Case Cover

Removal Procedure

Caution: Refer to Battery Disconnect Caution in Service Precautions.





1. Disconnect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging.
2. Remove the throttle body air inlet duct. Refer to Air Cleaner Intake Duct Replacement in Powertrain Management.
3. Install the engine support fixture. Refer to Engine Support Fixture.
4. Remove the engine mount struts. Refer to Engine Mount Strut Replacement (Left) and Engine Mount Strut Replacement (Right) in Engine.
5. Raise and support the vehicle. Refer to Vehicle Lifting.
6. Remove the left front wheel. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment.
7. Remove the left engine splash shield. Refer to Splash Shield Replacement - Engine in Body and Frame.
8. Remove the stabilizer shaft links from the lower control arms. Refer to Stabilizer Shaft Link Replacement in Steering and Suspension.
9. Remove the left tie rod end from the steering knuckle. Refer to Steering Knuckle Replacement in Steering and Suspension.
10. Remove the wheel speed sensor harness connector. Refer to Wheel Speed Sensor Jumper Harness Replacement (Front) in Brakes and Traction Control.
11. Remove the left lower ball joint from the left steering knuckle. Refer to Steering Knuckle Replacement in Steering and Suspension.
12. Disconnect the left drive axle from the transaxle. Refer to Wheel Drive Shafts Replacement (Left) in Drive Axle.
13. Secure the drive axle to the steering knuckle/strut.

Caution: Failure to disconnect the intermediate shaft from the rack and pinion stub shaft can result in damage to the steering gear and/or damage to the intermediate shaft. This damage may cause loss of steering control which could result in personal injury.

14. Remove the pinch bolt at the intermediate steering shaft. Refer to Intermediate Steering Shaft Replacement in Steering and Suspension.
15. Remove the intermediate shaft from the steering gear. Refer to Intermediate Steering Shaft Replacement in Steering and Suspension.
16. Disconnect the three-way catalytic converter pipe to the right (rear) exhaust manifold. Refer to Catalytic Converter Replacement in Powertrain Management.
17. Support the right side of the frame with jackstands.
18. Support the left side of the frame with jackstands.
19. Remove the transaxle mount bracket. Refer to A/T Mount Bracket Replacement
20. Remove the transaxle mount. Refer to A/T Mount Replacement.
21. Loosen the engine mount lower nuts. Refer to Engine Mount Replacement in Engine.
22. Loosen the right side frame to body bolts.
23. Remove the left side frame to body bolts.
24. Adjust the jackstand to the lower left side of the frame.
25. Position the drain pan under the transaxle.
26. Remove the wiring harness connector.
27. Remove the case side cover bolts (56-58).





28. Remove the case side cover pan (53).
29. Remove the case side cover gasket (54).
30. Remove the case side cover inner gasket (59).





31. Inspect the case side cover (53) for the following conditions:
^ Damaged or porous gasket sealing surfaces
^ Damaged or porous casting surfaces
^ Damaged or stripped bolt holes
32. Inspect the case side cover gasket (54) and case side cover inner gasket (59) for damage. The gaskets are reusable if they are NOT damaged.
33. Clean the case side cover.
34. Clean the case side cover gasket surfaces.


Installation Procedure





1. Install the case side cover inner gasket (59).
2. Install the case side cover gasket (54).
3. Install the case side cover pan (53).





Notice: Refer to Fastener Notice in Service Precautions.

4. Install the case side cover bolts (56-58).
^ Tighten the case side cover bolts (56-58) to 25 Nm (18 ft. lbs.).
5. Remove the drain pan from under the transaxle.
6. Install the wiring harness connector.
7. Adjust the jackstand to raise the left side of the frame.
8. Install the left side frame to body bolts.
9. Install the right side frame to body bolts.
10. Install the engine mount lower nuts. Refer to Engine Mount Replacement in Engine.
11. Install the transaxle mount. Refer to A/T Mount Replacement.
12. Install the transaxle mount bracket. Refer to A/T Mount Bracket Replacement.
13. Remove the jackstand support from the right side of the frame.
14. Remove the jackstand support from the left side of the frame.
15. Connect the three-way catalytic converter pipe to the right (rear) exhaust manifold. Refer to Catalytic Converter Replacement in Powertrain Management.

Caution: When installing the intermediate shaft make sure that the shaft is seated prior to pinch bolt installation. If the pinch bolt is inserted into the coupling before shaft installation, the two mating shafts may disengage. Disengagement of the two mating shafts will cause loss of steering control which could result in personal injury.

16. Install the intermediate shaft to the steering gear. Refer to Intermediate Steering Shaft Replacement in Steering and Suspension.
17. Install the pinch bolt at the intermediate steering shaft. Refer to Intermediate Steering Shaft Replacement in Steering and Suspension.
18. Install the left drive axle to the transaxle. Refer to Wheel Drive Shafts Replacement (Left) in Drive Axle.
19. Install the left lower ball joint to the left steering knuckle. Refer to Steering Knuckle Replacement in Steering and Suspension.
20. Install the wheel speed sensor harness connector. Refer to Wheel Speed Sensor Bumper Replacement (Front) in Brakes and Traction Control.
21. Install the left tie rod end to the steering knuckle. Refer to Steering Knuckle Replacement in Steering and Suspension.
22. Install the stabilizer shaft links to the lower control arms. Refer to Stabilizer Shaft Link Replacement in Steering and Suspension.
23. Install the left engine splash shield. Refer to Splash Shield Replacement - Engine in Body and Frame.
24. Install the left front wheel. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment.
25. Lower the vehicle.
26. Install the engine mount struts. Refer to Engine Mount Strut Replacement (Left) and Engine Mount Strut Replacement (Right) in Engine.
27. Remove the engine support fixture. Refer to Engine Support Fixture.
28. Remove the throttle body air inlet duct. Refer to Air Cleaner Intake Duct Replacement in Powertrain Management.
29. Connect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging.

Notice: Do NOT overfill the transaxle. The overfilling of the transaxle causes foaming, loss of fluid, shift complaints, and possible damage to the transaxle.

30. Adjust the fluid level. Refer to Transmission Fluid Checking Procedure, Fluid Capacity Specifications and Fluid and Lubricant Recommendations.
31. Inspect for proper completion of the repairs.
32. Inspect for fluid leaks.