REMOVAL & INSTALLATION
See Figures 1, 2, 3 and 4
- Disconnect the negative battery cable.
- Remove the air cleaner assembly for added working room.
- On some models it may be necessary to remove the cruise control actuator.
- Remove the clutch release cylinder and tube clamp and the cruise control actuator, if equipped.
- Remove the retainer from the clutch tube bracket and unbolt and remove the bracket.
- Remove the clips and washers that attach the transaxle control cables to the control levers. Remove the retaining clips and disconnect the transaxle control cables.
- Remove the starter.
- Disconnect the back-up light switch harness and ground strap.
- Remove the upper transaxle mounting bolts.
- Remove the front wheels.
- Raise the vehicle and support it safely.
- Remove the under covers.
- Drain the fluid from the transaxle.
- Disconnect the speedometer cable or sensor harness.
- Remove the lower suspension crossmember.
- Remove the front and rear engine mounting bolts and remove the engine mounting center member.
- Have an assistant depress the brake pedal. Loosen the six mounting bolts and disconnect both driveshafts.
- Remove the snapring from the center driveshaft bearing bracket. Remove the bearing bracket bolt and pull out the center driveshaft through the center bearing bracket. Discard the bolt and purchase a new one.
- Disconnect the left steering knuckle from the lower arm. Pull the steering knuckle outward and remove the driveshaft.
- On some models it may be necessary to remove the stabilizer bar.
- On 1992-96 models, disconnect the steering gear housing from the front suspension member and disconnect the exhaust.
- With a transaxle jack and block of wood, raise the transaxle and engine slightly and disconnect the left engine mounting.
- Remove the transaxle mounting bolts from the engine.
- Lower the left side of the engine and remove the transaxle. On 1992-96 models, remove the remaining components from the front suspension member and remove it. Then remove the transaxle as described.
Clean the mating surfaces of grease and dirt in preparation for reinstallation.To install:
- Move the transaxle into position so that the input shaft spline is aligned with the clutch disc.
- Install the transaxle into the engine and secure with the lower mounting bolts. Install the remaining mounting bolts. On the 1983-86 models tighten the 10mm bolts to 29 ft. lbs. (39 Nm) and the 12mm bolts to 47 ft. lbs. (64 Nm). On 1987-92 models tighten the 10mm mounting bolts to 34 ft. lbs. (46 Nm) and 12mm bolts to 47 ft. lbs. (64 Nm). On the 1993-96 models, tighten bolt A to 47 ft. lbs. (64 Nm)., bolt B to 34 ft. lbs. (46 Nm) and bolt C to 18 ft. lbs. (25 Nm).
- Connect the left engine mounting and tighten the mounting bolts to specifications. On 1992-96 models, install the front suspension member and other components related to it and tighten to specifications.
- Install all the remaining components in the reverse order of removal. Tighten all components to specifications.
- Fill the transaxle with the correct type and amount of fluid.
- Connect the negative battery cable, the air cleaner and the cruise control actuator, if removed.
- Check the front wheel alignment.
- Perform a road test and check for any unusual noises or vibrations.
See Figures 5 and 6
The transaxle on the All-Trac 4-Wheel Drive models is removed with the engine. For engine removal and installation procedures refer to Engine & Engine Rebuilding .
The cylinder block rib on these model engines contacts the transfer case. When disconnecting the transaxle from the engine the following points must be observed.