238 Manual Drive Trains and Axles Copyright by Goodheart-Willcox Co., Inc. Manual Transaxle Installation The transaxle installation procedure is the reverse of removal. If the installation is performed properly, the transaxle should be easily reattached to the engine and vehicle. The following general procedures detail how to install a manual transaxle in a vehicle. Note that you should always refer to the manufacturer’s service manual for specific procedures. 1. Begin by raising the transaxle with the transmission jack. When the transaxle is at the proper height, slide it into engagement with the throwout bearing, clutch disc hub, and crankshaft pilot bushing. If the clutch has been disturbed, you may need a clutch pilot shaft to align the clutch disc. (This was covered in Chapter 7.) If necessary, turn the engine crankshaft to help the input shaft engage the clutch. It may be necessary to remove an access cover to reach the front crankshaft pulley. As the input shaft passes through the clutch disc hub into engagement with the pilot bushing, the transaxle clutch housing should fit closely onto the engine. Any alignment dowels should smoothly engage their matching holes. Caution: Do not try to pull a binding transaxle into engagement with the engine by tightening the bolts. This will cause damage to the clutch disc and input shaft, and could possibly break the aluminum transaxle case. 2. Install the transaxle case-to-engine bolts. Make sure the engine and transaxle are properly aligned when all of the bolts are tight. There should be no gaps between any of the mating surfaces. As you tighten, check that no wires, brackets, or hoses are caught between the engine and transaxle. 3. Install and tighten the engine mounts and other fasteners holding the transaxle to the vehicle frame. Check for warpage New gasket or RTV sealer, as required Transaxle case halves Reverse shift lever Reverse operating lever Selector shaft housing Selector shaft Boot 1/16-inch bead of RTV sealant Stop plate Shift forks Torque wrench Torque all fasteners to specs Figure 11-28. A housing for the shift linkage, if used, should be installed carefully, so that the parts line up correctly. If the parts are installed incorrectly, the transaxle gears could be damaged. (Chrysler) Figure 11-29. Install all extension housings with the proper gas- kets or sealer, and torque them to specifications. Figure 11-27. The case can be reassembled after all internal parts have been replaced. Use the correct kind of gasket or sealer on the case sealing surfaces to prevent leaks and incor- rect bearing preloads. Remove all old gasket material from seal- ing surfaces before installing new material. (Honda) Reinstall any external case components, including electrical connectors and linkage. Install the clutch thro- wout bearing and clutch fork, if they were removed from their installation.