Removal and Replacement
REMOVALNOTE: Due to transaxle case configuration on models equipped with 2.3L engines, right hand halfshaft assembly must be removed first using halfshaft removal tool No. D83P-4026-A or equivalent. The differential rotator tool No. T81P-4026-A or equivalent is then inserted into the transaxle to drive the left hand inboard CV joint assembly from the transaxle case.
1. Disconnect battery ground cable, then isolate cable end with electrical tape or equivalent.
2. Remove air cleaner assembly, then disconnect electrical connector front neutral safety switch.
3. Disconnect Throttle Valve (TV) linkage (throttle cable on 3.0L and manual lever cable from transaxle levers.
CAUTION: Failure to disconnect linkage during transaxle removal, and allowing the transaxle to hang will fracture the TV cam shaft joint (located under the transaxle cover.
4. Cover timing window in the converter to prevent contamination.
5. On 2.3L engine, remove thermactor hose(s) retaining bolts, if equipped.
NOTE: Position valve and hoses away from brake lines and master cylinder to avoid interference.
6. Remove ground strap located above upper engine mount, then coil and bracket, if applicable.
7. On all models, remove two transaxle to engine upper bolts located below and to either side of distributor.
8. Install Three Bar Engine Support tool No. D88L-6000-A or equivalent, then raise and support vehicle.
9. Remove front wheel and tire assemblies.
10. Remove nut from control arm to steering knuckle bolt, on both sides of vehicle, then drive bolts out using punch and hammer.
NOTE: The bolts and nuts must be discarded.
Disengaging Control Arm From Steering Knuckle:
11. Disengage control arm from steering knuckle, on both sides of vehicle, using a pry bar.
CAUTION: Use care to avoid damaging ball joint boot. Pry bar must not contact lower arm. Do not use hammer on knuckle to remove ball joints. Plastic splash shield behind rotor has pocket into which lower ball joint fits. When disconnecting lower control arm from knuckle, shield should be bent back to clear ball joint and avoid damaging the shield.
12. Remove and discard stabilizer bar bracket bolts from both sides of vehicle.
13. Remove and discard stabilizer to control arm nut and washer from both sides of vehicle, then slide stabilizer bar out of control arms.
14. Remove brake hose routing clip attaching bolts from suspension strut bracket on both sides of vehicle.
15. Disconnect tie rod from steering knuckle on both sides of vehicle.
16. Pry halfshaft out of right side of transaxle and position shaft on transaxle housing.
NOTE: If difficulty is encountered when prying halfshaft, remove transaxle oil pan and discard gasket. Insert a large blade screwdriver between differential pinion shaft and inboard CV joint stub shaft. Tap screwdriver handle to dislodge circlip from side gear and free halfshaft from differential. Prior to installation of the halfshaft, install a new circlip on inboard stub shaft. Also, use a new gasket when installing oil pan.
17. Disengage left halfshaft from differential side gear using Differential Rotator tool No. T81P-4026-A or equivalent.
18. Slide halfshaft out of transaxle and support end of shaft.
CAUTION: Do not allow end of driveshaft to hang unsupported, as damage to outboard CV joint may result.
19. Install Transaxle Plugs part No. T81P-1177-B or equivalent into differential seals.
20. On 2.3L engine, remove starter support bracket.
21. Remove two converter tube bracket retaining bolts, then one exhaust converter retaining bolt from starter.
22. Disconnect exhaust converter Air Injection Reaction (AIR) tubes.
23. On all models, disconnect starter motor from wiring harness, then remove starter motor.
24. On 2.3L engines, remove transaxle support bracket.
25. On all models, remove torque converter housing dust cover.
26. Remove torque converter to flywheel attaching nuts. Rotate crankshaft as necessary to provide access to each nut.
27. Position Rotunda Hi-Lift Jack tool No. 014-00210 or equivalent under transaxle, then remove rear support bracket attaching nuts.
28. Remove left front body bracket attaching nuts and bolts and the bracket.
29. Disconnect upper transaxle cooler line using Cooler Line Disconnect tool No. T82L-9500-AH or equivalent. To remove lower cooler line, slide constant tension clamp off tube and remove hose.
30. Remove manual lever bracket attaching bolts from transaxle case.
31. Ensure engine is properly supported, then remove remaining transaxle to engine attaching bolts.
32. Insert a screwdriver between flywheel and torque converter and carefully move transaxle and converter away from engine. When converter studs clear flywheel, lower transaxle two to three inches and disconnect speedometer cable.
33. Lower transaxle and remove from vehicle.
NOTE: When lowering the transaxle away from the engine, watch the No. 1 insulator. If it contacts the body before the converter studs clear the flywheel, remove the insulator.
INSTALLATION
1. Reverse procedure to install, noting the following:
CV Stub Shaft Circlip Replacement:
a. Replace circlip on CV joint stub shaft. Avoid spreading the circlip any more than necessary.
Half Shaft Circlip Seating:
b. When inserting halfshaft in transaxle, push CV joint into differential until circlip seats in side gear.
NOTE: A rubber mallet may be used to tap the outboard CV joint stub shaft, if necessary.
New Pinch Bolt Installation:
c. When attaching lower ball joint to steering knuckle, use care to avoid damaging ball joint boot. Install new pinch bolt and nut and torque nut to 40-54 ft lbs.
NOTE: Do not torque bolt.