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Tech Article - IRS Tranny Removal and Replacement
Place the shift lever in first or third gear.
Take out the rear seat and unhook the negative cable from the battery.
Remove the inspection cover for he shift rod coupling and take out the bolt behind the coupling.
Move the shift lever to second or fourth in order to unhook the shift rod from the coupling.
Raise the vehicle and support it securely on jack-stands. Take off the rear wheels (swing axle models only).
Drain the transaxle fluid.
Take out the engine.
Disconnect and plug the rear brake lines.
Use a chisel to make alignment marks on the spring plate and the axleshaft bearing housing to ensure proper realignment during reassembly, on all models with swing axles.
Unhook the inner ends of both driveaxles from the transaxle if you re not going to move the vehicle. This is on models with driveaxles. If you plan to move the vehicle, remove the driveaxles entirely. Cover the CV joints with plastic bags to keep out dirt and moisture and hang the driveaxles out of the way.
Unhook the clutch cable from the clutch operating shaft lever, slide off the boot and take off the cable and sleeve from the bracket.
Unhook the starter wires.
Peel back the rubber caps and detach the back-up light electrical connectors form the transaxle on later models.
Remove the nuts form the transaxle front mount.
With a piece of wood on the jack head, place a floor jack down under the transaxle and raise the jack until it supports the transaxle.
Take off the transaxle carrier bolts.
Look over all the wires, for a final check, and make sure hoses have been disconnected from the transaxle, then carefully pull the transaxle and jack to the rear and lower the jack.
Remove and look over the rear mounts. Replace them if they are dried, cracked or damaged.
Install the transaxle carrier and mounts, if removed. Note: Don t tighten the three nuts for each rear mount until after the transaxle has been installed and youve tightened the front mount nuts.
If they have been removed, install the swing axles.
Place the transaxle on the floor jack and raise into place. Slide the swing axles into position in the spring plates on models with swing axles. Grease and install the transaxle carrier bolts and tighten them to the torque.
Align the marks on the axleshaft bearing housings with the match marks you made on the spring plates before disassembly, on models with swing axles, and install the spring plate mounting bolts and tighten them to the torque. Install the axle boots. Now put back in the brake lines and bleed the brakes. Re-hook and adjust the parking brake cable. Install the wheels.
Install the drive-axles or - if you only detached the inner ends - reattach the driveaxles to the transaxle, on models with drive-axles.
Look over all clutch components before proceeding. Usually, new clutch components should be routinely installed any time the engine is removed.
Install the engine.
Now re-hook the clutch cable and adjust it.
Reattach all of the electrical connectors that were unhooked.
Make a final check that all wires, hoses and linkages have been connected.
Fill the transaxle with lubricant to the proper level.
If the wheels have been removed, reinstall them.
Take off any jack(s) that were supporting the transaxle and/or engine and lower the vehicle.
Move the shift lever into neutral and re-hook the shift rod coupling.
Connect the negative battery cable.
You will want to road test the vehicle for proper operation and check for leaks.