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T350 Manual Transaxle: Removal

Fig 1: Air Cleaner Assembly Removal/Installation
GC0022226Courtesy of DAIMLERCHRYSLER CORP.
1 - AIR CLEANER ASSEMBLY
  1. Raise hood.
  2. Remove air cleaner assembly (1). See Fig 1.
    Fig 2: Battery Removal/Installation
    GC0021162Courtesy of DAIMLERCHRYSLER CORP.
    1 - BATTERY
  3. Disconnect both battery cables.
  4. Remove battery hold down clamp and bolt, and remove battery (1). See Fig 2.
    Fig 3: Battery Tray Removal/Installation
    GC0021163Courtesy of DAIMLERCHRYSLER CORP.
    1 - BATTERY TRAY
  5. Remove battery tray (1) from bracket. See Fig 3.
    Fig 4: Back-Up Lamp Switch & Connector
    GC0019939Courtesy of DAIMLERCHRYSLER CORP.
    1 - CONNECTOR
    2 - BACK UP LAMP SWITCH
  6. Disconnect back-up lamp switch connector (1). See Fig 4.
    Fig 5: Shift Cables at Transaxle
    GC0020065Courtesy of DAIMLERCHRYSLER CORP.
    1 - SHIFT CABLES
    2 - CLIPS
    3 - BRACKET
  7. Remove shift cable-to-bracket clips (2). See Fig 5.
  8. Disconnect shift selector and crossover cable (1) from levers. Remove cables and secure out of the way.
    Fig 6: Speed Sensor And Pinion Removal/Installation
    GC0020066Courtesy of DAIMLERCHRYSLER CORP.
    1 - CONNECTOR
    2 - SENSOR
    3 - O-RING
    4 - SPEEDO PINION
  9. Disconnect the vehicle speed sensor connector (1). See Fig 6.
    Fig 7: Drain Plug Location
    GC0020140Courtesy of DAIMLERCHRYSLER CORP.
    1 - DRAIN PLUG
  10. Raise vehicle on hoist.
  11. Remove transaxle oil drain plug (1) and drain oil into a suitable container. Reinstall drain plug (1) and torque to 14 N.m (120 in. lbs.) torque. See Fig 7.
    Fig 8: Clutch Slave Cylinder At Transaxle - 1.6L Models
    GC0019809Courtesy of DAIMLERCHRYSLER CORP.
    1 - SLAVE CYLINDER
    2 - BOLT
  12. Remove clutch slave cylinder (1) from transaxle, 1.6L.
    Fig 9: Clutch Slave Cylinder At Transaxle - 2.0L & 2.4L
    GC0019810Courtesy of DAIMLERCHRYSLER CORP.
    1 - SLAVE CYLINDER
    2 - BRACKET
  13. Remove clutch slave cylinder (1) from transaxle 2.4L. See Fig 9.
  14. Remove both axle half shafts (Refer to DIFFERENTIAL & DRIVELINE/HALF SHAFT - REMOVAL)
    Fig 10: Power Steering Hose Brackets
    GC0021238Courtesy of DAIMLERCHRYSLER CORP.
    1 - POWER STEERING HOSE
    2 - BOLT
  15. Disconnect power steering hose (1) from structural collar. See Fig 10.
    Fig 11: 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
  16. Remove the left engine-to-transaxle lateral bending brace (3) and structural collar (7). See Fig 11.
  17. Remove bellhousing dust cover if equipped.
  18. Remove the right engine-to-transaxle lateral bending brace (3).
  19. Remove starter motor (Refer to ELECTRICAL/STARTING/STARTER MOTOR - REMOVAL) .
    Fig 12: Left Mount & Bolt
    GC0021169Courtesy of DAIMLERCHRYSLER CORP.
    1 - BOLT
    2 - TRANSAXLE
    3 - LEFT MOUNT
  20. Support engine at oil pan with screw jack and wood block.
  21. Remove transaxle upper mount bolts (1). See Fig 12.
    Fig 13: Modular Clutch Assembly-Typical
    GC0019829Courtesy of DAIMLERCHRYSLER CORP.
    1 - MODULAR CLUTCH ASSEMBLY
    2 - CLIP
    3 - TRANSAXLE
    4 - CLUTCH TO DRIVE PLATE BOLTS (4)
  22. Remove four modular clutch-to-drive plate bolts (4). See Fig 13. While removing bolts, one tight-tolerance (slotted) drive plate hole will be encountered. When this bolt is removed, mark driveplate and modular clutch assembly (1) at this location, and be sure to align marks upon reassembly.
  23. Carefully lower engine and transaxle on screw jack until proper removal clearance is obtained.
  24. Obtain a helper to assist in holding transaxle while removing transaxle-to-engine mounting bolts. See Fig 13.
  25. Remove transaxle from vehicle (3). See Fig 13.
  26. Remove clutch module (1) from transaxle input shaft (if equipped). See Fig 13.
    Fig 14: Transaxle Upper Mount Bracket
    GC0022229Courtesy of DAIMLERCHRYSLER CORP.
    1 - BRACKET
    2 - TRANSAXLE
  27. If installing a new or replacement transaxle, remove the upper mount (1), transfer to the replacement unit and torque all bolts to 62 N.m (45 ft. lbs.) torque. See Fig 14.
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