Removal and Installation
REMOVAL1. Raise hood.
2. Disconnect and isolate both battery cables, remove battery hold down clamp and bolt, and remove battery.
Fig. 10:
3. Remove air cleaner/throttle body assy. (Fig. 10) as follows:
a. Disconnect Proportional Purge Solenoid (PPS) and crankcase vent hose from throttle body.
b. Disconnect the Throttle Position Sensor (TPS) and Idle Air Control (IAC) connectors.
c. Disconnect throttle body air duct at intake manifold.
d. Remove mounting bolt and nut (Fig. 10) and partially remove air cleaner assembly.
e. Disconnect accelerator and speed control (if equipped) cables after the assy. is removed from position. Remove air cleaner assembly from vehicle.
4. Remove battery tray from bracket.
5. Disconnect ground cable at battery tray bracket.
6. Disconnect back-up lamp switch connector.
Fig. 11:
7. Remove bellhousing cap (Fig. 11).
8. Disconnect clutch cable from release lever and remove from transaxle (Fig. 11).
Fig. 12:
9. Remove shift cable-to-bracket clips (Fig. 12).
10. Disconnect shift selector and crossover cable from levers (Fig. 12). Remove cables and secure out of the way.
Fig. 13:
11. Disconnect the vehicle speed sensor connector (Fig. 13).
12. Raise vehicle on hoist.
13. Remove transaxle oil drain plug and drain oil into a suitable container.
14. Remove both axle shafts. Refer to Drive Axles, Bearings and Joints for the correct procedures.
Fig. 14:
15. Remove structural collar (Fig. 14).
16. Remove the left engine-to-transaxle lateral bending brace (Fig. 14).
17. Remove bellhousing dust cover (Fig. 14).
Fig. 15:
18. Remove the right engine-to-transaxle lateral bending brace (Fig. 15).
Fig. 16:
19. Remove starter motor (Fig. 16).
20. Remove drive plate-to-clutch module bolts.
21. Support engine at oil pan with screw jack and wood block.
Fig. 17:
22. Remove transaxle upper mount thru-bolt. Gain access to this bolt through the driver's side wheel house (Fig. 17).
23. Carefully lower engine and transaxle on screw jack until proper removal clearance is obtained.
Fig. 18:
24. Obtain a helper to assist in holding transaxle while removing transaxle-to-engine mounting bolts (Fig. 18).
25. Remove transaxle from vehicle (Fig. 18).
26. Remove modular clutch assembly from transaxle input shaft.
INSTALLATION
1. Inspect clutch release bearing and lever for excessive wear and replace as necessary.
2. Install clutch module onto input shaft. Install transaxle into position.
3. Install transaxle-to-engine mounting bolts (Fig. 18) and tighten to 95 Nm (70 ft. lbs.) torque.
4. Raise engine and transaxle with screw jack until through hole in upper mount aligns with hole in mount bracket. Install mount bolt and tighten to 108 Nm (70 ft. lbs.) torque (Fig. 17).
5. Remove screw jack.
6. Install NEW drive plate-to-clutch module bolts and progressively tighten all bolts in a cries-cross pattern until the modular clutch assembly seats against the drive plate. Final torque the bolts to 88 Nm (65 ft. lbs.) torque.
7. Install starter motor and tighten bolts to 54 Nm (40 ft. lbs.) torque. Make sure to fasten ground cable to upper starter bolt as shown in (Fig. 16).
8. Connect starter electrical harness and tighten positive cable nut to 10 Nm (90 inch lbs.) torque.
9. Install bellhousing dust cover (Fig. 14).
10. Install left engine-to-transaxle bending brace (Fig. 14).
11. Install structural collar (Fig. 14) as follows:
a. Position collar and install all bolts finger tight.
b. Tighten the collar-to-oil pan bolts to 3 Nm (30 inch lbs.) torque.
c. Tighten the collar-to-transaxle bolts to 108 Nm (80 ft. lbs.) torque.
d. Final torque the collar-to-oil pan bolts to 54 Nm (40 ft. lbs.) torque.
12. Install the right lateral bending brace and tighten bolts to 81 Nm (60 ft. lbs.) torque (Fig. 15).
13. Install both front axle driveshafts.
14. Fill transaxle with suitable amount of Mopar(R) Manual Transaxle Lubricant (PN 04874465).
15. Lower vehicle.
16. Connect vehicle speed sensor connector (Fig. 13).
17. Connect shift crossover and selector cables to shift lever. Install cables to bracket and install retaining clips (Fig. 12).
18. Connect clutch cable to fork and secure to transaxle (Fig. 11).
19. Install bellhousing cap (Fig. 11).
20. Connect back-up lamp switch connector.
21. Connect ground strap to transaxle upper mount bracket.
22. Install battery lower tray and battery, and tighten battery hold down clamp to secure battery.
23. Install the air cleaner/throttle body assy. as follows:
a. Connect the accelerator and speed control (if equipped) cables to the air cleaner/throttle body assy.
b. Install assy. into position, making sure the air cleaner locating slot is engaged to the battery bracket tab, and tighten fasteners to 14 Nm (120 inch lbs.) torque.
c. Verify throttle body duct is fully seated to intake manifold and tighten clamp to 5 Nm (40 inch lbs.) torque.
d. Connect the Throttle Position Sensor (TPS) and Idle Air Control (IAC) connectors.
e. Connect Proportional Purge Solenoid (PPS) and crankcase vent hose from throttle body.
24. Connect the battery cables.
25. Road test vehicle and inspect for leaks.