Removal and Replacement
REMOVAL1. Disconnect battery negative cable.
2. Hoist vehicle.
Fig. 37:
3. Remove transaxle dipstick tube (Fig. 37).
Fig. 38:
4. Disconnect gearshift cable clamp at transaxle. Disconnect cable grommet at manual valve lever (Fig. 38). Shift transaxle to neutral.
5. Using Special Tool # 8193, disconnect transaxle cooler lines at transaxle.
6. Remove transaxle cooler and lines at rear of vehicle.
7. Remove clamps at front exhaust pipes. Remove rear pipe hangers and muffler hangers.
8. Remove exhaust, muffler, and rear pipes.
9. Remove 02 sensor connectors.
NOTE: The clamps that retain the catalytic converters to the exhaust manifolds cannot be reused. Replace clamps with new ones.
10. Remove clamps at front catalytic converters at exhaust manifolds. Remove catalytic converters.
Fig. 39:
11. Support transaxle (Fig. 39).
12. Remove rear frame crossmember supports.
Fig. 40:
13. Remove transaxle rear mount bolts and mount thru bolt (Fig. 40). Remove mount.
Fig. 41:
14. Remove transaxle front mounting bolts (Fig. 41).
Fig. 42:
15. Mark propshaft at rear (Fig. 42) drive flange for assembly reference.
CAUTION: Deattach the coupler from the flange only. Do not deattach coupler at the propeller shaft.
Fig. 43:
16. Remove propshaft rear bolts at transaxle bell housing drive flange (Fig. 43).
17. Support propshaft with suitable floor stand.
CAUTION: DO NOT TRY TO REMOVE THE PROPSHAFT UNLESS IT HAS CLEARED THE DRIVE FLANGE PILOT COMPLETELY. DO NOT ANGLE THE SHAFT DOWNWARD. DAMAGE TO THE INNER BEARING WILL RESULT.
18. Slide transaxle rearward to clear the drive flange pilot.
19. Remove propshaft.
Fig. 44:
Fig. 45:
20. Remove transaxle solenoid, input speed, output speed, and TRS connectors from the transaxle (Fig. 44) and (Fig. 45).
21. Remove rear sway bar assembly.
22. Support left lower control arm with jack stand.
Fig. 46:
Fig. 47:
23. Remove rear strut lower mounting bolt and nut (Fig. 46).
24. Remove left rear lower control arm ball stud nut.
25. Remove ball stud from knuckle. Refer to Steering and Suspension for proper procedure.
Fig. 48:
26. Dislodge inner tripod joint from stub shaft retaining snap ring on transaxle assembly (Fig. 48). Inner tripod joint is dislodged from stub shaft retaining snap ring, by inserting a pry bar between transaxle case and inner tripod joint and prying on tripod joint. Only disengage the inner tripod joint from the retaining snap ring. Do not attempt to remove the inner tripod joint from the transmission stub shaft at this time.
Fig. 49:
27. Remove halfshaft inner tripod joint from transaxle stub shaft. When removing halfshaft, do not pull on interconnecting shaft to remove inner tripod joint from stub shaft. Removal in this manner will separate the spider assembly from the tripod joint housing. Grasp inner tripod joint (Fig. 49) and interconnecting shaft and pull on both pieces at the same time.
28. Lift up and out on knuckle while grasping axle shaft.
29. Disconnect left axle shaft from stub shaft.
30. Pry right inner tripod off of right stub shaft while repositioning the transaxle to the left.
31. Reposition transmission jack stand under transaxle pan.
Fig. 50:
32. Remove rear lower crossmember (Fig. 50).
33. Lower and remove transaxle/bell housing assembly.
Fig. 51:
34. Remove inspection hole cover on bell housing (Fig. 51).
35. Mark torque converter to flex plate for assembly reference.
36. Remove torque converter bolts.
37. Remove bell housing bolts.
38. Remove bell housing.
INSTALLATION
1. Install bell housing.
2. Install bell housing bolts.
3. Install torque converter bolts.
4. Install inspection hole cover on bell housing.
5. Raise transaxle/bell housing assembly into position.
Fig. 52:
6. Install rear lower crossmember (Fig. 52).
Fig. 53:
7. Install rear frame crossmember supports (Fig. 53).
8. Install right inner tripod onto right stub shaft while repositioning the transaxle to the right.
9. Connect left axle shaft to stub shaft.
10. Support left lower control arm with jack stand.
11. Install left lower ball stud to left knuckle.
12. Install left rear lower control arm ball stud new nylok nut. Tighten nut to 129 Nm (95 ft. lbs.).
13. Install rear strut lower mounting bolt and nut.
14. Install rear sway bar assembly.
15. Connect transaxle solenoid, input speed, output speed, and TRS connectors to the transaxle.
16. Slide transaxle rearward to clear the drive flange pilot.
CAUTION: DO NOT TRY TO INSTALL THE TRANSAXLE UNLESS THE BELL HOUSING DRIVE FLANGE PILOT HAS CLEARED THE PROPSHAFT COMPLETELY. DO NOT ANGLE THE SHAFT. DAMAGE TO THE INNER BEARING WILL RESULT.
17. Align transaxle to propshaft and slide transaxle forward.
18. Install propshaft rear bolts at transaxle bell housing drive flange.
19. Connect gearshift cable clamp at transaxle. Connect cable grommet at manual valve lever.
20. Install transaxle front mounting bolts.
21. Install transaxle rear mount bolts and mount thru bolt.
NOTE: The clamps that retain the catalytic converters to the exhaust manifolds cannot be reused. Replace clamps with new ones.
22. Install catalytic converters. Install clamps at front catalytic converters at exhaust manifolds.
23. Install exhaust, muffler, and rear pipes.
24. Install clamps at front exhaust pipes. Install rear pipe hangers and muffler hangers.
25. Install transaxle dipstick tube.
26. Install transaxle cooler and lines at rear of vehicle.
27. Connect transaxle cooler lines at transaxle.
28. Check transaxle differential fluid. Fill to level.
29. Lower vehicle.
30. Connect battery negative cable.
31. Fill transaxle fluid to level with MOPAR ATF+4 Type 9602.
32. Check and adjust gearshift cable.