Avenger, Sebring Coupe, Stratus Coupe, 1999-2006

Transaxle Removal & Installation

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WARNING
If the vehicle is going to be rolled on its wheels while the transaxle is out of the vehicle, obtain 2 outer CV-joints to install to the hubs. If the vehicle is rolled without the proper torque applied to the front wheel bearings, the bearings will no longer be usable.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the transaxle.
  4.  
  5. Disconnect the negative battery cable from the left shock tower.
    NOTE
    The ground cable is equipped with an insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding.

  6.  
  7. Remove or disconnect the following:

    Air cleaner duct
     
    Transmission Control Module (TCM)
     
    Solenoid pack electrical connector

    Click image to see an enlarged view

    Fig. Location of the transaxle solenoid assembly 8-way connector and retaining bolt



    Click image to see an enlarged view

    Fig. Removing the shift cable and clamp

     
    Dipstick tube from the transaxle
     
    Transaxle cooler lines
     
    Shift lever cable from the transaxle lever
     

  8.  
  9. Using an engine support fixture tool, support the engine assembly.
  10.  
  11. Remove or disconnect the following:

    Upper transaxle mount top bolts from the left side
     
    Front wheels
     
    Lower splash shields from both sides
     
    Exhaust pipe from the exhaust manifold
     
    Upper transaxle mount remaining bolts from the left side
     
    Engine oil filter
     
    Starter
     
    Front engine mount bracket
     
    Rear mount bracket through-bolt
     
    Center member bolts
     
    Rear mount bracket
     
    Radiator lower crossmember
     
    Both lateral bending strut brackets
     
    Flexplate cover
     

  12.  
  13. Matchmark the converter-to-flexplate location. Rotate the crankshaft clockwise to align the converter bolts.
  14.  
  15. Install or connect the following:

    Converter-to-flexplate bolts
     
    Crankshaft Position (CKP) sensor (if equipped)
     
    Transaxle electrical connectors
     
    Right side steering gear and K-frame bolts
     
    Sway bar mounts
     

  16.  
  17. Using a transmission jack and a safety chain, secure the transaxle and support it.
  18.  
  19. Install or connect the following:

    Bell housing-to-engine bolts
     
    Transaxle, by moving the K-frame rearward
     

  20.  
  21. To prepare the vehicle for rolling, support the engine with a suitable support or reinstall the front motor mount to the engine. Then, reinstall the ball joints to the steering knuckle and install the retaining bolt. Install the obtained outer CV-joints to the hubs, install the washers and tighten the axle nuts to 180 ft. lbs. (244 Nm). The vehicle may now be safely rolled.
  22.  

To install:

  1. Install or connect the following:

    Transaxle, by moving the K-frame rearward
     
    Bell housing-to-engine bolts and torque the bolts to 70 ft. lbs. (95 Nm)
     
    Sway bar mounts
     
    Right side steering gear and K-frame bolts
     
    Transaxle electrical connectors
     
    CKP sensor (if equipped)
     

  2.  
  3. Align the converter-to-flexplate matchmark. Rotate the crankshaft clockwise to align the converter bolts.
  4.  
  5. Install or connect the following:

    Torque converter and torque the converter-to-flexplate bolts to 55 ft. lbs. (74 Nm)
     
    Flexplate cover and torque the bolts to 108 inch lbs. (12 Nm)
     
    Both lateral bending strut brackets and torque the bolts to 45 ft. lbs. (61 Nm)
     
    Radiator-s lower crossmember and torque the bolts to 45 ft. lbs. (61 Nm)
     
    Rear mount bracket
     
    Center member bolts and torque the bolts to 45 ft. lbs. (61 Nm)
     
    Rear mount bracket through-bolt and torque the through bolt to: 45 ft. lbs. (61 Nm)
     
    Front engine mount bracket and torque the bolts to 24 ft. lbs. (33 Nm)
     
    Starter
     
    New engine oil filter
     
    Upper transaxle mount remaining bolts to the left side
     
    Exhaust pipe to the exhaust manifold
     
    Lower splash shields to both sides
     
    Front wheels
     
    Upper transaxle mount top bolts, to the left side
     
    Shift lever cable to the transaxle lever and torque the nut to 14 ft. lbs. (19 Nm)
     
    Transaxle cooler lines
     
    Dipstick tube to the transaxle
     
    Solenoid pack electrical connector
     
    TCM
     
    Air cleaner duct
     
    Negative battery cable
     

  6.  
  7. Adjust the gearshift and throttle cables.
  8.  
  9. Refill the transaxle.
  10.  
  11. Check the transaxle for proper operation. Be sure the back-up lights and speedometer are working properly.
  12.  


NOTE
If transaxle assembly is being replaced or overhauled (clutch and/or seal replacement), it is necessary to perform the TCM Quick Learn Procedure.

  1. Disconnect battery cable.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Remove the dipstick tube. Plug hole to prevent debris from entering transaxle.
  6.  
  7. Using Tool 8875A, disconnect the transmission cooler line quick-connect fittings.
  8.  
  9. Disconnect the Solenoid/Pressure Switch Assy. connector.
  10.  
  11. Disconnect the Transmission Range Sensor connector.
  12.  
  13. Disconnect the Input Speed Sensor connector.
  14.  
  15. Disconnect the Output Speed Sensor connector.
  16.  
  17. Disconnect shift cable from manual valve lever and bracket.
  18.  
  19. Disconnect Crankshaft Position Sensor.
  20.  
  21. Remove the throttle body support bracket.
  22.  
  23. Disconnect Oxygen Sensor harness retainer from transaxle case.
  24.  
  25. Remove the rear mount bracket-to-transaxle case bolts.
  26.  
  27. Remove the starter upper bracket-to-block bolt.
  28.  
  29. Raise vehicle.
  30.  
  31. Remove the halfshafts.
  32.  
  33. Remove the rear mount bracket lower bolt.
  34.  
  35. Remove the rear mount through-bolt.
  36.  
  37. Remove the rear mount-to-cross member bolts.
  38.  
  39. Remove the rear mount and bracket.
  40.  
  41. Remove the front mount through-bolt.
  42.  
  43. Remove the front mount to radiator lower crossmember bolts.
  44.  
  45. Remove the front mount bracket to block and transaxle.
  46.  
  47. Remove the front mount bracket and mount.
  48.  
  49. Remove the starter lower bolt and starter motor assembly.
  50.  
  51. Remove the converter dust shield.
  52.  
  53. Remove the torque converter bolts.
  54.  
  55. Support engine/transaxle with screw jack and wood block on engine oil pan.
  56.  
  57. Remove the left mount bracket-to-transaxle bolts.
  58.  
  59. Carefully lower engine/transaxle assembly to gain access to and remove transaxle-to-engine bolts.
  60.  
  61. With aid of helper or transmission jack, remove transaxle assembly from vehicle.
  62.  

To install:

  1. Install the transaxle to engine. Install and torque transaxle-to-engine bolts to 70 ft. lbs. (95 Nm).
  2.  
  3. Install the upper mount to transaxle.
  4.  
  5. Raise engine/transaxle assembly into position and install the through-bolt. Torque through bolt to 55 ft. lbs. (70 Nm).
  6.  
  7. Remove the transmission jack and screw jack.
  8.  
  9. Install the torque converter bolts.
  10.  
  11. Install the torque converter dust shield.
  12.  
  13. Install the starter motor assembly and lower bolt.
  14.  
  15. Install the front mount/bracket assembly.
  16.  
  17. Install the rear mount/bracket assembly.
  18.  
  19. Install the halfshafts.
  20.  
  21. Lower vehicle.
  22.  
  23. Install the starter upper bracket-to-block bolt.
  24.  
  25. Connect oxygen sensor harness connector.
  26.  
  27. Install the throttle body support bracket (if equipped).
  28.  
  29. Connect crankshaft position sensor connector (if equipped).
  30.  
  31. Connect gearshift cable to manual valve lever.
  32.  
  33. Connect output speed sensor connector.
  34.  
  35. Connect input speed sensor connector.
  36.  
  37. Connect transmission range sensor connector.
  38.  
  39. Connect solenoid/pressure switch assembly connector.
  40.  
  41. Connect oil cooler lines to the transaxle. An audible -click- should be heard. Verify connection by pulling outward.
  42.  
  43. Install the dipstick tube.
  44.  
  45. Install the air cleaner assembly.
  46.  
  47. Connect battery negative cable.
  48.  


NOTE
If the transaxle assembly is being replaced or overhauled (clutch and/or seal replacement), it is necessary to perform the TCM Quick Learn Procedure.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    The negative battery cable
     
    The air cleaner assembly
     
    The dipstick tube. Plug the hole to prevent debris from entering the transaxle
     
    The transaxle cooler line quick-connect fittings using Tool 8875A
     
    The Solenoid/Pressure Switch Assembly connector
     
    The Transmission Range Sensor connector
     
    The Input Speed Sensor connector
     
    The Output Speed Sensor connector
     
    The shift cable from manual valve lever and bracket
     
    The Crankshaft Position Sensor
     
    The throttle body support bracket
     
    The Oxygen Sensor harness retainer from the transaxle case
     
    The rear mount bracket-to-transaxle case bolts
     
    The starter upper bracket-to-block bolt
     

  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Remove or disconnect the following:

    The halfshafts
     
    The rear mount bracket lower bolt
     
    The rear mount through-bolt
     
    The rear mount-to-cross member bolts
     
    The rear mount and bracket
     
    The front mount through-bolt
     
    The front mount to radiator lower crossmember bolts
     
    The front mount bracket to block and transaxle
     
    The front mount bracket and mount
     
    The starter lower bolt and starter motor assembly
     
    The converter dust shield
     
    The torque converter bolts
     

  8.  
  9. Support the engine/transaxle with a screw jack and a wood block on the engine oil pan.
  10.  
  11. Remove the left mount bracket-to-transaxle bolts.
  12.  
  13. Carefully lower the engine/transaxle assembly to gain access to and remove the transaxle-to-engine bolts.
  14.  
  15. With the aid of a helper or transaxle jack, remove the transaxle assembly from the vehicle.
  16.  

To install:

  1. Install the transaxle to the engine. Install and torque transaxle-to-engine bolts to 70 ft. lbs. (95 Nm).
  2.  
  3. Install the upper mount to the transaxle.
  4.  
  5. Raise the engine/transaxle assembly into position and install the through-bolt. Torque through-bolt to 55 ft. lbs. (70 Nm).
  6.  
  7. Remove the transaxle jack and the screw jack.
  8.  
  9. Install the torque converter bolts.
  10.  
  11. Install the torque converter dust shield.
  12.  
  13. Install the starter motor assembly and lower bolt.
  14.  
  15. Install the front mount/bracket assembly.
  16.  
  17. Install the rear mount/bracket assembly.
  18.  
  19. Install the halfshafts.
  20.  
  21. Lower the vehicle.
  22.  
  23. Install or connect the following:

    The starter upper bracket-to-block bolt
     
    The oxygen sensor harness connector
     
    The throttle body support bracket (if equipped)
     
    The crankshaft position sensor connector (if equipped)
     
    The gearshift cable to manual valve lever
     
    The output speed sensor connector
     
    The input speed sensor connector
     
    The transmission range sensor connector
     
    The solenoid/pressure switch assembly connector
     
    The oil cooler lines to the transaxle. An audible click should be heard. Verify the connection by pulling outward
     
    The dipstick tube
     
    The air cleaner assembly
     
    The negative battery cable
     

  24.  

2.0L & 2.5L Engines



The transaxle and torque converter must be removed as an assembly; otherwise, the torque converter drive plate, pump bushing or oil seal may be damaged. The drive plate will not support a load; therefore, none of the weight of the transaxle should be allowed to rest on the drive plate during removal.


NOTE
Transaxle removal does NOT require engine removal.

  1. Disconnect battery negative cable from remote negative terminal on shock tower and properly isolate to prevent accidental reconnection.
  2.  
  3. Remove or disconnect the following:

    Air cleaner duct.
     
    Transmission control module (TCM) and wiring
     
    Solenoid pack connector
     
    Dipstick tube
     
    Transaxle cooler lines
     
    Shift cable at lever and at clamp on transaxle
     

  4.  
  5. Install engine support fixture and support engine
  6.  
  7. Remove left upper transaxle mount top bolts
  8.  
  9. Raise vehicle.
  10.  
  11. Remove front wheels. Refer to Suspension to remove wheel hub nuts and both drive shafts.
  12.  
  13. Remove left and right side lower splash shields.
    WARNING
    The exhaust flex joint must be disconnected from the exhaust manifold anytime the engine is lowered. If the engine is lowered while the flex pipe is attached, damage will occur.

  14.  
  15. Continue by removing:

    Bolts securing exhaust flex joint to exhaust manifold.
     
    Exhaust pipe from manifold
     
    Remaining left upper mount bolts
     
    Engine oil filter
     
    Starter and wiring
     
    Front motor mount bracket
     
    Rear mount bracket through-bolt
     
    Center member bolts
     
    Rear mount bracket bolts
     
    Rear mount bracket
     
    Radiator lower crossmember
     
    Lateral bending strut brackets (front and rear)
     
    Flex plate cover
     

  16.  
  17. Rotate engine clockwise to line up converter bolts.
  18.  
  19. Remove converter bolts and mark converter to ease reassembly.
  20.  
  21. Remove crank position sensor, if equipped.
  22.  
  23. Remove transaxle wiring.
  24.  
  25. Loosen right side steering gear bolts.
  26.  
  27. Loosen right side K-frame bolts.
  28.  
  29. Continue removing:

    Left side steering gear bolts
     
    Left side K-frame bolts
     
    Sway bar mounts
     

  30.  
  31. Position transmission jack under transaxle and support with safety chain.
  32.  
  33. Remove upper and lower transaxle bell housing bolts.
  34.  
  35. Move K-frame rearward and carefully lower the transaxle assembly from vehicle.

    Click image to see an enlarged view

    Fig. Overview of automatic transaxle, mounts and K-member-2.0L and 2.5L engines



    Click image to see an enlarged view

    Fig. Position of transmission control module-2.0L and 2.5L engines



    Click image to see an enlarged view

    Fig. Removal of transmission shift cable-2.0L and 2.5L engines

  36.  

To install:

  1. Install transaxle in the reverse order of removal
  2.  
  3. Check and/or adjust gear shift cable.
  4.  
  5. Refill transaxle with MOPAR® ATF PLUS 3 (Automatic Transmission Fluid) Type 7176.
  6.  

2.4L & 3.0L Engines



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect battery negative cable from remote negative terminal on shock tower and properly isolate to prevent accidental reconnection.
  4.  
  5. Drain the transaxle fluid.
  6.  
  7. Remove or disconnect the following:
    NOTE
    To make installation easier, use chalk or paint to make matchmarks on the torque converter and flexplate. These marks will be used during reinstallation to align the assembly, keeping these parts in balance.


    WARNING
    After removing the bolts, push the torque converter toward the transaxle. This will prevent the converter from remaining in contact with the engine, possibly damaging the converter.



    Battery and battery tray
     
    Battery brace
     
    Air cleaner and intake hoses
     
    Shifter lever-to-transaxle nut, cable retaining clip and cable from the transaxle
     
    Shifter cable mounting bracket
     
    Speedometer, solenoid, neutral safety switch (inhibitor switch), the pulse alternator, kickdown servo switch and oil temperature sensor electrical connectors
     
    Transaxle oil cooler lines
     
    Transaxle dipstick and tube
     
    Starter and using Special Tool 7137 or C-4852, support the engine assembly
     
    Rear roll stopper mounting bracket
     
    Transaxle mount bracket
     
    Upper transaxle mounting bolts
     
    Front wheels
     
    Left side undercover
     
    Tie rod end from the steering knuckle
     
    Stabilizer bar link from the damper fork
     
    Damper fork from the lateral lower control arm
     
    Lateral lower arm and compression lower arm, lower ball joints from the steering knuckle
     
    Halfshafts from the transaxle and secure aside
     
    Bell housing cover
     
    Engine front roll stopper through-bolt
     
    Centermember
     
    Flexplate-to-torque converter bolts. Rotate the crankshaft to bring the bolts into a position for removal, one at a time.
     

  8.  
  9. Support the transaxle using a transmission jack (at the side of the case, NOT at the pan), and remove the transaxle lower coupling bolt.
    NOTE
    The coupling bolt is inserted from the engine side into the transaxle and is located just above the halfshaft opening.

  10.  
  11. Slide the transaxle rearward and carefully lower it from the vehicle.

    Click image to see an enlarged view

    Fig. Overview of transaxle, mounts and K-member-2.4L and 3.0L engines

  12.  

To install:

  1. Install or connect the following:
    WARNING
    When installing the halfshaft, keep the inboard joint straight in relation to the axle to avoid damaging the oil seal lip of the transaxle with the splined part of the halfshaft.



    Bell housing cover and torque the bolts to 108 inch lbs. (12 Nm)
     
    Centermember and torque the front mounting bolts to 65 ft. lbs. (88 Nm) and the rear bolts to 51-58 ft. lbs. (69-78 Nm).
     
    Front engine roll stopper through-bolt and lightly tighten. Once the full weight of the engine is on the mounts, torque the bolt to 42 ft. lbs. (56 Nm).
     
    Halfshafts using new circlips
     



    Tie rod and ball joints to the steering knuckle. Torque the ball joint self-locking nuts to 48 ft. lbs. (65 Nm), the tie rod end nut to 21 ft. lbs. (28 Nm) and secure with a new cotter pin.
     
    Damper fork to the lower control arm and torque the through-bolt to 65 ft. lbs. (88 Nm)
     
    Stabilizer link to the damper fork and torque the self-locking nut to 29 ft. lbs. (39 Nm)
     
    Left side undercover
     
    Wheels
     
    Transaxle mount bracket and torque the mounting nuts to 32 ft. lbs. (43 Nm)
     
    Rear roll stopper mounting bracket and remove the engine support
     
    Transaxle mount through-bolt to 51 ft. lbs. (69 Nm) and torque the front engine roll stopper bolt
     
    Upper transaxle mounting bolts and tighten to 35 ft. lbs. (48 Nm)
     
    Starter
     
    Dipstick tube and dipstick
     
    Shifter cable mounting bracket
     
    Shifter lever and torque the nut to 14 ft. lbs. (19 Nm)
     
    Oil cooler lines and secure with clamps
     
    Speedometer, solenoid, neutral safety switch (inhibitor switch), the pulse alternator, kickdown servo switch and oil temperature sensor electrical connectors
     
    Air cleaner and air intake hose
     
    Battery tray and battery
     

  2.  
  3. Refill the transaxle with DIAMOND® ATF SP III transmission fluid. Start the engine and allow it to idle for 2 minutes. Apply the parking brake and move the selector through each gear position, ending in N . Recheck fluid level and add if necessary. Fluid level should be between the marks in the HOT range on the dipstick.
  4.  
  5. Check the transaxle for proper operation.
  6.  

 
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