INTRODUCTION
Page iv
Dana Electric Transaxle Shop Rebuild and Parts Manual
Read all of each section before attempting any procedure. Pay particular attention to all Warnings, Cautions, and Notes.
Before working on vehicle, remove all jewel-
ry (watch, rings, necklaces, etc.).
Be sure that no loose clothing or hair can
contact moving parts.
Wear eye protection when working
on or around vehicle. In particular,
use care when working around
batteries, or when using solvents
or compressed air.
Use care not to contact hot objects.
Before attempting to operate or adjust the
powertrain, the rear of the vehicle must be
raised and supported on jack stands.
Wear OSHA approved clothing and eye pro-
tection when working on anything that
could expose the body or eyes to potential
injury. In particular, use care when working
with or around batteries, compressed air, or
solvents.
Always turn the key switch to ‘OFF’ and
remove the key before disconnecting a live
circuit.
When connecting battery cables, pay partic-
ular attention to the polarity of the battery
terminals. Never confuse the positive and
negative cables.
Battery posts, terminals and related acces-
sories contain lead and lead compounds.
Wash hands after handling.
Set the parking brake before performing any
work on the vehicle.
Keep all smoking materials, open flame, or
sparks away from gasoline or batteries.
If repairs are to be made that will require
welding or cutting, the battery and fuel tank
must be removed and the fuel system
drained.
Never operate the starter with the spark
plugs removed unless the ignition system
has been disabled and the engine/exhaust
is cold. Fuel expelled from the cylinders
could be ignited by the ignition system or
the hot exhaust system.
Never work on an engine that is hot.
Never work around or operate a vehicle in
an environment that does not ventilate
exhaust gases from the area.
Exhaust gas (carbon monoxide) is deadly.
Carbon monoxide is an odorless gas that is
formed as a natural part of the incomplete
combustion of hydrocarbon fuels. Carbon
monoxide is a dangerous gas that can
cause unconsciousness and is potentially
lethal.
The following are symptoms of carbon mon-
oxide inhalation:
• Dizziness
• Vomiting
• Intense headache
• Muscular twitching
• Weakness and sleepiness
• Throbbing in temples
If experiencing any of these symptoms, get
fresh air immediately.
Never test the ignition system without either
connecting the spark plug lead to a tester or
spare grounded spark plug.
If the spark function is to be observed at the
spark plug, be sure to install a spare spark
plug into the open cylinder before operating
the starter.
Never test the function of a fuel pump in the
vicinity of a hot engine or other source of
flame or combustion.
Never confuse the hoses to and from the
fuel pump. Verify that the carburetor and
pulse lines are correctly installed before
starting the engine (see FUEL SYSTEM Sec
-
tion in your Repair and Service Manual).
Aerosol containers of battery terminal pro-
tectant must be used with extreme care.
Insulate the metal container to prevent the
metal can from contacting battery terminals
which could result in an explosion.
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