Diesel Data: Automotive Repair
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Part 1

The content of this article/image reflects the changes identified in TSB-SB0351-10.

TRANSAXLE REPLACEMENT SUPPLEMENT

Parts Information





Required Tools & Equipment









NOTE: Additional SSTs may be ordered by calling 1-800-933-8335.


REMOVAL





1. Remove the Battery.

A. Loosen the nut, and separate the negative (-) battery terminal.

B. Loosen the nut and separate the positive (+) battery terminal.

C. Loosen the nut and remove the bolt and battery clamp.

D. Remove the battery and battery tray.





2. Remove the No. 1 engine cover sub-assembly.

A. Lift the rear of the engine cover to detach the cover from the 2 pins.

B. Lift the front of the engine cover to detach the cover from the pin and remove the engine cover.

NOTICE
Attempting to disengage both the front and rear clips at the same time may cause the cover to break.





3. Remove the inlet air cleaner assembly by removing the 2 bolts.





4. For PZEV vehicles: Remove the air cleaner cap sub-assembly.

Disconnect the vacuum hose and separate it from the air cleaner hose.

5. Remove the air cleaner cap sub-assembly (for PZEV and non PZEV).





A. Disconnect the mass air flow meter connector and separate the wire harness clamp from the air cleaner cap.





B. Disconnect the vacuum switching valve connector and 2 hoses.





C. Separate the hose from the air cleaner cap sub-assembly.





D. Loosen the hose clamp and disconnect the hose.





E. Loosen the hose clamp and disconnect the air cleaner hose.





F. Remove the 2 bolts and the air cleaner cap sub-assembly.





6. Remove the air cleaner case sub-assembly.

A. Disconnect the wire harness clamp.

B. Remove the 3 bolts and air cleaner case sub-assembly.

7. Remove the starter.





A. Disconnect the terminal 50 connector from the starter assembly.

B. Turn back the terminal cap.

C. Remove the nut and disconnect the wire harness from terminal 30.





D. Remove the 2 bolts and starter assembly.

8. Disconnect the engine wire.





A. Disconnect the engine wire clamp, then remove the bolt and separate the ground cable.





B. Remove the bolt and separate the ground cable.





C. Remove the 2 bolts and the air cleaner bracket.





9. Disconnect the transmission control cable.

Remove the clip and nut, and separate the transmission control cable.





10. Remove the transmission oil cooler.

A. Remove the transmission oil cooler to the front engine mounting bracket with the 3 bolts.

B. Disconnect the No. 1 oil cooler outlet hose and No. 1 oil cooler inlet hose.





11. Remove the upper bell housing (4) bolts.





12. Install the 2 engine hangers with the 2 bolts as shown in the illustration.

Part Number:

* No. 1 Engine Hanger: P/N 12281-36020
* No. 2 Engine Hanger: P/N 12282-36020
* Bolts: P/N 91552-81040, 91552-81025 (or equivalent)

Torque: 43 Nm (438 kgf*cm, 32 ft*lbf)

13. Install the Engine Support Bar and secure engine weight with a chain.

SST: 00002-ESUPPT-01










A. Assemble and place the main bar onto the vehicle's strut towers.

NOTICE:
* To prevent damage caused by contact between the main bar legs and body panels, apply protective tape on the strut tower before installing the main bar.
* To prevent dents in the strut tower panel, please assure that the main bar legs with 90 degree brackets are installed.

NOTE:
* Ensure that the main bar swivel is already installed on the main bar and that the main bar legs are oriented correctly (passenger side / drivers side).
* The plastic cowl cover and / or cowl may need to be removed to accommodate the bar.





B. Assemble the front bar assembly and position the legs so they can sit onto the right and left frame rails.





C. Adjust the front bar arms so they can be bolted to the upper radiator core support mounting holes.





D. Place the front bar on the vehicle with the legs sitting firmly on the right and left frame rails near the radiator support, and secure the front bar arms to the radiator core support.

NOTE:
Once in position, ensure that the hex nuts on the front bar legs are tight and the front bar is still square after installation.





E. Install the Engine Support Bar hook #2 onto the crossbar and place the crossbar assembly through the swivel on the main bar.

HINT:
The main bar swivel may be placed above or below the main bar.

NOTICE:
Be sure not to let the main bar swivel fall and damage the windshield, or damage the hood when installing the crossbar assembly.





F. Insert the straddle bar into the crossbar.

G. Adjust the height of the crossbar so it is level and insert the quick release pin through the nearest open slot in the straddle bar.





H. Attach the chain from the engine hooks to the hook #2 of the Engine Support Bar and place tension on the chain until the Engine Support Bar self centers.

CAUTION
Ensure the Engine Support Bar is stable when fully assembled and mounted to the vehicle to ensure no damage to vehicle or technician.

14. Remove the front wheels.





15. Remove the front axle hub nut.

A. Using the SST and a hammer, release the staked part of the front axle hub nut.

SST: 09930-00010-01

NOTICE
Loosen the staked part of the nut completely; otherwise the thread of the drive shaft may be damaged.

B. While applying the brakes, remove the front axle hub nut.

Continued: Part 2
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