Dodge Omni/Horizon/Rampage 1978-1989 Repair Guide

Transaxle Assembly

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REMOVAL & INSTALLATION





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Fig. Fig. 1 Cutaway view of the A-412 transaxle

A-412 Models

WARNING
Any time the differential cover is removed, a new gasket should be formed from RTV sealant.

  1. Remove the engine timing mark access plug.
  2.  
  3. Rotate the engine to align the drilled mark on the flywheel with the pointer on the engine.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Part the shift linkage rods.
  8.  
  9. Detach the starter and ground wires.
  10.  
  11. Disconnect the backup light switch wire.
  12.  
  13. Remove the starter.
  14.  
  15. Separate the clutch cable.
  16.  
  17. Disconnect the speedometer cable.
  18.  
  19. Support the weight of the engine from above, preferably with a shop hoist or the fabricated holding fixture.
  20.  



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Fig. Fig. 2 Support the weight of the engine using a suitable holding fixture

  1. Raise and support the vehicle.
  2.  
  3. Disconnect the driveshafts and support them out of the way.
  4.  
  5. Remove the left splash shield.
  6.  
  7. Drain the transaxle.
  8.  
  9. Unbolt the left engine mount.
  10.  



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Fig. Fig. 3 Unbolt the left engine mount, if in the way remove the backup light switch

  1. Remove the transaxle-to-engine bolts.
  2.  
  3. Slide the transaxle to the left until the mainshaft clears, then, carefully lower it from the car.
  4.  

To install:

  1. Position the transaxle so the mainshaft will slide straight into the center of the clutch. Turn the transaxle slightly, if necessary, and change the angle until the mainshaft engages, and then slide the transaxle to the right until the bell housing bolt-holes line up with the corresponding bores in the block.
  2.  
  3. Install the transaxle-to-engine bolts. Reinstall the through bolt for the left engine mount.
  4.  
  5. Install the left side splash shield.
  6.  
  7. Install the driveshafts back into the transaxle.
  8.  
  9. Lower the vehicle to the ground. Remove the engine support system.
  10.  
  11. Reconnect the speedometer and clutch cables.
  12.  
  13. Install the starter. Connect the backup light switch wire.
  14.  
  15. Reconnect the shift rods. Reconnect the battery cable. Install the engine timing mark access plug.
  16.  
  17. Adjust the clutch cable and the shift linkage.
  18.  
  19. Fill the transaxle with the recommended fluid. See .
  20.  

A-460, A-465, A-525 Models
  1. Disconnect the negative battery cable.
  2.  
  3. Install a shop crane and lifting eye under the number 4 cylinder exhaust manifold bolt to securely support the engine.
  4.  



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Fig. Fig. 4 Cross-section of the A-460 transaxle



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Fig. Fig. 5 Cross-section of the A-465-525 transaxles

  1. Disconnect the shift linkage.
  2.  
  3. Remove both front wheels.
  4.  
  5. Remove the left front splash shield, and left engine mount.
  6.  
  7. Follow the procedures under Halfshaft Removal and Installation later in this section.
  8.  
  9. On 1987-89 models, disconnect the anti-rotation link or damper at the crossmember, leaving it connected at the transaxle.
  10.  


WARNING
It will be easier to locate the transaxle, so as to align the bell housing bolt-holes with those in the block, if two locating pins are fabricated and are used in place of the top two locating bolts. To fabricate the pins: Buy two extra bolts. Hacksaw the heads off the bolts. Then, cut slots in the ends of the bolts for a flat-bladed screwdriver. Finally, remove all burrs with a grinding wheel.

  1. Before installing the transaxle onto the engine block, install the two locating pins into the top two engine block holes.
  2.  
  3. Install a positive means of supporting the engine, such as a support fixture that runs across between the two front fenders.
  4.  
  5. Remove the upper bolts those that are accessible from above from the bell housing.
  6.  
  7. For 1986 and later vehicles, refer to the appropriate procedure in this section to remove or install the driveshafts. This will include removing both front wheels and raising the car and supporting it securely so it can be worked on from underneath. On 1985 and earlier vehicles, remove the driveshafts as follows:
  8.  
    1. Remove the left splash shield. Drain the differential and remove the cover.
    2.  
    3. Remove the speedometer adapter, cable and gear.
    4.  
    5. Remove the sway bar.
    6.  
    7. Remove both lower ball joint-to-steering knuckle bolts.
    8.  
    9. Pry the lower ball joint from the steering knuckle.
    10.  
    11. Remove the driveshaft from the hub.
    12.  
    13. Rotate both driveshafts to expose the circlip ends. Note the flat surface on the inner ends of both axle tripod shafts. Pry the circlip out.
    14.  
    15. Remove both driveshafts.
    16.  

  9. On 1986 and later vehicles, remove the left side splash shield.
  10.  
  11. Disconnect the plug for the neutral safety/backup light switch.
  12.  
  13. Remove the engine mount bracket from the front crossmember.
  14.  
  15. Support the transaxle from underneath.
  16.  
  17. Remove the front mount insulator through-bolts.
  18.  
  19. Remove the long through-bolt from the left hand engine mount.
  20.  
  21. Remove the starter. Then, remove any bell housing bolts that are still in position.
  22.  
  23. 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.
  24.  

To install:

  1. 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. Turn the input shaft slightly, if necessary, to get the splines to engage.
  2.  
  3. Install the lower bell housing bolts and the starter. Bell housing bolts are tightened to 70 ft. lbs. (95 Nm).
  4.  
  5. Install the long through-bolt into the left hand engine mount.
  6.  
  7. Install the front mount insulator through-bolts.
  8.  
  9. Remove the jack supporting the transaxle. Then, install the engine mount bracket onto the front crossmember.
  10.  
  11. Reconnect the electrical connector for the backup light/neutral safety switch.
  12.  
  13. Install the driveshafts by reversing the removal procedure. Install the left side splash shield.
  14.  
  15. 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).
  16.  
  17. Remove the engine support fixture.
  18.  
  19. Connect the anti-rotation strut. Tighten the bolts to 70 ft. lbs. (95 Nm).
  20.  
  21. Connect the shift linkage. Always use new self-locking nuts on the shift linkage. Observe the following torques:

    Shift housing-to-case: 21 ft. lbs. (28 Nm)
     
    Strut-to-case: 70 ft. lbs. 95 Nm)
     
    Flywheel-to-crankshaft: 65 ft. lbs. (88 Nm)
     

  22.  



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Fig. Fig. 6 Transaxle case A-460 assembly

 
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