Removal & Installation - A/t Dodge Shadow I

1. Disconnect negative battery cable. On vehicles using A-604 transaxles, drain engine cooling system and remove coolant return extension pipe. On all models, disconnect throttle linkage and shift linkage from transaxle. Disconnect cooler line hoses.
2. Attach engine support fixture to upper engine compartment and support engine. Remove upper bellhousing bolts. Raise and support vehicle and remove front wheels. Remove oil pan bolts and drain transaxle. Replace oil pan.
3. Remove axle nut cotter pin, nut lock and spring washer. Remove axle nut. Remove speedometer pinion gear and cable assembly from transaxle. Remove ball joint-to-steering knuckle clamp bolt.
4. Remove clamp bolt securing ball joint stud into steering knuckle. Separate ball joint stud from steering knuckle by prying against knuckle leg and control arm. Do not damage ball joint or CV joint boots.
5. Separate outer CV joint splined shaft from hub by holding CV housing while pushing knuckle assembly away from shaft. Support CV joint housing assemblies out of the way.
6. Remove left splash shield. Remove torque converter dust cover and index mark torque converter to drive plate. Remove access plug in right splash shield to rotate engine crankshaft and remove torque converter mounting bolts.
7. Disconnect neutral safety switch connector from neutral safety switch and disconnect all other sensor connectors. Remove engine mount bracket from front crossmember and remove front mount insulator through-bolt.
8. Support transaxle with transmission jack. Remove left engine mount near transaxle differential cover. Remove starter mounting bolts and lower bellhousing bolts.
9. Pry transaxle away from engine and slightly lower from engine. Pry transaxle from engine at extension housing (if needed). Ensure all external connections are clear from transaxle and lower unit from vehicle.

To install transaxle, reverse removal procedures. Adjust throttle cable and shift linkage as necessary. Replace pan gasket and fill transaxle with required amount of fluid to correct level. See appropriate article in AUTOMATIC TRANSMISSION SERVICING.

TORQUE SPECIFICATIONS

1. Disconnect negative battery cable. Loosen throttle valve cable lock nuts, disconnect cable and remove from engine bracket. Raise and support vehicle.
2. Remove front wheels. Remove steering knuckle upper nut and bolt. Only loosen nut from lower knuckle connection. Do not rotate steering knuckle bolts; bolts are splined and can be removed by tapping with a soft mallet.
3. Tilt steering knuckle outward and remove splash shield. Position drain pan under transmission oil pan. Loosen nut attaching transmission filler tube to oil pan and allow fluid to drain completely. Remove filler tube and install plug into hole.
4. Remove torque converter housing bottom and side covers. Remove 3 torque converter bolts. Remove roll pins attaching drive axle shafts to differential output shafts. Pull axle shafts off differential output shafts and support out of the way.
5. Support transaxle with transmission jack. Remove nuts attaching crossmember to side supports. Remove long bolt attaching rear mount to transaxle bracket. Remove exhaust pipe bracket from rear mount. Remove crossmember and mount as an assembly.
6. Remove nuts attaching exhaust pipe bracket to front "Y" pipe. Remove nuts attaching catalytic converter to "Y" pipe. Disconnect oxygen sensor wires. Loosen (do not remove) engine cradle bolts until there is 1/2-7/8" working clearance between cradle and side supports.
7. Remove front exhaust pipe assembly from manifolds. Disconnect starter cables and relay wires. Remove bolts and remove starter, starter plate and alignment dowel. Disconnect shift cable at transaxle lever. Remove shift cable bracket bolts and remove cable bracket.
8. Remove brace rod. Reinstall rear bolt to hold neutral switch in place. Squeeze lock tabs on shift selector cable and remove cable from bracket. Remove engine speed sensor.
9. Disconnect transmission fluid cooler hoses. Plug hoses to prevent fluid loss. Disconnect speedometer sensor wire and remove sensor. Remove engine-to-converter housing bolts and remaining engine-to-converter bolts. Pull transaxle away from engine and lower transaxle.

1. Inspect drive plate for warpage, wear or damage and replace if necessary. To install transaxle, reverse removal procedure. Before installing transaxle, coat torque converter pilot hub with bearing grease and ensure that torque converter is fully installed into transaxle pump.
2. Use Loctite No. 271 on torque converter mounting bolts. When installing inner ends of drive axle shafts into transaxle, ensure roll pin holes of axle shafts and output shafts are aligned. Refill transaxle and differential. Ensure proper adjustment of shift cable and throttle valve cable.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS (ZF 4HP-18)