Manual Transmission/Transaxle: Service and Repair

QUATTRO COUPE

1. Disconnect battery ground cable.
2. Disconnect RPM sensor.
3. Remove upper engine to transmission attaching bolts.
4. Disconnect speedometer cable.
5. Disconnect tie rod coupling from steering rack, first removing self locking nuts below tie rod coupling, then the mounting bolts.
6. Drive out clutch slave cylinder lock pin, then remove clutch slave cylinder, leaving hydraulic lines attached.
7. Disconnect back-up light switch and the shift linkage.

Fig. 2 Engine support tool No. 10-222:

8. Attach tool No. 10-222 or equivalent and support engine, Fig. 2.
9. Remove deflector for axle shaft and right transmission mount, then the right transmission mount.
10. Disconnect exhaust pipe at flange and the right axle shaft at transmission.
11. Remove left transmission mount, then disconnect left axle shaft at transmission.
12. Disconnect driveshaft at rear of transmission.
13. Disconnect differential lock cable.
14. Remove transmission cover plate.
15. Turn spindle of tool 10-222 to raise engine slightly.
16. Place suitable jack under transmission.
17. Remove lower engine to transmission attaching bolts.
18. Remove transmission from under vehicle.
19. Reverse procedure to install, noting the following:
a. Ensure that engine and transmission mounts are free of tension.
b. Adjust shift linkage as necessary.
c. Coat driveshaft and axle shaft flanges with suitable lubricant.
d. Torque exhaust pipe to flange attaching bolts to 18 ft.lbs.
e. Torque exhaust pipe to transmission mount attaching bolts to 22 ft.lbs.
f. Torque tie rod coupling to steering rack attaching bolts and transmission mount to transmission attaching bolts to 29 ft.lbs.
g. Torque transmission mount to subframe attaching bolts and driveshaft attaching bolts to 32 ft.lbs.
h. Torque engine to transmission mounting bolts to 43 ft.lbs.
i. Torque axle shaft to transmission mounting bolts to 58 ft.lbs.




QUATTRO TURBO

1. Disconnect battery ground cable.
2. Disconnect RPM sensor.
3. Remove upper engine to transmission attaching bolts.
4. Disconnect speedometer cable.
5. Disconnect tie rod coupling from steering rack, first removing self locking nuts below tie rod coupling, then the mounting bolts.
6. Drive out clutch slave cylinder lock pin and remove clutch slave cylinder, leaving hydraulic line connected.
7. Disconnect electrical connector for back-up light switch, then the shift linkage.
8. Install tool 10-222 or equivalent to support engine.
9. Remove deflector for axle shaft and right transmission mount, then the right transmission mount.
10. Disconnect exhaust pipe at flange and the right axle shaft at transmission.
11. Remove left transmission mount, then disconnect left axle shaft at transmission.
12. Disconnect driveshaft at rear of transmission.
13. Disconnect differential lock cable.
14. Remove transmission cover plate.
15. Turn spindle on tool 10-222 to raise engine slightly.
16. Place suitable jack under transmission and remove lower engine to transmission attaching bolts.
17. Remove transmission toward rear of vehicle, ensuring transmission clears axle shafts, driveshaft, tie rods and shift linkage.
18. Reverse procedure to install, noting the following:
a. Ensure engine to transmission mounts are free of tension.
b. Adjust shift linkage as necessary.
c. Clean driveshaft and axle shaft flanges and lightly coat with suitable lubricant.
d. If lifting eye is still in place on transmission housing near starter, it may be necessary to hacksaw it off to facilitate assembly of exhaust pipe.
e. Torque engine to transmission attaching bolts to 43 ft.lbs.
f. Torque tie rod coupling to steering rack and the transmission mount to transmission attaching bolts to 29 ft.lbs.
g. Torque axle shaft to transmission attaching bolts to 58 ft.lbs.
h. Torque exhaust pipe to transmission mount attaching bolts to 22 ft.lbs.
i. Torque transmission mount to subframe and the driveshaft to transmission attaching bolts to 32 ft.lbs.
j. Torque exhaust pipe to flange attaching bolts to 18 ft.lbs.