ch 7 drive train

8/14/2019 Ch 7 Drive Train

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TRANSAXLE 7-2TRANSAXLE 7-2SHIFTLINKAGE 7-2LIGHTSWITCH 7-2REMOVAL& INSTALLATION 7-27-2REMOVAL&INSTALLATION 7-2REMOVAL& INSTALLATION 7-3CV-JOINTSOVERHAUL 7-5

INGTHE LUTCH 7-7DISCAND PRESSURE LATE 7-i'REMOVAL&INSTALLATION 7-7ADJUSTMENTS 7-8CABLE 7-9ADJUSTMENT 7-9REMOVAL ND INSTALLATION 7-9MASTERCYLINDER 7-9REMOVALANDINSTALLATION 7-9LUTCHSLAVECYLINDER 7-9REMOVAL&INSTALLATION 7-9HYDRAULIC YSTEMBLEEDING 7-9C TRANSAXLE 7-10NDERSTANDINGTHEAUTOMATICTRANSAXLE 7-10FLUID PAN 7-10REMOVAL& INSTALLATION 7-10PARK/NEUTRAL OSITION WITCH 7-10REMOVAL& INSTALLATION 7-10

ADJUSTMENT 7-10TRANSAXLEASSEMBLY 7-10REMOVAL&INSTALLATION 7-10ADJUSTMENTS 7-13HALFSHAFTS 7-13CASE 7-14REAROUTPUTSHAFTSEAL 7-14REMOVAL& INSTALLATION 7-14RANSFER ASEASSEMBLY 7-14REMOVAL&INSTALLATION 7-14DRIVELINE 7-14DRIVESHAFT ND U-JOINTS 7-14REMOVAL& INSTALLATION 7-14REPLACEMENT 7-14DRIVESHAFT ALANCING 7-15CENTER EARING 7-15REMOVAL& INSTALLATION 7-15REAR AXLE DIFFERENTIAL 7-15REARHALFSHAFTANDSEAL 7-15REMOVAL&INSTALLATION 7-15STUBAXLESHAFT,BEARlNGAND SEAL 7-15REMOVAL&INSTALLATION 7-15 'PINIONSEAL 7-16REMOVAL&INSTALLATION 7-16AXLEHOUSINGASSEMBLY 7-16REMOVAL&INSTALLATION 7-16SPECIFICATIONS CHARTTORQUE PECIFICATIONS 7-16


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7-2 'DRIVETRAIN

Because f the way an internalcombustron nginebreathes,t can produce orque,or twisting orce,only within a narrowspeed ange.Most modern,overhead alve pushrodenginesmust urn at about2500 rpm o produce heir peak orque By 4500 rpmthey are producrng o lrttle orque hat contrnuedn-creases n enginespeedproduceno power ncreases.The orquepeakon overhead amshaft ngines Sgenerallymuchhigher,but much narrower.Themanual ransaxle ndclutchare employedovary he relationship etween nginespeed nd hespeedof thewheelsso thatadequate nginepowercanbe produced nderall crrcumstances.heclutchal-lowsengine orque o beapplied o the ransaxle nputshaftgradually, ue o mechanical lippage.Conse-quently,he vehiclemaybe started moothly rom afull stop The ransaxle hangeshe ratio betweenherotatingspeeds f the engineand hewheelsby heuseof gears.The gear atiosallow u ll enginepower obeapplied o the wheelsduringacceleration t lowspeeds ndat highway/passingpeeds.In a front wheeldrive ransaxle,power s usuallytransmitted rom the input shaft o a mainshaftor out-put shaft ocatedslightly beneath nd o the side ofthe nput shaft.The gearsof the mainshaftmeshwithgearson the input shaft,allowing power o be carriedfrom one o the other.All forwardgearsare n con-stantmeshand are ree rom rotatingwith the shaftunless he synchronizer nd clutch Sengaged.Shaft-ing from one gear o the next causesone of the gearsto be reed rom rotatingwith the shaftand ocksan-other o it. Gearsare lockedand unlockedby nternaldog clutcheswhich slide betweenhe centerof thegearand he shaft.The orwardgearsemploysyn-chronizers; riction memberswhich smoothlybringgearand shaft o the samespeedbefore he ootheddog clutchesare engaged.

SHIFTLINKAGE1. Disconnect he shift linkage rom the ransaxle.2. On he ransaxle,put select ever n N andmove he shift lever n 4th gear.Depress he clutch,if necessary,o shift.3. Move the shift lever n the vehicle o the4thgearposition until it contacts he stop.4. Turn he adjuster urnbuckle o the shift cableeye alignswith the eye n the gearshift ever.Wheninstalling he cableeye,makesure he langeside ofthe plasticbushingat the shift cableend s on thecotter pin side.5 The cablesshouldbe adjusted o the clear-ancebetween he shift lever and he 2 stoppersareequalwhen he shift lever Smoved o 3rd and4thgear.Move the shift lever o eachpositronand checkthat he shifting s smooth

REMOVAL&INSTALLATION1, Disconnect he negativebatterycable

2. Removeany components ecessaryo accessthe back-up igh t switch.3. Unplug he back-up ight switch connector.4. Remove he switch rom the caseusing he ap-propriatesize socketand drive ool.To install:5. Install he switchand ighten t to 22-25 ft. Ibs.(30-35 Nm).6. Attach he back-up ight switch connector7. Installany components emoved o access heback-up igh t switch8. Connect he negativebatterycable.

REMOVAL& INSTALLATIONMirage*If the vehicle s going o be roiled while thehalfshaftsare out of the vehicle, obtain2 outerCV-joints r properequivalent ools and nstallto the hubs. f the vehicle s rolled without heproper orqueapplied o the front wheel bear-ings, he bearingswill no onger be usable.*The suspension omponents hould not betighteneduntil the vehicles weight is restingon he ground.

1. Remove he batteryand battery ray.2. Remove he air cleanerassemblyandvacuumhoses.3. Note he locationsand disconnect he shiftercables.4. If equippedwith 1.61 engine, emove he en-sion rod.5. Detach he backup ampswitch connector,speedometer ableconnection nd remove he startermotor.6. Raise he vehicleand supportsafely.7. Remove he ront wheelsand he nnerwheelpanels.8. Remove he undercover nd splashpan.9. Drain he ransaxleoil into a suitablecon-tainer10. Support he engineand remove he cross-member.11. Remove he upper ransaxlemountingboltand bracket.12 Disconnect he stabilizerbar, ie rod endsandthe ower ball oint connections.13 Remove he clutch release ylinderand clutchoil line bracket.Do not disconnect he luid lines andsecure he slave cylinderwith wire.14 Disconnect he clutchcable, f equippedwithcablecontrolledclutchsystem.15. Remove he halfshafts y insertinga prybarbetweenhe ransaxle aseand he driveshaftandprying he shaft rom the ransaxle.Do not pull on thedriveshaft Doing so damages he nboard oint. Donot nsert he prybarso far the oil seal n the case sdamaged.

*It is not necessary o disconnect he half-shafts rom the steering knuckle. Remove heshaft with the huband knuckleas an assem-bly. Tie the shafts aside. Note he circle clipon he end of the inboardshafts should notbe reused.

16. Remove he bellhousing ower cover.17 Remove he ransaxle o enginebolts andlower he ransaxle rom the vehrcle.To install:*When installing the transaxle, be sure oalign the splines of the transaxle with theclutch disc.18 Install he ransaxle o the engineand nstallthe mountingbolts.Tighten he bolts o 31-40 ft. Ibs.(43-55 Nm) on 1990-92 modelsand 35 ft. Ibs. (48Nm) on 1993-00 models.19 Install he bellhousing over.*When installing the halfshafts, use newcirclips on the axle ends. Care mustbe takento ensure hat the oil seal lip of the transaxleis not damagedby he serrated part of thedriveshaft.

20. Installand ully seat he halfshafts nto hetransaxle.21. Install he slave cylinder.22. Connect he ball oints, tie rod endsand hestabilizerbar connections.23. Install he upper ransaxlemountingbracketand bolt.24. Install he crossmember.25. Install he undercover.26. Install he upper ransaxle-to-enginemount-ing bolts,Tighten he bolts o 31-40 ft. Ibs. (43-55Nm) on 199C-92 modelsand 35 ff. Ibs. (48 Nm) on1993-00 models.27. Install he startermotor.28 Connect he backup ight switch connectorand speedometer able.29 Connect nd adjust he shifter cables.30 Install he air cleanerassembly.31. Install he ront wheels.32 Make sure he vehicle s level when efillingthe ransaxle Use Hypoid gearoil or equivalent,GL-4 or higher.33. Connect he negativebatterycableand checkthe ransaxle or properoperation.Make sure he re-verse ights operatewhen n reverse.

Galant1999-93MODELSrlf the vehicle is going o be rolled on itswheels while the halfshaftsare out of the ve-hicle, obtain wo outer CV-jointsor properequivalent ools and nstall to the hubs. f thevehicle is rolled without the proper orqueapplied o the front wheel bearings, he bear-ings will no longer be usable.

1. Remove he batteryand he air intakehoses.2. If equippedwith Active-ECS,unplug hecompressorwiring.3. Remove he auto-cruiseactuatorand under-hood bracket, ocatedon the passenger ide nnerfenderwell.4. Drain he ransaxleand ransfercase luid, ifequipped, nto a suitablewastecontainer.5. Remove he retainerbolt and pull hespeedometer able rom the ransaxleassembly.6. Remove he cotterpin securing he selectandshift cablesand remove he cableends rom thetransaxle.


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DRIVETRAIN -37. Removeheconnectionor heclutchelease 38. Installhebattery. bolt o 54 t. Ibs. 73Nm).nstallhe rontengineollcylinder ndwithout isconnectinghehydraulicine, 39. If equipped ithActive-ECS,onnectheair stopperhrough-boltndhand-tighten.ncehe ulland ecuret aside. compressor. weight f heengines on hemounts,ightenhe8. Disconnecthebackupight witch arness 40. Make ure hevehicles evelwhen efilling bolt o 42 t. Ibs. 57Nm).andposition side. the ransaxle. seHypoid ear il or equivalent,L- 30. Installhe riangulartaybracketnd ighten9. Detachhestarter lectricalonnections,f 4 or higher. themountingolts o 65 t. Ibs. 88Nm).necessary,emovehestartermotor ndposition 41. Checkhe ransaxlend ransferaseor 31. Connectheclutch eleaseylinder.aside. proper peration. ake ure he everseights ome 32. Installhehalfshafts,sing ew irclips n10. Removehe ransaxle ount racket. onwhen n reverse. theaxleends.11. Removeheupperransaxle ountingolts.12. Raisehevehicle nd upport afely n ack- 1!I94-Ol? ODELSstands.13. Removeheundercovernd he rontwheels. 1. Disconnecthenegativeatteryable nd Whenhistalling he axleshaft, keep he in-14. Removehecotter inanddisconnecthe ie waitat east 0secondsefore erformingnywork. board oint straight n relation to the axle, sorodend rom hesteeringnuckle. 2. Removeheair cleaner nd ntake oses. not o damage he oil seal lip of the15. Removeheself-lockingut rom hehalf- 3. Drainhe ransaxlentoa suitable aste on- transaxle, with the serrated part of the half-

ShaftS. tainer. shaft.16. Disconnecthe ower rmball oint rom he 4. Removehecotter insand lipssecuringhesteeringnuckle. select nd hiftcables nd emovehecable nds 33. Connecthe ie odand all oints o he teer-17. Removehehalfshaftsrom he ransaxle. from he ransaxle. ingknuckle.ightenheball oint elf-lockingutso18. OnAWDmodels,isconnecthe rontex- 5. If equippedithActive-ECS,isconnecthe 48 t. bs. 65Nm). ightenhe ie rodend ut o 21 t.haust ipe. air compressor. Ibs. 28Nm) nd ecure itha new otter in.19. OnAWDmodels,emovehe ransferase y 6. Disconnecthebackupightswitch arness 34. Connecthedamperork o he ower ontrolremovingheattachingolts,movinghe ransfer andposition side. arm nd ightenhe hrough-bolto 65 t. bs. 88Nm).caseo he eftand oweringhe rontside.Removet 7. Disconnecthespeedometerlectricalon- 35. Connecthestabilizerink o hedamperork,from he eardriveshaft.ecareful f heoil seal.Do nectar,rom he ransaxlessembly. and ightenheself-lockingut o 29 t. bs. 39Nm).notallow hedriveshafto hang; ncehe ront s re- 8. Removehestartermotor ndposition side. 36. Installheunderpan.movedrom he ransfer,ie t up.Coverhe ransfer 9. Using pecialool M2203827r equivalent, 37. Install heels nd ower ehicle.case peningso keep utdirt. supportheengine ssembly. 38. Installhe ransaxle ount racketo he20. Removehecoverrom he ransaxleell- 10. Removehe ear oll stoppermounting transaxle,nd ightenhemountingutso 32 t. Ibs.housing. bracket. (43Nm).21. OnAWDmodels,emovehecrossmember 11. Removehe ransaxle ount racket. 39. installhe ear oll stopper ountingracket.and he riangularusset. 12. Removeheupperransaxle ountingolts. 40. Removeheengine upport. ightenhe22. Removehe ransaxleower oupling olt. t 13. Raise nd afely upporthevehicle. transaxle ounthrough-bolto 51 t. bs. 69Nm)is ustabovehehalfshaftpening nFWD r rans- 14. Removehe rontwheel ssemblies. and ightenhe rontengineoll stopperhrough-bolt.fer case pening nAWD. 15. Removehe ighthand ndercover. 41. Installheupperransaxle ountingolts23. Supportheweight f heengineromabove 16. Removehecotter inanddisconnecthe ie and ighteno 35 t. Ibs. 48Nm).(chain oist). upporthe ransaxlesing ransmis- rodend, rom hesteeringnuckle. 42. Installhestartermotor.sion ackand emovehe emainingowermounting 17. Disconnecthestabilizerar ink, rom he 43. Attachhebackupightswitch nd hebolts. damperork. speedometeronnector.24. On urbochargedehicle, ecareful ot o 18. Disconnecthedamperork, rom he ateral 44. Connectheselect nd hiftcables nd nstalldamagehe ower adiator osewith he ransaxle lower ontrol rm. new otter ins.housing uringemoval. rapape n both he ower 19. Disconnecthe ater ower rm, nd hecom- 45. Installheaircleaner nd heair ntake ose.hose nd he ransaxleousingo prevent amage. pressionrm,owerball oints, rom hesteering 46. Connecthenegativeattery able.Move he ransaxlessemblyo he ightand are- knuckle. 47. Make ure hevehicles level, nd efill hefully ower t from hevehicle. 20. Pry hehalfshaftsrom he ransaxle,nd e- transaxle.To install: cure side. 48. Checkhe ransaxleor proper peration. ake25. Installhe ransaxleo heengine nd nstall 21. Removeheconnectionor heclutch elease surehe everseights ome nwhenn reverse.themountingolts, ightenhebolts o 35 t. Ibs. 48 cylinder ndwithout isconnectinghehydraulicine,Nm). nstallhe ransaxleower oupling olt. secure side.26. Installheunderpan,rossmembernd he 22. Removehecover rom he ransaxleell-triangularusset. housing.27. Installhe ransferase nAWDmodels nd 23. Removeheengineront oll stopper REMOVAL&INSTALLATIONconnectheexhaustipe. through-bolt.28. Installhehalfshafts,sing ew irclips n 24. Removehecrossmembernd he riangular ) See Figures 1 thru 13theaxleends. ry o keephe nboardointstraightn righthand tay.relationo heaxle.Be areful ot o damageheoil 25. Supporthe ransaxle,sing ransmissionseal ip of he ransaxle ith heserratedart f he jack, nd emovehe ransaxleower oupling olt.halfshaft.29. Connecthe ie rodandball oint o hesteer- *The couplingbolt threads rom the englneside, into the transaxle, and s located ustingknuckle.30. Installhe ransaxle ount racket. above he halfshaft opening.31. Installwheels nd ower ehicle. etorque 26. Slide he ransaxleearwardnd arefullyaxle haft utso 145-188t. Ibs. 200-260 m). lower t from hevehicle.32. Installhestartermotor. To install:33. Connecthebackupight witch nd he 27. Installhe ransaxleo heengine.nstallhespeedometerable. mountingolts nd ighteno 35 t. Ibs. 48Nm).n-34. Installheclutcheleaseylinder. stall he ransaxleower oupling oltand ighteno35. Connectheselect nd hiftcables nd nstall 22-25 t. Ibs. 30-34Nm).new otter ins. 28. Installhecovero he ransaxleellhousing36. Installheair ntake ose. and ightenhemountingolts o 7 t. Ibs. 9 Nm).37. Installheauto-cruisectuatorndbracket. 29. Installhecrossmembernd ightenhe rontmountingolts o 65 t. Ibs. 88Nm) nd he ear


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.

Fig. 2 . . . then loosen the axle nut whilethe vehicle is still on the ground

Fig. 5 Remove the lower coil-over shocklower mount ing bolt and nut from the con-trol arm I

93157po7Fig. 8 Use a suitable prytool to release theinner CV-joint retaining ring from thetransaxle by gently prying outward

Fig, 11 , , . then slide the halfshaft out ofthe knuckle

Fig. 9 Remove the inner joint from thetransaxle until the spline completely clearsthe transaxle

Fig. 7 . . , the lotig. 7 . . / the lower ball joints from thesteering knuckleteering knuckle

93157pcnFig. 10 Uslng a suitable punch and ham-mer, gently tap the halfshaft out of thesteering knuckle . . .

I I ig, 13 Always replace the clrcllp on the in-Fig. 12 Remove he halfshaft from the ve- ner joint before installing the shaft Into thehlcle transaxle


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DRIVETRAIN -51, Whilehe ehicles still on heground,e- IO. Inserthehalfshaftnto he ram&e. Besure cle s being ervicedouldmake differencen ointmovehecotter in,and oosenheaxlenut. it is fullyseated. type.Be ure o properlydentifyhe ointbefore t-2. Raisehevehicle nd upportt safely. 1 . Pull hestrutassemblyutand nstallhe temptingointor boot eplacement.ookor dentifi-3. If equippedithABS,emovehe rontwheel other nd o thehub. cation umberst he arge ndof theboots nd/orspeed ensor. 12. Installhecenter earing racket olts nd on heendof themetaletainer ands.4. If equippedithActiveElectronicontrol tighteno 33 t. Ibs. 45Nm). The types f oints sed re heBirfield oint,SuspensionActive-ECS),erformhe ollowing: 13. Installhewasher n heaxle haft o he (B.J.),heTripod oint T.J.) nd heDouble ffseta. Loosenhenut hatsecuresheair line o chamfereddgeaces utward.nstallheaxlenut, \ Joint D.O.J.).the o the op of thestrutanddiscardheO-ring.b. Removehebolts hatsecureheactuator

butdo not ightent fullyat his ime.14. Connectheball oint o hesteeringnuckle. *Do not disassemblea Birfield joint. Ser-to.the op of thestrutand emovehecompo- Torquehenew etainingut o 43-52 t. Ibs. 68-72 vice with a new oint or clean and repack us-nent.Disconnecthewiringharness. Nm) nd ecure itha new otter in. ing a new boot kit.5. Disconnecthe owerball ointand he ie rod 15. Connecthe ie rodend o thesteering Thedistanceetweenhe arge nd mall ootend rom hesteeringnuckle. knuckle.orquehe etainingut o 21 t. Ibs. 29 bandss mportantnd hould echeckedrior o6. Removeheaxlenutand hewasher. Nm) nd ecure itha new otter in. andafterboot ervice. his s so hebootwill notbe7. If removinghe eftsideaxlewithan nner 16. If equipped ithABS,nstallhe rontwheel installed itheroo oose r oo ight,which ouldshaft,emovehecenter upport earing racket speed ensor. cause arlywear nd racking,llowinghegreaseoboltsandwashers.hen,emovehehalfshaftyset- 17. If equipped ithActive-KS, erformhe ol- getoutandwater nddirt n, eadingo early ointtingupa puller n heoutside heel ub ndpush- lowing: failure.ing hehalfshaftrom he ronthub. ap heshaft a. Installheair linewitha newO-ring.union t he ointcasewitha plastic ammero re- b. Installheactuatoro the op of thestrut. *The drfveshaft oints use special grease;movehehalfshaftnd nner haftrom he ransaxle. Connecthewiringharness. do not add any grease other han that sup-8. If removingight ideaxle hafts ithout n 18. Installhewheel nd ower hevehicleo the plied with the kit.

inner haft, emovehehalfshaftysetting pa floor.puller n heoutside heel ub ndpushinghehalf- 19. Tightenheaxlenut o 145-188t. Ibs. Double Offset Jointshaftrom he ronthub.After ressingheouter (200-260 m) nd ecure itha new otter in.shaft,nsert prybar etweenhe ransaxlease nd TheDouble ffset oint D.O.J.)s biggerhanthehalfshaftndpry heshaftrom he ransaxle. CV-JOINTSVERHAUL otherointsand, n hese pplications,s normally*Do not pull on the shaft; doingso damages used san nboardoint.the inboard oint. b See Figures 14 thru 27 1. Removehehalfshaftrom hevehicle.2. Side utter liers anbeusedo cut hemetalTo install: These ehicles se everal ifferentypes f oints. retaining ands. emoveheboot rom he ointouter9. Replacehecirclips n heends f thehalf- Engineize,ransaxleype,whetherhe oint s an n- race.shafts. board r outboardoint,evenwhich ideof thevehi-

TCCS7030 TCCS7031I I

TCCS7032Fig. 15 Removing he outer band from the Fig. 16 Removing he inner band from theFig. 14 Check he CV-boot or wear W-boot

ho~sing IFi7~ /Fig 17 Removing he CV-boot rom the joint

1 1CV-boot

TCCS703Fig 18 Clean the CV-joint housing prior toremoving boot Tccs7W 1 embiyFig 19 Removing he CV-joint housing as-


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fig. 20 Removing he CV-joint Fig. 21 inspecting he M-joint housing

TCCS7042Fig. 26 Removing the CV-joint innersnapring Fig, 27 installing the CV-joint assembly

Removing the CV-joint outer

Fig. 25 Removing he CV-joint assembly

11. Installhehalfshafto thevehicle.ExceptDouble OtfsetJoint

1. Disconnectheneaativeatterv able. emovethehalfshaft. - 2. Use ide utter liers o removehemetale-taining andsrom heboot(s)hatwill be emoved.Slide heboot rom heT.J. ase.3. Removehesnapringnd he ripod ointspi-derassemblyrom hehalfshaft. onotdisassemblethespider nduse are n handling.4. If theboot s be eused, rap inyl ape roundthespline artof theshaft o heboot(s) ill notbeI

3. Locate nd emovehe arge irclipat he Removeheouter ace thebody f4. Removehesmall napringnd ake ff hece, age ndballsasanassembly.leanhece, age ndballswithout isassembling.5. If theboot s o be eused. ioe heareasesplines ndwrap hesplfnesn vin$ apeheboot rom heshaft.6. Removehe nner D.O.J.) oot rom hef theouter B.J.) oot s o be eplaced,e-heboot etainerings nd lide hebootdownoff of theshaft t his ime.To install:7. Be ure o ape he haft plines eforen-heboots. ill he nside f thebootwith he

(typiW1

specifiedrease. ftenhegreaseuppliedn he e-placementarts it s meanto bedividedn half,withhalfbeing sedo ubricatehe ointandhalfbe-ingusednsideheboot.Installhecage nto hehalfshafto hesmall.diameterideof thecages nstalledirst.Withbrass riftpin, ap ightly nde * emy rouname nnerraceo installhe ace ntil t comesntocontact iththe ib of theshaft. pplyhespecified reaseo heinner ace nd age nd it themogether.nsertheballs nto hecage.9. Installheouter ace thebody f the oint)after illingwith hespecifiedrease. he uter aceshould e illedwith hisgreas .10. Tightenhebootbandsecurely. ake urethedistanceetweenheboot ,, IuJ J ,I Gbl.onrlo.i *nrro+

damagedhen emoved. emovehedynamicTo install:damper,f used, nd hebootsrom heshaft.5.- Double heckhat hecorrecteplacementparts rebeingnstalled. rap inyl ape roundhesplineso protecthebootand nstallheboots nddamper,f used,n hecorrect rder,6. Installhe ointspider ssemblyo theshaftand ipctdl the cnmrinn7. Fill he nside fthe bootwith hespecifiedgrease. ftenhegreaseuppliedn he eplacementparts it s meanto bedividedn half,withhalfbeingusedo lubricatehe ointandhalfbeing sednsidetheboot.Keep reaseff he ubber artof thedy-namic amperif used).8. Securehebootbands ith hehalfshaftn ahorizontalosition. ake ure istanceetweenootbandss correct.9. Installhehalfshafto thevehicle nd econ-necthenegativeatteryable.


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DRlVETRilN 7-7bansaxle. henhepedals pushednward,hediscandplate eparatethe lutchs disenqaqed)iscon-nectiMno heenoinerom he ransaxie.-

The clutch driven disc mav comamasoestos. Galantand Mirageb See Figures 28 thru 41

ostclutches tilize single late, ry riction REMOVAL&INSTALLATION.* * _ discwitha diaphragm-stylepring ressurelate.which has been determined o be a cancer The lutch ischasa splined ubwhich ttacheshecausingagent. Never clean clutch surfaces

disc o he nput haft. hedischas rictionmaterialwith compressed ir! Avoid inhaling any dust wheret contactshe lywheel ndpressurelate.from any clutchsurface! Whencleaning Torsion prings n hedischelpabsorb ngineclutchsurfaces, use a commerciallyavail- torque ulses. he ressurelate pplies ressureoable brake cleaning luid. theclutch isc,holdingt tightagainsttheurfacefthe lywheel. he lutch perating echanismon-sistsof a release earing,orkand ylinder ssembly. The clutch driven disc may contain asbestos,The urposef heclutchs o disconnectnd The eleaseorkand ctuatinginkageransfer which has been determined o be a cancerconnectngine ower t he ram&e.A vehicle t pedalmotiono he eleaseearing.n heengaged causingagent. Never clean clutch surfacesrest equires ot of engineorqueo getall hatweightmoving. n nternalombustionngine oes positionpedaleleased)hediaphragmpring olds with compressed ir! Avoid nhaling any dustthepressurelate gainstheclutch isc, oengine from any clutchsurface! Whencleaningnotdevelop high tartingorqueunlike team n- torques ransmittedo he nput haft.Whenhe clutch surfaces, use a commerciallyavail-gines) o t must eallowedo operate ithout ny clutch edals depressed,he elease earing ushes able brake cleaning luid.loaduntil t builds penoughorqueo moveheve-hicle. orquencreasesithenginepm. he lutch thediaphragmpring enterowardhe lywheel. hediaphragmpring ivots he ulcrum,elievinghe 1. Disconnecthenegativeattery able.allows heengineo buildup orque yphysicallydisconnectingheenginerom he ransaxle,elieving loadon hepressurelate. teel pring trapsiveted 2. Raise nd afely upporthevehicle.theengine f any oador resistance. to heclutch overift hepn---- -I-^ I--- !-- 3. Removehe ransaxlessemblvrom he e-The ransfer f engine owero he ransaxlethe clutch isc,disengagingheGllyl,lo llVcIVIIII1c 4. Removeheoressurelate ttachinaolts.load)must esmooth ndgradual;f it werent,rive transaxlendenablinghegc-- +,, ,n----linecomponentsouldwear utor break uickly. The lutchs operatingryVuV,J,.l to be eused,oosenhebolts n a diagonal atternThisgradual owerransfers made ossible y It will stall heengine hen eleased ith hevehicle eld tationary. or 2 urns ta ime. hiswill prevent arpinghegraduallyeleasingheclutch edal. he lutch isc l The hift ever anbemovedreelybetweenst clutch over ssembly.andpressurelate re heconnectinginkbetween and everse ears henhevehicles stationarynd 5. Removehe eturn lipand hepressurelatetheengine nd ransaxle. henheclutch edals theclutch isengaged. release earing. onotuse olvento cleanhebear-released,hediscandplate ontact ach ther the ing.clutchs engaged)hvsicallvoininaheenaine nd 6. lnsoectheclutch eleaseorkand ulcrumor

hicle.Refero heprocedurearlier n hissection.pressurelate nd lutch isc. f hepressurelates

TCCS7118Fig. 28 Loosen and remove the clutch and . . . then carefully remove he clutchessureplate bolts evenly, a little at a time1~~~~~ -1 [it&ouldbeflatand pressure plate assembly rom the fly

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1 . Fig. 33 Upon installation, it is usually a1 / F@%!,d . then remove the flywhee;;:! 1 1poundto he flywheel bolts . Tccs7z3~Ftg. 31 If necessary, lock the flywheel III the crankshaft m order replace d or have dplace and remove he retaining bolts . . . good Idea to apply a threadlockmg com-


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7-8 DRIVETRAIN

/ sive Wear TCCS7124 1Fig 34 Check he pressure plate for exces-TCCS7126 j / .Fig 38 Be sure that the flywheel surface isclean, before installing the clutch

Fig. 38 Use the clutch alignment tool toalign the clutch disc during assembly

Fig. 40 You may want to use a threadlock- Fig, 41 Be sure to use a torque wrench toing compoundon the clutch assembly bolts tighten all boltsdamager wear. f necessary,emovehe eleaseork theendof he eleaseylinder ushrodnd heandunthreadhe ulcrumrom he ransaxle. pushrod ole n he eleaseork.7. Carefullynspectheconditionf theclutch 13. Applymulti-purposereaseo heclutch e-componentsnd eplace nywornor damagedarts. lease earing. ackhebearingnner urface nd he r

Fig. 36 Typical clutch alignment ool, noteshaft ,,, 1how the splines match he transaxles input

TCCS7130Fig. 39 Pressure plate-to-flywheel boltholes should alignnodels nd16 t. Ibs. 22Nm) nall othermodels.3emovehealigningool.. 18. Installhe ransaxlessembly.19. Checkor proper lutch peration.4DJUSTMENTSPedal Free Play

1. Measureheclutch edal eightrom he aceof hepedal ad o he irewall. he esired istancesare s ollows:a. Mirage--&6148 in. (168-171mm)b. Galant6.93-7.17 in. (176182mm)2. Measureheclutch edal levispinplayat heace f hepedal ad. he tandardalues reas ol-

DWS:a. Mirage--0.04--0.12n. (l-3mm)b. Galant4.04-0.12 n. (l-3mm)3. If heclutch edal eight r clevis inplayarerotwithin hestandardalues, djust s ollows:


9/16

DRIVETRAIN -9*When adjusting he clutch pedal height orthe clutch pedal clevis pin play, be carefulnot to push he pushrod oward the mastercylinder.

d. Check hat when he clutch pedal s de-pressedall the way, he interlockswitch switchesover from ON o OFF.

ADJUSTMENT# See Figure 42*The following adjustment s for the cableactuatedclutchsystemon he Mirage. TheHydraulicsystemson all other modelsareself-adjusting.

1. Measure he clutchpedalheight measurementA). The specificatrons 6.38-6.50 in.(162-165mm).*The clutch pedal height s not adjustable.If not within specifications, part replacementis required.

2. Depress lutch pedalseveral imes and checkthe pedal ree-play measurement ).3. If measurements not 0.67-0.87 in.(17-22mm), adjustment s required.4. To adjust, urn he outercableadjustingnut,locatedat the irewall,until free-play s within range.5. Depress he clutch pedalseveral imes andrecheck he measurement.REMOVALANDINSTALLATION

1. Rotate he adjustingwheelcounterclockwiseoloosen he cable.2. Remove he cable etainingclamps.3. Remove he cotter pin from the clutchactuat-ing arm at the ransaxleand disconnect he cable.4. Disconnect he cableat the pedaland removethe cable rom the vehicle.rln order to preventcable bindingor abra-sion, be sure o take note of the cable rout-ing, so that it can be reinstalled in the sameposition.

To install:5. Route he cableand make he connectionat theclutchpedal.6. Make the connection t the ransaxleand se-cure he cablewith the retainingclamp. nstalla newcotter pin.7. Lubricateall pivot points.8 Adjust he cable o achieveproper ree-play.

REMOVAL&INSTALLATION I1. Disconnect he negativebatterycable.2. Removenecessary nderhood omponentsnorder o gain access o the clutchmastercylinder.

Clutch pedal height

Fig. 42 Clutch pedal height (A) measure-ment-Mirage7923PGDl

3. Placea suitabledrain pan under he vehicle ocatch he luid once he ine ISdrsconnected, r placea rag or shop owel under he luid line of the mastercylinder.4. Loosen he line at the cylinderand allow hefluid to drain.

Clean, high quality brake luid is essential othe safe and proper operation of the brakesystem.Youshould always buy he highestquality brake luid that is available. If thebrake luid becomes ontaminated,drain andflush the system, hen refill the mastercylin-der with new luid. Never reuse any brakefluid. Any brake luid that is removed romthe systemshould be discarded.Also, do notallow any brake luid to come n contactwitha oainted surface; t will damage he paint.5. Remove he clevis pin retainerat the clutchpedaland remove he washerand clevis pm.6. Remove he 2 nutsand pull he cylinder romthe irewall.A sealshould be betweenhe mountingflangeand irewall.This seal shouldbe replaced.7. The nstallation s the reverseof the removalprocedure.8. Lubricate ll pivot pointswith grease.9. Bleed he systemat the slave cylinderusingDOT3 brake lu id and check he adjustment f theclutch pedal.

REMOVAL&INSTALLATION1. Disconnect he negativebatterycable2. Removenecessary nderhood omponents norder o gain access o the clutch release ylinder.3. Placea suitabledrain pan under he vehicle,then remove he hydraulic ine andallow the systemto drain.

Clean, high quality brake luid is essential othe safe and proper operation of the brakesystem.You should always buy he highest

quality brake luid that is available. If thebrake luid becomes ontaminated,drain andflush the system, hen refill the mastercylin-der with new fluid. Never reuse any brakefluid. Any brake luid that is removed romthe systemshould be discarded.Also, do notallow any brake luid to come n contactwitha uaintedsurface; t will damage he paint.4. Remove he bolts and pull the cylinder romthe ransaxlehousing.On some 1.5L engines, n-steadof a pushrodbearingagainst he clutcharm, aclevis pin and yoke s used.Simply remove he cir-clip, pull out he clevis pin and remove he cylinder.5. The nstallation S he reverseof the removalprocedure.6. Lubricateall pivot points with grease.7. Bleed he systemusing DOT3 brake luid.

HYDRAULIC YSTEMBLEEDING) See Figure 43With Hydraulic Clutch1, Fill the reservoirwith cleanbrake luid meetingDOT3 specificatrons.

Clean, high quality brake luid is essential othe safe and proper operationof the brakesystem.Youshould always buy he highestquality brake luid that is available. If thebrake luid becomes ontaminated,drain andflush the system, hen refill the mastercylin-der with new fluid. Never reuse any brakefluid. Any brake luid that is removed romthe systemshouldbe discarded.Also, do notallow any brake luid to come n contactwitha painted surface; t will damage he paint.

2. Press he clutch pedal o the loor, then openthe bleederscrewon the slave cvlinder.3. Tighten he bleedscrewand release he clutchpedal.4. Repeathe procedure ntil the lu id is free ofair bubbles.

7923PG91Fig. 43 Bleeding a typical clutch hydraulicsystem


10/16

7-10 DRIVETRAIN

The automatic ransaxle llowsengine orqueandpower o be ransmittedo the ront wheelswithin anarrow angeof engineoperating peeds. t will allowthe engine o turn ast enough o produceplentyofpowerand orqueat very low speeds,while keeping tat a sensible pm at highvehiclespeeds and t doesthis ob withoutdriver assistance). he ransaxle sesa light luid as he medium or the ransmissionofpower.This fluid also works n ths operationof vari-ous hydraulic ontrol circuitsand as a lubr icant.Be-cause he ransaxle luid performsall of these unc-tions, roublewithin he unit can easily ravel rom onepart o another For his reason, nd because f thecomplexityand unusual peratingprinciplesof thetransaxle, very soundunderstanding f the basicprinciplesof operationwill simplify roubleshooting

REMOVAL&INSTALLATIONPan removal, luid and ilterin Section1 of this manual changes re covered

REMOVAL&INSTALLATION1990-97 Mirage and 1990-93 Galant# See Figure 44

1. Disconnect he negativebatterycable.2. Disconnect he selectorcable rom the ever3. Remove he wo retainingscrewsand ift offthe switch.To install:4. Mount and position newswitch. Do not ightenthe bolts until he switch s adjusted.5. Connectselectorcableand adjustswitch.6. After nstallation ndadjustment akesure heengineonly starts n thePandN selections. lso checkthat he reverseightsoperate nly n theRselectlon.1994-00 Galant and 1998-00 Miragee See Figure 44

93157pmFig. 44 Typically, the park/neutral positionswitch is located on the top of the transaxle

1. Disconnect he negativebatterycable.2. Remove he nut attaching he shift control ca-ble rom the ransaxlemanualshaft ever.Positionthe control cableout of the way.3. Place he manual haft ever n the Neutralposition, remove he nut and he manual haft ever.4. Detach he park/neutral witch electricalcon-nector.5. Remove he park/neutral witch mountingboltsand remove he switch rom the ransaxleman-ual shaft.To install:6. Install he park/neutral witch o the ransaxlemanual haftand nstall he switch mountingboltsDo not ighten he mountingbolts unh the switch sadjusted.7. Install he manualshaft ever o the park/neu-tral switchwith the nut. Make sure hat he shaft everis in the Neutralposition.8. Adjust he switch n the ollowing manner:turn he switch body until he hole n the body of theswitchaligns with he hole n the manualshaft ever.Inserta drill bit or equivalent nto he holes.Tightenthe switch mountingbolts o 8 ft. Ibs. (11 Nm).9. Attach he electricalconnector.10. Install he control cable o the manualshaftleverwith the nut.Adjust he cableso that here s noslack n the cableand hat he selector evermovessmoothly11. Reconnecthe negativebatterycable Checkfor properstartingand proper everse ight operatron.Diamanteti See Figure 44

1. Disconnect he negativebattery able.

Wait at least 90 secondsafter the negativebattery cable is disconnectedo preventpos-sible deploymentof the air bag.2. Disconnect he selectorcable rom the ever.3. Remove he wo retainingscrewsand ift offthe switch.To install:4. Install he ever, ighten he bolts only handtight.5. Rotate witch body so the manualcontrol ever

0.20 inch (5mm) hole and he switch body0.20 inch(5mm) holesare aligned.6. Tighten he mountingbolts o 7-8 ft. Ibs.(10-12 Nm).7. Connect he selectorcable o the ever.8. Connect he negativebattery able.9. After installahon nd adjustmentmakesure heengineonly starts n thePand N selections.Alsocheck hat he reverse ights operateonly in the R se-lection.ADJUSTMENT1990-97 Mirage and 1990-93 Galant

1. Disconnect he negativebattery ableand o-cate he neutralsafetyswitch on the op of thetransaxle.

*Apply parking brake and chockwheels be-fore placing ransaxle nto the N position2. At the ransmission, oosen he shift cablead-justmentnut. nside he vehicle place he gearshiftselector ever n N3. Place he manualshift control ever n N.4. Loosenneutralsafetyswitch mounhng crewsand rotateswitch bodyso the manual ontrol ever0.20 in. (5mm) holeand he switch body0.20 in.(5mm) holesare aligned.5. Tightenswitch body mountingbolts o 7-8 ft.Ibs. (lo-12 Nm).6. At the shift cableadjustingnut, gentlypull ca-ble o removeany slack.Tighten ocknut o 8 ft. Ibs.(12 Nm)7. Verify hat he switch ever moves o positionscorrespondingo eachposition of the selector ever.Connect he negativebattery erminal.8. Make sure he engineonly starts n thePandN positions.Also makesure he reverse ights oper-ate only in Rselection.

REMOVAL&INSTALLATIONDiamante) See Figures 45, 46, 47, and 48

1. Properlydisarm he SRSsystem air bag).Refer o Section6.2. Raiseand safelysupport he vehicle.3. Remove he ront wheels.4. Remove he engineside cover and undercov-ers. 5. Drain he ransaxleassembly nto a suitablecontainer.6. If equipped, emove he ront catalyticcon-verter.7. Remove he exhaustpipe, main mufflerandcatalyticconverter.8. Disconnect he ie rod end and ball oint fromthe steeringknuckle.9. Unbolt he supportbearing or the eft sidehalfshaft.10. Remove he halfshafts y insertinga prybarbetweenhe ransaxlecaseand he driveshaftandprying he shaft rom the ransaxle.11. Remove he air cleanerassemblyandadjoin-ing ductwork.12. Detach he engineharness onnection.13. If the vehicle s equippedwith Active Elec-tronlc ControlledSuspension Active-ECS), emovethe compressorassembly rom the ransaxleand sus-pendwith wire. Do not allow he compressor o hangfrom the air hose.14. If equipped, emove he roll stopperstaybracket.15. Disconnect he speedometer able rom hetransaxle.16. Remove he clip that secures he shifteranddisconnect he shiftercontrol cable rom the

transaxle.17. Disconnect nd plug he oil cooler hosesfrom the ransaxle.18. Detach he ollowing:


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DRIVETRAIN -11

Fig. 45 location of 4-wheel steering oil

l Park/neutral witch electricalharnessl Kickdownservo switchl Pulsegeneratorl Oil temperature ensorelectricalharnessl Shift control solenoidvalve harness.19. Support he ransaxleand remove hetransaxlemountingbracket.20. Remove he hreeupper ransaxle-to-enginemountingbolts.21. For vehicleswith 4WS, remove he heatshield or the 4WS oil pumpand remove he pump.Do not allow he pump o hang rom the oil hoses.22. For vehiclesequippedwith Active-ECS,dis-connect he heightsensor od rom the owercontrolarm.23. Remove he bolt hat secures he HeatedOxy-gen (HOaS) ensorharness o the right side cross-member. 4. Remove he starterassembly.25. Remove he mountingbrackets or access othe bell housingcover,26. Remove he bell housing/oil pancovers as-

sembly.

27. Remove he bolts holding he lexplate o thetorqueconverter.28. Remove he lower ransaxle o engineboltsand remove he ransaxleassembly.To install:29. Install he ransaxleassembly o the engineblock, ns tall he mountingbolts and ighten o 54 ft.tbs. (75 Nm).30. Install he bolts hat secure he orquecon-verter o the driveplate.Tighten he bolts o 34-38 ft.Ibs (4653 Nm).31. Install he bell housing/oil pancovers.32. Install he ransaxle tay brackets hatwereremoved or access o the be ll housingcover.33. Install he starterassemblyand connect hewiring.34. Install he bolt hat secures he HO& sensorharness o the right side crossmember nd ightenthe bolt o 7-9 ft. Ibs. (X-12 Nm).35. For vehiclesequippedwith Active-ECS, on-nect he heightsensor od rom the ower controlarm. Check he heightsensor rod or a length A) of10.59-10.63 in. (269-270mm)36. If removed, nstall he 4WS oil pumpandtighten he mountingbolts o 17 ft. Ibs. (24 Nm).37. If removed, nstall he 4WS oil pumpheatshield and ighten he mountingbolts o 17 ft. Ibs.(24 Nm).38. Install he hreeupper ransaxle-to-enginemountingbolts.Tighten he mountingbolts o 54 ft.Ibs. (75 Nm).*One of the upper bolts has a groundingstrap o secure under he bolt.

39. Installand connect he ransaxlemountingbracket.Tighten he mountingnut and bolts o 51 ft.Ibs. (70 Nm).40. Connect he shift control solenoidvalve har-ness

Removal steps1. Transaxle control cable connection2. Transaxle 011 ooler hoses connection3. PNP swrtch connector4. FvT contro l solenoid valve co nnector5. Input shaft speed sensor connector6. Output shaft speed sensor connector7. Vehicle speed sensor connector6. Spht pin9. Connection of the tie rod end10. Drwe shaft nut

11. Connectton for the lower arm balljomt12. Drwe shaft and inner shaft assembly(RH) and the drwe shaft (LH)CautionMounting locations marked by l should beprovisionally tightened, and then fully tightenedwhen the body is supporting the full weight of theengine.

7923PG84:io. 46 Transaxie removal (1 of 2)-Diamante with F4A51 ransaxie

41. Connect he kickdownservo switch,pulsegenerator nd oil temperature ensorelectricalhar-ness42. Connect he park/neutral witch electricalharness.43. Using new hoseclamps, nstall he oil coolerhoses o the ransaxle.44. Installshifter control cable o the ransaxleand secure he cablewith clip.45. Connect he speedometer able o thetransaxle.46. If removed, nstall he roll stopperstaybracketand ighten he one hroughnut and bolt o36-43 ft. Ibs. (50-60 Nm). Tighten he wo mountingbolts o 16 ft. Ibs. (22 Nm).47. If removed, nstall he Active-ECScompres-sor assembly.Tighten he mountingbolts o 48 inchIbs. (5 Nm) and connect he electricalharness.48. Attach he engineharness onnection.49. Install he air cleanerassembly nd adjoiningduct work.50. Using newcirclips, install he halfshafts ndseathalfshafts nto he ransaxle. nstall he bolt hatsecure he eft side supportbearingand ighten he

bolts o 33 ft. Ibs. (45 Nm).51. Connect he ball oint and ie rod end o thesteeringknuckle.Using new nuts, ighten he balljoint castlenut o 43-52 ft. Ibs. (60-72 Nm) andtighten he ie rod castlenut o 22 ft. ibs. (30 Nm). n-stall newcotter pins.52. Using newgaskets, nstall he exhaust ys-tem.53. If removed, nstall ront catalyticconverter.54. Install he engineundercovers.55. Connect he negativebatterycable.56. Fill the ransaxle o the correct evel.57. Start he engineand check or leaks.Gaiant1999-1993 MODELS

1. Onvehiclesequippedwith auto-cruise, e-move he control actuatorand bracket.2. If equippedwith an active ECS,disconnectthe air compressor.3. Drain he ransaxle luid into a suitablecon-tainer.4. Remove he air cleanerassembly, ntercoolerand air hose,as required.5. Mark he shift cable.Remove he adjustingnut and disconnect he shift cable.6. Tag and detach he electricalconnectors orthe solenoid,neutralsafetyswitch (inhibitor switch),the pulsegenerator ickdownservo switchand oiltemperature ensor.7. Disconnect he speedometer ableand oilcooler ines.8. Disconnect he wires o the startermotor andremove he starter.9. Remove he upper ransaxle o enginebolts.10. Support he ransaxleand remove hetransaxlemountingbracket.11. Raise he vehicleand supportsafely.Removethe sheetmetalunderguard12. Remove he ie rod endsand he bail ointsfrom the steeringknuckle.13. Remove he halfshafts y nsertinga prybarbetweenhe ransaxle aseand he driveshaftandprying he shaft rom the ransaxle.Do not pull on thedriveshaft.Doing so damages he inboard oint. Use


12/16

.

26-33Nm19 - 24 itlbs. 45 - 52 Nm

69 Nm51 ftlbs.\

66 Nm65 ftlbs. 52 Nm36 fl.lbs.

:ig.Do not nsert he prybarso far the oil seale s damaged. ie the halfshafts side.14. On AWD vehicles,disconnect he exhaustcase.15. Remove he ower bellhousing over and re-bolts holding he flexplate o theconverter.To remove, urn the enginecrank-with a box wrenchand bring he bolts nto a po-e or removal,one at a time. After re-push he orqueconverter owardtransaxle o it doesntstay on the engineallowingto pour out the converterhub or causedamage o

16. Remove he ower ransaxle o engineboltsassembly.

To install:17. After he torqueconverterhas beenmountedon the transaxle, nstall he transaxleassemblyon theengine.Tighten he driveplatebolts o 34-38 ft. Ibs.(4653 Nm). Tighten he ransaxle-to-engine olts o35 ft. Ibs. (48 Nm). Install he bellhousing over.18. OnAWD vehicles, nstall he transfercaseand rame pieces.Connect he exhaustpipe using anewgasket.19. Replace he circlips and nstall he halfshaftsto the ransaxle.20. Install he tie rods and ball oint to the steer-ing arm.21. Install he ransaxlemountingbracket.22. install he underguard.23. Install he starter.24. Connect he speedometer ableand oil coolerlines.25 Connect he solenoid,neutralsafetyswitch(inhibitor switch), he pulsegenerator ickdownservo switch and oil temperature ensor.26. Install he shift control cable.27. Install he air hose, ntercoolerand air cleanerassembly.If equippedwith an active ECS,connect he

with a F4A33automatic ransaxle

30 Refill with Dexron I, Mopar ATF Plus ype7176, Mitsubishi PlusATF or equivalent, utomatictransaxle luid. If vehicle s AWD checkand ill thetransfercase.31. Start he engineand allow to idle for 2 min-utes.Apply parkrngbrakeand move selector h rougheachgear posrtion,ending n N. Recheckluid leveland add f necessary. luid evel shouldbe betweenthe marks n the HOT ange.1994-90 MODELS

1. Disconnect he negativebattery able.2. Remove he air cleanerand ntakehoses.3. Drain he ransaxle nto a suitablewastecon-tainer.4. Remove he nut securing he shifter ever othe ransaxle.Remove he cable retainingclip and re-move he cable rom the transaxle.5. Remove he shifter cablemountingbracket,6. Tag and detach he electricalconnectors orthe speedometer, olenoid,neutral afetyswitch (in-hibitor switch), he pulsegenerator, ickdownservoswitch,and he oil temperature ensor.7. Tag and disconnect he oil cooler lines at thetransaxle.8. Remove he bolt securing he fluid dipsticktube o the ransaxle.Remove he dipstrckand ubefrom the transaxle.9. Remove he startermotor and position taside.10. Usingspecial ool MZ203827or equivalent,support he engineassembly.11. Remove he rear roll stoppermountingbracket.12. Remove he ransaxlemount bracket.13. Remove he upper ransaxlemountingbolts.

14. Raiseand safelysupport he vehicle.15. Remove he ront wheelassemblies.16. Remove he right handundercover.17. Removeand discard he cotter pin, thendis-connect he tie rod end rom the steeringknuckle,18. Disconnect he stabilizerbar ink from thedamper ork.19. Disconnect he damper ork from the aterallower control arm.20. Disconnect he ateral owerarm, and hecompression rm lower ball oints from the steeringknuckle.21. Pry he halfshaftsrom the transaxle, nd se-cure aside.22. Remove he cover from the ransaxlebell-housing.23. Remove he engine ront roll stopperthrough-bolt.24. Remove he crossmember nd he triangularright handstay.25. Remove he bolts holding he lexplate o thetorqueconverterwith a box wrench Rotate he engineto bring he bolts nto a position appropriateor re-moval, one at a time. After removing he bolts, pushthe torqueconverter oward he transaxle.This willprevent he converter rom remaining ntactwith theengine,possiblydamaging he converter,26. Support he ransaxle,using a transmissionjack, and remove he ransaxle owercoupling bolt.

*The couplingbolt threads rom the engineside, into the transaxle, and s located ustabove he halfshafl opening.


13/16

DRIVETRAIN -1327. Shde he ransaxle earward nd carefullylower t from the vehicle.To install:28. After he orqueconverterhas beenmountedon the ransaxle, nstall he ransaxleassembly o theengine. nstall he mountingboltsand ighten o 35ft. Ibs. (48 Nm).29. Install he ransaxle owercoupling bolt andtighten o 21-25 ft Ibs. (29-34 Nm).30. Connect he orqueconverter o the lexplateand ighten he bolts o 33-38 ft. Ibs. (45-52 Nm).31. Install the cover to the transaxle bellhous-ing and tighten he mounting bolts to 7 ft. Ibs. (9Nm).32 Install he crossmember nd ighten he rontmountingbolts o 65 ft. Ibs (88 Nm) and he rearbolt o 54 ft. Ibs. (73 Nm) Install he ront engine ollstopper hrough-boltand ightly ighten.Once he ullweight of the engine s on the mounts, ighten he bolt o 42 ft. Ibs. (57 Nm),33. Install he riangularstay bracketand ightenthe mountingbolts o 65 ft. Ibs . (88 Nm).34. Install he halfshafts, s ing newcirclips on

the axle ends.

When nstalling the axleshaft, keep he in-board oint straight n relation to the axle, soas not o damage he oil seal lip of thetransaxle with the serrated part of the half-shaft.35. Connect he ie rod and ball oints o thesteeringknuckle.Tighten he ball oint self-lockingnuts o 48 ft. Ibs. (65 Nm). Tighten he ie rod end nutto 21 ft. Ibs. (28 Nm) and securewith a newcotterpin.36. Connect he damper ork to the lower controlarm and ighten he hrough-bolt o 65 ft Ibs. (88Nm).37. Connect he stabilizer ink to the damper ork,and ighten he self-lockingnut o 29 ft. Ibs. (39 Nm).38. Install he undercover.39. Install he wheelsand carefully ower he ve-hicle40. Install he ransaxlemountbracket o thetransaxle,and ighten he mountingnuts o 32 ft. Ibs.(43 Nm).41. Install he rear roll stoppermountingbracket.42. Remove he enginesupport.Tighten hetransaxlemount hrough-bolt o 51 ft. Ibs. (69 Nm)

and ighten he ront engine oll stopper hrough-bolt.43. Install he upper ransaxlemountingboltsand ighten o 35 fl. Ibs. (48 Nm).44. Install he startermotor.45. Install he dipstick ubeand he dipstick46. Install he shifter cablemountingbracket.47. Connect he shifter everand ighten he re-taining nut o 14 ft. Ibs. (19 Nm).48. Connect he oil cooler ines and securewithclamps.49. Attach he electricalconnectors or thespeedometer, olenoid,neutralsafetyswitch (in-,hibitor switch), he pulse generator, ickdownservoswitch and oil temperature ensor.50. Install he air cleanerand he air intakehose.51. Connect he negativebattery able.52. Make sure he vehicle s level,and refill thetransaxle.Start he engineand allow o idle or 2

minutes.Apply parkingbrakeand move selectorthrougheachgearposition, ending n N. Recheckfluid level andadd f necessary. lu id eve l should bebetweenhe marks n the HOT ange.53. Check he ransaxle or properoperation.Make sure he reverse ights come on when n re-verse and he enginestartsonly in Por N.Mirage*If the vehicle is going o be rolled on itswheels while the halfshafts are out of the ve-hicle, obtain wo outer CV-jointsor properequivalent ools and nstall to the hubs. f thevehicle is rolled without the proper orqueapplied o the front wheel bearings, he bear-ings will no longer be usable.

1. Disconnect he negativebatterycable henthe positive battery able.2. Remove he batteryand battery ray.3. Remove he air hoseand air cleanerassem-bly. 4. Raise he vehicleand supportsafely.5. Remove he underguardpan.6. Drain he ransaxleoil into a suitablecon-tainer.7. If equippedwith 1.6L engine, emove he en-sion rod.8. Disconnect he control cableand coolerlines.9. On3-speed ransaxles, isconnect he hrot-tle control cable.10. On4-speed ransaxles, erform he ollowing:a. Detach he shift control solenoid valveconnector.b. Disconnect he inhibitor switch and kick-down servo switch.

c. Disconnect he pulse generator nd oiltemperature ensor.11. Disconnect he speedometer ableand re-move he starter.12. Remove he ransaxlemountingbolts andbracket.13. Disconnect he stabilizerbar rom the owercontrol arm.14. Disconnect he steering ie rod endand heball oint from the steeringarm.15. Remove he halfshafts t the nboardsidefrom the ransaxle.Tie the oint assemblyaside.*It is not necessary o disconnect he half-shafts rom the wheel hubs.

16. Support he engineand remove he centermember.17. Remove he bellhousing over and removethe driveplatebolts.18 Remove he ransaxleassembly ower con-nectingbolt, ocated ust over he halfshaft pening.19. Properlysupport he ransaxleassembly, henlower t, moving t to the right or clearance.To install:20. After he orqueconverterhas beenmountedon the ransaxle, nstall he ransaxleassemblyon theengine. nstall he mountingbolts and ighten o31-40 ft. Ibs. (43-55 Nm) on 1990-92 modelsand35 ft. Ibs. (48 Nm) on 1993-00 models.21. Tighten he driveplatebolts o 33-38 ft. Ibs.(46-53 Nm). nstall he bellhousing over.22. Install he centermember.

23. Replacehe circlips and nstall he halfshaftsto the ransaxle.24. Install he ie rods, ball oints and stabilizerlinks o the steeringarm25. Install he ransaxlemountingbracketandbolts.26. Install he starter.27. Connect he speedometer able.28. Connect he nhibitor switch, kickdownservoswitch, he pulsegenerator nd oil temperature en-sor, if disconnected.29. Connect he shift control solenoidvalve con-nector.30. Connect he control cablesand oil coolerlines.31. Install he ension od, f removed.32. Install he air cleanerassembly.33. Install he battery ray and battery.34. Connect he positive hen he negative ermi-nal.35. Refillwith Dexron@I, Mopar ATF Plus ype7176 or equivalent, utomatic ransaxle luid.36. Start he engineandallow to idle or two min-utes.Apply parkingbrakeand move selector hrougheachgearposition,ending n N. Recheckluid leveland add f necessary. lu id evel shouldbe betweenthe marks n the HOT ange.ADJUSTMENTSShifter Control Cable Adjustment

1. The shifter cableadjustments doneat theneutralsafetyswitch (inhibitor switch). Locate heswitch on the ransaxleand note he alignmentholesin the arm and he bodyof the switch. Place he se-lector ever n N. Place he manual ever of thetransaxle n the neutralposition.2. Checkalignmentof the hole n the manualcontrol ever o the hole n the inhibitor switch body.If the holes do not align, adjustments required.3. To adjust, oosen he nut on the cableend andpull the cableend by handuntil the alignmentholesmatch.Tighten he nut. Check hat he ransaxleshifts and conforms o the positions of the selectorlever.Throttle Valve Cable

The hrottlevalve adjustment ppliesonly o the1990-96 Mirage.1. Placeselector ever and manualcontrol everin N position.2. Loosenadjustingnut.While ightly pulling oncontrol cable ightenmountingnut o 7-10 ft . Ibs.(X-14 Nm).3. Whenadjustments complete,be sure selectorlever s still in the N position.Verify all functionscorrespond o the position indicatedon the selectorlever.

The halfshaft emovaland nstallationand over-haulare he sameas a manual ransaxle Please eferto ManualTransaxle n this Section


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The only modelcoveredby this manualequippedcase s the 1990-93 AWD Galant. assembly.Placea drain pan under he rear of thetransferassembly o catchany luid hat eaksout.3. Usinqa flat-bladed rying ool, carefully e-

&INSTALLATIONmove he ofi seal rom the ransferdustseal guardTo install:4. Using propersize seal driver ool, install heseal nto he dustseal quardand he ransferassem-blv.See Figures 49 and 50

1. Raiseand support he vehicle safely.2. Remove he propel lershaft rom the ransfer5. Install he rear propellershaft.6. Carefu lly ower he vehicleand nspect hetransferassembly luid level.

a9577g50view of the transfer casehousing and related componentsa9577g51Fig. 50 Install the oil seal using the propersized driver and a hammer

REMOVAL&INSTALLATION1. Disconnect he batterynegative able.2. Raise he vehicleand supportsafely.Drain he

transferoil.3. Disconnect he ront exhaustpipe.4. Unbolt he ransfercaseassembly nd removeby sliding t off the rear driveshaft.Be carefulnot odamage he oil seal n the ransfercaseoutputhous-ing. Do not et he reardriveshafthang;suspend tfrom a frame piece.Cover he opening n thetransaxleand ransfercase o keepoil from drippingand o keepdirt out.5. Lubricate he driveshaft leeveyoke and oilseal ipan the ransferextensionhousing. nstall hetransfercaseassembly o the ransaxle.Use carewhen nstalling he reardriveshaft o the ransfer aseoutputshaft.6. Tighten he ransfer ase o transaxlebolts o40-43 ft. Ibs. (55-60 Nm) with manual ransaxle;43-58 ft. Ibs. (60-80 Nm) with automatic ransaxle.7. Install he exhaustpipe usinga new gasket. n-stall removedbumper omponents.8. Refill he ransfercaseand checkoil levels ntransaxleand ransfercase.

The only modelcoveredby his manualequipped

&INSTALLATIONSee Figures 51 and 521. Disconnect he negativebatterycable.Raiseand supportsafely.2. The rear driveshaft s a 3-piece unit, with aand rear propellershaft.Remove heand msulators rom the centersupportbearing.Therewill be a numberof spacersrom vehicle o vehicle. Check heof spacersand write down heir locations or3. Matchmark he reardifferential ompanionand he rear driveshaft langeyoke. Removeshaftbolts and remove he driveshaft,as possibleso as to ensure hatUse care o keephe oil seal n the outputhousingofcase.

to the boot can be avoided andbe easier if a piece of cloth or simi-4. Do not lower he rearof the vehicle or o il wi llthe ransfercase.Cover he opening odirt out.To install:5. Position he driveshaft n the vehicle,makingo align he matchmarks t the rearyoke.6. Install he bolts at the reardifferential langeighten o 22-25 ft. Ibs. (30-35 Nm).

7. Install he centersupportbearingwith all spac- 2 Forceout he bearing ournals rom the yokeers n place.Tighten he retainingnuts o 22-25 ft. using a largeC-clamp. nstalla collar on the ixedIbs. (3C-35 Nm). side of the C-clamp.Press he ournal bearing nto8. Check he luid levels n the ransfercaseand the collar by applyingpressurewith the C-clamp,onreardifferential ase. the oppositeside.U-JOINTREPLACEMENT

1. Make matingmarkson the yoke and he uni-versa1oint that s to be disassembled. emove hesnaprings rom the yoke with snapringpliers.

3. Pull he ournal bearing rom the yoke.rlf the journal bearing s hard o remove,strike the yoke with a plastic hammer.

4. Press he ournalshaft using C-clampor simi-lar ool, to remove he remainingbearings.

Fiu. 51 Exploded iew of the proueller shafl mount ing


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DRIVETRAiN -15MATING MARKS /

89577Q5EFig. 52 Apply mating marks on the flangeyoke and differential companion flange

5. Onceall bearingsare removed, emove hejournal.To install:6. Apply multi-purposegrease o the shafts,greasesumps,dustseal ips and needle oller bear-ings of the replacement -joint Do not applyexces-sive grease Otherwse, aulty itting of bearingcapsand errors n selectionof snapringsmay result.7. Press it the ournal bearings o the yoke usinga C-clampas follows:a. Install a solid baseonto the bottom of theC-clamp.b. Insert both bearings nto the yoke. Holdand press it them by tightening he C-clamp.c. Install snapringsof the same hicknessonto both sides of each yoke.d. Press he bearingand ournal nto one

side, using a brass bar with diameterof 0.59 in.(15mm).8. Measure he clearance etweenhe snapringand he groovewall of the yoke with a feelergauge. fthe clearance xceeds0.0008-0.0024 in.(0.02-O.O6mm),he snap rings should be replaced.DRIVESHAFT ALANCING

Driveshaftbalancing s a processbest eft or aprofessionalwrth he properequipment.Makeshiftmethodsusing hoseclampsor similar devicescanwork, but he processof correcting he imbalance nthis manner s very toughand extremely ime con-suming.Many machineshopscan balancedriveshafts;some partsstores and obberscan also balance ri-veshaftsusing outsidecontractors.

REMOVAL&INSTALLATION1. Placematmgmarkson the companron langeand he Lobro oint assembly2. Remove he Lobro oint installationbolts.Separatehe Lobro oint from the companion lange.3. Placematingmarkson the centeryoke andcenterpropellershaft,and he companion langeandthe rear propellershaft.4. Remove he self-lockingnuts.Remove hecenteryoke and companion lange.

5. Placematingmarkson the centerbearingas-sembly ront bracket nd he centerpropellershaft,and he centerbearingassembly ear bracketand herear propellershaft.Remove he centerbearingbracket.*The mounting rubber can not be removedfrom the center bearing bracket.

6. Pull out he ront and rear centerbearingswith a commercially vailablepullerTo install:7. Apply multi-purposegrease o the centerbearing ront and rear greasegroovesand o the dustseal ip Be sure o fit the bearing nto he rubbermount grooveon the centerbearingbracket.*Face the bearing dust seal to the side ofthe center bearing bracket mating mark.

8. Assemble he centerbearing o the centerpropellershaftand rear propellershaft.Face he sideonto which he centerbearingbracketmatingmarksIS placedand he dust seal s insta lled oward heside of the centerpropellershaftand rear propellershaft.9 Apply a thin and evencoat of the grease, n-closedwith the repair kit, to the rubberpackingonthe companion lange.Align the matingmarkson thecenterpropellershaftand he companion lange, henpress it the centerbearingwith self-lockingnuts.10 Install he Lobro oint assembly nstallationbolts. Secure he companron langeand Lobro ointassemblywith the nstallationbolts Check or greaseleakagerom the Lobro oint boot and companionflange nstallabon arts.

The only modelcoveredby his manualequippedwith a rearaxle differential s the 1990-93 AWDGalant.

REMOVAL&INSTALLATION# See Figures 53 and 54

1. Disconnect he negativebatterycable.Raisethe vehicle and supportsafely.2. Remove he bolts hat attach he rear halfshaftto the comoanion lanae.3. Usea prybar opry the nner shaftout of the

IFig. 53 Rear driveshaft mounting89577g5

differential ase.Dont nsert he prybar oo far or theseal could be damaged.4 Remove he reardriveshaft rom the vehicle.5. If necessary, arefullypry the oil seal rom therear differentialusing a flat tipped prying ool.To install:6. Installa new oil seal nto he rear differentialhousing usingproper size driver.7. Replace he circlip and nstall he rear drive-shaft o the differential ase.Make sure t snaps nplace.8. Install he companion langebolts and ightento 40-47 ft. Ibs. (55-65 Nm).9. Check he luid level n the rear differential.

69577958Fig. 54 Remove the driveshaft from the dif-ferential carrier with a prybar

REMOVAL&INSTALLATION1. Disconnect he negativebatterycable.2. Raiseand support he vehicle safely.3 Remove he ire andwheelassembly rom thevehicle.4 If equippedwith ABS, remove he rearwheelspeedsensor.

*Be cautious to ensure that the tip of thepole piece on the rear speed sensor does notcome in contact with other parts during re-moval. Sensor damage could occur.

5. Remove he rear caliperand supportassem-bly out of the way. Remove he brakedisc.6. Remove he driveshaftand companion langeinstallationbolts, nuts and washers.Move the end ofshaftslightly o access he self-lockingnut.7. Using axle holding ool MBSbll-01 orequivalent, ecure he rearaxle shaft n position, henremove he self-locking nut.8. Using puller and adapterMBSbll-01 andMB9b41-01 or equivalents, emove he rearaxleshaft rom the railing arm9. If equippedwith ABS, remove he rear rotorfrom the axle assemblyusing collar and press.Therotor is a press it.10 Remove he outer bearingand dust coverconcurrentlyrom the axle shaft using a press.


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.11. Using puller, emove he oil seal and nner 18. Whileholding he rearaxle shaft n positronusingholding ixture ool MB9g67-01or equivalent,12. Inspect he companion langeand axle shaft tightena newself-lockingnut o 159 ft. Ibs. (220 Nm).st cover for defor- 19. Install he drive shaftnuts,washersand bolts.or damage. nspect he bearings or burning Tighten o 40-47 ft. Ibs. (55-65 Nm).Replace omponents s required 20. Install he rear brakedisc, caliperassemblyTo install: and parkingbrake.13. Using he properdriver, press it the nneronto the trailing arm. Press it the oil seal

railing arm with the depression n the oilacing upward,and until it contacts he shoulderarm.

21. Install he ire and wheelassembly nd owerthe vehrcle.Check he parkingbrakestrokeand ad-just as required.22. Beforemoving he vehicle, pump he brakesuntil a firm pedal s achieved.

n tapping he oil seal in, use a plasticer o lightly tap the top and circumfer-of the seal installation tool, press ittingevenly.14. Press it the dust covers onto the axle until itshoulder. nstall he innermosts facino UDWard.

REMOVAL&INSTALLATION1. Raise he vehicle and supportsafely.2. Matchmark he driveshaftand comoanion,

n tapping he oil seal in, use a plasticer o lightly tap the top and circumfer-of the seal installation tool, press ittingflangeand remove he shaft.Dont et t hang rom thetransaxle.Tie It up to the underbody.3. Hold he companion langestationaryand re-move he argeself-lockingnut n the centerof thecomoanion lanoe.15. Apply multi-purposegreasearound he entire 4: Usinga Gller, remove he flange.Pry he oldside of the outer bearing seal out.ip. Press it the outerbearing o the axle shaftso To install:he bearrng eal ip surface s facing owards he 5. Applya thin coatof multi-purpose rease o theshaft lange. seal ip and he companionlangesealcontacting ur-16. Press it the rear rotor to the axle shaftwith face. nstall he newsealwith an appropriate river.surface owards he axle shaft 6. Install he companionlange. nstalla new ock-nutand orque o 116-159 fl Ibs. (157-220 Nm).The17. Install he rearaxle shaft o the railing arm rotation orqueof the drive pinionshouldbe about4o the rear inch Ibs. or newor reused, iled bearingsshaft, hen nstall a newself-lockingnut. 7. Install he driveshaft.

REMOVAL&INSTALLATION1. Raise he vehicleand supportsafely.2. Drain he differentialgear oil and remove hecenterexhaustpipe.3. Matchmark nd remove he reardriveshaft.4. Remove he rear halfshafts.5. Remove he centerexhaustpipe and mufflerassembly, s required.6. Removeor disconnect he 4 wheelsteeringoil pump.7. The argemountingbolts hat hold he differ-ential carrier supportplate o the underbodymay useself-lockingnuts.Before emoving hem, support herearaxle assembly n the middlewith a transaxlejack. Remove he nuts, hen remove he supportplate(s)and he squaredynamicdamper rom the rearof the carrier.8 Lower he differential arrier and remove romthe vehicle.

To install:9. Raise he rear differential arrier nto positionand nstall supportmemberbolts. Installnew ock-nutson all supportbolts.10. Install he 4 wheelsteeringoil pump.11. Install newcirclips on both rear driveshaftsand nstall.12. Install he propellershaft.13. Install he centerexhaustpipe and muffler.14. Lower he vehicle.15. With the vehicle evel, ill the rear differential.

TORQUESPECIFICATIONSComponents EnglishAutomatic Vansaxle-toengme mountrng bolts

Diamante models 54ft Ibs.1990-92 Mrrage 3140ft Ibs.199390 Mrrage 35ft Ibs.1990-93 Galant 32-39 ft Ibs.199400 Galant 35ft Ibs.

Axle hub nuts 145-188 ft tbsBack-up lamp swatch 22-25 ft Ibs.Clutch release fork fulcrum 25ft IbsDriveshaft-to-rear drfferentral lange bolts 22-25 fl lb?..Driveshaft center bearrng support bracket mountrng nuts 22-25 fl. Ibs.Halfshaft center bearing support bracket 33ft Ibs.Manual transaxle-toengrne mountrng bolts

1990-92 Mtrage 3140 ft. Ibs.1993-00 Mrrage 35 ft. Ibs.1990-93 Galant 32-39 fl Ibs.199400 Galant 35ft Ibs.

Manual transaxle lower coupling bolt 22-25ft IbsManual transaxle mount retaining nuts 32ft Ibs.Manual transaxle mount through-bolt 51 R Ibs.Park/neutral safety swatch retainrng bolts

1990-97 Mrrage and 1990-93 Galant 76 ft. Ibs1994-00 Galant and 199600 Mirage afl IbsDramante models 78 fl. Ibs

Pinion nut 116-159fl lb?..Pressure plate-to-flywheel bolts1994-98 Galant 14ft Ibs./All other models 16ft Ibs.Rear halfshaft-tocompanron flange bolts 4047ft Ibs.Stub axle shaft hub nut 159n Ibs.Throttle valve cable mounting nut 7-10 ft. Ibs.Torque converter-todnveplate bolts 34-38 n. ibsTransfer case-to-transaxle mounttng bolts

Metric75 Nm

43-55 Nm48 Nm

43-55 Nm48 Nm

200-260 Nm30-35 Nm

35 Nm30-35 Nm30-35 Nm

45 Nm43-55 Nm48 Nm43-55 Nm

48 Nm30-35 Nm

40 Nm69 Nm

IO-12 Nm11 Nm

IO-12 Nm157-220 Nm

19 Nm22 Nm

5565 Nm220 Nm

lo-14 Nm46-53 Nm

ch 7 drive train

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