41AE/Te Automatic Transaxle: Installation

Install transaxle into position. Install two (2) transaxle-to-engine lower bolts and torque to 95 N.m (70 ft. lbs.)..
Remove transmission jack.
Lower vehicle.
Raise engine/transaxle assembly into position with overhead fixture.
Install and torque four (4) transaxle-to-engine upper bolts and torque to 95 N.m (70 ft. lbs.).
Raise vehicle.
Install four (4) torque converter-to-driveplate bolts and torque to 88 N.m (65 ft. lbs.)
Install torque converter dust shield (Fig 1).

Fig 1: Removing Torque Converter Dust Shield
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Loosely assemble engine-to-transmission collar (Fig 2).
AWD models:
1. Install PTU lower bracket.
2. Install PTU into position. Install two (2) lower PTU-to-bracket bolts and torque to 28 N.m (21 ft. lbs.) (Fig 3).
3. Install PTU-to-transaxle upper bolts and torque to 54 N.m (40 ft. lbs.) (Fig 4).
4. Install PTU/rear mount bracket. Install and torque six (6) bolts to 54 N.m (40 ft. lbs.). (Fig 5)
5. Install PTU heat shield (Fig 5).
  
  Fig 2: Removing Oil Pan-To-Transaxle Collar
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  Fig 3: Removing Power Transfer Unit Lower Bolts
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6. Install propeller shaft assembly. Refer to PROPELLER SHAFT (AWD) for proper procedure.
  
  Fig 4: Removing Power Transfer Unit Mounting
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  Fig 5: Removing Rear Mount Assembly
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Install starter motor and shim (Fig 6). Install and torque bolts to 47 N.m (35 ft. lbs.).
Install starter motor electrical connectors.

Fig 6: Removing Starter Motor And Shim
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Install engine front mount/bracket assembly and torque to 67 N.m (50 ft. lbs.) (Fig 7).
Install cradle and fixture into position under vehicle.
Slowly lower vehicle (Fig 8). Have helper guide power steering and brake hydraulic lines into position, while aligning cradle to body. While lowering vehicle, align engine front and rear mount studs to their respective thru-holes in cradle.
Aligning index/scribe mark placed upon disassembly, Install four (4) cradle-to-body bolts and torque to 162 N.m (120 ft. lbs.).
Verify that power steering and brake hydraulic lines can be properly routed and installed.

Fig 7: Removing Engine Front Mount/Bracket
Courtesy of DAIMLERCHRYSLER CORP.

Fig 8: Identifying Driveline Support Table In Position
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Remove overhead powertrain support fixture from engine compartment:
1. Remove rear support/lift bracket and connect coolant temperature sensor.
2. Remove front support/lift bracket. Install and torque engine oil dipstick fastener.
Raise vehicle on hoist and remove driveline support table.
Install and torque engine front and rear mount-to-cradle nuts to 54 N.m (40 ft. lbs.).
Using Tool 6831A, install steering shaft-to-gear coupler (Fig 9) (Fig 10)

Fig 9: Identifying Intermediate Shaft Extension At Gear
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Connect power steering hoses to steering gear (Fig 11). Torque fittings to 31 N.m (23 ft. lbs.).

Fig 10: Identifying Roll Pin Installation
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Fig 11: Identifying Hoses At Steering Gear
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Install power steering cooler and fasten to cradle (Fig 12).

Fig 12: Identifying Cooler Mounting Screws
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Fasten steering hose routing clip to cradle (Fig 13).

Fig 13: Identifying Hose Routing Clip At Cradle
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Install torque strut and torque two (2) bolts to 54 N.m (40 ft. lbs.).
Install halfshaft assemblies. Refer to AXLE SHAFTS - FRONT .
Install sway bar links to strut attaching points (Fig 14). Torque link-to-strut nuts to 88 N.m (65 ft. lbs.).

Fig 14: Identifying Stabilizer Bar Link To Strut
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Install ABS sensor brackets to struts (Fig 15).

Fig 15: Identifying Wheel Speed Sensor Mounting To Strut
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Connect ABS sensors (Fig 16).
Install both front tire/wheel assemblies.
Connect front brake lines to hydraulic control unit (Fig 17).

Fig 16: Identifying Sensor Mounting To Front Hub And Bearing
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Fig 17: Identifying Brake Lines At Hydraulic Control Unit
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Install coolant bypass tube fasteners.
Connect solenoid/pressure switch connector (Fig 18). Torque screw to 4 N.m (35 in. lbs.).
Connect transaxle range sensor connector (Fig 18).
Connect input speed sensor connector (Fig 18).
Connect output speed sensor connector (Fig 18).

Fig 18: Removing transmission Connectors
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Secure transaxle harness with respective retainers (Fig 19).

Fig 19: Identifying Transmission Harness/Retainers
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Install and connect crankshaft position sensor (Fig 20).

Fig 20: Identifying Crankshaft Position Sensor
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Install ground cable to case and torque bolt.
Install transaxle oil cooler splice kit. Refer to instructions provided with kit.
Connect gearshift cable to transaxle manual valve lever. Verify adjustment.
Install battery tray (Fig 21). Connect battery temperature sensor.
Install battery (Fig 22).
Install battery hold-down clamp.
Connect battery cables.
Bleed brake hydraulic system. Refer to (Refer to BLEEDING BRAKE SYSTEM ).
Add power steering fluid as required.
Check and adjust transaxle fluid level. Refer to (Refer to STANDARD PROCEDURE )
AWD models: Check and adjust PTU fluid level. Refer to procedure in this group.
Align front end. Refer to (Refer to SPECIFICATIONS & PROCEDURES ).

Fig 21: Identifying Battery Tray
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Fig 22: Identifying Battery
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