Caliber 2007

Transaxle Removal & Installation

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  1. Remove the splash shields and drain the transaxle fluid.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the engine appearance cover.
  6.  
  7. Remove the air intake assembly.
  8.  
  9. Unplug the speed sensor connector.
  10.  
  11. Disconnect the back-up lamp switch.
  12.  
  13. Remove the shift cables from the bracket clips.
  14.  
  15. Disconnect the shift selector and crossover cable from the levers. Remove the cables and secure them out of the way.
  16.  
  17. Remove the slave cylinder hose from the bracket.
  18.  
  19. Remove the air inlet tube from the throttle body.
  20.  
  21. Remove the throttle body support bracket.
  22.  
  23. Remove the upper bell housing bolts.
  24.  
  25. Remove the starter mounting bolts and secure the starter out of the way.
  26.  
  27. Support the transaxle with a suitable jack.
  28.  
  29. Loosen the left-upper transaxle mount through-bolt.
  30.  
  31. Remove the transaxle mount bolts.

    Click image to see an enlarged view

    Fig. Location of the left-upper transaxle mount through-bolt (1) and transaxle mount bolts (2)-Manual Transaxle

  32.  
  33. Raise and safely support the vehicle.
  34.  
  35. Remove the halfshafts. For additional information, see Front Halfshaft
  36.  
  37. Remove the transfer case, if equipped.
  38.  
  39. Support the engine with a suitable jack.
  40.  
  41. Support the transaxle with a suitable transmission jack.
  42.  
  43. Remove the bell housing dust cover.
  44.  
  45. Remove 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 drive plate and modular clutch assembly at this location, and be sure to align marks upon reassembly.
  46.  
  47. Remove the front transaxle mount through-bolt.
  48.  
  49. Remove the transaxle crossmember mounting bolts and remove the crossmember.

    Click image to see an enlarged view

    Fig. Location of the front transaxle through-bolt (4) and transaxle crossmember mounting bolts (2, 3) and crossmember (1)-Manual Transaxle

  50.  
  51. Remove the rear transaxle through-bolt.
  52.  
  53. Remove the rear transaxle mount bolts and mount from the frame.
  54.  
  55. Remove the rear transaxle mount bracket bolts and bracket from the transaxle.

    Click image to see an enlarged view

    Fig. Location of the rear transaxle mount (1), mount bracket (2), and transaxle mount bolts (3)-Manual Transaxle

  56.  
  57. Remove the remaining transaxle bell housing bolts.

    Click image to see an enlarged view

    Fig. Location of the lower transaxle bell housing bolts-Manual Transaxle

  58.  
  59. Carefully lower the engine/transaxle assembly on the two jacks until the enough clearance is obtained to remove the transaxle.
  60.  
  61. Obtain a helper to assist in holding transaxle assembly while removing transaxle-to-engine mounting bolts.
  62.  
  63. Remove the transaxle from the vehicle.
  64.  

To install:

  1. Using a suitable transmission jack, raise the transaxle assembly into position.
  2.  
  3. Install the transaxle bell housing bolts and tighten to 35 ft. lbs. (48 Nm).
  4.  
  5. Install the transfer case, if equipped.
  6.  
  7. Install the rear transaxle mount bracket and tighten the mounting bolts to 50 ft. lbs. (68 Nm).
  8.  
  9. Install the rear transaxle mount and tighten the bolts to 50 ft. lbs. (68 Nm).
  10.  
  11. Install the rear transaxle mount through-bolt and tighten to 50 ft. lbs. (68 Nm).
  12.  
  13. Install the front mount bracket to the transaxle and tighten the bolts to 50 ft. lbs. (68 Nm).
  14.  
  15. Install the transaxle crossmember and tighten the mounting bolts to 50 ft. lbs. (68 Nm).
  16.  
  17. Lower the vehicle slightly, and raise the engine/transaxle assembly until the upper mount bracket aligns with the upper mount. Tighten the upper mount bolts to 50 ft. lbs. (68 Nm).
  18.  
  19. Tighten the upper mount through-bolt to 50 ft. lbs. (68 Nm).
  20.  
  21. Remove the transaxle jack.
  22.  
  23. Raise and safely support the vehicle.
  24.  
  25. Install the four modular clutch-to-driveplate bolts. Align the driveplate and modular clutch alignment matchmarks made during the removal process. Start with the tight-tolerance (slotted) hole and install the torque bolts to 65 ft. lbs. (88 Nm).
  26.  
  27. Install the starter.
  28.  
  29. Install the bell housing dust cover.
  30.  
  31. Install the axle shafts.
  32.  
  33. Fill the transaxle with fluid to the correct level.
  34.  
  35. Install the splash shields.
  36.  
  37. Lower the vehicle.
  38.  
  39. Install the top remaining bell housing bolts and tighten to 35 ft. lbs. (48 Nm).
  40.  
  41. Connect the hydraulic clutch slave cylinder.
  42.  
  43. Connect the shift and selector cables to shift lever. Install the cables to the bracket clips.
  44.  
  45. Connector the back-up lamp connector.
  46.  
  47. Connect the vehicle speed sensor.
  48.  
  49. Install the air intake tube and air intake assembly.
  50.  
  51. Connect the negative battery cable.
  52.  
  53. Test drive the vehicle for proper operation and check for leaks.
  54.  

 
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