Transaxle Removal – 2.5L NA

Overview

This guide outlines the procedure for removing the transaxle from all Porsche 944 variants with an 8-valve engine, covering both pre-1985.5 and 1985.5 onwards models. The transaxle, which integrates the transmission and differential, must be removed for tasks such as clutch replacement or transmission repairs. This process involves disconnecting the shift linkage, drive shaft, CV joints, and supporting components before lowering the transaxle from the vehicle. Model-specific steps are clearly marked for clarity.

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Tools Required

• Metric wrench set
• Metric socket set
• Jack stands
• Floor jack
• Small flat tip screwdriver
• 8mm (5/16 inch) Allen head socket
• 8mm (5/16 inch) cheesehead tool

Step-by-Step Procedure

Step 1: Prepare the Vehicle

1. Disconnect the negative battery lead to prevent electrical hazards.
2. Raise the vehicle and secure it on jack stands to provide safe access to the underside.

Step 2: Disconnect the Shift Linkage at the Transaxle

3. Locate the rubber boot on the shift linkage at the transaxle. Push it back to access the retaining bolt.
4. Cut the lock wire on the retaining bolt, remove the bolt using a metric wrench, and disconnect the shift linkage from the transaxle.

Step 3: Disconnect the Shift Linkage at the Shifter

5. For Pre-85.5 models:

   • Pull up the bottom of the leather shift lever boot inside the vehicle to separate it from the rubber inner boot.

   • Pull up the carpet around the rubber boot to access the trim piece.

   • Slide a small flat tip screwdriver under the edge of the trim piece at the base of the rubber boot. Push on the clips to remove the trim piece.

   • Pull up the rubber shift boot to separate it from the shifter opening.

   • Use a small flat tip screwdriver to remove the clip holding the shift knob to the shifter.

   • Remove the clip holding the shift linkage to the shifter using a small flat tip screwdriver.

6. For 85.5 Onwards models:

   • Gently pry around the base of the shifter boot next to the console using a flat tip screwdriver, being careful not to damage the boot. This separates the boot and inner trim ring from the console.

   • Pull up the rubber inner boot to separate it from the shifter opening.

   • Use a small flat tip screwdriver to remove the clip holding the shift knob to the shifter.

   • Remove the clip holding the shift linkage rod to the shift lever using a small flat tip screwdriver.

7. Once the shift linkage rod is disconnected, turn it downward and push it toward the front of the vehicle to disengage it from the transaxle.

Step 4: Remove Bellhousing Covers and Access Drive Shaft Bolts

8. Remove the covers on the bottom of the transaxle bellhousing to access the drive shaft retaining bolts.
9. Engage the clutch pedal and roll the rear wheels until the two drive shaft retaining bolts are accessible through the bellhousing opening.

Step 5: Disconnect the Drive Shaft

10. Mark the position of the clamping sleeve on the drive shaft to ensure correct reassembly.
11. Using an 8mm (5/16 inch) Allen head socket, remove the clamping sleeve bolts.
12. Slide the clamping sleeve off the drive shaft splines toward the transaxle.

Step 6: Disconnect CV Joints

13. Set the parking brake to prevent wheel movement.
14. Using an 8mm (5/16 inch) cheesehead tool, disconnect the CV joints at the transaxle.
15. Secure the CV joints out of the way using shock cords or bailing wire.

Step 7: Disconnect Electrical Connections

16. Disconnect the backup light wires located near the top of the transaxle.
17. For 85.5 Onwards models:

    • Disconnect the cable for the speedometer sensor on the transaxle, if equipped with an electronic speedometer.

Step 8: Support and Disconnect the Transaxle

18. Remove the four nuts and bolts attaching the torque tube bellhousing to the transaxle using a metric socket set.
19. Support the transaxle with a floor jack.
20. Disconnect the fuel filter from the transaxle support cross-member.
21. Remove the two M10 bolts attaching the transaxle cross-member to the chassis using a metric socket set.

Step 9: Lower the Transaxle

22. Move the transaxle rearward enough to slide the shift linkage tube out of the way and disconnect the drive shaft clamping sleeve.
23. Lower the transaxle while moving it rearward to clear the spare tire well.
24. Once the shift linkage tube is removed and the drive shaft is clear, fully lower the transaxle from the vehicle.

Post Procedure Checklist

• Verify that all tools and debris are removed from the work area.
• Ensure the shift linkage, CV joints, and drive shaft are properly disconnected and secured.
• Inspect the transaxle and surrounding components for any signs of damage or wear.
• Confirm the vehicle remains securely supported on jack stands.

Sources

• Clark’s Garage
• Pelican Parts
• Porsche 944 Workshop Manuals
• YouTube