Removal

REMOVAL

2.4L GAS

1. Raise hood.
2. Disconnect gearshift cables from shift levers/cover assembly (Figure 1).




Figure 1 Gearshift Cables at Transaxle






3. Remove gearshift cable retaining clips from mounting bracket (Figure 1). Remove cables and secure out of way.
4. Remove three (3) right engine mount bracket-to-transaxle bolts (Figure 2).




Figure 2 Transaxle Right Mount and Bracket






5. Raise vehicle on hoist.
6. Remove front wheel/tires and halfshafts.
7. Drain transaxle fluid into suitable container.
8. Remove front harness retainer and secure harness out of way.
9. Using Tool 6638A, disconnect clutch hydraulic circuit quick connect (located on slave cylinder tube). Remove clutch slave cylinder by depressing towards case and rotating counter-clockwise 60�, while lifting anti-rotation tab out of case slot with screwdriver (Figure 3).




Figure 3 Slave Cylinder Removal/Installation






10. Remove engine left mount bracket.
11. Remove starter motor (Figure 4).




Figure 4 Starter Motor Removal/Installation






12. Disconnect back-up lamp switch connector.
13. Remove structural collar.
14. Remove modular clutch assembly-to-drive plate bolts.
15. Position screw jack and wood block to engine oil pan.
16. Remove transmission upper mount through-bolt from left frame rail.
17. Lower engine/transaxle assembly on screw jack.
18. Remove four (4) upper mount-to-transaxle bolts and remove mount (Figure 5).




Figure 5 Transaxle Upper Mount






19. Obtain helper and transmission jack. Secure transaxle to transmission jack and remove transaxle-to-engine bolts.
20. Remove transaxle from engine.
21. Inspect modular clutch assembly, clutch release components, and engine drive plate.

2.5L TD

1. Raise hood.
2. Disconnect both battery cables.
3. Remove battery thermal shield (Figure 6).




Figure 6 Battery Thermal Shield


1 - BATTERY THERMAL SHIELD

4. Remove battery hold down bolt, clamp, and battery (Figure 7).




Figure 7 Battery and Hold-Down Clamp






5. Remove battery tray (Figure 8). Disconnect battery temperature sensor.




Figure 8 Battery Tray


1 - BATTERY TRAY

6. Remove coolant recovery bottle from bracket.
7. Remove coolant recovery bottle mounting bracket (Figure 9).




Figure 9 Coolant Recovery Bottle Bracket






8. Disconnect gearshift cables from shift levers/cover assembly (Figure 10).
9. Remove gearshift cable retaining clips from mounting bracket (Figure 10). Remove cables and secure out of way.




Figure 10 Gearshift Cables at Transaxle






10. Remove three (3) right engine mount bracket-to-transaxle bolts (Figure 11).




Figure 11 Transaxle Right Mount and Bracket






11. Raise vehicle on hoist.
12. Remove front wheel/tires and halfshafts.
13. Remove underbody splash shield.
14. Drain transaxle fluid into suitable container.
15. Remove front harness retainer and secure harness out of way.
16. Using Tool 6638A, disconnect clutch hydraulic circuit quick connect (located on slave cylinder tube). Remove clutch slave cylinder by depressing towards case and rotating counter-clockwise 60�, while lifting anti-rotation tab out of case slot with screwdriver (Figure 12).




Figure 12 Slave Cylinder Removal/Installation






17. Remove engine left mount bracket (Figure 13).




Figure 13 Left Mount Bracket Removal/Installation






18. Remove starter motor (Figure 14).




Figure 14 Starter Motor Removal/Installation






19. Disconnect back-up lamp switch connector.
20. Position screw jack and wood block to engine oil pan.
21. Remove transmission upper mount through-bolt from left frame rail.
22. Lower engine/transaxle assembly on screw jack.
23. Remove four (4) upper mount-to-transaxle bolts and remove mount (Figure 15).




Figure 15 Transaxle Upper Mount






24. Obtain helper and transmission jack. Secure transaxle to transmission jack and remove transaxle-to-engine bolts.
25. Remove transaxle from engine (Figure 16).
26. Inspect clutch, clutch release components, and flywheel.




Figure 16 Transaxle Removal/Installation