Neon, 2000-2005

Transaxle Removal & Installation

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T-350 Transaxle



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

    Battery
     
    Air cleaner/throttle body assembly
     
    Proportional Purge Solenoid (PSS)
     
    Crankcase vent hose
     
    Throttle Position Sensor (TPS) and Idle Air Control (IAC) connectors
     
    Throttle body air duct from the intake manifold
     
    Accelerator cable
     
    Cruise control cable, if equipped
     
    Battery tray from the bracket
     
    Ground cable from the battery tray bracket
     
    Back-up light switch connector
     
    Bell housing cap and clutch cable from the fork and transaxle, on 2000 vehicles
     
    Hydraulic line quick-connect fitting, on 2001-05 vehicles
     
    Shift cable-to-bracket clips
     
    Shift selector and crossover cables from the levers and move aside
     
    Halfshafts
     
    Structural collar
     
    Left engine-to-transaxle lateral bending brace
     
    Bell housing dust cover
     
    Right engine-to-transaxle lateral bending brace
     
    Starter
     
    Driveplate-to-clutch module bolts
     

  6.  
  7. Place a jack and block of wood under the engine-s oil pan and support the engine. Remove the transaxle upper mount through-bolt.
  8.  
  9. Lower the engine/transaxle assembly to provide clearance.

    Transaxle-to-engine bolts, using an assistant to support the transaxle
     
    Transaxle

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    Fig. View of the air cleaner assembly and throttle body duct

    View of the air cleaner assembly and throttle body duct

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    Fig. View of the clutch cable and bell housing cap-2000 manual transaxle

    View of the clutch cable and bell housing cap-2000 manual transaxle

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    Fig. View of the clutch slave cylinder connection -T-350 manual transaxle

    View of the clutch slave cylinder connection -T-350 manual transaxle

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    Fig. View of the shift cables-T-350 manual transaxle

    View of the shift cables-T-350 manual transaxle

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    Fig. View of the Vehicle Speed Sensor (VSS)- T-350 manual transaxle

    View of the Vehicle Speed Sensor (VSS)- T-350 manual transaxle

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    Fig. View of the left lateral bending brace and structural collar-T-350 manual transaxle

    View of the left lateral bending brace and structural collar-T-350 manual transaxle

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    Fig. View of the right lateral bending brace-T-350 manual transaxle

    View of the right lateral bending brace-T-350 manual transaxle

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    Fig. View of the upper mount through-bolt-T-350 manual transaxle

    View of the upper mount through-bolt-T-350 manual transaxle

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    Fig. Exploded view of the transaxle and related components-T-350 manual transaxle

    Exploded view of the transaxle and related components-T-350 manual transaxle

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    Fig. View of the upper mount-T-350 manual transaxle

    View of the upper mount-T-350 manual transaxle
     

  10.  

To install:

  1. If installing a new or replacement transaxle, transfer the upper mount to the new transaxle; then, torque the upper mount-to-transaxle bolts to 50 ft. lbs. (68 Nm).
  2.  
  3. Install or connect the following:

    Transaxle
     
    Transaxle-to-engine bolts, using an assistant to support the transaxle. Torque the transaxle-to-engine bolts to 70 ft. lbs. (95 Nm).
     

  4.  
  5. Raise the engine/transaxle assembly until the upper mount aligns with the mount bracket hole. Torque the upper mount-to-mount bracket through-bolt to 80 ft. lbs. (108 Nm).
  6.  
  7. Remove the jack and wooden block.

    Driveplate-to-clutch module bolts and torque to 65 ft. lbs. (88 Nm)
     
    Starter and torque the bolts to 40 ft. lbs. (54 Nm)
     
    Starter electrical connectors and torque the positive cable bolt to 89 inch lbs. (10 Nm)
     
    Left engine-to-transaxle lateral bending brace and torque the bolts to 60 ft. lbs. (81 Nm)
     

  8.  
  9. Install the structural collar and torque the bolts as follows:
    1. Step 1-Structural collar-to-oil pan bolts: 30 inch lbs. (3 Nm).
    2.  
    3. Step 2-Structural collar-to-transaxle bolts: 80 ft. lbs. (108 Nm).
    4.  
    5. Step 3-Structural collar-to-oil pan bolts: 40 ft. lbs. (54 Nm).
    6.  

  10.  
  11. Install or connect the following:

    Right engine-to-transaxle lateral bending brace and torque the bolts to 60 ft. lbs. (81 Nm)
     
    Halfshafts
     
    Bell housing dust cover
     
    VSS electrical connector
     
    Shift selector and crossover cables to the levers
     
    Shift cable-to-bracket clips
     
    Hydraulic line quick-connect fitting, on 2001-05 vehicles
     
    Clutch cable to the fork and transaxle and bell housing cap, on 2000 vehicles
     
    Back-up light switch connector
     
    Ground cable to the battery tray bracket
     
    Battery tray to the bracket
     
    Accelerator cable
     
    Cruise control cable, if equipped
     
    Air cleaner assembly and torque the nuts and bolts to 10 ft. lbs. (14 Nm)
     
    Throttle body air duct to the intake manifold
     
    TPS and IAC connectors
     
    Crankcase vent hose to the throttle body
     
    PSS to the throttle body
     
    Battery
     

  12.  
  13. Fill the transaxle to the proper level.
  14.  
  15. Road test the vehicle and inspect for leaks.
  16.  

T-850 Transaxle



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

    Turbocharger solenoid pack from the air cleaner assembly and position it aside
     
    AAT sensor and remove air cleaner assembly
     
    Throttle body inlet hose from the inter-cooler
     
    Idle Air Control (IAC) and Throttle Position Sensor (TPS) connectors
     
    Accelerator cable from throttle body linkage
     
    Throttle body adapter
     
    Battery and battery tray
     
    Shift cables from the transaxle shift levers and bracket
     
    Both front wheel/tire assemblies
     
    Both Anti-lock Brake System (ABS) front wheel speed sensors
     
    Halfshafts and intermediate shaft
     
    Clutch hydraulic circuit quick-connect fitting, using Tool 6638A, or equivalent
     

  6.  
  7. Back-up lamp switch connector

    Starter motor-to-transaxle case bolts
     
    Front lateral bending brace
     
    Turbocharger pipe and power steering lines from the structural collar
     
    Structural collar
     
    4 modular clutch-to-engine driveplate bolts. While removing the bolts, you will find one tight-tolerance (slotted) hole. When this bolt is removed, matchmark the driveplate and modular clutch assembly at this location, and make sure to align marks upon reassembly.
     

  8.  
  9. Install and secure a suitable transmission jack.

    Left mount through-bolt
     

  10.  
  11. Lower the engine/transaxle assembly enough to gain access to left mount and bell housing bolts.

    Left mount-to-transaxle bolts and mount
     

  12.  
  13. Install a screw jack and wood block to support the engine after transaxle removal.

    Transaxle bell housing-to-block bolts, then remove the transaxle and modular clutch assembly.
     

  14.  
  15. If replacing the transmission, transfer the impact blocker, back-up lamp switch, vehicle speed sensor and gearshift cable bracket.

    Click image to see an enlarged view

    Fig. View of the turbocharger solenoids and mounting bracket-T-850 manual transaxle

    View of the turbocharger solenoids and mounting bracket-T-850 manual transaxle

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    Fig. Exploded view of the halfshaft assemblies-2.4L turbo models

    Exploded view of the halfshaft assemblies-2.4L turbo models

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    Fig. Lateral bending brace mounting-2.4L turbo models

    Lateral bending brace mounting-2.4L turbo models

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    Fig. Structural collar/power steering hose retainers-2.4L turbo models

    Structural collar/power steering hose retainers-2.4L turbo models

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    Fig. Structural collar mounting-2.4L turbo models

    Structural collar mounting-2.4L turbo models

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    Fig. Modular clutch-to-driveplate mounting-T-850 manual transaxle

    Modular clutch-to-driveplate mounting-T-850 manual transaxle

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    Fig. View of the transaxle upper mount and fasteners-T-850 manual transaxle

    View of the transaxle upper mount and fasteners-T-850 manual transaxle
  16.  

To install:

  1. Install or connect the following:

    Modular clutch to the input shaft assembly
     
    Transaxle assembly to a suitable transmission jack, making sure it is secure
     
    Transaxle into position. Torque the transaxle-to-block bolts to 80 ft. lbs. (108 Nm)
     
    Upper mount/bracket to transaxle and tighten the bolts to 50 ft. lbs. (68 Nm)
     

  2.  
  3. Raise the engine/transaxle assembly into position. Install and torque the through-bolt to 90 ft. lbs. (122 Nm).

    4 modular clutch-to-driveplate bolts. Align the driveplate and modular clutch marks made during removal. Start with the tight-tolerance (slotted) hole, install and torque the bolts to 65 ft. lbs. (88 Nm).
     
    Structural collar and lateral bending brace. Finger-tighten all bolts, then tighten the structural collar horizontal bolts to 80 ft. lbs. (108 N). Torque the structural collar vertical bolts to 40 ft. lbs. (54 Nm) and the lateral bending brace bolts to 45 ft. lbs. (61 Nm).
     
    Intercooler pipe and power steering hoses into position and secure with nuts
     
    Clutch hydraulic plumbing to the slave cylinder quick-connect. You should hear a -click- when the connection is properly installed.
     
    Halfshafts and intermediate shaft
     
    ABS wheel speed sensors and torque the bolts to 105 inch lbs. (12 Nm)
     
    Gearshift cables to the transaxle bracket and secure with new retaining clips
     
    Battery tray
     
    Battery (with thermal wrap) and hold-down clamp/bolt. Connect battery temperature sensor.
     
    Throttle body adapter housing
     
    Accelerator cable while placing the throttle body into position. Torque the 2 throttle body-to-manifold bolts to 21 ft. lbs. (28 Nm).
     
    IAC and TPS connectors
     
    Intercooler-to-throttle body hose
     
    IAT sensor and TIP hose
     
    Air cleaner assembly and AAT sensor connector
     
    Turbo solenoid pack
     
    Air cleaner inlet tube to turbocharger
     

  4.  
  5. Fill the transaxle to the proper level.
  6.  
  7. Road test the vehicle and inspect for leaks.
  8.  

 
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