### Automatic Transmission Assembly

#### REMOVAL AND INSTALLATION

##### 240SX

1. Disconnect the negative battery terminal.
2. Raise and safely support the vehicle.
3. Drain the fluid from the transmission.
4. Disconnect the cooler lines from the transmission and plug the openings.

   NOTE: It may be necessary disconnect to the left side cooler line after the transmission has been slightly lowered.

5. Disconnect the electrical harness connections from the transmission.
6. Disconnect the shift linkage from the transmission.
7. Matchmark the driveshaft to the rear flange and disconnect the driveshaft. Unbolt the driveshaft center support and remove the shaft from the vehicle.

   NOTE: Insert a plug into the rear of the transmission to prevent oil leakage.

8. Remove the heat insulator from the catalytic converter.
9. Remove the exhaust tube bracket and separate rear exhaust tube from the catalytic converter.
10. Disconnect the wiring connections and remove the starter motor assembly.
11. Remove the transmission support brackets and remove the torque converter cover plate.
12. Mark the relationship between the torque converter and the drive plate. Remove the bolts that secure the torque converter to the drive plate. Gain access to the bolts by turning the front crankshaft bolt.
13. Support the transmission with a jack under the transmission oil pan. Also, place a jack, with a piece of wood, under the oil pan to support the engine.
14. Remove the rear crossmember.
15. Unbolt the transmission from the engine and remove it. Be careful not to damage the steering gear and the tubes.

    NOTE: The transmission bolts are different lengths. Tag each bolt according to location to ensure proper installation.

    To install:

16. Using a dial indicator, measure the drive plate runout. The maximum allowable runout should be less than 0.020 inches (0.5mm).
17. If the torque converter was removed from the transmission for any reason, after it is installed, the distance from the face of the converter bolt mounts to the edge of the converter housing must be checked prior to installing the transmission. This is done to ensure proper installation of the torque converter. The dimension should be 1.024 inches (26mm) or more.
18. Raise the transmission and bolt the transmission to the engine. Torque the transmission mounting bolts as follows:
    1. Tighten bolts No. 1 and No. 2 to 29–36 ft. lbs. (39–49 Nm)
    2. Tighten bolt No. 3 to 22–29 ft. lbs. (29–39 Nm)
    3. Tighten the gusset mounting bolts to 22–29 ft. lbs. (29–39 Nm).

       Fig. 1: Transmission bolt torque sequence — 240SX

19. Torque the torque converter mounting bolts to 33–43 ft. lbs. (44–59 Nm).

    NOTE: After the converter is installed, rotate the crankshaft several times to make sure the transmission rotates freely and does not bind.

20. Install the remaining components in the reverse order of removal.
21. Connect the negative battery cable, fill the transmission to the proper level, and make any necessary adjustments.
22. Perform a road test and check the fluid level.

##### 300ZX

Fig. 2:Transmission mounting bolt identification and torque specification — 1993–95 300ZX

1. Disconnect the negative battery cable.
2. Remove the accelerator linkage.
3. Detach the shift linkage.
4. Disconnect the neutral safety switch and downshift solenoid wiring.
5. Remove the crankshaft position sensor.
6. Raise and safely support the vehicle.
7. Remove the drain plug and drain the torque converter. If there is no converter drain plug, remove the transmission drain plug located in the pan.
8. Remove the front exhaust pipe.
9. Remove the vacuum tube and speedometer cable.
10. Disconnect the fluid cooler and dipstick tubes. Plug the tube ends to prevent leakage.
11. Matchmark the driveshaft to the companion flange at the center support bearing and unbolt the center support bearing from the vehicle.

    NOTE: The rear section of the driveshaft will remain in the vehicle. Be sure to support the shaft with wire. DO NOT allow the driveshaft to hang by the rear joint.

12. Remove the driveshaft from the rear of the transmission and install a plug to the rear of the transmission to prevent fluid leakage.
13. Disconnect the wiring from the starter motor and remove the starter. Be sure to note the location of the starter wiring for reassembly.
14. Remove the bracket (gusset) that secures the engine to the transmission.
15. Support the transmission with a jack under the oil pan. Support the engine also.
16. Remove the rear crossmember.
17. Mark the relationship between the torque converter and the drive plate.
18. Remove the bolts holding the torque converter to the drive plate through the access hole. Rotate the crankshaft to gain access to the additional bolts.
19. Remove the transmission-to-engine mounting bolts and lower the transmission assembly.

    NOTE: The transmission bolts are different lengths. Tag each bolt according to location to ensure proper installation.

20. Check the drive plate runout with a dial indicator. Maximum allowable runout is 0.0059 inch (0.15mm).

    To install:

    If the torque converter was removed from the transmission for any reason, after it is installed, the distance from the face of the converter bolt mounting lug to the edge of the converter housing must be checked prior to installing the transmission. This is done to ensure proper installation of the torque converter.

21. The converter measured distance should be:
    1. 0.984 in. (25mm) for RE4R03A transmissions (turbo models)
    2. 1.024 inches (26mm) for RE4R01A transmissions (non-turbo models)
22. Raise the transmission and tighten the transmission to the engine mounting bolts to the proper torque. Be sure to position the bolts in the proper locations.

    Fig. 3: Transmission mounting bolt identification and torque specification — 1996–97 300ZX

23. Tighten the drive plate to the converter mounting bolts to 33–43 ft. lbs. (44–59 Nm).

    NOTE: After the torque converter is installed, rotate the crankshaft several times to make sure the transmission rotates freely and does not bind.

24. Install the rear crossmember.
25. The balance of installation is the reverse of the removal procedure.
26. Tighten all driveshaft flange mounting bolts to 29–33 ft. lbs. (34–44 Nm) for Non-turbo models, or to 40–47 ft. lbs. (54–64 Nm) for Turbo models.
27. Tighten the center support bolts to 43–58 ft. lbs. (59–78 Nm).
28. Connect the negative battery cable, fill the transmission to the proper level and make any necessary adjustment.
29. Perform a road test and check the fluid level.