Breeze, Cirrus, Sebring Convertible and Sedan, Stratus Sedan, 1999-2005

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 the in 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, please familiarize yourself with safety procedures.
  2.  
  3. Remove or disconnect the following:
    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.


    WARNING
    Using equal force, pry up on both sides of the shifter cable isolator bushings to avoid damaging the cable isolator bushing.



    Negative battery cable from the left shock tower.
     



    Air cleaner and intake hoses
     
    Clutch housing vent cap
     
    Clutch cable from the bell housing
     



    Selector lever and crossover cables from the transaxle
     
    Shift cable mounting bracket from the transaxle
     
    Accelerator cables from the throttle body
     
    Accelerator cable bracket from the throttle body
     
    Upper starter to throttle body support bracket bolt
     
    Upper bell housing to throttle body support bracket stud nut
     
    Throttle body support bracket
     
    Left transaxle mount upper bolts
     
    Upper bell housing bolts
     
    Vehicle Speed Sensor (VSS)
     
    Back-up light electrical connector from the transaxle
     

  4.  
  5. Install an engine support fixture tool and support the engine.
  6.  
  7. Remove or disconnect the following:

    Front wheels
     
    Halfshafts
     
    Lower splash shield/battery cover from the left side
     
    Lower bracket bolts, from the left transaxle mount
     
    Engine-to-lower crossbar bolts
     
    Front steel engine mount bracket
     
    3 front aluminum engine mount bracket bolts
     
    Starter
     
    Rear transaxle mount bracket
     
    Transaxle-to-rear lateral bending strut from engine/transaxle assembly
     
    Transaxle bell housing cover
     

  8.  
  9. Using a transaxle jack, support the transaxle.

    Click image to see an enlarged view

    Fig. Secure the engine assembly with an appropriate support fixture-2001-04



    Click image to see an enlarged view

    Fig. Remove the driveplate clutch bolts-rotate the engine clockwise to advance to the next bolt



    Click image to see an enlarged view

    Fig. Removing the lower engine-to-transaxle mounting bolts-2001-04 models

  10.  
  11. Rotate the engine clockwise to gain access to the driveplate clutch bolts.

    Driveplate clutch bolts
     
    Lower engine-to-transaxle bolts
     
    Transaxle
     

  12.  

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.

To install:

  1. Install or connect the following:

    Transaxle and torque the transaxle to engine bolts to 70 ft. lbs. (95 Nm)
     
    Driveplate clutch bolts
     
    Lower engine-to-transaxle bolts and torque the bolts to 70 ft. lbs. (95 Nm)
     
    Transaxle bell housing cover and torque bolts to 9 ft. lbs. (12 Nm)
     
    Transaxle-to-rear lateral bending strut to the engine/transaxle assembly and torque the bolt to: 40 ft. lbs. (54 Nm)
     
    Rear transaxle mount bracket and torque the bolts to 40 ft. lbs. (54 Nm)
     
    Starter
     
    3 front aluminum engine mount bracket bolts and torque the bolts to 40 ft. lbs. (54 Nm)
     
    Front steel engine mount bracket and torque the bolt to 45 ft. lbs. (61 Nm)
     
    Engine-to-lower crossbar bolts
     
    Lower bracket bolts to the left transaxle mount and torque the bolts to 40 ft. lbs. (54 Nm)
     
    Lower splash shield/battery cover to the left side
     
    Halfshafts
     
    Front wheels
     

  2.  
  3. Remove the engine support fixture tool.
  4.  
  5. Install or connect the following:

    Back-up light electrical connector
     
    VSS sensor
     
    Upper bell housing bolts and torque the bolts to 70 ft. lbs. (95 Nm)
     
    Left transaxle mount upper bolts and torque the bolts to 40 ft. lbs. (54 Nm)
     
    Throttle body support bracket
     
    Upper bell housing-to-throttle body support bracket stud nut and torque the nut to 32 ft. lbs. (43 Nm)
     
    Upper starter-to-throttle body support bracket bolt
     
    Accelerator cable bracket to the throttle body
     
    Accelerator cables to the throttle body
     
    Shift cable mounting bracket to the transaxle
     
    Selector lever and crossover cables to the transaxle
     
    Clutch cable to the bell housing
     
    Clutch housing vent cap
     
    Air cleaner and intake hoses
     
    Negative battery cable

    Click image to see an enlarged view

    Fig. Be sure to connect the ground cable at the starter

     

  6.  
  7. Check to be sure that all fasteners are tightened and connections made.
  8.  
  9. Refill the transaxle.
  10.  
  11. Check the transaxle for proper operation. Be sure the reverse lights turn ON when in reverse.
  12.  

  1. Raise hood.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the air cleaner assembly.
  6.  
  7. Disconnect Vehicle Speed Sensor/Back-up Lamp Switch harness connector.
  8.  
  9. Remove the clutch release access cap.
  10.  
  11. Disconnect clutch release cable.
  12.  
  13. Disconnect crossover and selector cables from transaxle.
  14.  
  15. Remove the gearshift cable retainer clips from bracket and position gearshift cables out of way.
  16.  
  17. Remove the starter motor and secure out of way.
  18.  
  19. Remove the three rear mount bracket-to-transaxle bolts.
  20.  
  21. Raise vehicle on hoist.
  22.  
  23. Remove the halfshafts.
  24.  
  25. Remove the rear mount bracket-to-transaxle horizontal bolt.
  26.  
  27. Remove the rear mount through-bolt.
  28.  
  29. Remove the three rear mount-to-crossmember bolts.
  30.  
  31. Remove the rear mount and bracket.
  32.  
  33. Remove the front mount through bolt.
  34.  
  35. Remove the engine front pencil strut brace.
  36.  
  37. Remove the front mount bracket from engine/transaxle.
  38.  
  39. Remove the structural cover.
  40.  
  41. Remove the bell housing dust cover.
  42.  
  43. Remove the left wheel opening splash shield.
  44.  
  45. Remove the four modular clutch-to-drive plate bolts. While removing bolts, one tight-tolerance (slotted) drive plate hole will be encountered. When this bolt is removed, mark driveplate and modular clutch assembly at this location, and be sure to align marks upon reassembly.
  46.  
  47. Position screw jack and wood block to oil pan.
  48.  
  49. Remove the transaxle upper mount through bolt.
  50.  
  51. Lower engine transaxle assembly.
  52.  
  53. Remove the transaxle upper mount.
  54.  
  55. Obtain helper and transmission jack.
  56.  
  57. Remove the transaxle-to-engine block bolts.
  58.  
  59. Remove the transaxle from engine.
  60.  

To install:

  1. Install the modular clutch assembly to transaxle input shaft.
  2.  
  3. Using a helper and transmission jack, install the transaxle to engine.
  4.  
  5. Install and torque transaxle-to-engine bolts to 70 ft. lbs. (95 Nm).
  6.  
  7. Install the transaxle upper mount bracket and torque bolts to: 48 ft. lbs. (65 Nm).
  8.  
  9. Raise engine/transaxle assembly into position with screw jack.
  10.  
  11. Install and torque transaxle upper mount to bracket bolts to 45 ft. lbs. (61 Nm)
  12.  
  13. Remove the screw jack and wood block.
  14.  
  15. Install the four modular clutch-to-driveplate bolts. Align drive plate and modular clutch alignment marks placed upon disassembly. Start with tight-tolerance (slotted) hole, install the and torque bolts to 65 ft. lbs. (88 Nm).
  16.  
  17. Install the bell housing dust cover.
  18.  
  19. Install the structural cover.
  20.  
  21. Install the left wheel house splash shield.
  22.  
  23. Install the front mount and bracket.
  24.  
  25. Install the rear mount to crossmember.
  26.  
  27. Install the rear mount bracket into position and loosely Install the horizontal bolt.
  28.  
  29. Install the halfshafts.
  30.  
  31. Lower vehicle.
  32.  
  33. Install the three rear mount bracket-to-transaxle and torque to 80 ft. lbs. (110 Nm)
  34.  
  35. Raise vehicle.
  36.  
  37. Torque rear mount bracket-to-transaxle horizontal bolt to 80 ft. lbs. (110 Nm)
  38.  
  39. Install the rear mount through-bolt and torque to 45 ft. lbs. (61 Nm).
  40.  
  41. Install the starter motor.
  42.  
  43. Install the gearshift cables to bracket and install the new retaining clips.
  44.  
  45. Connect gearshift crossover and selector cable to crossover and selector levers.
  46.  
  47. Install the clutch release cable to release lever and case. Install the cap.
  48.  
  49. Connect Vehicle Speed Sensor and Back-up Lamp Switch harness.
  50.  
  51. Install the air cleaner assembly.
  52.  
  53. Connect battery negative cables.
  54.  
  55. Fill transaxle with suitable amount of fluid.
  56.  

2.0L & 2.5L Engines





Click image to see an enlarged view

Fig. For transaxle removal, properly support the engine assembly as shown



Click image to see an enlarged view

Fig. Also, use a transmission jack to support the transaxle assembly

  1. Before servicing the vehicle, refer to the Precautions section.

    Drain the transaxle fluid.
     

  2.  
  3. Remove or disconnect the following:

    Battery and battery tray
     
    Battery brace
     
    Air cleaner and intake hoses
     
    Select and shift cable cotter pins and the cable ends from the transaxle
     
    Back-up light switch harness and position it aside
     
    Speedometer electrical connector, from the transaxle assembly
     
    Starter
     

  4.  
  5. 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
     
    Under cover
     
    Cotter pin and 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, compression lower arm and lower ball joints from the steering knuckle
     
    Halfshafts from the transaxle and secure aside
     
    Clutch release cylinder connection and move aside without disconnecting the hydraulic line
     
    Bell housing cover
     
    Engine front roll stopper through-bolt
     
    Centermember
     

  6.  
  7. Support the transaxle, using a transmission jack, and remove the transaxle lower coupling bolt.
    NOTE
    The coupling bolt threads from the engine side, into the transaxle, and is located just above the halfshaft opening.

  8.  
  9. Slide the transaxle rearward and carefully lower it from the vehicle.
  10.  

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 serrated part of the halfshaft.



    Transaxle and torque the transaxle-to-engine bolts to 70 ft. lbs. (95 Nm)
     
    Bell housing cover and torque the bolts to 84 inch lbs. (9 Nm)
     
    Centermember and torque the front mounting bolts to 65 ft. lbs. (88 Nm) and the rear bolt to 54 ft. lbs. (73 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. (57 Nm).
     
    Clutch release cylinder
     
    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). Torque 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)
     
    Under cover
     
    Wheels
     
    Transaxle mount bracket to the transaxle and torque the nuts to 32 ft. lbs. (43 Nm)
     
    Rear roll stopper mounting bracket
     

  2.  
  3. Remove the engine support. Tighten the transaxle mount through-bolt to 51 ft. lbs. (69 Nm) and tighten the front engine roll stopper through-bolt.

    Upper transaxle mounting bolts and torque them to 35 ft. lbs. (48 Nm)
     
    Starter
     
    Back-up light switch and speedometer connector
     
    Select and shift cables and new cotter pins
     
    Air cleaner and air intake hose
     
    Battery tray and battery
     
    Battery stay
     

  4.  
  5. Be sure the vehicle is level, and refill the transaxle with Mopar® MS9417 MTX fluid, part number 4773167.
  6.  
  7. Check the transaxle for proper operation. Be sure the reverse lights come ON when in reverse.
  8.  

2.4L & 3.0L Engines



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the transaxle fluid.
  4.  
  5. Remove or disconnect the following:

    Battery and tray
     
    Air cleaner assembly
     
    Front exhaust pipe, 3.0L engine
     
    Shift and selection cable connections
     
    Back-up light switch connection
     
    Vehicle Speed Sensor (VSS) connector
     
    Starter
     
    Clutch release cylinder connector
     
    Transaxle assembly upper coupling bolts
     
    Centermember
     
    Rear roll stopper
     
    Transaxle mount bracket and stopper
     
    Stabilizer link
     
    Wheel Speed Sensor (WSS), if equipped
     
    Brake hose clamp
     
    Tie rod end
     
    Lower arm
     
    Clutch release bearing engagement, 3.0L engine
     
    Driveshaft connection
     
    Upper oil pan bolt, 3.0L engine
     
    Bell housing cover
     
    Transaxle assembly lower coupling bolts
     
    Transaxle assembly
     

  6.  

To install:

  1. Install or connect the following:

    Transaxle assembly. Torque the lower coupling bolts to 36 ft. lbs. (48 Nm) on the 2.4L engine and to 52 ft. lbs. (71 Nm) for the 3.0L engine.
     
    Bell housing cover. Torque the cover-to-engine bolt to 78 inch lbs. (9 Nm) and the cover-to-transaxle bolt to 19 ft. lbs. (26 Nm).
     
    Upper oil pan bolt, 3.0L engine
     
    Driveshaft connection
     
    Clutch release bearing engagement
     
    Lower arm and torque the nut to 80 ft. lbs. (108 Nm)
     
    Tie rod end and torque the nut to 21 ft. lbs. (28 Nm)
     
    WSS, if equipped
     
    Stabilizer link and torque the nut to 33 ft. lbs. (45 Nm)
     
    Transaxle mount bracket and torque the nut to 42 ft. lbs. (57 Nm)
     
    Transaxle mount stopper and torque the nut to 60 ft. lbs. (81 Nm)
     
    Rear roll stopper and torque the nut to 33 ft. lbs. (45 Nm)
     
    Centermember
     
    Clutch release cylinder and torque to 13 ft. lbs. (18 Nm)
     
    Starter motor and electrical connectors
     
    VSS connector
     
    Back-up light switch connector
     
    Shift and selection cable connections
     
    Front exhaust pipe, 3.0L engine
     
    Air cleaner assembly
     
    Battery and tray
     

  2.  
  3. Fill the transaxle fluid to the proper level.
  4.  
  5. Start the vehicle, check for leaks and repair if necessary.
  6.  

 
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