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41AE/Te Automatic Transaxle: Removal

  1. Open hood.
  2. Disconnect battery cables (Fig 1).
  3. Remove battery hold-down clamp.
  4. Remove battery (Fig 1).
    Fig 1: Identifying Battery Hold-Down Clamp
    G03573940Courtesy of DAIMLERCHRYSLER CORP.
  5. Remove battery tray (Fig 2). Disconnect battery temperature sensor.
    Fig 2: Removing Battery Tray
    G03573941Courtesy of DAIMLERCHRYSLER CORP.
  6. Disconnect gearshift cable from transaxle manual valve lever.
  7. Release and slide transaxle oil cooler hose clamps off of hose/fitting connection. Using suitable cutting tool, cut oil cooler hoses off flush at fittings. A service splice kit will be installed upon assembly. Cap off hoses and fittings to prevent debris intrusion.
  8. Remove ground cable/bolt from top of transaxle case.
  9. Disconnect and remove crankshaft position sensor (Fig 3).
  10. Disconnect input speed sensor connector (Fig 4).
  11. Disconnect output speed sensor connector (Fig 4).
  12. Disconnect transaxle range sensor connector (Fig 4).
  13. Disconnect solenoid/pressure switch assembly connector (Fig 4).
    Fig 3: Disconnecting Crankshaft Position Sensor
    G03573942Courtesy of DAIMLERCHRYSLER CORP.
    Fig 4: Disconnecting Transmission Connectors
    G03573943Courtesy of DAIMLERCHRYSLER CORP.
  14. Release transaxle harness from retainers and position out of way (Fig 5).
    Fig 5: Identifying Transmission Harness
    G03573944Courtesy of DAIMLERCHRYSLER CORP.
  15. Remove coolant bypass tube-to-engine and transaxle fasteners.
  16. Disconnect front brake lines from the hydraulic control unit (Fig 6). Position out of way for removal clearance.
    Fig 6: Disconnecting Brake Lines At Hydraulic Control Unit
    G03573945Courtesy of DAIMLERCHRYSLER CORP.
  17. Remove intermediate shaft extension from steering gear (Fig 8). Remove roll pin using Tool 6831A (Fig 7). Slide shaft extension off of gear.
    Fig 7: Identifying Roll Pin Removal
    G03573946Courtesy of DAIMLERCHRYSLER CORP.
    Fig 8: Removing Intermediate Shaft Extension At Gear
    G03573947Courtesy of DAIMLERCHRYSLER CORP.
  18. Install overhead powertrain support fixture (Tool 8534B and adapter kit 8534-12) (Fig 9):
    Fig 9: Identifying Engine Support Fixture 8534B
    G03573948Courtesy of DAIMLERCHRYSLER CORP.
    1. Remove engine oil dipstick tube-to-cylinder head fastener (Fig 10). Install lift/support bracket 8534-8 and secure with dipstick tube bolt.
      Fig 10: Identifying Lift Bracket 8534-8
      G03573949Courtesy of DAIMLERCHRYSLER CORP.
    2. Disconnect coolant temperature sensor (at thermostat housing). Remove engine harness-to-cylinder head bolt. Position harness out of the way. Install and secure lift/support bracket and bolt 8534-7 as shown in (Fig 11).
      Fig 11: Identifying Lift Bracket 8534-7
      G03573950Courtesy of DAIMLERCHRYSLER CORP.
    3. Assemble 8534-2 mounting bracket/sleeve assemblies to support tube 8534-1 and install to vehicle, allowing brackets to rest on inner fender ledges (Fig 12).
      Fig 12: Identifying Support Tube And Sleeve/Brackets
      G03573951Courtesy of DAIMLERCHRYSLER CORP.
    4. Assemble cross-bar 8534-3, clamp 8534-5 and support leg 8534-4 to support tube, allowing support leg to rest on radiator upper support (Fig 13).
      5. Fig 13: Identifying Crossbar And Support Leg
      G03573952Courtesy of DAIMLERCHRYSLER CORP.
    5. Tighten cross-bar-to-support tube clamp 8534-5 (Fig 14), as well as mounting bracket/sleeve 8534-2 thumb screw and hex nut to secure fixture (Fig 15).
      Fig 14: Identifying Clamp 8534-5
      G03573953Courtesy of DAIMLERCHRYSLER CORP.
    6. Install lift bracket/hook assemblies as shown in (Fig 15) (Fig 16) (Fig 17) (Fig 18). Tighten t-handles just enough to build tension between the fixture and drivetrain.
      Fig 15: Identifying Torque Thumb Screw And Pivot Nut
      G03573954Courtesy of DAIMLERCHRYSLER CORP.
      Fig 16: Identifying T-Handle, Bracket, And Hook Assy At Rear Lift Bracket
      G03573955Courtesy of DAIMLERCHRYSLER CORP.
  19. Raise vehicle on hoist.
  20. Remove both front tire/wheel assemblies.
    Fig 17: Identifying T-Handle, Bracket, And Hook Assy At Front Lift Bracket
    G03573956Courtesy of DAIMLERCHRYSLER CORP.
    Fig 18: Identifying Engine Support Fixture 8534B
    G03573957Courtesy of DAIMLERCHRYSLER CORP.
  21. Disconnect ABS sensor connector. Remove ABS sensor brackets from struts.
  22. Disconnect sway bar links from struts (Fig 19).
    Fig 19: Identifying Stabilizer Bar Link To Strut
    G03573958Courtesy of DAIMLERCHRYSLER CORP.
  23. Remove front halfshaft assemblies.
  24. Remove engine front and rear mount-to-cradle nuts.
  25. Disconnect brake hydraulic line and brackets from frame rails.
  26. Disconnect power steering hydraulic line bracket at cradle on passenger side (Fig 20).
    Fig 20: Identifying Hose Routing Clip At Cradle
    G03573959Courtesy of DAIMLERCHRYSLER CORP.
  27. Disconnect power steering oil cooler from cradle (Fig 21).
    Fig 21: Identifying Cooler Mounting Screw
    G03573960Courtesy of DAIMLERCHRYSLER CORP.
  28. Disconnect power steering pressure and return lines from steering gear (Fig 22). Cap lines to prevent debris intrusion and tie out of way.
    Fig 22: Identifying Hoses At Steering Gear
    G03573961Courtesy of DAIMLERCHRYSLER CORP.
  29. Remove the transmission-to-cradle torque strut (Fig 23).
    Fig 23: Identifying Powertrain Torque Strut
    G03573962Courtesy of DAIMLERCHRYSLER CORP.
  30. Set Driveline Support Table, Tool 8874 into position (Fig 24) (Fig 25).
    Fig 24: Identifying Driveline Support Table 8874
    G03573963Courtesy of DAIMLERCHRYSLER CORP.
    Fig 25: Identifying Driveline Support Table In Position
    G03573964Courtesy of DAIMLERCHRYSLER CORP.
  31. Lower vehicle until cradle and fixture engage as shown in (Fig 26).
    Fig 26: Identifying Locating Brackets At Cradle
    G03573965Courtesy of DAIMLERCHRYSLER CORP.
  32. Scribe alignment marks to reference the cradle to the body for installation. Remove four (4) cradle-to-body bolts.
  33. Slowly raise vehicle on hoist to separate cradle from vehicle. Verify that overhead fixture is secure to inner fenders and radiator upper support  . Have helper guide brake and power steering hydraulic lines through, as they will remain attached to cradle assembly.
  34. Remove engine front mount/bracket (Fig 27).
    Fig 27: Identifying Engine Front Mount/Bracket
    G03573966Courtesy of DAIMLERCHRYSLER CORP.
  35. Disconnect starter motor electrical connectors (Fig 28). Remove starter motor and shim.
    Fig 28: Identifying Starter Motor And Shim
    G03573967Courtesy of DAIMLERCHRYSLER CORP.
  36. AWD Models: 
    1. Remove propeller shaft assembly. (Refer to PROPELLER SHAFT (AWD) ).
    2. Remove PTU/rear mount bracket (Fig 29).
      Fig 29: Identifying PTU Bracket/Rear Mount Assembly
      G03573968Courtesy of DAIMLERCHRYSLER CORP.
    3. Remove oil pan-to-transaxle collar (Figure).
    4. Remove heat shield (Fig 30).
    5. Remove PTU-to-transaxle upper bolts (Fig 30).
    6. Remove PTU-to-bracket lower bolts (Figure).
    7. Remove PTU from vehicle.
  37. Remove torque converter dust shield (Figure).
  38. Remove four (4) torque converter-to-driveplate bolts. Upon removing bolts, a tight-tolerance (slotted) bolt will be encountered. Mark this location (drive-plate and converter) with paint for assembly reference.
  39. Lower vehicle.
  40. Remove four (4) transaxle upper bellhousing-to-block bolts.
  41. Lower engine/transaxle at overhead fixture.
  42. Raise vehicle.
  43. Install transmission jack into position. Secure transaxle to jack.
  44. Remove two (2) transaxle-to-engine lower bolts.
  45. Lower transaxle from engine compartment.
    Fig 30: Removing Power Transfer Unit Mounting
    G03573969Courtesy of DAIMLERCHRYSLER CORP.
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