Chrysler Front Wheel Drive Cars 6-CYL 1988-1995 Repair Information

Transaxle

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REMOVAL & INSTALLATION



Except Premier and Monaco
1988 MODELS

The automatic transaxle can be removed with the engine installed in the car, but the transaxle and torque converter must be removed as an assembly. Otherwise, the drive plate, pump bushing or oil seal could be damaged. The drive plate will not support a load-no weight should be allowed to bear on the drive plate as the unit is removed; it must be fully disconnected from the converter before the transaxle is shifted out of its normal position.

  1. Disconnect the positive battery cable.
  2.  
  3. Disconnect the throttle and shift linkage from the transaxle.
  4.  
  5. Put a drain pan underneath and then disconnect both the upper and lower oil cooler hoses. If the car has a lockup converter, unplug the electrical connector, which is located near the dipstick.
  6.  
  7. Install a positive means of supporting the engine, such as a support fixture that runs across between the two front fenders.
  8.  
  9. Remove the upper bolts-those that are accessible from above from the bell housing.
  10.  
  11. Remove the halfshafts, for more details refer to the appropriate procedure earlier in this section. This will include removing both front wheels and raising the car and supporting it securely so it can be worked on from underneath.
  12.  
  13. Remove the left side splash shield.
  14.  
  15. Remove the dust cover from under the torque converter. Remove the access plug in the right splash shield to rotate the engine. Matchmark the torque converter and drive plate. Then, remove the torque converter mounting bolts, rotating the engine after each bolt is removed for access to the next one.
  16.  
  17. Disconnect the plug for the neutral safety/back-up light switch.
  18.  
  19. Support the transaxle from underneath. It must be supported in a positive manner and without the weight resting on the pan; it should be supported by its corners.
  20.  
  21. Remove the engine mount bracket from the front crossmember.
  22.  
  23. Remove the front mount insulator through-bolts.
  24.  
  25. Remove the long through-bolt from the left hand engine mount.
  26.  
  27. Remove the starter. Then, remove any bell housing bolts that are still in position.
  28.  
  29. Pry the transaxle away from the engine to ensure that the torque converter will clear the drive plate. If removing a manual transaxle, slide the transaxle directly away from the engine so the transaxle input shaft will slide smoothly out of the bearing in the flywheel and the clutch disc. Lower the transaxle and remove it from the engine compartment.
  30.  

To install:
  1. To install the transaxle, first support the unit securely and raise it into precise alignment with the engine block. Then, move it toward the block, inserting the transaxle input shaft into the clutch disc, if it is a manual transaxle (turn the input shaft slightly, if necessary, to get the splines to engage). With automatic units, make sure to align the lower bolt holes in the transaxle bell housing with those in the block.
  2.  
  3. Install the lower bell housing bolts and the starter. Tighten the bell housing bolts to 105 inch lbs. (12 Nm).
  4.  
  5. Turn the engine via the crankshaft pulley bolt as necessary to align the torque converter bolt holes with those in the flex drive plate. Make sure the matchmarks made prior to disassembly are aligned. Install each bolt and tighten it to 55 ft. lbs. (75 Nm). Then, turn the crankshaft for access to the next set of bolt holes and install the bolt in that position.
  6.  
  7. Install the long through-bolt into the left hand engine mount.
  8.  
  9. Install the front mount insulator through-bolts.
  10.  
  11. Remove the jack supporting the transaxle. Then, install the engine mount bracket onto the front crossmember.
  12.  
  13. Attach the electrical connector for the back-up light/neutral safety switch.
  14.  
  15. Install the dust cover under the torque converter. Install the access plug in the right splash shield.
  16.  
  17. Install the halfshafts. Install the left side splash shield.
  18.  
  19. With the wheels remounted and the car back on the floor, install the remaining bell housing bolts and tighten them to 105 inch lbs. (12 Nm).
  20.  
  21. Remove the engine support fixture.
  22.  
  23. Connect both the upper and lower oil cooler hoses. If the car has a lockup converter, replug the electrical connector.
  24.  
  25. Reconnect the throttle and shift cables and adjust them.
  26.  
  27. Install the differential cover on those transaxles from which it was removed. Form a new gasket from RTV sealant when installing the cover. Refer to General Information & Maintenance for more details. Fill the differential or combined transaxle and differential with the approved automatic transaxle fluid. Reconnect the battery.
  28.  

1989-95 MODELS

See Figure 1

If the vehicle is going to be rolled 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. Disconnect the negative battery cable.
  2.  
  3. Drain the coolant.
  4.  
  5. Remove the transaxle dipstick.
  6.  
  7. Remove the air cleaner assembly if it is preventing access to the upper bell housing bolts. Remove the upper bell housing bolts and water tube, where applicable. Unplug all electrical connectors from the transaxle.
  8.  
  9. Raise the vehicle and support safely. Remove the tire and wheel assemblies. Remove the axle end cotter pins, nut locks, spring washers and axle nuts.
  10.  
  11. Remove the ball joint retaining bolts and pry the control arm from the steering knuckle. Position a drain pan under the transaxle where the axles enter the differential or extension housing. Remove the axles from the transaxle or center bearing. Unbolt the center bearing and remove the intermediate axle from the transaxle, if equipped.
  12.  
  13. Drain the transaxle. Disconnect and plug the fluid cooler hoses. Disconnect the shifter and kickdown linkage from the transaxle, if equipped.
  14.  
  15. Remove the speedometer cable adaptor bolt and remove the adaptor from the transaxle.
  16.  
  17. Remove the starter. Remove the torque converter inspection cover, matchmark the torque converter to the flexplate and remove the torque converter bolts.
  18.  
  19. Using the proper equipment (such as an engine support fixture or a floor jack), support the weight of the engine.
  20.  



Click image to see an enlarged view

Fig. Fig. 1: Chrysler recommends using this type of engine support fixture; however, a floor jack can also be used

  1. Remove the front motor mount and bracket.
  2.  
  3. Position a suitable transaxle jack under the transaxle.
  4.  
  5. Remove the lower bell housing bolts.
  6.  
  7. Remove the left side splash shield. Remove the transaxle mount bolts.
  8.  
  9. Carefully pry the transaxle from the engine.
  10.  
  11. Slide the transaxle rearward until dowels disengage from the mating holes in the transaxle case.
  12.  
  13. Pull the transaxle completely away from the engine and remove it from the vehicle.
  14.  
  15. 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.
  16.  

To install:
  1. Install the transaxle securely on the transaxle jack. Rotate the converter so it will align with the positioning of the flexplate.
  2.  
  3. Apply a coating of high temperature grease to the torque converter pilot hub.
  4.  
  5. Raise the transaxle into place and push it forward until the dowels engage and the bell housing is flush with the block. Install the transaxle to bell housing bolts.
  6.  
  7. Raise the transaxle and install the left side mount bolts. Install the torque converter bolts and tighten to 55 ft. lbs. (74 Nm).
  8.  
  9. Install the front motor mount and bracket. Remove the engine and transaxle support fixtures.
  10.  
  11. Install a new O-ring to the speedometer cable adaptor and install to the extension housing; make sure it snaps in place. Install the retaining bolt.
  12.  
  13. Connect the shifter and kickdown linkage to the transaxle, if equipped.
  14.  
  15. Install the axles and center bearing, if equipped. Install the ball joints to the steering knuckles. Tighten the axle nuts to 180 ft. lbs. (244 Nm) and install new cotter pins. Install the splash shield and install the wheels. Lower the vehicle. Install the dipstick.
  16.  
  17. Install the upper bell housing bolts and water pipe, if removed.
  18.  
  19. Connect all electrical wiring to the transaxle.
  20.  
  21. Install the air cleaner assembly, if removed. Refill all fluid levels. Fill the transaxle with the proper amount of the specified fluid to the correct level.
  22.  
  23. Connect the negative battery cable and check the transaxle for proper operation. Refer to the upshift and kickdown learning procedure in the adjustment portion of this section.
  24.  

Premier and Monaco
  1. Disconnect the negative battery cable.
  2.  
  3. Loosen the throttle valve cable adjusting nut and remove the cable from the engine bracket.
  4.  
  5. Remove the upper steering knuckle mounting nut, remove the bolt, and loosen the lower bolt.
  6.  
  7. Remove the halfshaft retaining pin. Swing each rotor and steering knuckle outward and slide the halfshafts from the transaxle.
  8.  
  9. Remove the underbody splash shield. Loosen the nut attaching the fill tube to the pan and drain the transaxle. When fluid has drained, tighten the nut.
  10.  
  11. Remove the converter housing covers. Remove the converter-to-flexplate bolts. Support the transaxle.
  12.  
  13. Remove the nuts attaching the crossmember to the side sills. Remove the large bolt and nut that attach the rear cushion to the support bracket.
  14.  
  15. Remove the support bracket and rear cushion.
  16.  
  17. Disconnect the header pipes from the exhaust manifold and the catalytic converter.
  18.  
  19. Loosen the engine cradle bolts only until there is 1 / 2 - 7 / 8 in. (13-19mm) clearance between the cradle and the side sill.
  20.  
  21. Remove the front exhaust pipe. Remove the starter, plate and dowel.
  22.  
  23. Disconnect the shift cable from the transaxle lever. Remove the cable bracket bolts and separate the bracket from the case. Remove the brace rod.
  24.  
  25. Disconnect and remove the TDC sensor, speedometer sensor, and engine speed sensor. Disconnect and plug the transaxle cooling lines.
  26.  
  27. Using a suitable transaxle jack, support the weight of the transaxle. Remove the transaxle-to-engine bolts, then pull the transaxle back and away from the engine.
  28.  

To install:
  1. Position the transaxle to the engine. Install the transaxle-to-engine bolts and tighten to 31 ft. lbs. (42 Nm).
  2.  
  3. Install removed sensors and connect all electrical leads. Connect the transaxle cooler lines. Install the brace rod.
  4.  
  5. Attach the shift bracket to the case and tighten the bolts to 125 inch lbs. (14 Nm). Install the shift cable to the bracket.
  6.  
  7. Install the starter. Connect the exhaust head pipes to the manifolds and he converter.
  8.  
  9. Install the rear support and cushion, install the mounting bolts and tighten to 49 ft. lbs. (66 Nm).
  10.  
  11. Tighten the engine cradle bolts to 92 ft. lbs. (125 Nm). Install the halfshafts.
  12.  
  13. Coat the threads with Loctite® and install the converter-to-flexplate bolts. Tighten to 24 ft. lbs. (33 Nm). Install the converter housing covers.
  14.  
  15. Install the halfshafts. Tilt the steering knuckles in and install the top bolts. Tighten the nuts to 148 ft. lbs. (200 Nm).
  16.  
  17. Install the front wheels. Install the under body splash shield. Attach the throttle valve cable.
  18.  
  19. Fill the transaxle with Mopar Mercon® transaxle fluid. Check the differential fluid level. If it is low, fill with synthetic type 75W-140 gear oil.
  20.  
  21. Connect the negative battery cable and check the transaxle for proper operation.
  22.  

 
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