MANUAL TRANSAXLE 7-2

UNDERSTANDINGTHEMANUAL
TRANSAXLE 7-2
ADJUSTMENTS 7-2
SHIFTLINKAGE 7-2
BACK-UPLIGHTSWITCH 7-2
REMOVAL& INSTALLATION 7-2
MANUALTRANSAXLEASSEMBLY7-2
REMOVAL&INSTALLATION 7-2
HALFSHAFTS 7-3
REMOVAL& INSTALLATION 7-3
CV-JOINTSOVERHAUL 7-5
CLUTCH 7-7
UNDERSTANDINGTHE CLUTCH 7-7
DRIVENDISCAND PRESSURE PLATE 7-i'
REMOVAL&INSTALLATION 7-7
ADJUSTMENTS 7-8
CLUTCHCABLE 7-9
ADJUSTMENT 7-9
REMOVALAND INSTALLATION 7-9
CLUTCHMASTERCYLINDER 7-9
REMOVALANDINSTALLATION 7-9
CLUTCHSLAVECYLINDER 7-9
REMOVAL&INSTALLATION 7-9
HYDRAULICSYSTEMBLEEDING 7-9
AUTOMATIC TRANSAXLE 7-10
UNDERSTANDINGTHEAUTOMATIC
TRANSAXLE 7-10
FLUIDPAN 7-10
REMOVAL& INSTALLATION 7-10
PARK/NEUTRALPOSITIONSWITCH 7-10
REMOVAL& INSTALLATION 7-10
ADJUSTMENT 7-10
AUTOMATICTRANSAXLE
ASSEMBLY 7-10
REMOVAL&INSTALLATION 7-10
ADJUSTMENTS 7-13
HALFSHAFTS 7-13
TRANSFER CASE 7-14
REAROUTPUTSHAFTSEAL 7-14
REMOVAL& INSTALLATION 7-14
TRANSFERCASEASSEMBLY 7-14
REMOVAL&INSTALLATION 7-14
DRIVELINE 7-14
DRIVESHAFTAND U-JOINTS 7-14
REMOVAL& INSTALLATION 7-14
. U-JOINTREPLACEMENT 7-14
DRIVESHAFTBALANCING 7-15
CENTERBEARING 7-15
REMOVAL& INSTALLATION 7-15
REAR AXLE DIFFERENTIAL 7-15
REARHALFSHAFTANDSEAL 7-15
REMOVAL&INSTALLATION 7-15
STUBAXLESHAFT,BEARlNG
AND SEAL 7-15
REMOVAL&INSTALLATION 7-15 '
PINIONSEAL 7-16
REMOVAL&INSTALLATION 7-16
AXLEHOUSINGASSEMBLY 7-16
REMOVAL&INSTALLATION 7-16
SPECIFICATIONS CHART
TORQUESPECIFICATIONS 7-16
7-2 'DRIVETRAIN
Becauseof the way an internalcombustronengine
breathes,it can producetorque,or twisting force,
only within a narrowspeedrange.Most modern,
overheadvalve pushrodenginesmustturn at about
2500 rpm to producetheir peaktorque By 4500 rpm
they are producrngso lrttletorquethat contrnuedin-
creasesin enginespeedproduceno powerincreases.
Thetorquepeakon overheadcamshaftenginesIS
generallymuchhigher,but much narrower.
Themanualtransaxleandclutchareemployedto
varythe relationshipbetweenenginespeedand the
speedof thewheelsso thatadequateenginepowercan
beproducedunderall crrcumstances. Theclutchal-
lowsenginetorqueto beappliedto thetransaxleinput
shaftgradually,dueto mechanicalslippage.Conse-
quently,the vehiclemaybe startedsmoothlyfroma
full stop Thetransaxlechangesthe ratiobetweenthe
rotatingspeedsof the engineandthewheelsby the
useof gears.Thegearratiosallowfull enginepowerto
beappliedto the wheelsduringaccelerationat low
speedsandat highway/passingspeeds.
In a front wheeldrive transaxle,poweris usually
transmittedfrom the input shaftto a mainshaftor out-
put shaftlocatedslightly beneathand to the side of
the input shaft.The gearsof the mainshaftmeshwith
gearson the input shaft,allowing powerto be carried
from oneto the other.All forwardgearsare in con-
stantmeshand are freefrom rotatingwith the shaft
unlessthe synchronizerand clutch ISengaged.Shaft-
ing from one gearto the nextcausesone of the gears
to befreedfrom rotatingwith the shaftand locksan-
otherto it. Gearsare lockedand unlockedby internal
dog clutcheswhich slide betweenthe centerof the
gearand the shaft.Theforwardgearsemploysyn-
chronizers;friction memberswhich smoothlybring
gearand shaftto the samespeedbeforethe toothed
dog clutchesare engaged.
SHIFTLINKAGE
1. Disconnectthe shift linkagefrom the transaxle.
2. Onthe transaxle,put selectleverin N and
movethe shift lever in 4th gear.Depressthe clutch,
if necessary,to shift.
3. Move the shift leverin the vehicleto the 4th
gearposition until it contactsthe stop.
4. Turn the adjusterturnbuckleso the shift cable
eyealignswith the eye in the gearshift lever.When
installingthe cableeye,makesurethe flangeside of
the plasticbushingat the shift cableend is on the
cotterpin side.
5 The cablesshouldbe adjustedso the clear-
ancebetweenthe shift leverandthe 2 stoppersare
equalwhenthe shift lever ISmovedto 3rd and4th
gear.Move the shift leverto eachpositronand checki
that the shifting is smooth
REMOVAL&INSTALLATION
1, Disconnectthe negativebatterycable
2. Removeanycomponentsnecessaryto access
the back-uplight switch.
3. Unplugthe back-uplight switch connector.
4. Removethe switchfrom the caseusingthe ap-
propriatesize socketand drive tool.
To install:
5. Installthe switchand tighten it to 22-25 ft. Ibs.
(30-35 Nm).
6. Attachthe back-uplight switchconnector
7. Installanycomponentsremovedto accessthe
back-uplight switch
8. Connectthe negativebatterycable.
REMOVAL& INSTALLATION
Mirage
*If the vehicle is goingto be roiled while the
halfshaftsare out of the vehicle, obtain2 outer
CV-jointsor properequivalenttools andinstall
to the hubs.If the vehicle is rolled withoutthe
propertorqueappliedto the front wheel bear-
ings,the bearingswill no longerbe usable.
*The suspensioncomponentsshouldnot be
tighteneduntil the vehicles weight is resting
on the ground.
1. Removethe batteryand batterytray.
2. Removethe air cleanerassemblyandvacuum
hoses.
3. Notethe locationsand disconnectthe shifter
cables.
4. If equippedwith 1.61 engine,removethe ten-
sion rod.
5. Detachthe backuplampswitchconnector,
speedometercableconnectionand removethe starter
motor.
6. Raisethe vehicleand supportsafely.
7. Removethe front wheelsand the innerwheel
panels.
8. Removethe undercoverand splashpan.
9. Drainthe transaxleoil into a suitablecon-
tainer
10. Supportthe engineand removethe cross-
member.
11. Removethe uppertransaxlemountingbolt
and bracket.
12 Disconnectthe stabilizerbar,tie rod endsand
the lower ball joint connections.
13 Removethe clutch releasecylinderand clutch
oil line bracket.Do not disconnectthe fluid lines and
securethe slavecylinderwith wire.
14 Disconnectthe clutchcable,if equippedwith
cablecontrolledclutchsystem.
15. Removethe halfshaftsby insertinga prybar
betweenthe transaxlecaseand the driveshaftand
pryingthe shaftfrom the transaxle.Do not pull on the
driveshaft Doingso damagesthe inboardjoint. Do
not insertthe prybarso far the oil seal in the caseis
damaged.
*It is not necessaryto disconnectthe half-
shafts from the steering knuckle.Removethe
shaft with the huband knuckleas an assem-
bly. Tie the shafts aside. Notethe circle clip
on the end of the inboardshafts shouldnot
be reused.
16. Removethe bellhousinglowercover.
17 Removethe transaxleto enginebolts and
lowerthe transaxlefrom the vehrcle.
To install:
*When installing the transaxle, be sure to
align the splines of the transaxle with the
clutchdisc.
18 Installthe transaxleto the engineand install
the mountingbolts.Tightenthe bolts to 31-40 ft. Ibs.
(43-55 Nm) on 1990-92 modelsand 35 ft. Ibs. (48
Nm) on 1993-00 models.
19 Installthe bellhousingcover.
*When installing the halfshafts, use new
circlips on the axle ends. Caremustbe taken
to ensurethat the oil seal lip of the transaxle
is not damagedby the serratedpart of the
driveshaft.
20. Installandfully seatthe halfshaftsinto the
transaxle.
21. Installthe slavecylinder.
22. Connectthe ball joints, tie rod endsand the
stabilizerbarconnections.
23. Installthe uppertransaxlemountingbracket
and bolt.
24. Installthe crossmember.
25. Installthe undercover.
26. Installthe uppertransaxle-to-enginemount-
ing bolts,Tightenthe bolts to 31-40 ft. Ibs. (43-55
Nm) on 199C-92 modelsand 35 ff. Ibs. (48 Nm) on
1993-00 models.
27. Installthe startermotor.
28 Connectthe backuplight switchconnector
and speedometercable.
29 Connectand adjustthe shifter cables.
30 Installthe air cleanerassembly.
31. Installthe front wheels.
32 Make surethe vehicle is level whenrefilling
the transaxle UseHypoidgearoil or equivalent,GL-
4 or higher.
33. Connectthe negativebatterycableand check
the transaxlefor properoperation.Makesurethe re-
verse lights operatewhenin reverse.
Galant
1999-93MODELS
rlf the vehicle is goingto be rolled on its
wheels while the halfshaftsare out of the ve-
hicle, obtaintwo outer CV-jointsor proper
equivalenttools and install to the hubs. If the
vehicle is rolled without the propertorque
appliedto the front wheel bearings,the bear-
ings will no longer be usable.
1. Removethe batteryand the air intakehoses.
2. If equippedwith Active-ECS,unplugthe
compressorwiring.
3. Removethe auto-cruiseactuatorand under-
hood bracket,locatedon the passengerside inner
fenderwell.
4. Drainthe transaxleand transfercasefluid, if
equipped,into a suitablewastecontainer.
5. Removethe retainerbolt and pull the
speedometercablefrom the transaxleassembly.
6. Removethe cotterpin securingthe selectand
shift cablesand removethe cableendsfrom the
transaxle.
 DRIVETRAIN7-3
7. Remove theconnection fortheclutchrelease 38. Installthebattery. boltto 54ft. Ibs.(73Nm).Installthefrontengineroll
cylinderandwithoutdisconnecting thehydraulicline, 39. If equippedwithActive-ECS,connect theair stopperthrough-bolt andhand-tighten. Oncethefull
andsecureit aside. compressor. weightof theengineis onthemounts, tightenthe
8. Disconnectthebackuplightswitchharness 40. Makesurethevehicleis levelwhenrefilling boltto 42ft. Ibs.(57Nm).
andpositionaside. thetransaxle.UseHypoidgearoil orequivalent, GL- 30. Installthetriangularstaybracketandtighten
9. Detachthestarterelectricalconnections,
if 4 or higher. themounting boltsto65ft. Ibs.(88Nm).
necessary,removethestartermotorandposition 41. Checkthetransaxle andtransfercasefor 31. Connect theclutchrelease cylinder.
aside. properoperation. Makesurethereverselightscome 32. Installthehalfshafts,usingnewcirclipson
10. Remove thetransaxlemountbracket. onwhenin reverse. theaxleends.
11. Remove theuppertransaxle mountingbolts.
12. Raisethevehicleandsupportsafelyonjack- 1!I94-Ol?MODELS
stands.
13. Remove theundercover andthefrontwheels. 1. Disconnect thenegative batterycableand Whenhistalling the axleshaft, keepthe in-
14. Remove thecotterpinanddisconnect thetie waitatleast90seconds beforeperforming anywork. boardjoint straight in relation to the axle, so
rodendfromthesteeringknuckle. 2. Remove theaircleanerandintakehoses. not to damagethe oil seal lip of the
15. Remove theself-lockingnutfromthehalf- 3. Drainthetransaxle intoa suitablewastecon- transaxle, with the serrated part of the half-
ShaftS. tainer. shaft.
16. Disconnect thelowerarmballjointfromthe 4. Remove thecotterpinsandclipssecuring the
steeringknuckle. selectandshiftcablesandremove thecableends 33. Connect thetierodandballjointstothesteer-
17. Remove thehalfshafts fromthetransaxle. fromthetransaxle. ingknuckle. Tighten theballjointself-locking nutsto
18. OnAWDmodels,disconnect thefrontex- 5. If equipped withActive-ECS, disconnectthe 48ft. Ibs.(65Nm).Tighten thetierodendnutto 21ft.
haustpipe. aircompressor. Ibs.(28Nm)andsecurewitha newcotterpin.
19. OnAWD‘models, remove thetransfercaseby 6. Disconnect thebackuplightswitchharness 34. Connect thedamper forktothelowercontrol
removing theattaching bolts,movingthetransfer andpositionaside. armandtightenthethrough-bolt to65ft. Ibs.(88Nm).
caseto theleftandloweringthefrontside.Remove it 7. Disconnect thespeedometer electricalcon- 35. Connect thestabilizerlinktothedamper fork,
fromthereardriveshaft. Becarefulof theoil seal.Do nectar,fromthetransaxle assembly. andtightentheself-lockingnutto 29ft. Ibs.(39Nm).
notallowthedriveshaft to hang;oncethefrontis re- 8. Remove thestartermotorandpositionaside. 36. Installtheunderpan.
movedfromthetransfer, tie it up.Coverthetransfer 9. UsingspecialtoolM2203827 or equivalent, 37. Installwheelsandlowervehicle.
caseopenings to keepoutdirt. supporttheengineassembly. 38. Installthetransaxle mountbrackettothe
20. Remove thecoverfromthetransaxle bell- 10. Remove therearrollstoppermounting transaxle,andtightenthemounting nutsto 32ft. Ibs.
housing. bracket. (43Nm).
21. OnAWDmodels,removethecrossmember 11. Remove thetransaxle mountbracket. 39. installtherearroll stoppermounting bracket.
andthetriangular gusset. 12. Remove theuppertransaxle mounting bolts. 40. Remove theenginesupport.Tightenthe
22. Remove thetransaxle lowercouplingbolt.It 13. Raiseandsafelysupportthevehicle. transaxlemountthrough-bolt to51ft. Ibs.(69Nm)
is justabovethehalfshaftopeningonFWDor trans- 14. Remove thefrontwheelassemblies. andtightenthefrontenginerollstopperthrough-bolt.
fercaseopeningonAWD. 15. Remove therighthandundercover. 41. Installtheuppertransaxle mounting bolts
23. Supporttheweightof theenginefromabove 16. Remove thecotterpinanddisconnect thetie andtightento 35ft. Ibs.(48Nm).
(chainhoist).Supportthetransaxle usinga transmis- rodend,fromthesteeringknuckle. 42. Installthestartermotor.
sionjackandremovetheremaining lowermounting 17. Disconnect thestabilizerbarlink,fromthe 43. Attachthebackuplightswitchandthe
bolts. damper fork. speedometer connector.
24. Onturbocharged vehicle,becarefulnotto 18. Disconnect thedamper fork,fromthelateral 44. Connect theselectandshiftcablesandinstall
damage thelowerradiatorhosewiththetransaxle lowercontrolarm. newcotterpins.
housingduringremoval. Wraptapeonboththelower 19. Disconnect thelaterlowerarm,andthecom- 45. Installtheaircleanerandtheair intakehose.
hoseandthetransaxle housingto preventdamage. pressionarm,lowerballjoints,fromthesteering 46. Connect thenegative batterycable.
Movethetransaxle assembly to therightandcare- knuckle. 47. Makesurethevehicleis level,andrefillthe
fully lowerit fromthevehicle. 20. Prythehalfshafts fromthetransaxle, andse- transaxle.
To install: cureaside. 48. Checkthetransaxle for properoperation. Make
25. Installthetransaxle to theengineandinstall 21. Remove theconnection fortheclutchrelease surethereverse lightscomeonwheninreverse.
themounting bolts,Tightentheboltsto 35ft. Ibs.(48 cylinderandwithoutdisconnecting thehydraulicline,
Nm).Installthetransaxle lowercouplingbolt. secureaside.
26. Installtheunderpan, crossmember andthe 22. Remove thecoverfromthetransaxle bell-
triangulargusset. housing.
27. InstallthetransfercaseonAWDmodelsand 23. Remove theenginefrontroll stopper REMOVAL&INSTALLATION
connect theexhaustpipe. through-bolt.
28. Installthehalfshafts, usingnewcirclipson 24. Remove thecrossmember andthetriangular ) See Figures 1 thru 13
theaxleends.Tryto keeptheinboardjointstraightin righthandstay.
relationto theaxle.Becarefulnotto damage theoil 25. Supportthetransaxle, usinga transmission
seallip of thetransaxle withtheserrated partof the jack,andremovethetransaxle lowercouplingbolt.
halfshaft. *The couplingbolt threadsfrom the englne
29. Connect thetierodandballjointto thesteer- side, into the transaxle, and is locatedjust
ingknuckle. abovethe halfshaftopening.
30. Installthetransaxle mountbracket.
31. Installwheelsandlowervehicle.Retorque 26. Slidethetransaxle rearward andcarefully
axleshaftnutsto 145-188ft. Ibs.(200-260Nm). lowerit fromthevehicle.
32. Installthestartermotor. To install:
33. Connect thebackuplightswitchandthe 27. Installthetransaxle to theengine.Installthe
speedometer cable. mounting boltsandtightento 35ft. Ibs.(48Nm).In-
34. Installtheclutchreleasecylinder. stallthetransaxle lowercouplingboltandtightento
35. Connect theselectandshiftcablesandinstall 22-25ft. Ibs.(30-34Nm).
newcotterpins. 28. Installthecoverto thetransaxle bellhousing
36. Installtheair intakehose. andtightenthemounting boltsto 7 ft. Ibs.(9 Nm).
37. Installtheauto-cruise actuatorandbracket. 29. Installthecrossmember andtightenthefront
mounting boltsto 65ft. Ibs.(88Nm)andtherear
 .
7-4 DRIVETRAIN

Fig. 2 . . . then loosen the axle nut while

the vehicle is still on the ground

Fig. 5 Remove the lower coil-over shock

lower mounting bolt and nut from the con- Fig. 7 . . /, the lower
lot ball joints from the
trol arm steering knuckle
I

93157po7 93157pcn

Fig. 8 Use a suitable prytool to release the Fig. 9 Remove the inner joint from the Fig. 10 Uslng a suitable punch and ham-
inner CV-joint retaining ring from the transaxle until the spline completely clears mer, gently tap the halfshaft out of the
transaxle by gently prying outward the transaxle steering knuckle . . .

Fig, 11 , , . then slide the halfshaft out of

the knuckle
Fig. 12 Removethe halfshaft from the ve-
hlcle
II
Fig, 13 Always replace the clrcllp on the in-
ner joint before installing the shaft Into the
transaxle

1, Whilethevehicleisstill ontheground,re-
movethecotterpin,andloosentheaxlenut.
2. Raisethevehicleandsupportit safely.
3. If equippedwithABS,removethefrontwheel
speedsensor.
4. If equippedwithActiveElectronic Control
Suspension (Active-ECS),performthefollowing:
a. Loosenthenutthatsecurestheair lineto
theto thetopof thestrutanddiscardtheO-ring.
b. Remove theboltsthatsecuretheactuator
to.thetopof thestrutandremovethecompo-
nent.Disconnect thewiringharness.
5. Disconnect thelowerballjointandthetierod
endfromthesteeringknuckle.
6. Remove theaxlenutandthewasher.
7. If removing theleftsideaxlewithaninner
shaft,remove thecentersupportbearingbracket
boltsandwashers. Then,remove thehalfshaftbyset-
tingupa pullerontheoutsidewheelhubandpush-
ingthehalfshaft fromthefronthub.Taptheshaft
unionatthejointcasewitha plastichammer to re-
movethehalfshaft andinnershaftfromthetransaxle.
8. If removing rightsideaxleshaftswithoutan
innershaft,remove thehalfshaftbysettingupa
pullerontheoutsidewheelhubandpushingthehalf-
shaftfromthefronthub.Afterpressing theouter
shaft,inserta prybarbetween thetransaxlecaseand
thehalfshaft andprytheshaftfromthetransaxle.
*Do not pull on the shaft; doingso damages
the inboardjoint.
To install:
9. Replace thecirclipsontheendsof thehalf-
shafts.
IO. Insertthehalfshaftintothetram&e.Besure
it is fullyseated.
1I. Pullthestrutassembly outandinstallthe
otherendto thehub.
12. Installthecenterbearingbracketboltsand
tightento33ft. Ibs.(45Nm).
13. Installthewasherontheaxleshaftsothe
chamfered edgefacesoutward.Installtheaxlenut, \
butdo nottightenit fullyatthistime.
14. Connect theballjointtothesteeringknuckle.
Torquethenewretaining nutto 43-52ft. Ibs.(68-72
Nm)andsecurewitha newcotterpin.
15. Connect thetie rodendto thesteering
knuckle. Torquetheretainingnutto 21ft. Ibs.(29
Nm)andsecurewitha newcotterpin.
16. If equipped withABS,installthefrontwheel
speedsensor.
17. If equipped withActive-KS,performthefol-
lowing:
a. Installtheair linewitha newO-ring.
b. Installtheactuatorto thetopof thestrut.
Connect thewiringharness.
18. Installthewheelandlowerthevehicleto the
floor.
19. Tightentheaxlenutto 145-188ft. Ibs.
(200-260Nm)andsecurewitha newcotterpin.
CV-JOINTS
OVERHAUL
b See Figures14 thru 27
Thesevehiclesuseseveraldifferenttypesof joints.
Enginesize,transaxle
type,whetherthejointisanin-
boardoroutboard joint,evenwhichsideof thevehi-
DRIVETRAIN7-5
cleis beingserviced couldmakea difference injoint
type.Besureto properlyidentifythejointbeforeat-
tempting jointor bootreplacement.Lookfor identifi-
cationnumbers atthelargeendof thebootsand/or
ontheendof themetalretainerbands.
The3 typesof jointsusedaretheBirfieldJoint,
(B.J.),theTripodJoint(T.J.)andtheDoubleOffset
Joint(D.O.J.).
*Do not disassemblea Birfield joint. Ser-
vice with a new joint or clean andrepackus-
ing a new boot kit.
Thedistance between thelargeandsmallboot
bandsis important andshouldbechecked priorto
andafterbootservice.Thisissothebootwill notbe
installedeithertoolooseortootight,whichcould
causeearlywearandcracking, allowingthegreaseto
getoutandwateranddirtin,leadingto earlyjoint
failure.
*The drfveshaftjoints use special grease;
do not add any greaseotherthan that sup-
plied with the kit.
DoubleOffsetJoint
TheDoubleOffsetJoint(D.O.J.)is biggerthan
otherjointsand,intheseapplications,
is normally
usedasaninboardjoint.
1. Remove thehalfshaftfromthevehicle.
2. Sidecutterplierscanbeusedto cutthemetal
retainingbands.Remove thebootfromthejointouter
race.

TCCS7030 TCCS7031 TCCS7032

Fig. 15 Removingthe outer band from the I I

Fig. 16 Removingthe inner band from the
Fig. 14 Checkthe CV-bootfor wear W-boot 1 1CV-boot

Fig 17 Removingthe CV-bootfrom the joint Fig 18 Clean the CV-joint housing prior to Fig 19 Removingthe CV-joint housingas-
lho~sing IFi7~ / removing boot Tccs7W 1 1sembiy TCCS703

7-6 DRIVETRAIN
fig. 20 Removingthe CV-joint
TCCS7042
1 4. If thebootis bereused, wrapvinyltapearound
Fig. 26 Removing the CV-joint inner
snapring
I 1
3. Locateandremovethelargecirclipatthe ’
baseof thejoint.Remove theouterrace(thebodyof
thejoint).
4. Remove thesmallsnapring andtakeoffthe
innerrace,cageandballsasanassembly. Cleanthe
innerrace,cageandballswithoutdisassembling.
5. If thebootisto bereused.wioethearease
fromthesplinesandwrapthesplfnesin vin$tape
beforeslidingthebootfromtheshaft.
6. Remove theinner(D.O.J.)bootfromthe
shaft.If theouter(B.J.)bootisto bereplaced,
re-
movethebootretainerringsandslidethebootdown
andoff of theshaftatthistime.
To install:
7. Besuretotapetheshaftsplinesbeforein-
stallingtheboots.Filltheinsideof thebootwiththe
Fig. 21 inspectingthe M-joint housing
Fig, 27 installing the CV-joint assembly
(typiW
specifiedgrease.Oftenthegreasesuppliedinthere-
placement partskit is meantto bedividedin half,
withhalfbeingusedto lubricatethejointandhalfbe-
ingusedinsidetheboot.
8. Installthecageontothehalfshaftsothesmall
diameter sideof thecageis installedfirst.Witha
brassdriftpin,taplightlyandenemy ’ arouna ’ me
‘* Inner
’ grease.Oftenthegreasesuppliedinthereplacement
raceto installtheraceuntilit comesintocontactwith
theribof theshaft.Applythespecifiedgreasetothe
innerraceandcageandfit themtogether. Insertthe
ballsintothecage.
9. Installtheouterrace(thebodyof thejoint)
afterfillingwiththespecifiedgrease.Theouterrace
shouldbefilledwiththisgrease.
10. Tightenthebootbandssecurely.Makesure
thedistancebetween \onrlo
theboott,, IuJi.i
IJ*nrro”+
,,“IlGbl.
-
Removing the CV-joint outer
Fig. 25 Removingthe CV-joint assembly
11. Installthehalfshaft
to thevehicle.
ExceptDouble OtfsetJoint
1. Disconnect theneaativebattervcable.Remove
thehalfshaft. - ’
2. Usesidecutteroliersto removethemetalre-
tainingbandsfromtheboot(s)thatwill beremoved.
SlidethebootfromtheT.J.case.
3. Remove thesnapringandthetripodjointspi-
derassembly fromthehalfshaft.Donotdisassemble
thespiderandusecarein handling.
thesplinepartof theshaftsotheboot(s)will notbe
damaged whenremoved. Remove thedynamic
damper,
- if used,andthebootsfromtheshaft.
To install:
5. Doublecheckthatthecorrectreplacement
partsarebeinginstalled. Wrapvinyltapearoundthe
splinesto protectthebootandinstallthebootsand
damper, if used,inthecorrectorder,
6. Installthejointspiderassembly to theshaft
and ipctdl the cnmrinn
7. Filltheinsideofthebootwiththespecified
partskit is meantto bedividedin half,withhalfbeing
usedto lubricate thejointandhalfbeingusedinside
theboot.Keepgreaseofftherubberpartof thedy-
namicdamper(if used).
8. Securethebootbandswiththehalfshaftina
horizontal position.Makesuredistance between boot
bandsis correct.
9. Installthehalfshaft to thevehicleandrecon-
nectthe negative batterycable.
 DRlVETRilN 7-7

bansaxle. Whenthepedalis pushedinward,thedisc

andplateseparate (theclutchis disenqaqed) discon-
nectinotheenoinefromthetransaxie.-.
Mostclutchesutilizea singleplate,dryfriction REMOVAL&INSTALLATION
.* * _ discwitha diaphragm-style springpressure plate.
Theclutch driven disc mav comamasoestos. Theclutchdischasa splinedhubwhichattaches the
which has beendeterminedto be a cancer ’ discto theinputshaft.Thedischasfrictionmaterial Galantand Mirage
causingagent. Neverclean clutchsurfaces whereit contacts theflywheelandpressure plate.
with compressedair! Avoid inhaling any dust b See Figures28 thru 41
Torsionspringsonthedischelpabsorbengine
from any clutchsurface! Whencleaning torquepulses.Thepressure plateappliespressure to
clutchsurfaces,use a commerciallyavail- theclutchdisc,holdingit tightagainstthesurfaceof
able brakecleaningfluid. theflywheel.Theclutchoperating mechanism con-
sistsof a releasebearing, forkandcylinderassembly. The clutchdriven disc may contain asbestos,
Thepurposeof theclutchis to disconnect and Therelease forkandactuating linkagetransfer which has beendeterminedto be a cancer
connectenginepoweratthetram&e.A vehicleat pedalmotiontotherelease bearing.Intheengaged causingagent. Never clean clutchsurfaces
restrequiresa lotof enginetorqueto getall that position(pedalreleased) thediaphragm springholds with compressedair! Avoid inhaling any dust
weightmoving.Aninternalcombustion enginedoes thepressure plateagainsttheclutchdisc,soengine from any clutchsurface! Whencleaning
notdevelopa highstartingtorque(unlikesteamen- torqueistransmitted to theinputshaft.Whenthe clutchsurfaces,use a commerciallyavail-
gines)so it mustbeallowedto operate withoutany clutchpedalis depressed, thereleasebearingpushes able brake cleaningfluid.
loaduntilit buildsupenoughtorqueto movetheve- thediaphragm springcentertowardtheflywheel.The
hicle.Torqueincreases withenginerpm.Theclutch diaphragm springpivotsthefulcrum,relievingthe 1. Disconnect thenegativebatterycable.
allowstheengineto builduptorquebyphysically loadonthepressure plate.Steelspringstrapsriveted 2. Raiseandsafelysupportthevehicle.
disconnecting theenginefromthetransaxle, relieving to theclutchcoverlift thepn--“-- -I-‘^ I--- ‘!-- 3. Remove thetransaxleassemblv fromtheve-
theengineof anyloador resistance. clutchdisc,disengaging theGllyl,loUllVcIIVIIIII1c hicle.Referto theprocedure earlierinthissection.
Thetransferof enginepowerto thetransaxle (the transaxle andenabling thegc”--+,,h,n-‘----’ 4. Remove theoressure elateattachinabolts.
load)mustbesmoothandgradual;if it weren’t,drive Theclutchis operating pryV’uV,J ,,. pressure plateandclutchdisc.If thepressure plateis
linecomponents wouldwearoutor breakquickly. l It will stalltheenginewhenreleased withthe to bereused,loosentheboltsina diagonalpattern1
Thisgradualpowertransferis madepossibleby vehicleheldstationary. or 2 turnsata time.Thiswill preventwarpingthe
graduallyreleasingtheclutchpedal.Theclutchdisc l Theshiftlevercanbemovedfreelybetween 1st clutchcoverassembly.
andpressure platearetheconnecting linkbetween andreversegearswhenthevehicleisstationary and 5. Remove thereturnclipandthepressure plate
theengineandtransaxle. Whentheclutchpedalis theclutchdisengaged. releasebearing.Donotusesolventtocleanthebear-
released,thediscandplatecontacteachother(the ing.
clutchis engaged) ohvsicallvioininatheenaineand 6. lnsoecttheclutchrelease forkandfulcrumfor

TCCS7118

Fig. 28 Loosen and remove the clutch and . . . then carefully removethe clutch
essureplate bolts evenly, a little at a time and pressure plate assembly from the fly
1~~~~~ -1 [it&ouldbeflat - ‘(

1. 7 1 / F@%!,d . then remove the flywhee;;:! 1 1Fig.

pound’to the flywheel
33 Upon bolts it is usually
installation, . Tccs7’z3~
a
Ftg. 31 If necessary, lock the flywheel III the crankshaftm order replace d or have d good Idea to apply a threadlockmg com-
place and remove the retaining bolts . . .
7-8 DRIVETRAIN

/ sive Wear TCCS7126 j / . TCCS7124 1 Fig. 36 Typical clutch alignmenttool, note

Fig 34 Checkthe pressureplate for exces- Fig 38 Be sure that the flywheel surface is how the splines matchthe transaxle’s input
clean, before installing the clutch shaft ,,, 1

TCCS7130

Fig. 38 Use the clutch alignment tool to Fig. 39 Pressure plate-to-flywheel bolt
align the clutch disc during assembly holes should align

nodelsand16ft. Ibs.(22Nm)onall othermodels.

3emove thealigningtool.
. 18. Installthetransaxle
assembly.
19. Checkfor properclutchoperation.
4DJUSTMENTS

PedalFree Play
1. Measuretheclutchpedalheightfromtheface
ofthepedalpadto thefirewall.Thedesireddistances
areasfollows:
a. Mirage--&6148 in. (168-171mm)
b. Galant-6.93-7.17 in. (176182mm)
Fig. 40 You may want to use a threadlock- Fig, 41 Be sure to use a torque wrench to 2. Measuretheclutchpedalclevispinplayatthe
ing compoundon the clutch assemblybolts tighten all bolts aceof thepedalpad.Thestandard valuesareasfol-
DWS:
damageorwear.If necessary,removetherelease fork theendof thereleasecylinderpushrodandthe a. Mirage--0.04--0.12 in.(l-3mm)
andunthread
thefulcrumfromthetransaxle. pushrodholeintherelease fork. b. Galant4.04-0.12in. (l-3mm)
7. Carefullyinspecttheconditionof theclutch 13. Applymulti-purposegreaseto theclutchre- 3. If theclutchpedalheightor clevispinplayare
components
andreplaceanywornor damaged parts. rrotwithinthestandardvalues,adjustasfollows:
leasebearing.Packthebearinginnersurfaceandthe

*When adjustingthe clutchpedal heightor
the clutch pedal clevis pin play, be careful
not to pushthe pushrodtoward the master
cylinder.
d. Checkthat whenthe clutch pedal is de-
pressedall the way, the interlockswitch switches
over from ONto OFF.
ADJUSTMENT
# See Figure 42
*The following adjustmentis for the cable
actuatedclutchsystemon the Mirage. The
Hydraulicsystemson all other modelsare
self-adjusting.
1. Measurethe clutchpedalheight(measurement
A). The specificatronis 6.38-6.50 in.
(162-165mm).
*The clutch pedal height is not adjustable.
If not within specifications,part replacement
is required.
2. Depressclutch pedalseveraltimes and check
the pedalfree-play(measurementB).
3. If measurementis not 0.67-0.87 in.
(17-22mm), adjustmentis required.
4. To adjust,turn the outercableadjustingnut,
locatedat the firewall,until free-playis within range.
5. Depressthe clutch pedalseveraltimes and
recheckthe measurement.
REMOVALANDINSTALLATION
1. Rotatethe adjustingwheelcounterclockwiseto
loosenthe cable.
2. Removethe cableretainingclamps.
3. Removethe cotterpin from the clutchactuat-
ing arm at the transaxleand disconnectthe cable.
4. Disconnectthe cableat the pedaland remove
the cablefrom the vehicle.
rln order to preventcable bindingor abra-
sion, be sure to take note of the cable rout-
ing, so that it can be reinstalled in the same
position.
To install:
5. Routethe cableand makethe connectionat the
clutchpedal.
6. Make the connectionat the transaxleand se-
curethe cablewith the retainingclamp.Installa new
cotterpin.
7. Lubricateall pivot points.
8 Adjust the cableto achieveproperfree-play.
REMOVAL&INSTALLATION I Fig. 43 Bleeding a typical clutch hydraulic
1. Disconnectthe negativebatterycable.
2. Removenecessaryunderhoodcomponentsin
orderto gain accessto the clutchmastercylinder.
Clutch pedal height
7923PGDl
Fig. 42 Clutch pedal height (A) measure-
ment-Mirage
3. Placea suitabledrain pan underthe vehicleto
catchthe fluid oncethe line ISdrsconnected,or place
a rag or shop towel underthe fluid line of the master
cylinder.
4. Loosenthe line at the cylinderand allow the
fluid to drain.
Clean, high quality brakefluid is essentialto
the safe and proper operationof the brake
system.Youshouldalways buythe highest
quality brakefluid that is available. If the
brakefluid becomescontaminated,drain and
flush the system,then refill the mastercylin-
der with new fluid. Never reuseany brake
fluid. Any brakefluid that is removedfrom
the systemshouldbe discarded.Also, do not
allow any brakefluid to comein contactwith
a oaintedsurface; it will damagethe paint.
5. Removethe clevis pin retainerat the clutch
pedaland removethe washerand clevis pm.
6. Removethe 2 nutsand pull the cylinderfrom
the firewall.A sealshould be betweenthe mounting
flangeandfirewall.This sealshouldbe replaced.
7. The installationis the reverseof the removal
procedure.
8. Lubricateall pivot pointswith grease.
9. Bleedthe systemat the slavecylinderusing
DOT3 brakefluid and checkthe adjustmentof the
clutch pedal.
REMOVAL&INSTALLATION
1. Disconnectthe negativebatterycable
2. Removenecessaryunderhoodcomponentsin
orderto gain accessto the clutch releasecylinder.
3. Placea suitabledrain pan underthe vehicle,
then removethe hydraulicline andallow the system
to drain.
Clean, high quality brake fluid is essentialto
the safe and properoperation of the brake
system.Youshouldalways buythe highest
DRIVETRAIN7-9
quality brakefluid that is available. If the
brakefluid becomescontaminated,drain and
flush the system,then refill the mastercylin-
der with new fluid. Never reuseany brake
fluid. Any brakefluid that is removedfrom
the systemshouldbe discarded.Also, do not
allow any brakefluid to come in contactwith
a uaintedsurface; it will damagethe paint.
4. Removethe bolts and pull the cylinderfrom
the transaxlehousing.On some 1.5L engines,in-
steadof a pushrodbearingagainstthe clutcharm, a
clevis pin and yoke is used.Simply removethe cir-
clip, pull out the clevis pin and removethe cylinder.
5. The installationISthe reverseof the removal
procedure.
6. Lubricateall pivot points with grease.
7. Bleedthe systemusing DOT3 brakefluid.
HYDRAULICSYSTEMBLEEDING
) See Figure 43
With Hydraulic Clutch
1, Fill the reservoirwith cleanbrakefluid meeting
DOT3 specificatrons.
Clean, high quality brakefluid is essentialto
the safe and proper operationof the brake
system.Youshouldalways buythe highest
quality brakefluid that is available. If the
brakefluid becomescontaminated,drain and
flush the system,then refill the mastercylin-
der with new fluid. Neverreuse any brake
fluid. Any brakefluid that is removedfrom
the systemshouldbe discarded.Also, do not
allow any brakefluid to comein contactwith
a paintedsurface;it will damagethe paint.
2. Pressthe clutch pedalto the floor, then open
the bleederscrewon the slavecvlinder.
3. Tightenthe bleedscrewand releasethe clutch
pedal.
4. Repeatthe procedureuntil the fluid is free of
air bubbles.
7923PG91
system
7-10 DRIVETRAIN
Theautomatictransaxleallowsenginetorqueand
powerto betransmittedto the front wheelswithin a
narrowrangeof engineoperatingspeeds.It will allow
the engineto turn fastenoughto produceplentyof
powerand torqueat very low speeds,while keepingit
at a sensiblerpm at highvehiclespeeds(and it does
this job withoutdriverassistance).Thetransaxleuses
a light fluid as the mediumfor the transmissionof
power.This fluid also works in ths operationof vari-
ous hydrauliccontrol circuitsand as a lubricant.Be-
causethe transaxlefluid performsall of thesefunc-
tions, troublewithin the unit caneasilytravelfrom one
partto another Forthis reason,and becauseof the
complexityand unusualoperatingprinciplesof the
transaxle,a very soundunderstandingof the basic
principlesof operationwill simplify troubleshooting
REMOVAL&INSTALLATION
Panremoval,fluid and filter changesare covered
in Section1 of this manual
REMOVAL&INSTALLATION
1990-97 Mirage and 1990-93 Galant
# See Figure 44
1. Disconnectthe negativebatterycable.
2. Disconnectthe selectorcablefrom the lever
3. Removethe two retainingscrewsand lift off
the switch.
To install:
4. Mount and position newswitch. Do not tighten
the bolts until the switch is adjusted.
5. Connectselectorcableand adjustswitch.
6. Afterinstallationandadjustmentmakesurethe
engineonly startsin the P andN selections.Also check
thatthe reverselightsoperateonly in the R selectlon.
1994-00 Galantand 1998-00 Mirage
e See Figure 44
93157pm
Fig. 44 Typically, the park/neutral position
switch is located on the top of the transaxle
1. Disconnectthe negativebatterycable.
2. Removethe nut attachingthe shift control ca-
ble from the transaxlemanualshaft lever.Position
the control cableout of the way.
3. Placethe manualshaft lever in the Neutral
position, removethe nut andthe manualshaft lever.
4. Detachthe park/neutralswitchelectricalcon-
nector.
5. Removethe park/neutralswitchmounting
boltsand removethe switchfrom the transaxleman-
ual shaft.
To install:
6. Installthe park/neutralswitch to the transaxle
manualshaftand install the switchmountingbolts
Do not tightenthe mountingbolts unh the switch is
adjusted.
7. Installthe manualshaft leverto the park/neu-
tral switchwith the nut. Makesurethat the shaftlever
is in the Neutralposition.
8. Adjustthe switch in the following manner:
turn the switch body until the hole in the body of the
switchaligns with the hole in the manualshaftlever.
Inserta drill bit or equivalentinto the holes.Tighten
the switch mountingboltsto 8 ft. Ibs. (11 Nm).
9. Attachthe electricalconnector.
10. Installthe control cableto the manualshaft
leverwith the nut.Adjustthe cableso that thereis no
slackin the cableand that the selectorlevermoves
smoothly
11. Reconnectthe negativebatterycable Check
for properstartingand properreverselight operatron.
Diamante
ti See Figure 44
1. Disconnectthe negativebatterycable.
Wait at least 90 secondsafter the negative
batterycable is disconnectedto preventpos-
sible deploymentof the air bag.
2. Disconnectthe selectorcablefrom the lever.
3. Removethe two retainingscrewsand lift off
the switch.
To install:
4. Installthe lever,tightenthe bolts only hand
tight.
5. Rotateswitch body so the manualcontrol lever
0.20 inch (5mm) hole and the switch body0.20 inch
(5mm) holesare aligned.
6. Tightenthe mountingbolts to 7-8 ft. Ibs.
(10-12 Nm).
7. Connectthe selectorcableto the lever.
8. Connectthe negativebatterycable.
9. After installahonand adjustmentmakesurethe
engineonly startsin the P and N selections.Also
checkthat the reverselights operateonly in the Rse-
lection.
ADJUSTMENT
1990-97 Mirage and 1990-93 Galant
1. Disconnectthe negativebatterycableand lo-
catethe neutralsafetyswitchon the top of the
transaxle.
*Apply parkingbrake and chockwheels be-
fore placingtransaxle into the N position
2. At the transmission,loosenthe shift cablead-
justmentnut. Insidethe vehicleplacethe gearshift
selectorleverin N
3. Placethe manualshift control lever in N.
4. Loosenneutralsafetyswitch mounhngscrews
and rotateswitch bodyso the manualcontrol lever
0.20 in. (5mm) holeandthe switch body0.20 in.
(5mm) holesare aligned.
5. Tightenswitch body mountingbolts to 7-8 ft.
Ibs. (lo-12 Nm).
6. At the shift cableadjustingnut, gentlypull ca-
ble to removeany slack.Tightenlocknutto 8 ft. Ibs.
(12 Nm)
7. Verifythat the switch levermovesto positions
correspondingto eachposition of the selectorlever.
Connectthe negativebatteryterminal.
8. Makesurethe engineonly startsin the P and
N positions.Also makesurethe reverselights oper-
ateonly in R selection.
REMOVAL&INSTALLATION
Diamante
) See Figures45, 46, 47, and 48
1. Properlydisarmthe SRSsystem(air bag).
Referto Section6.
2. Raiseand safelysupportthe vehicle.
3. Removethe front wheels.
4. Removethe engineside coverand undercov-
ers.
5. Drainthe transaxleassemblyinto a suitable
container.
6. If equipped,removethe front catalyticcon-
verter.
7. Removethe exhaustpipe, main mufflerand
catalyticconverter.
8. Disconnectthe tie rod end and ball joint from
the steeringknuckle.
9. Unboltthe supportbearingfor the left side
halfshaft.
10. Removethe halfshaftsby insertinga prybar
betweenthe transaxlecaseand the driveshaftand
prying the shaftfrom the transaxle.
11. Removethe air cleanerassemblyandadjoin-
ing ductwork.
12. Detachthe engineharnessconnection.
13. If the vehicle is equippedwith Active Elec-
tronlc ControlledSuspension(Active-ECS),remove
the compressorassemblyfrom the transaxleand sus-
pendwith wire. Do not allow the compressorto hang
from the air hose.
14. If equipped,removethe roll stopperstay
bracket.
15. Disconnectthe speedometercablefrom the
transaxle.
16. Removethe clip that securesthe shifterand
disconnectthe shiftercontrol cablefrom the
transaxle.
17. Disconnectand plug the oil cooler hoses
from the transaxle.
18. Detachthe following:

Fig. 45 location of 4-wheel steering oil
l Park/neutralswitch electricalharness
l Kickdownservoswitch
l Pulsegenerator
l Oil temperaturesensorelectricalharness
l Shift control solenoidvalve harness.
19. Supportthe transaxleand removethe
transaxlemountingbracket.
20. Removethe threeuppertransaxle-to-engine
mountingbolts.
21. Forvehicleswith 4WS,removethe heat
shieldfor the 4WSoil pumpand removethe pump.
Do not allow the pumpto hangfrom the oil hoses.
22. Forvehiclesequippedwith Active-ECS,dis-
connectthe heightsensorrod from the lowercontrol
arm.
23. Removethe bolt that securesthe HeatedOxy-
gen (HOaS)sensorharnessto the right side cross-
member.
24. Removethe starterassembly. ’
25. Removethe mountingbracketsfor accessto
the bell housingcover,
26. Removethe bell housing/oil pancoversas-
sembly.
Removal steps
1. Transaxle control cable connection
2. Transaxle 011cooler hoses connection
3. PNP swrtch connector
4. FvT control solenoid valve connector
5. Input shaft speed sensor connector
6. Output shaft speed sensor connector
7. Vehicle speed sensor connector
6. Spht pin
9. Connection of the tie rod end
10. Drwe shaft nut
:io. 46 Transaxie removal (1 of 2)-Diamante with F4A51transaxie
27. Removethe bolts holdingthe flexplateto the
torqueconverter.
28. Removethe lowertransaxleto enginebolts
and removethe transaxleassembly.
To install:
29. Installthe transaxleassemblyto the engine
block, installthe mountingbolts and tightento 54 ft.
tbs. (75 Nm).
30. Installthe bolts that securethe torquecon-
verterto the driveplate.Tightenthe bolts to 34-38 ft.
Ibs (4653 Nm).
31. Installthe bell housing/oil pancovers.
32. Installthe transaxlestay bracketsthatwere
removedfor accessto the bell housingcover.
33. Installthe starterassemblyand connectthe
wiring.
34. Installthe bolt that securesthe HO& sensor
harnessto the right side crossmemberand tighten
the bolt to 7-9 ft. Ibs.(X-12 Nm).
35. For vehiclesequippedwith Active-ECS,con-
nectthe heightsensorrod from the lowercontrol’
arm. Checkthe heightsensorrod for a length(A) of
10.59-10.63 in. (269-270mm)
36. If removed,installthe 4WSoil pumpand
tightenthe mountingbolts to 17 ft. Ibs. (24 Nm).
37. If removed,installthe 4WSoil pumpheat
shield and tightenthe mountingbolts to 17 ft. Ibs.
(24 Nm).
38. Installthe threeuppertransaxle-to-engine
mountingbolts.Tightenthe mountingbolts to 54 ft.
Ibs. (75 Nm).
*One of the upperbolts has a grounding
strap to secureunderthe bolt.
39. Installand connectthe transaxlemounting
bracket.Tightenthe mountingnut and boltsto 51 ft.
Ibs. (70 Nm).
40. Connectthe shift control solenoidvalve har-
ness
11. Connectton for the lower arm ball
jomt
12. Drwe shaft and inner shaft assembly
(RH) and the drwe shaft (LH)
Caution
Mounting locations marked by l should be
provisionally tightened, and then fully tightened
when the body is supporting the full weight of the
engine.
7923PG84
DRIVETRAIN7-11
41. Connectthe kickdownservo switch,pulse
generatorand oil temperaturesensorelectricalhar-
ness
42. Connectthe park/neutralswitch electrical
harness.
43. Usingnewhoseclamps,install the oil cooler
hosesto the transaxle.
44. Installshifter control cableto the transaxle
and securethe cablewith clip.
45. Connectthe speedometercableto the
transaxle.
46. If removed,install the roll stopperstay
bracketand tightenthe onethroughnut and bolt to
36-43 ft. Ibs.(50-60 Nm).Tightenthe two mounting
bolts to 16 ft. Ibs. (22 Nm).
47. If removed,install the Active-ECScompres-
sor assembly.Tightenthe mountingbolts to 48 inch
Ibs. (5 Nm) and connectthe electricalharness.
48. Attachthe engineharnessconnection.
49. Installthe air cleanerassemblyand adjoining
duct work.
50. Usingnewcirclips, installthe halfshaftsand
seathalfshaftsinto the transaxle.Installthe bolt that
securethe left sidesupportbearingand tightenthe
bolts to 33 ft. Ibs. (45 Nm).
51. Connectthe ball joint and tie rod endto the
steeringknuckle.Usingnewnuts,tightenthe ball
joint castlenutto 43-52 ft. Ibs. (60-72 Nm) and
tightenthe tie rod castlenutto 22 ft. ibs. (30 Nm). in-
stall newcotterpins.
52. Using newgaskets,install the exhaustsys-
tem.
53. If removed,installfront catalyticconverter.
54. Installthe engineundercovers.
55. Connectthe negativebatterycable.
56. Fill the transaxleto the correctlevel.
57. Startthe engineand checkfor leaks.
Gaiant
1999-1993 MODELS
1. Onvehiclesequippedwith auto-cruise,re-
movethe control actuatorand bracket.
2. If equippedwith an active ECS,disconnect
the air compressor.
3. Drainthe transaxlefluid into a suitablecon-
tainer.
4. Removethe air cleanerassembly,intercooler
and air hose,as required.
5. Mark the shift cable.Removethe adjusting
nut and disconnectthe shift cable.
6. Tagand detachthe electricalconnectorsfor
the solenoid,neutralsafetyswitch (inhibitor switch),
the pulsegeneratorkickdownservo switchand oil
temperaturesensor.
7. Disconnectthe speedometercableand oil
cooler lines.
8. Disconnectthe wires to the startermotor and
removethe starter.
9. Removethe uppertransaxleto enginebolts.
10. Supportthe transaxleand removethe
transaxlemountingbracket.
11. Raisethe vehicleand supportsafely.Remove
the sheetmetalunderguard
12. Removethe tie rod endsand the bail joints
from the steeringknuckle.
13. Removethe halfshaftsby insertinga prybar
betweenthe transaxlecaseand the driveshaftand
pryingthe shaftfrom the transaxle.Do not pull on the
driveshaft.Doingso damagesthe inboardjoint. Use

7-12 DRIVETRAIN
\ hibitor switch),the pulsegenerator,kickdownservo
66 Nm
65 ftlbs.
:ig.
the prybar.Do not insertthe prybarso far the oil seal
in the caseis damaged.Tie the halfshaftsaside.
14. On AWDvehicles,disconnectthe exhaust
pipe and removethe transfercase.
15. Removethe lowerbellhousingcover and re-
movethe specialbolts holdingthe flexplateto the
torqueconverter.To remove,turn the enginecrank-
shaftwith a box wrenchand bringthe bolts into a po-
sition appropriatefor removal,oneat a time. After re-
movingthe bolts, pushthe torqueconvertertoward
the transaxleso it doesn’tstayon the engineallowing
oil to pour out the converterhub or causedamageto
the converter,
16. Removethe lowertransaxleto enginebolts
and removethe transaxleassembly.
mantewith a F4A33automatictransaxle
26-33Nm
19 - 24 itlbs.
45 - 52 Nm
69 Nm
51 ftlbs.
52 Nm
36 fl.lbs.
To install:
17. Afterthe torqueconverterhas beenmounted
on the transaxle,installthe transaxleassemblyon the
engine.Tightenthe driveplatebolts to 34-38 ft. Ibs.
(4653 Nm).Tightenthe transaxle-to-enginebolts to
35 ft. Ibs. (48 Nm). Installthe bellhousingcover.
18. OnAWDvehicles,installthe transfercase
andframepieces.Connectthe exhaustpipe using a
newgasket.
19. Replacethe circlips and installthe halfshafts
to the transaxle.
20. Installthe tie rods and ball joint to the steer-
ing arm.
21. Installthe transaxlemountingbracket.
22. install the underguard.
23. Installthe starter.
24. Connectthe speedometercableand oil cooler
lines.
25 Connectthe solenoid,neutralsafetyswitch
(inhibitor switch),the pulsegeneratorkickdown
servoswitchand oil temperaturesensor.
26. Installthe shift control cable.
27. Installthe air hose,intercoolerand air cleaner
assembly.
If equippedwith an active ECS,connectthe
.
30 Refill with DexronII, Mopar ATF Plustype
7176, Mitsubishi PlusATFor equivalent,automatic
transaxlefluid. If vehicleis AWD checkandfill the
transfercase.
31. Startthe engineand allow to idle for 2 min-
utes.Apply parkrngbrakeand move selectorthrough
eachgearposrtion,endingin N. Recheckfluid level
and add if necessary.Fluid level shouldbe between
the marksin the HOTrange.
1994-90 MODELS
1. Disconnectthe negativebatterycable.
2. Removethe air cleanerand intakehoses.
3. Drainthe transaxleinto a suitablewastecon-
tainer.
4. Removethe nut securingthe shifter leverto
the transaxle.Removethe cable retainingclip and re-
movethe cablefrom the transaxle.
5. Removethe shifter cablemountingbracket,
6. Tagand detachthe electricalconnectorsfor
the speedometer,solenoid,neutralsafetyswitch (in-
switch,and the oil temperaturesensor.
7. Tagand disconnectthe oil cooler lines at the
transaxle.
8. Removethe bolt securingthe fluid dipstick
tubeto the transaxle.Removethe dipstrckandtube
from the transaxle.
9. Removethe startermotor and position it
aside.
10. Usingspecialtool MZ203827or equivalent,
supportthe engineassembly.
11. Removethe rear roll stoppermounting
bracket.
12. Removethe transaxlemount bracket.
13. Removethe uppertransaxlemountingbolts.
14. Raiseand safelysupportthe vehicle.
15. Removethe front wheelassemblies.
16. Removethe right handundercover.
17. Removeand discardthe cotterpin, thendis-
connectthe tie rod endfrom the steeringknuckle,
18. Disconnectthe stabilizerbar link from the
damperfork.
19. Disconnectthe damperfork from the lateral
lowercontrol arm.
20. Disconnectthe laterallowerarm,and the
compressionarm lowerball joints from the steering
knuckle.
21. Prythe halfshaftsfrom the transaxle,and se-
cure aside.
22. Removethe cover from the transaxlebell-
housing.
23. Removethe enginefront roll stopper
through-bolt.
24. Removethe crossmemberand the triangular
right handstay.
25. Removethe bolts holdingthe flexplateto the
torqueconverterwith a box wrench Rotatethe engine
to bringthe bolts into a position appropriatefor re-
moval,one at a time. After removingthe bolts, push
the torqueconvertertowardthe transaxle.This will
preventthe converterfrom remainingintactwith the
engine,possiblydamagingthe converter,
26. Supportthe transaxle,using a transmission
jack, and removethe transaxlelowercoupling bolt.
*The couplingbolt threadsfrom the engine
side, into the transaxle, and is locatedjust
abovethe halfshafl opening.

27. Shdethe transaxlerearwardand carefully
lowerit from the vehicle.
To install:
28. Afterthe torqueconverterhasbeenmounted
on the transaxle,install the transaxleassemblyto the
engine.Installthe mountingboltsand tightento 35
ft. Ibs.(48 Nm).
29. Installthe transaxlelowercoupling bolt and
tightento 21-25 ft Ibs. (29-34 Nm).
30. Connectthe torqueconverterto the flexplate
and tightenthe boltsto 33-38 ft. Ibs. (45-52 Nm).
31. Install the cover to the transaxlebellhous-
ing and tighten the mounting bolts to 7 ft. Ibs. (9
Nm).
32 Installthe crossmemberand tightenthe front
mountingbolts to 65 ft. Ibs (88 Nm) and the rear
bolt to 54 ft. Ibs. (73 Nm) Installthe front engineroll
stopperthrough-boltand lightlytighten.Oncethe full
weightof the engineis on the mounts,tightenthe ’
bolt to 42 ft. Ibs. (57 Nm),
33. Installthe triangularstaybracketand tighten
the mountingboltsto 65 ft. Ibs.(88 Nm).
34. Installthe halfshafts,using newcirclips on
the axleends.
Wheninstalling the axleshaft, keepthe in-
boardjoint straight in relation to the axle, so
as not to damagethe oil seal lip of the
transaxle with the serratedpart of the half-
shaft.
35. Connectthe tie rod and ball joints to the
steeringknuckle.Tightenthe ball joint self-locking
nutsto 48 ft. Ibs.(65 Nm).Tightenthe tie rod end nut
to 21 ft. Ibs. (28 Nm) and securewith a newcotter
pin.
36. Connectthe damperfork to the lowercontrol
arm and tightenthe through-boltto 65 ft Ibs. (88
Nm).
37. Connectthe stabilizerlink to the damperfork,
andtightenthe self-lockingnut to 29 ft. Ibs. (39 Nm).
38. Installthe undercover.
39. Installthe wheelsand carefullylowerthe ve-
hicle
40. Installthe transaxlemountbracketto the
transaxle,andtightenthe mountingnutsto 32 ft. Ibs.
(43 Nm).
41. Installthe rear roll stoppermountingbracket.
42. Removethe enginesupport.Tightenthe
transaxlemountthrough-boltto 51 ft. Ibs. (69 Nm)
and tightenthe front engineroll stopperthrough-bolt.
43. Installthe uppertransaxlemountingbolts
and tightento 35 fl. Ibs. (48 Nm).
44. Installthe startermotor.
45. Installthe dipsticktubeand the dipstick
46. Installthe shifter cablemountingbracket.
47. Connectthe shifter leverand tightenthe re-
taining nut to 14 ft. Ibs.(19 Nm).
48. Connectthe oil cooler lines and securewith
clamps.
49. Attachthe electricalconnectorsfor the
speedometer,solenoid,neutralsafetyswitch (in-,
hibitor switch),the pulse generator,kickdownservo
switchand oil temperaturesensor.
50. Installthe air cleanerand the air intakehose.
51. Connectthe negativebatterycable.
52. Makesurethe vehicle is level,and refill the
transaxle.Startthe engineand allowto idle for 2
minutes.Apply parkingbrakeand moveselector
througheachgearposition,endingin N. Recheck
fluid levelandadd if necessary.Fluid levelshould be
betweenthe marksin the HOTrange.
53. Checkthe transaxlefor properoperation.
Make surethe reverselights come on whenin re-
verseandthe enginestartsonly in P or N.
Mirage
*If the vehicle is goingto be rolled on its
wheels while the halfshaftsare out of the ve-
hicle, obtaintwo outer CV-jointsor proper
equivalenttools and install to the hubs.If the
vehicle is rolled without the propertorque
applied to the front wheel bearings,the bear-
ings will no longer be usable.
1. Disconnectthe negativebatterycablethen
the positive batterycable.
2. Removethe batteryand batterytray.
3. Removethe air hoseand air cleanerassem-
bly.
4. Raisethe vehicleand supportsafely.
5. Removethe underguardpan.
6. Drainthe transaxleoil into a suitablecon-
tainer.
7. If equippedwith 1.6L engine,removethe ten-
sion rod.
8. Disconnectthe control cableand cooler
lines.
9. On3-speedtransaxles,disconnectthe throt-
tle control cable.
10. On4-speedtransaxles,performthe following:
a. Detachthe shift control solenoidvalve
connector.
b. Disconnectthe inhibitor switch and kick-
down servo switch.
c. Disconnectthe pulse generatorand oil
temperaturesensor.
11. Disconnectthe speedometercableand re-
movethe starter.
12. Removethe transaxlemountingbolts and
bracket.
13. Disconnectthe stabilizerbarfrom the lower
control arm.
14. Disconnectthe steeringtie rod endand the
ball joint from the steeringarm.
15. Removethe halfshaftsat the inboardside
from the transaxle.Tie the joint assemblyaside.
*It is not necessaryto disconnectthe half-
shaftsfrom the wheel hubs.
16. Supportthe engineand removethe center
member.
17. Removethe bellhousingcoverand remove
the driveplatebolts.
18 Removethe transaxleassemblylowercon-
nectingbolt, locatedjust over the halfshaftopening.
19. Properlysupportthe transaxleassembly,then
lower it, moving it to the right for clearance.
To install:
20. Afterthe torqueconverterhasbeenmounted
on the transaxle,installthe transaxleassemblyon the
engine.Installthe mountingbolts and tightento
31-40 ft. Ibs. (43-55 Nm) on 1990-92 modelsand
35 ft. Ibs.(48 Nm) on 1993-00 models.
21. Tightenthe driveplateboltsto 33-38 ft. Ibs.
(46-53 Nm). Installthe bellhousingcover.
22. Installthe centermember.
DRIVETRAIN7-13
23. Replacethe circlips and installthe halfshafts
to the transaxle.
24. Installthe tie rods, ball joints and stabilizer
links to the steeringarm
25. Installthe transaxlemountingbracketand
bolts.
26. Installthe starter.
27. Connectthe speedometercable.
28. Connectthe inhibitor switch,kickdownservo
switch,the pulsegeneratorand oil temperaturesen-
sor, if disconnected.
29. Connectthe shift control solenoidvalve con-
nector.
30. Connectthe control cablesand oil cooler
lines.
31. Installthe tensionrod, if removed.
32. Installthe air cleanerassembly.
33. Installthe batterytray and battery.
34. Connectthe positivethenthe negativetermi-
nal.
35. Refillwith Dexron@II, Mopar ATF Plustype
7176 or equivalent,automatictransaxlefluid.
36. Startthe engineandallow to idle for two min-
utes.Apply parkingbrakeand move selectorthrough
eachgearposition,ending in N. Recheckfluid level
and add if necessary.Fluid levelshouldbe between
the marksin the HOTrange.
ADJUSTMENTS
Shifter Control CableAdjustment
1. Theshifter cableadjustmentis doneat the
neutralsafetyswitch (inhibitor switch).Locatethe
switchon the transaxleand notethe alignmentholes
in the arm andthe bodyof the switch. Placethe se-
lectorlever in N. Placethe manualleverof the
transaxlein the neutralposition.
2. Checkalignmentof the hole in the manual
control leverto the hole in the inhibitor switchbody.
If the holes do not align, adjustmentis required.
3. To adjust, loosenthe nut on the cableend and
pull the cableend by handuntil the alignmentholes
match.Tightenthe nut. Checkthat the transaxle
shifts and conformsto the positions of the selector
lever.
Throttle Valve Cable
Thethrottlevalve adjustmentappliesonly to the
1990-96 Mirage.
1. Placeselectorleverand manualcontrol lever
in N position.
2. Loosenadjustingnut.While lightly pulling on
control cabletightenmountingnut to 7-10 ft. Ibs.
(X-14 Nm).
3. Whenadjustmentis complete,besureselector
lever is still in the N position.Verify all functions
correspondto the position indicatedon the selector
lever.
The halfshaftremovaland installationand over-
haulare the sameas a manualtransaxle Pleaserefer
to ManualTransaxlein this Section
7-14 DRIVETRAIN
Theonly modelcoveredby this manualequipped
with a transfercaseis the 1990-93 AWD Galant.
REMOVAL&INSTALLATION
# See Figures49 and 50
1. Raiseand supportthe vehiclesafely.
2. Removethe propellershaftfrom the transfer
a9577g50
1Fig. 49 Explodedview of the transfer case
1extension housingand related components
Theonly modelcoveredby this manualequipped
with a driveshaftis the 1990-93 AWDGalant.
REMOVAL&INSTALLATION
) See Figures 51 and 52
1. Disconnectthe negativebatterycable.Raise
the vehicleand supportsafely.
2. The reardriveshaftis a 3-pieceunit, with a
front, centerand rearpropellershaft.Removethe
nutsand msulatorsfrom the centersupportbearing.
Work carefully.Therewill bea numberof spacers
which will differ from vehicleto vehicle.Checkthe
numberof spacersand write downtheir locationsfor
referenceduring reassembly.
3. Matchmarkthe reardifferentialcompanion
flangeand the rear driveshaftflangeyoke.Remove
the companionshaftbolts and removethe driveshaft,
keepingit as straightas possibleso as to ensurethat
the boot is not damagedor pinched.Usecareto keep
from damagingthe oil seal in the outputhousingof
the transfercase.
*Damage to the boot can be avoidedand
work will be easier if a piece of cloth or simi-
lar material is inserted in the boot.
4. Do not lowerthe rearof the vehicleor oil will
flow from the transfercase.Coverthe openingto
keepdirt out.
To install:
5. Positionthe driveshaftin the vehicle,making
sureto align the matchmarksat the rearyoke.
6. Installthe bolts at the reardifferentialflange
and tightento 22-25 ft. Ibs. (30-35 Nm).
assembly.Placea drain pan underthe rearof the
transferassemblyto catchany fluid that leaksout.
3. Usinqa flat-bladedpryingtool, carefullyre-
movethe ofi sealfrom the transferdustsealguard
To install:
4. Using propersizesealdriver tool, installthe
seal into the dustseal quardand the transferassem-
blv.
‘5. Installthe rearpropellershaft.
6. Carefullylowerthe vehicleand inspectthe
transferassemblyfluid level.
a9577g51
Fig. 50 Install the oil seal using the proper
sized driver and a hammer
7. Installthe centersupportbearingwith all spac-
ers in place.Tightenthe retainingnutsto 22-25 ft.
Ibs. (3C-35 Nm).
8. Checkthe fluid levelsin the transfercaseand
reardifferentialcase.
U-JOINTREPLACEMENT
1. Make matingmarkson the yokeandthe uni-
versa1joint that is to be disassembled.Removethe
snapringsfrom the yokewith snapringpliers.
Fiu. 51 Explodedview of the proueller shafl mounting
REMOVAL&INSTALLATION
1. Disconnectthe batterynegativecable.
2. Raisethe vehicleand supportsafely.Drainthe
transferoil.
3. Disconnectthe front exhaustpipe.
4. Unboltthe transfercaseassemblyand remove
by sliding it off the reardriveshaft.Becarefulnot to
damagethe oil seal in the transfercaseoutputhous-
ing. Do not let the reardriveshafthang;suspendit
from a framepiece.Coverthe openingin the
transaxleandtransfercaseto keepoil from dripping
and to keepdirt out.
5. Lubricatethe driveshaftsleeveyokeand oil
seal lipan the transferextensionhousing.Installthe
transfercaseassemblyto the transaxle.Usecare
when installingthe reardriveshaftto the transfercase
outputshaft.
6. Tightenthe transfercaseto transaxlebolts to
40-43 ft. Ibs. (55-60 Nm)with manualtransaxle;
43-58 ft. Ibs. (60-80 Nm) with automatictransaxle.
7. Installthe exhaustpipe usinga newgasket.In-
stall removedbumpercomponents.
8. Refill the transfercaseand checkoil levelsin
transaxleand transfercase.
2 Forceout the bearingjournalsfrom the yoke
using a largeC-clamp.Installa collar on the fixed
side of the C-clamp.Pressthe journal bearinginto
the collar by applyingpressurewith the C-clamp,on
the oppositeside.
3. Pull the journal bearingfrom the yoke.
rlf the journal bearingis hard to remove,
strike the yoke with a plastic hammer.
4. Pressthe journalshaft using C-clampor simi-
lar tool, to removethe remainingbearings.

MATING MARKS
/
89577Q5E
Fig. 52 Apply mating marks on the flange
yoke and differential companion flange
5. Onceall bearingsare removed,removethe
journal.
To install:
6. Apply multi-purposegreaseto the shafts,
greasesumps,dustseal lips and needleroller bear-
ings of the replacementU-joint Do not applyexces-
sive grease Otherwse,faultyfitting of bearingcaps
and errors in selectionof snapringsmay result.
7. Pressfit the journal bearingsto the yoke using
a C-clampas follows:
a. Install a solid baseonto the bottomof the
C-clamp.
b. Insertboth bearingsinto the yoke. Hold
and pressfit them by tighteningthe C-clamp.
c. Install snapringsof the samethickness
onto both sides of eachyoke.
d. Pressthe bearingand journal into one
The only modelcoveredby this manualequipped
with a rearaxle differentialis the 1990-93 AWD
Galant.
REMOVAL&INSTALLATION
# See Figures 53 and 54
1. Disconnectthe negativebatterycable.Raise
the vehicleand supportsafely.
2. Removethe bolts that attachthe rearhalfshaft
to the comoanionflanae.
3. Use’aprybartopry the inner shaftout of the
89577g5
IFig. 53 Rear driveshaft mounting
side, using a brassbar with diameterof 0.59 in.
(15mm).
8. Measurethe clearancebetweenthe snapring
andthe groovewall of the yokewith a feelergauge.If
the clearanceexceeds0.0008-0.0024 in.
(0.02-O.O6mm),the snap rings should be replaced.
DRIVESHAFTBALANCING
Driveshaftbalancingis a processbest leftfor a
professionalwrththe properequipment.Makeshift
methodsusing hoseclampsor similar devicescan
work, but the processof correctingthe imbalancein
this manneris very toughand extremelytime con-
suming.
Many machineshopscan balancedriveshafts;
some partsstoresandjobberscan also balancedri-
veshaftsusing outsidecontractors.
REMOVAL&INSTALLATION
1. Placematmgmarkson the companronflange
and the Lobrojoint assembly
2. Removethe Lobrojoint installationbolts.
Separatethe Lobrojoint from the companionflange.
3. Placematingmarkson the centeryoke and
centerpropellershaft,and the companionflangeand
the rear propellershaft.
4. Removethe self-lockingnuts.Removethe
centeryokeand companionflange.
differentialcase.Don’tinsertthe prybartoo far or the
sealcould be damaged.
4 Removethe reardriveshaftfrom the vehicle.
5. If necessary,carefullypry the oil sealfrom the
rear differentialusing a flat tipped pryingtool.
To install:
6. Installa newoil seal into the reardifferential
housing usingproper sizedriver.
7. Replacethe circlip and installthe reardrive-
shaftto the differentialcase.Makesure it snapsin
place.
8. Installthe companionflangebolts and tighten
to 40-47 ft. Ibs.(55-65 Nm).
9. Checkthe fluid levelin the rear differential.
69577958
Fig. 54 Remove the driveshaft from the dif-
ferential carrier with a prybar
DRIVETRAiN7-15
5. Placematingmarkson the centerbearingas-
semblyfront bracketand the centerpropellershaft,
and the centerbearingassemblyrearbracketand the
rearpropellershaft.Removethe centerbearing
bracket.
*The mounting rubber can not be removed
from the center bearing bracket.
6. Pull out the front and rearcenterbearings
with a commerciallyavailablepuller
To install:
7. Apply multi-purposegreaseto the center
bearingfront and reargreasegroovesand to the dust
seal lip Be sureto fit the bearinginto the rubber
mount grooveon the centerbearingbracket.
*Face the bearing dust seal to the side of
the center bearing bracket mating mark.
8. Assemblethe centerbearingto the center
propellershaftand rearpropellershaft.Facethe side
onto which the centerbearingbracketmatingmarks
IS placedand the dust seal is installedtowardthe
side of the centerpropellershaftand rearpropeller
shaft.
9 Apply a thin and evencoatof the grease,en-
closedwith the repairkit, to the rubberpackingon
the companionflange.Align the matingmarkson the
centerpropellershaftand the companionflange,then
pressfit the centerbearingwith self-lockingnuts.
10 Installthe Lobrojoint assemblyinstallation
bolts. Securethe companronflangeand Lobrojoint
assemblywith the installationbolts Checkfor grease
leakagefrom the Lobrojoint boot and companion
flangeinstallabonparts.
REMOVAL&INSTALLATION
1. Disconnectthe negativebatterycable.
2. Raiseand supportthe vehiclesafely.
3 Removethe tire andwheelassemblyfrom the
vehicle.
4 If equippedwith ABS,removethe rearwheel
speedsensor.
*Be cautious to ensure that the tip of the
pole piece on the rear speed sensor does not
come in contact with other parts during re-
moval. Sensor damage could occur.
5. Removethe rearcaliperand supportassem-
bly out of the way. Removethe brakedisc.
6. Removethe driveshaftand companionflange
installationbolts, nuts and washers.Move the end of
shaftslightlyto accessthe self-lockingnut.
7. Usingaxle holding tool MBSbll-01 or
equivalent,securethe rearaxle shaft in position,then
removethe self-locking nut.
8. Usingpuller and adapterMBSbll-01 and
MB9b41-01or equivalents,removethe rearaxle
shaftfrom the trailing arm
9. If equippedwith ABS,removethe rearrotor
from the axleassemblyusing collar and press.The
rotor is a pressfit.
10 Removethe outerbearingand dust cover
concurrentlyfrom the axle shaft using a press.
 .
7-16 DRIVETRAIN
11. Using puller,removethe oil sealand inner 18. Whileholdingthe rearaxleshaftin positron
bearingfrom the trailing arm. usingholdingfixturetool MB9g67-01or equivalent,
12. Inspectthe companionflangeand axle shaft tightena newself-lockingnutto 159 ft. Ibs.(220 Nm).
for wearor damage.Inspectthe dust cover for defor- 19. Installthe drive shaftnuts,washersand bolts. REMOVAL&INSTALLATION
mationor damage.Inspectthe bearingsfor burning Tightento 40-47 ft. Ibs.(55-65 Nm).
or declaration.Replacecomponentsas required 20. Installthe rear brakedisc, caliperassembly 1. Raisethe vehicleand supportsafely.
To install: and parkingbrake. 2. Drainthe differentialgearoil and removethe
13. Usingthe properdriver, pressfit the inner 21. Installthe tire and wheelassemblyand lower centerexhaustpipe.
bearingonto the trailing arm. Pressfit the oil seal the vehrcle.Checkthe parkingbrakestrokeand ad- 3. Matchmarkand removethe reardriveshaft.
onto the trailing arm with the depressionin the oil just as required. 4. Removethe rearhalfshafts.
sealfacing upward,and until it contactsthe shoulder 22. Beforemovingthe vehicle,pumpthe brakes 5. Removethe centerexhaustpipe and muffler
on the innerarm. until a firm pedalis achieved. assembly,as required.
6. Removeor disconnectthe 4 wheelsteering
*When tappingthe oil seal in, use a plastic
hammerto lightly tap the top and circumfer- oil pump.
7. The largemountingbolts that hold the differ-
ence of the seal installation tool, pressfitting
gradually and evenly. ential carriersupportplateto the underbodymayuse
REMOVAL&INSTALLATION self-lockingnuts.Beforeremovingthem, supportthe
14. Pressfit the dust coversonto the axle until it rearaxle assemblyin the middlewith a transaxle
contactsthe axle shaftshoulder.Installthe innermost 1. Raisethe vehicleand supportsafely. jack. Removethe nuts,then removethe support
. UDWard.
cover so the deDressionis facino , 2. Matchmarkthe driveshaftand comoanion plate(s)and the squaredynamicdamperfrom the rear
flangeand removethe shaft.Don’t let it hangfrom the of the carrier.
*When tappingthe oil seal in, use a plastic transaxle.Tie It up to the underbody. 8 Lowerthe differentialcarrierand removefrom
hammerto lightly tap the top and circumfer- 3. Hold the companionflangestationaryand re- the vehicle.
ence of the seal installation tool, pressfitting movethe largeself-lockingnut in the centerof the To install:
graduallyand evenly. comoanionflanoe. 9. Raisethe reardifferentialcarrier into position
15. Apply multi-purposegreasearoundthe entire 4: Usinga Gller, removethe flange.Prythe old and install supportmemberbolts. Installnewlock-
circumferenceof the Innerside of the outer bearing sealout. nutson all supportbolts.
seal lip. Pressfit the outerbearingto the axle shaftso To install: 10. Installthe 4 wheelsteeringoil pump.
that the bearrngseal lip surfaceis facingtowardsthe 5. Applya thin coatof multi-purposegreaseto the 11. Install newcirclips on both reardriveshafts
axle shaftflange. seallip andthe companionflangesealcontactingsur- and install.
16. Pressfit the rearrotor to the axle shaftwith face.Installthe newsealwith an appropriatedriver. 12. Installthe propellershaft.
the rear rotor groovesurfacetowardsthe axle shaft 6. Installthe companionflange.Installa newlock- 13. Installthe centerexhaustpipe and muffler.
flange. nutandtorqueto 116-159 fl Ibs.(157-220 Nm).The 14. Lowerthe vehicle.
17. Installthe rearaxle shaftto the trailing arm rotationtorqueof the drive pinionshouldbeabout4 15. With the vehiclelevel,fill the reardifferential.
temporarily.Installthe companionflangeto the rear inch Ibs.for newor reused,oiled bearings
axle shaft,then install a newself-lockingnut. 7. Installthe driveshaft.
TORQUESPECIFICATIONS
Components English Metric
Automatic Vansaxle-toengme mountrng bolts
Diamante models 54ft Ibs. 75 Nm
1990-92 Mrrage 3140ft Ibs. 43-55 Nm
199390 Mrrage 35ft Ibs. 48 Nm
1990-93 Galant 32-39 ft Ibs. 43-55 Nm
199400 Galant 35ft Ibs. 48 Nm
Axle hub nuts 145-188 ft tbs 200-260 Nm
Back-up lamp swatch 22-25 ft Ibs. 30-35 Nm
Clutch release fork fulcrum 25ft Ibs 35 Nm
Driveshaft-to-rear drfferentral flange bolts 22-25 fl lb?.. 30-35 Nm
Driveshaft center bearrng support bracket mountrng nuts 22-25 fl. Ibs. 30-35 Nm
Halfshaft center bearing support bracket 33ft Ibs. 45 Nm
Manual transaxle-toengrne mountrng bolts
1990-92 Mtrage 3140 ft. Ibs. 43-55 Nm
1993-00 Mrrage 35 ft. Ibs. 48 Nm
1990-93 Galant 32-39 fl Ibs. 43-55 Nm
199400 Galant 35ft Ibs. 48 Nm
Manual transaxle lower coupling bolt 22-25ft Ibs 30-35 Nm
Manual transaxle mount retaining nuts 32ft Ibs. 40 Nm
Manual transaxle mount through-bolt 51 R Ibs. 69 Nm
Park/neutral safety swatchretainrng bolts
1990-97 Mrrage and 1990-93 Galant 76 ft. Ibs IO-12 Nm
1994-00 Galant and 199600 Mirage afl Ibs 11 Nm
Dramante models 78 fl. Ibs IO-12 Nm
Pinion nut 116-159fl lb?.. 157-220 Nm
Pressure plate-to-flywheel bolts
1994-98 Galant / 14ft Ibs. 19 Nm
All other models 16ft Ibs. 22 Nm
Rear halfshaft-tocompanron flange bolts 4047ft Ibs. 5565 Nm
Stub axle shaft hub nut 159n Ibs. 220 Nm
Throttle valve cable mounting nut 7-10 ft. Ibs. lo-14 Nm
Torque converter-todnveplate bolts 34-38 n. ibs 46-53 Nm
Transfer case-to-transaxle mounttng bolts
Manual transaxle 4043n Ibs. 5560 Nm
Automatic transaxle 43-58 ft. Ibs. 60-80 Nm
93157co1