Transaxle Removal and Installation

Tools

• Metric wrench and socket set
• Jack stands (minimum 4)
• Floor jack
• Probe or small flat-tip screwdriver
• 8 mm Allen head socket
• 8 mm cheesehead socket tool

Removal

1. Raise the vehicle and support it securely on jack stands. The transaxle end of the car must be high enough to allow the transaxle to be lowered clear of the chassis.

2. Apply the parking brake to prevent the rear wheels from rotating when disconnecting the CV joints.

3. Disconnect the shift linkage at the transaxle.

   Early cars (carpet console shifter):

   1. Remove the shift knob.
   2. Pull back the carpet and console trim to expose the shift lever base.
   3. Remove the shift lever retaining hardware and lift the lever from the console.
   4. Disconnect the shift linkage rod from the shift lever (remove the retaining clip).
   5. With the rod free of the lever, turn the shift rod down and push it toward the front of the vehicle to disengage the shift linkage rod from the transaxle.

   Late cars and 968 (plastic trim console shifter):

   1. Remove the shift knob.
   2. Unclip and remove the plastic console trim panel surrounding the shift lever.
   3. Remove the shift lever retaining hardware and lift the lever from the console.
   4. Disconnect the shift linkage rod from the shift lever (remove the retaining clip).
   5. With the rod free of the lever, turn the shift rod down and push it toward the front of the vehicle to disengage the shift linkage rod from the transaxle.

4. At the transaxle, disconnect the shift rod from the intermediate lever. Remove the shift rod retaining bolt. Note: this bolt uses Loctite and is locked with steel wire in the factory — cut the wire and apply fresh Loctite on reassembly.

5. Disconnect the drive shaft clamping sleeve. Remove the covers on the bottom of the transaxle bellhousing. Roll the rear wheels until the drive shaft retaining bolts are accessible through the opening in the bottom of the bellhousing (engage the clutch pedal to roll the wheels). Mark the position of the clamping sleeve on the drive shaft so it can be reassembled in the same orientation. Using an 8 mm Allen head socket, remove the clamping sleeve bolts and slide the clamping sleeve off the drive shaft splines toward the transaxle.

6. Disconnect the speedometer cable or sensor connector at the transaxle.

7. Disconnect the reverse light switch connector.

8. Disconnect the CV joint bolts at the transaxle output flanges on both sides. Use the parking brake to hold the wheels while breaking loose the bolts.

9. Support the transaxle with a floor jack or transmission jack. A transmission jack is recommended for safety and control.

10. Disconnect the fuel filter from the transaxle support cross-member, then remove the transaxle cross-member bolts (two M10 bolts). Lower the cross-member clear of the chassis.

11. Remove the fasteners securing the transaxle case to the torque tube bellhousing. There are both M12 and M10 fasteners — keep track of which size goes where.

12. Move the transaxle toward the rear of the car enough to slide the shift linkage tube out of the way and disconnect the drive shaft clamping sleeve. Lower the transaxle as you move it rearward to clear the spare tire well. Once the shift linkage tube is clear and the drive shaft is free of the transaxle, lower the transaxle from the vehicle.

Caution: The transaxle is heavy. Use a jack and have an assistant guide it during removal to avoid injury or damage to surrounding components.

Installation

1. Clean the mating faces of the transaxle case and torque tube bellhousing.

2. Apply a thin film of gear oil to the transaxle input shaft and pilot area to ease assembly.

3. Raise the transaxle into position and align it with the torque tube bellhousing. Slide it forward to engage.

4. Install and torque the bellhousing fasteners:

   Fastener	Torque
   M12 fasteners	85 N·m63 ft·lb
   M10 fasteners	42 N·m31 ft·lb

5. Reinstall the transaxle cross-member and torque the bolts:

   Fastener	Torque
   Cross-member bolts (2 × M10)	46 N·m34 ft·lb

6. Reconnect the CV joints at the transaxle output flanges. Torque the CV joint bolts:

   Fastener	Torque
   CV joint bolts	41 N·m30 ft·lb

7. Reconnect the reverse light switch connector and speedometer cable or sensor connector.

8. Reinstall the shift rod. Apply Loctite to the retaining bolt and torque it. Lock with new steel wire:

   Fastener	Torque
   Shift rod retaining bolt	21 N·m15 ft·lb

9. Through the access opening in the bottom of the transaxle bellhousing, slide the drive shaft clamping sleeve back onto the drive shaft splines in the same orientation as marked during removal. Torque the clamping collar Allen bolt:

   Fastener	Torque
   Clamping collar Allen bolt	80 N·m59 ft·lb

10. Reinstall the shift lever following the reverse of the removal steps appropriate to the shifter design (early carspet console or late plastic trim).

11. Lower the vehicle and check transaxle fluid level. Fill to the bottom of the fill plug hole if needed. See TRANS-06 for fluid specifications and capacity.

12. Road test and verify smooth shifting through all gears, including reverse. Check for leaks.

Note: If the shift linkage requires adjustment after installation, refer to TRANS-07 for shift lever and linkage adjustment procedures.