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T350 Manual Transaxle: Installation

Fig 1: Modular Clutch Assembly-Typical
GC0019829Courtesy of DAIMLERCHRYSLER CORP.
1 - MODULAR CLUTCH ASSEMBLY
2 - CLIP
3 - TRANSAXLE
4 - CLUTCH TO DRIVE PLATE BOLTS (4)
  1. Install clutch module (1) (if equipped) onto input shaft. Install transaxle into position. See Fig 1.
  2. Install transaxle-to-engine mounting bolts and tighten to 108 N.m (80 ft. lbs.) torque.
    Fig 2: Left Mount & Bolt
    GC0021169Courtesy of DAIMLERCHRYSLER CORP.
    1 - BOLT
    2 - TRANSAXLE
    3 - LEFT MOUNT
  3. Raise engine and transaxle (2) with screw jack until upper mount bracket aligns with upper mount. Install mount bolts (1) and tighten to 68 N.m (50 ft. lbs.) torque. See Fig 2.
  4. Remove screwjack.
    Fig 3: Modular Clutch Assembly-Typical
    GC0019829Courtesy of DAIMLERCHRYSLER CORP.
    1 - MODULAR CLUTCH ASSEMBLY
    2 - CLIP
    3 - TRANSAXLE
    4 - CLUTCH TO DRIVE PLATE BOLTS (4)
  5. Install four (4) modular clutch-to-driveplate bolts (4). See Fig 3. Align drive plate and modular clutch alignment marks placed upon disassembly. Start with tight-tolerance (slotted) hole, install and torque bolts to 88 N.m (65 ft. lbs.) torque.
  6. Install starter motor and tighten bolts (4) to 54 N.m (40 ft. lbs.) torque. Make sure to fasten ground cable to upper starter bolt (Refer to ELECTRICAL/STARTING/STARTER MOTOR - INSTALLATION) .
  7. Connect starter electrical harness and tighten positive cable nut to 10 N.m (90 in. lbs.) torque.
  8. Install bellhousing dust cover.
    Fig 4: Left Lateral Bending Brace and Structural Collar-Typical
    GC0022227Courtesy of DAIMLERCHRYSLER CORP.
    1 - CLUTCH SLAVE CYLINDER 5 - COLLAR TO ENGINE BOLT
    2 - TRANSAXLE 6 - POWER STEERING HOSE
    3 - LATERAL BENDING BRACE 7 - COLLAR
    4 - STRUT TO TRANSMISSION BOLT 8 - COLLAR TO TRANSMISSION BOLTS
  9. Install left engine-to-transaxle bending brace (3) and structural collar (7). Refer to appropriate Engine Service Information for proper tightening procedure. See Fig 4.
  10. Install power steering hose (6) to structural collar (7).
  11. Install the right lateral bending brace (3) and tighten bolts to 81 N.m (60 ft. lbs.) torque.
    Fig 5: Clutch Slave Cylinder At Transaxle - 2.0L & 2.4L
    GC0019810Courtesy of DAIMLERCHRYSLER CORP.
    1 - SLAVE CYLINDER
    2 - BRACKET
  12. Install bolts to hold slave cylinder (1) to transaxle, 2.4L
    Fig 6: Clutch Slave Cylinder At Transaxle - 1.6L Models
    GC0019809Courtesy of DAIMLERCHRYSLER CORP.
    1 - SLAVE CYLINDER
    2 - BOLT
  13. Install bolts to hold slave cylinder (1) to transaxle, 1.6L
  14. Install both front axle driveshafts. (Refer to DIFFERENTIAL & DRIVELINE/HALF SHAFT - INSTALLATION) .
  15. Fill transaxle with suitable amount of fluid.
  16. Connect clutch master cylinder tube to the hydraulic clutch slave cylinder (1). See Fig 6. See Fig 5. An audible click should be heard. Verify connection by pushing and pulling quick connect.
  17. Lower vehicle.
    Fig 7: Speed Sensor And Pinion Removal/Installation
    GC0020066Courtesy of DAIMLERCHRYSLER CORP.
    1 - CONNECTOR
    2 - SENSOR
    3 - O-RING
    4 - SPEEDO PINION
  18. Connect vehicle speed sensor connector (1). See Fig 7.
    Fig 8: Shift Cables at Transaxle
    GC0020065Courtesy of DAIMLERCHRYSLER CORP.
    1 - SHIFT CABLES
    2 - CLIPS
    3 - BRACKET
  19. Connect shift crossover and selector cables (1) to shift lever. Install cables to bracket and install retaining clips (2). See Fig 8.
    Fig 9: Back-Up Lamp Switch & Connector
    GC0019939Courtesy of DAIMLERCHRYSLER CORP.
    1 - CONNECTOR
    2 - BACK UP LAMP SWITCH
  20. Connect back-up lamp switch connector (1). See Fig 9.
    Fig 10: Battery Tray Removal/Installation
    GC0021163Courtesy of DAIMLERCHRYSLER CORP.
    1 - BATTERY TRAY
  21. Install battery tray (1). See Fig 10.
    Fig 11: Battery Removal/Installation
    GC0021162Courtesy of DAIMLERCHRYSLER CORP.
    1 - BATTERY
  22. Install battery (1) and tighten hold down clamp to secure battery. See Fig 11.
    Fig 12: Air Cleaner Assembly Removal/Installation
    GC0022226Courtesy of DAIMLERCHRYSLER CORP.
    1 - AIR CLEANER ASSEMBLY
  23. Install the air cleaner assembly (1). See Fig 12.
  24. Connect the battery cables.
  25. Road test vehicle and inspect for leaks.
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