Torque converter removal

STARTER REPLACEMENT (ENGINE ELECTRICAL) Document ID# 688149 Starter Replacement

Removal Procedure

Important: This vehicle uses the PG260 F1 starter motor. The starter motor is serviced only as a complete unit.

1. Disconnect the battery ground (negative) cable from the battery. Refer to Battery Negative Cable Disconnection and Connection.
2. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.



3. Remove the starter motor BAT terminal nut and electrical leads.
4. Remove the starter motor S terminal nut and electrical lead.
5. Remove the torque converter cover. Refer to Torque Converter Cover Replacement in Automatic Transaxle - 4T65-E.



6. Remove the starter motor bolts.
7. Remove the starter motor.

Installation Procedure

1. Install the starter motor.
Notice: Refer to Fastener Notice in Cautions and Notices.

2. Install the starter motor bolts.Tighten:
   Tighten the starter motor bolts to 47 [n-m] (35 lb ft).
3. Install the torque converter cover. Refer to Torque Converter Cover Replacement in Automatic Transaxle - 4T65-E.



4. Install the starter motor S terminal electrical lead and nut. Tighten:
   Tighten the starter motor solenoid S terminal nut to 3 [n-m] (27 lb in).
   
5. Install the starter motor BAT terminal electrical leads and nut. Tighten:
   Tighten the starter motor solenoid BAT terminal nut to 10 [n-m] (89 lb in).
   
6. Lower the vehicle.
7. Install the battery ground (negative) cable to the battery. Refer to Battery Negative Cable Disconnection and Connection.

The torque converter is connected to the flex plate by 4 or 5 bolts. There is an access plate or hole at the bottom of the bellhousing. So yes, you will need to rotate the engine by hand to access these bolts one at a time to remove them. Remove all the plugs from the engine put a half inch ratchet on the bolt on the front of the crankshaft and rotate the crank to position the bolts on the torque converter.

Try using an impact socket on the balancer bolt, with a 3/4" Johnson bar and a long steel pipe for leverage. If that doesn't work your only other option may be to remove the heads, spray WD40 all around the edge of the pistons, then place a piece of wood like a 4 x 4 on top of each piston and give it a few really good hits with a heavy hammer, that may free the pistons enough so you can turn the crankshaft.

disconnect all electrical wiring harness that is attached to motor, disconnect exhaust, disconnect intake hoses, drain cooling system remove radiator, undo motor mounts, disconnect transmission, disconnect auto trans flex plate and attach engine crane remove engine replace torque converter and solenoids and reinstall or disconnect electrical from transmission and cooler lines and driveshaft and support trans with jack and undo cross member and drop transmission out of vehicle with jack supporting it and then rebuild transmission

When removing an engine from any automatic box the best tip is to remove the bolts holding the torque converter to the flex plate/flywheel and leave the torque converter in position on the shaft in the front of the box. It will move back to the box enough to separate the engine . Turn the engine around to get to each bolt. If the transmission is going to be unsupported then restrain the torque converter with a plate bolted through a flange hole or a strap across the front a note here is that what you call a skip loader may be known as a skid steer loader in which case there will be no torque converter as it hooks directly to a hydraulic pump via a splined shaft.

Hi, if you have the 3.0 liter engine, see instructions below. If you have the 4.6 liter, the starter is under the intake manifold.

Removal & Installation

1. Before servicing the vehicle, refer to the Precautions Section.
2. Remove or disconnect the following:
   
   Negative battery cable Starter electrical connectors Right hand catalytic converter Right side engine mount nuts Intake air resonator to the throttle body ducts
   
3. Install an Engine Support Fixture to the right side of the engine.
4. Raise the right side of the engine approximately 1.5 inches (38mm) to gain access to the starter motor bolts.
5. Remove or disconnect the following:
   
   Engine mount from the bracket and cradle Engine mount bracket bolts and reposition the bracket Starter motor
6. 
   
7. 
   
   
   

   Fig. Remove the starter motor and bolts
   
   

To install:

1. Install or connect the following:
   
   Starter motor. Torque the bolts to 44 ft. lbs. (60 Nm). Engine mount to the bracket and front crossmember. Torque the bolts to 30 ft. lbs. (40 Nm).
   
2. Lower the engine into position and make certain that the mount locator tab is fully seated in the front crossmember slot.
3. Remove the special tools from the engine.
4. Install or connect the following:
   
   Engine mount nuts. Torque the upper nut to 30 ft. lbs. (40 Nm) and the lower nut to 41 ft. lbs. (55 Nm). Intake air resonator to the throttle body ducts Catalytic converter. Torque the bolt to 25 ft. lbs. (34 Nm) and the nuts to 18 ft. lbs. (25 Nm). Starter electrical connectors. Torque the battery cable nut to 115 inch lbs. (13 Nm) and the starter solenoid nut to 35 inch lbs. (4 Nm). Negative battery cable

Removal & Installation To Remove:
Starter

1. Before servicing the vehicle, refer to the service precautions in the beginning of this section
2. Disconnect the battery negative cable
3. Raise and support the vehicle
4. Remove the transmission cooler line clip if necessary
5. Remove the torque converter cover
6. Disconnect the battery positive cable from the starter
7. Disconnect the wire from the starter solenoid S terminal
8. Remove the 2 starter motor mounting bolts and the starter motor

To Install:

1. Install the starter motor
   • Torque the mounting bolts to 32 ft-lbs (43 Nm)
2. Connect the battery positive cable to the starter
   • Torque nut to 12 ft-lbs (16 Nm) (1997-2000);
   • Torque nut to 89 in-lbs (10 Nm) (2001-2005)
3. Connect the starter motor S terminal wire
   • Torque nut to 22 in-lbs (2.5 Nm)
4. Install the torque converter cover
   • Torque the bolts to 115 in-lbs (13 Nm)
5. Attach the transmission cooler line clip
6. Lower the vehicle
7. Reconnect the negative battery cable

Radiator side of engine block lower

Removal & Installation - Starter

1. Before servicing the vehicle.
   
2. Remove or disconnect the following:
   Negative battery cable Radiator air baffle assembly
   Electrical connections Torque converter cover Starter
   

To install:

1. Install or connect the following:
   Starter. Torque the bolts to 35 ft. lbs. (47 Nm). Torque converter cover Solenoid -BAT- terminal. Torque the nut to 89 inch lbs. (10 Nm). Solenoid -S- terminal. Torque the nut to 27 inch lbs. (3 Nm). Radiator air baffle assembly Negative battery cable
2. Perform a charging system test and verify the starter is operating properly
   

Fig. Showing the starter motor location and electrical connections

1. Before servicing the vehicle.
2. Remove or disconnect the following:
   Negative battery cable Radiator air baffle, for clearance if necessary Flywheel inspection cover bolts Flywheel inspection cover Electrical connections from the starter motor Starter motor mounting bolts Starter motor
   

To install:

1. Install or connect the following:
   NOTE Before installing the starter motor to the engine, tighten the nut next to the cap on the solenoid BAT terminal. If this terminal is not tight in the solenoid cap, the cap may be damaged during installation of electrical connections and cause the starter motor to fail later.
   
   Starter motor Starter motor mounting bolts and tighten the bolts to 30 ft. lbs. (40 Nm) Electrical connection to the battery terminal on the solenoid and tighten the battery terminal nut to 13 ft. lbs. (17 Nm) Electrical connections to the S terminal on the solenoid and tighten solenoid S terminal nut to 27 inch lbs. (3 Nm) Flywheel inspection cover Flywheel inspection cover bolts Radiator air baffle, if removed
2. Connect the negative battery cable

Hope helps, remember rated this.

get the front end up on some jack stands, take the starter out, and you can access torque converter nuts from starter hole. you will need to turn the engine by hand and have someone else hold the engine still while you undo the nuts. Once those nuts are off and every thing else is removed from the transmission (CV shafts, wire connectors, etc) remove the bell housing bolts (5 or 6 I think) and pull (may need to pry with a bar some) the trans away from the engine and let it down gently. I believe (although I don't do much transmission work) that you may need to remove the sub-frame a as well.