Page 1 of 7 Section 07-01: Transaxle, Automatic FLC REMOVAL AND INSTALLATION 1992 Tempo/Topaz Workshop Manual Differential In Vehicle Removal Before beginning the Removal procedure, perform the following preliminary Steps: Position vehicle on a hoist. Refer to the Pre-Delivery manual, Section 00-02. Raise hood. Position fender covers. Disconnect battery ground cable. 1. Remove bolts attaching managed air valve-to-transaxle valve body cover, if so equipped. 2. Remove bolt that retains Thermactor hoses. CAUTION: Position hoses and valve away from brake tubing and master cylinder to avoid interference when raising transaxle. 3. Raise vehicle on a hoist. Remove front wheels and tires. Refer to Section 04-04. Remove nuts from control arm ball joint pinch bolts. Drive bolts out of the knuckles using a punch and hammer. CAUTION: The nuts and bolts must be discarded. 4. Remove brake hose clip retaining bolts. 5. Remove tie rod-to-steering knuckle retaining nuts. 6. Disengage control arms from steering knuckles.

Page 2 of 7 CAUTION: Do not use a hammer on knuckle to remove ball joints. NOTE: The plastic shield installed behind the rotor contains a moulded pocket into which the lower control arm ball joint fits. When disengaging the control arm from the knuckle, clearance for the ball joint can be provided by bending the shield back toward the rotor. Failure to provide clearance for the ball joint may result in damage to the shield. NOTE: Exercise care not to damage or cut ball joint boot. Pry bar must not contact lower arm. 7. Remove 13 transaxle oil pan retaining bolts. Remove pan, drain fluid and discard gasket. 8. To remove halfshafts, insert a large-blade screwdriver between differential pinion shaft and inboard CV joint stub shaft. Give a sharp tap to handle end of screwdriver to dislodge circlip from side gear, freeing halfshaft from the differential. CAUTION: Care should be taken not to damage differential seals or bottom pan during halfshaft removal. 9. Pull halfshaft out of transaxle. Support end of shaft by suspending from a convenient underbody component with a length of wire. NOTE: Do not allow the shaft to hang unsupported as damage to the CV joints may result.

Page 3 of 7 10. Remove three oil filter retaining bolts and remove filter. Thoroughly clean filter. Discard seal. 11. Position Rotunda Hi-Lift Jack 014-00210 or equivalent under rear oil pan rail of transaxle case. Place a wood block between jack and case to protect oil pan and case mating surface. CAUTION: Extreme care should be taken not to damage transaxle case. 12. With jack supporting transaxle, remove two motor mount-to-transaxle retaining bolts. Remove rear mount assembly. 13. Remove six differential bearing retainer retaining bolts. 14. Raise Rotunda Hi-Lift Jack 014-00210 or equivalent to allow clearance for bearing retainer removal. Remove bearing retainer and shim while supporting differential.

Page 4 of 7 15. Move differential assembly to the left to clear differential bearing. Remove from transaxle case. Installation NOTE: If the differential case, bearing retainer, or differential bearing is replaced, reshimming will be required. Refer to Differential Ball Bearing End Play. 1. Raise Rotunda Hi-Lift Jack 014-00210 or equivalent high enough to allow installation of bearing retainer. CAUTION: Extreme care must be taken not to damage transaxle case. NOTE: Inspect both differential seals for any evidence of damage. Replace, if necessary, prior to differential installation. 2. Install differential, shims, and bearing retainer using new O-ring seal or gasket. 3. Apply Threadlock and Sealer E0AZ-19554-AA (ESE-M4G204-A) or equivalent to threads of bearing retainer retaining bolts. Install bolts. Tighten to 20-26 Nm (15-19 lb-ft). 4. Lower jack far enough to install rear motor mount on transaxle. Install two mount retaining bolts. Tighten to 41-61 Nm (31-44 lb-ft).

Page 5 of 7 5. Install two support bracket retaining nuts. Tighten nuts to 61-88 Nm (45-64 lb-ft). Remove jack. 6. Install new circlips on inboard CV joint stub shafts. NOTE: To install the circlip properly, start on end in the groove and work the circlip over the stub shaft end and into the groove. This will avoid over-expanding the circlip. CAUTION: The circlip must not be reused. A new circlip must be installed each time the inboard CV joint is installed into the transaxle differential. 7. Carefully align splines of inboard CV joint stub shaft with splines in differential. Exerting some force, push CV joint into differential until circlip is felt to seat in differential side gear. Use care to prevent damage to differential oil seal. CAUTION: Install Transaxle Plug T81P-1177-B or equivalent to ensure alignment of CV joint stub shaft with side gear. NOTE: A non-metallic mallet may be used to aid in seating the circlip into the differential side gear groove. If a mallet is necessary, tap only on the outboard CV joint stub shaft. 8. Position a new seal on filter and install filter. Install filter retaining bolts. Tighten to 9-12Nm (7-9 lb-ft).

Page 6 of 7 9. Install new oil pan gasket. 10. Install oil pan and 13 retaining bolts. Tighten alternately to 20-26 Nm (15-19 lb-ft). 11. Connect control arms to steering knuckles and install new nuts and bolts. Tighten nuts to 54-74 Nm (40-54 lb-ft). CAUTION: New bolts and nuts must be installed. 12. Position brake hose routing clip on suspension strut and install retaining bolt. Tighten bolt to 11 Nm (8 lb-ft).

Page 7 of 7 13. Install steering gear tie rods to steering knuckles using new nuts and cotter pins. 14. Install wheels and tires. Lower vehicle. Tighten wheel lug nuts to 108-144 Nm (80-105 lb-ft). 15. Install managed air valve to transaxle valve body cover retaining bolts, if so equipped. 16. Install bolt retaining Thermactor hoses. 17. Connect battery ground cable. 18. Fill transaxle to the proper level as outlined.