remove the bolts. 2. Remove the upper radiator support brackets, the jack handle and the wheel nut wrench retainers. 3. Lift the radiator off the radiator mounting insulators. 4. Remove the radiator mounting insulators. 13. Remove the accessory drive belt. For additional information, refer to Section 303-05. 14. Disconnect the generator electrical connectors. 1. B+ 2. Stator 3. Voltage regulator 15. Remove the lower bracket bolts and the generator. 16. Disconnect the exhaust gas recirculation (EGR) tube from the exhaust manifold. 17. Disconnect the transmission wiring harness retainers from the right cylinder head and position the harness aside. 18. Remove the bolts retaining the transmission to the engine. 19. Disconnect the bulkhead connectors. 20. Remove the ground strap retaining bolt. 21. Disconnect the degas return hose.

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NOTICE: The use of any fluid other than what is recommended for this transmission will cause transmission damage. Draining 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02. 2. Remove the transmission fluid drain plug and allow the transmission fluid to drain. Refill 3. Install the transmission fluid drain plug. Tighten to 47 Nm (35 lb-ft). 4. Remove the transmission fluid fill plug. 5. Fill the transaxle with approximately 3.7L (4 qt) of clean transmission fluid. 6. Install the transmission fluid fill plug. Tighten to 39 Nm (29 lb-ft). 7. With the transaxle in (P) PARK, the vehicle should be on a level surface, the engine at idle (680-780 rpm), foot pressed on the brake, move the selector lever through each gear and allow engagement of each gear. Place the selector lever back in the PARK position. 8. Wipe the transmission fluid level indicator cap and remove the fluid level indicator. 9. Wipe the transmission fluid level indicator with a clean cloth. 10. NOTE: In order to get an accurate transmission fluid level reading, the vehicle should be on a level surface, the engine at idle (680-780 rpm) for 5 minutes and the transmission fluid temperature should be at least 70°C-80° (158° C F-176° using the scan tool. F) If transmission fluid needs to be added, add transmission fluid in 0.25L (1/2 pint) increments through the transmission fluid fill plug located on the top of the transaxle near the transmission fluid level indicator. Do not overfill the transmission fluid. Install the transmission fluid level indicator back in the transmission fluid filler tube until it is fully seated, then remove the indicator. The transmission fluid level should be at the upper-most mark on the transmission fluid level indicator. Only fill to the upper-most mark on the transmission fluid indicator. Do not overfill. Damage to the transaxle will occur.

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02. 2. NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. If equipped, loosen the nut and position the heat shield out of the way. 3. Drain transmission fluid. Remove all the transmission fluid pan screws except for two in the front. Loosen the two front transmission fluid pan screws. Pry the rear of the transmission fluid pan down and allow fluid to drain. After fluid is drained, remove the front two transmission fluid pan screws. 4. Remove the transmission fluid pan. 1. Remove the transmission fluid pan. 2. Remove and discard the transmission fluid pan gasket. 5. Remove and discard the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter. 6. Unclip main control valve body wire harness. Lift up on wire harness guide and protector and disengage the retaining pins from the solenoid clamps. 7. Disconnect the six solenoid electrical connectors. 1. Disconnect the SSA, SSB, SSC and SSD electrical connectors. 2. Disconnect the torque converter clutch (TCC) solenoid electrical connector. 3. Disconnect the electronic pressure control (EPC) solenoid electrical connector. 8. Remove the manual control valve detent lever spring. 1. Remove the manual control valve detent lever spring screw. 2. Remove the manual control valve detent lever spring. 9. Remove the low/reverse servo. 1. Remove the low/reverse servo cover screws. 2. Remove the low/reverse band servo cover and gasket. Discard the low/reverse servo separator plate cover gasket. 10. Remove the low/reverse band servo piston and rod. 11. CAUTION: Support the main control valve body. Do not remove the two (gold) screws specified. 12. CAUTION: Support the main control valve body. Remove the screws. 13. Remove the main control valve body. Installation 1. Install the special tool into the transmission case. 2. Position the main control valve body, using the two special tools as a guide. 3. NOTE: The main control valve body screws will be tightened in later steps. Loosely install four M6 x 45 mm (1.8 in) screws.

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1. If equipped, turn the air suspension switch OFF. 2. Disconnect battery ground cable. 3. Raise and support the vehicle; refer to Section 100-02. 4. Drain transmission fluid and remove the transmission fluid pan and filter; refer to Transmission Fluid Drain and Refill in this section. 5. CAUTION: Do not pull on the plastic lead frame. This may cause damage to the connector ends. Carefully pry up on the locking tabs to disconnect the sensors. Disconnect the molded lead frame from the sensors. Disconnect the molded lead frame from the sensors. 1. Disconnect the shift solenoid SSA/SS1 and SSB/SS2. 2. Disconnect the torque converter clutch (TCC). 3. Disconnect the electronic pressure control (EPC) solenoid. 4. Disconnect the bulkhead inter connector. 6. Remove the shift solenoid and the torque converter clutch (TCC) solenoid. 1. Remove the bolts. 2. Remove the shift solenoid and the torque converter clutch (TCC) solenoid. 7. Remove the manual control valve detent lever spring (7A261) 1. Remove the bolt. 2. Remove the manual control valve detent lever spring 8. Remove the 23 valve body to case bolts. 9. Remove the main control valve body (7A100) Installation 1. NOTE: Make sure that the drive pin of the manual valve detent lever assembly engages the manual valve in the proper location prior to installing the bolts. Position the main control valve body gasket and main control valve body using the two alignment bolts as a guide. 2. NOTE: The main control valve body bolts will be tightened in later steps. Loosely install the bolts. 3. NOTE: The main control valve body bolts will be tightened in later steps. Loosely install the bolts. 4. Install the manual control valve detent lever spring. 1. Position the manual control valve detent lever spring. 2. Install the bolt.

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NOTICE: Whenever a transmission has been disassembled to install new parts, the transmission fluid cooler tubes must be cleaned and backflushed using a suitable torque converter/fluid cooler cleaner. A new Oil-To-Air (OTA) transmission fluid cooler must also be installed. When internal wear or damage has occurred in the transmission, metal particles, clutch plate material or band material may have been carried into the torque converter and fluid cooler. These contaminants are a major cause of recurring transmission concerns and must be removed from the system before the transmission is put back into service. NOTE: After the transmission is removed for a major overhaul, it is important to completely clean all transmission components, including torque converter, cooler inlet tube, main control valve body, clutches and all coasting booster valve shuttle balls after any transmission service that generates contamination. These contaminants are a major cause for recurring transmission concerns and must be removed from the system before the transmission is returned to service. The cleaning of foreign material from the direct clutch check ball is often omitted. This omission can lead to a repeat servicing of the transmission. A new Oil-To-Air (OTA) transmission fluid cooler must be installed under the following condition. For additional information, refer to Section 307-02. Evidence of broken transmission components or transmission fluid contamination found due to the following transmission or converter failure modes: Major metallic failure Multiple clutches or clutch plate failure Sufficient component wear which results in metallic contamination 1. Disconnect the battery ground cable. For additional information, refer to Section 414-01. 2. WARNING: Before servicing a vehicle equipped with a fire suppression system, depower the system by following the procedure in Section 419-03. Failure to follow the instructions may result in serious personal injury. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02. 3. NOTE: Only if transmission disassembly or replacement is required, drain the transmission fluid. For additional information, refer to Fluid Pan, Gasket and Filter in this section. Drain the transmission fluid. Loosen the transmission fluid pan bolts and allow the transmission fluid to drain. After transmission fluid has drained remove the bolts and the pan and drain the remaining transmission fluid that is in the pan. 4. Install the transmission fluid pan and the old transmission fluid pan gasket. 1. Position the transmission fluid pan gasket. 2. Position the transmission fluid pan. 5. NOTE: To maintain the initial driveshaft balance, mark the rear driveshaft yoke and the axle pinion flange so they can be installed in their original positions. Mark the rear driveshaft yoke and the axle pinion flange and remove the 4 bolts.