Manual Transaxle Assembly

REMOVAL & INSTALLATION

Mirage

NOTE: If the vehicle is going to be rolled while the halfshafts are out of the vehicle, obtain 2 outer CV-joints or proper equivalent tools and install to the hubs. If the vehicle is rolled without the proper torque applied to the front wheel bearings, the bearings will no longer be usable.

NOTE: The suspension components should not be tightened until the vehicles weight is resting on the ground.

1. Remove the battery and battery tray.
2. Remove the air cleaner assembly and vacuum hoses.
3. Note the locations and disconnect the shifter cables.
4. If equipped with 1.6L engine, remove the tension rod.
5. Detach the backup lamp switch connector, speedometer cable connection and remove the starter motor.
6. Raise the vehicle and support safely.
7. Remove the front wheels and the inner wheel panels.
8. Remove the undercover and splash pan.
9. Drain the transaxle oil into a suitable container.
10. Support the engine and remove the crossmember.
11. Remove the upper transaxle mounting bolt and bracket.
12. Disconnect the stabilizer bar, tie rod ends and the lower ball joint connections.
13. Remove the clutch release cylinder and clutch oil line bracket. Do not disconnect the fluid lines and secure the slave cylinder with wire.
14. Disconnect the clutch cable, if equipped with cable controlled clutch system.
15. Remove the halfshafts by inserting a prybar between the transaxle case and the driveshaft and prying the shaft from the transaxle. Do not pull on the driveshaft. Doing so damages the inboard joint. Do not insert the prybar so far the oil seal in the case is damaged.

    NOTE: It is not necessary to disconnect the halfshafts from the steering knuckle. Remove the shaft with the hub and knuckle as an assembly. Tie the shafts aside. Note the circle clip on the end of the inboard shafts should not be reused.

16. Remove the bellhousing lower cover.
17. Remove the transaxle to engine bolts and lower the transaxle from the vehicle.

    To install:

    NOTE: When installing the transaxle, be sure to align the splines of the transaxle with the clutch disc.

18. Install the transaxle to the engine and install the mounting bolts. Tighten the bolts to 31–40 ft. lbs. (43–55 Nm) on 1990–92 models and 35 ft. lbs. (48 Nm) on 1993–00 models.
19. Install the bellhousing cover.

    NOTE: When installing the halfshafts, use new circlips on the axle ends. Care must be taken to ensure that the oil seal lip of the transaxle is not damaged by the serrated part of the driveshaft.

20. Install and fully seat the halfshafts into the transaxle.
21. Install the slave cylinder.
22. Connect the ball joints, tie rod ends and the stabilizer bar connections.
23. Install the upper transaxle mounting bracket and bolt.
24. Install the crossmember.
25. Install the undercover.
26. Install the upper transaxle-to-engine mounting bolts. Tighten the bolts to 31–40 ft. lbs. (43–55 Nm) on 1990–92 models and 35 ft. lbs. (48 Nm) on 1993–00 models.
27. Install the starter motor.
28. Connect the backup light switch connector and speedometer cable.
29. Connect and adjust the shifter cables.
30. Install the air cleaner assembly.
31. Install the front wheels.
32. Make sure the vehicle is level when refilling the transaxle. Use Hypoid gear oil or equivalent, GL-4 or higher.
33. Connect the negative battery cable and check the transaxle for proper operation. Make sure the reverse lights operate when in reverse.

Galant

1990–93 MODELS

NOTE: If the vehicle is going to be rolled on its wheels while the halfshafts are out of the vehicle, obtain two outer CV-joints or proper equivalent tools and install to the hubs. If the vehicle is rolled without the proper torque applied to the front wheel bearings, the bearings will no longer be usable.

1. Remove the battery and the air intake hoses.
2. If equipped with Active-ECS, unplug the compressor wiring.
3. Remove the auto-cruise actuator and underhood bracket, located on the passenger side inner fender well.
4. Drain the transaxle and transfer case fluid, if equipped, into a suitable waste container.
5. Remove the retainer bolt and pull the speedometer cable from the transaxle assembly.
6. Remove the cotter pin securing the select and shift cables and remove the cable ends from the transaxle.
7. Remove the connection for the clutch release cylinder and without disconnecting the hydraulic line, and secure it aside.
8. Disconnect the backup light switch harness and position aside.
9. Detach the starter electrical connections, if necessary, remove the starter motor and position aside.
10. Remove the transaxle mount bracket.
11. Remove the upper transaxle mounting bolts.
12. Raise the vehicle and support safely on jackstands.
13. Remove the undercover and the front wheels.
14. Remove the cotter pin and disconnect the tie rod end from the steering knuckle.
15. Remove the self-locking nut from the halfshafts.
16. Disconnect the lower arm ball joint from the steering knuckle.
17. Remove the halfshafts from the transaxle.
18. On AWD models, disconnect the front exhaust pipe.
19. On AWD models, remove the transfer case by removing the attaching bolts, moving the transfer case to the left and lowering the front side. Remove it from the rear driveshaft. Be careful of the oil seal. Do not allow the driveshaft to hang; once the front is removed from the transfer, tie it up. Cover the transfer case openings to keep out dirt.
20. Remove the cover from the transaxle bellhousing.
21. On AWD models, remove the crossmember and the triangular gusset.
22. Remove the transaxle lower coupling bolt. It is just above the halfshaft opening on FWD or transfer case opening on AWD.
23. Support the weight of the engine from above (chain hoist). Support the transaxle using a transmission jack and remove the remaining lower mounting bolts.
24. On turbocharged vehicle, be careful not to damage the lower radiator hose with the transaxle housing during removal. Wrap tape on both the lower hose and the transaxle housing to prevent damage. Move the transaxle assembly to the right and carefully lower it from the vehicle.

    To install:

25. Install the transaxle to the engine and install the mounting bolts. Tighten the bolts to 35 ft. lbs. (48 Nm). Install the transaxle lower coupling bolt.
26. Install the underpan, crossmember and the triangular gusset.
27. Install the transfer case on AWD models and connect the exhaust pipe.
28. Install the halfshafts, using new circlips on the axle ends. Try to keep the inboard joint straight in relation to the axle. Be careful not to damage the oil seal lip of the transaxle with the serrated part of the halfshaft.
29. Connect the tie rod and ball joint to the steering knuckle.
30. Install the transaxle mount bracket.
31. Install wheels and lower vehicle. Retorque axle shaft nuts to 145–188 ft. lbs. (200–260 Nm).
32. Install the starter motor.
33. Connect the backup light switch and the speedometer cable.
34. Install the clutch release cylinder.
35. Connect the select and shift cables and install new cotter pins.
36. Install the air intake hose.
37. Install the auto-cruise actuator and bracket.
38. Install the battery.
39. If equipped with Active-ECS, connect the air compressor.
40. Make sure the vehicle is level when refilling the transaxle. Use Hypoid gear oil or equivalent, GL-4 or higher.
41. Check the transaxle and transfer case for proper operation. Make sure the reverse lights come on when in reverse.

1994–00 MODELS

1. Disconnect the negative battery cable and wait at least 90 seconds before performing any work.
2. Remove the air cleaner and intake hoses.
3. Drain the transaxle into a suitable waste container.
4. Remove the cotter pins and clips securing the select and shift cables and remove the cable ends from the transaxle.
5. If equipped with Active-ECS, disconnect the air compressor.
6. Disconnect the backup light switch harness and position aside.
7. Disconnect the speedometer electrical connector, from the transaxle assembly.
8. Remove the starter motor and position aside.
9. Using special tool MZ203827 or equivalent, support the engine assembly.
10. Remove the rear roll stopper mounting bracket.
11. Remove the transaxle mount bracket.
12. Remove the upper transaxle mounting bolts.
13. Raise and safely support the vehicle.
14. Remove the front wheel assemblies.
15. Remove the right hand undercover.
16. Remove the cotter pin and disconnect the tie rod end, from the steering knuckle.
17. Disconnect the stabilizer bar link, from the damper fork.
18. Disconnect the damper fork, from the lateral lower control arm.
19. Disconnect the later lower arm, and the compression arm, lower ball joints, from the steering knuckle.
20. Pry the halfshafts from the transaxle, and secure aside.
21. Remove the connection for the clutch release cylinder and without disconnecting the hydraulic line, secure aside.
22. Remove the cover from the transaxle bellhousing.
23. Remove the engine front roll stopper through-bolt.
24. Remove the crossmember and the triangular right hand stay.
25. Support the transaxle, using a transmission jack, and remove the transaxle lower coupling bolt.

    NOTE: The coupling bolt threads from the engine side, into the transaxle, and is located just above the halfshaft opening.

26. Slide the transaxle rearward and carefully lower it from the vehicle.

    To install:

27. Install the transaxle to the engine. Install the mounting bolts and tighten to 35 ft. lbs. (48 Nm). Install the transaxle lower coupling bolt and tighten to 22–25 ft. lbs. (30–34 Nm).
28. Install the cover to the transaxle bellhousing and tighten the mounting bolts to 7 ft. lbs. (9 Nm).
29. Install the crossmember and tighten the front mounting bolts to 65 ft. lbs. (88 Nm) and the rear bolt to 54 ft. lbs. (73 Nm). Install the front engine roll stopper through-bolt and hand-tighten. Once the full weight of the engine is on the mounts, tighten the bolt to 42 ft. lbs. (57 Nm).
30. Install the triangular stay bracket and tighten the mounting bolts to 65 ft. lbs. (88 Nm).
31. Connect the clutch release cylinder.
32. Install the halfshafts, using new circlips on the axle ends.

    WARNING
    When installing the axleshaft, keep the inboard joint straight in relation to the axle, so not to damage the oil seal lip of the transaxle, with the serrated part of the halfshaft.

33. Connect the tie rod and ball joints to the steering knuckle. Tighten the ball joint self-locking nuts to 48 ft. lbs. (65 Nm). Tighten the tie rod end nut to 21 ft. lbs. (28 Nm) and secure with a new cotter pin.
34. Connect the damper fork to the lower control arm and tighten the through-bolt to 65 ft. lbs. (88 Nm).
35. Connect the stabilizer link to the damper fork, and tighten the self-locking nut to 29 ft. lbs. (39 Nm).
36. Install the underpan.
37. Install wheels and lower vehicle.
38. Install the transaxle mount bracket to the transaxle, and tighten the mounting nuts to 32 ft. lbs. (43 Nm).
39. Install the rear roll stopper mounting bracket.
40. Remove the engine support. Tighten the transaxle mount through-bolt to 51 ft. lbs. (69 Nm) and tighten the front engine roll stopper through-bolt.
41. Install the upper transaxle mounting bolts and tighten to 35 ft. lbs. (48 Nm).
42. Install the starter motor.
43. Attach the backup light switch and the speedometer connector.
44. Connect the select and shift cables and install new cotter pins.
45. Install the air cleaner and the air intake hose.
46. Connect the negative battery cable.
47. Make sure the vehicle is level, and refill the transaxle.
48. Check the transaxle for proper operation. Make sure the reverse lights come on when in reverse.