Part 1

Fig. 291:

To install the output bearing cups, use Special Tool # 5050A.

Fig. 292:

Fig. 293:

Fig. 294:

Fig. 295:

Fig. 296:

Fig. 297:

Fig. 298:

CAUTION: When installing, be sure guide bracket and split sleeve touch the rear of the transaxle case.

Fig. 299:

Fig. 300:

Fig. 301:

Fig. 302:

Fig. 303:

Fig. 304:

OUTPUT SHAFT BEARING PRELOAD SHIM SELECTION
When assembling, the output bearing preload must be checked and/or adjusted if any of the following items have been replaced:
- Output shaft (rear carrier assembly)
- Output shaft bearings
- Transaxle case

SHIM SELECTION

Fig. 305:

1. Install rear output shaft bearing cone and special tool 6618A (Fig. 305).

Fig. 306:

2. Install special tool 6618A (Fig. 306). Lightly tighten retaining screws. Screws should be below the plate surface, but do not snug screws.
3. Turn case over on arbor press so that the plate is resting on the press base

CAUTION: The output shaft will extend through the hole of tool 6618A. Ensure your press table has clearance for the output shaft.

Fig. 307:

Output Shaft Rear Shim Chart:

4. Install shim on output shaft (Fig. 307). Apply small amount of petrolatum onto the shim to hold it in place. Use the original shim as a starting point. If original shim is not available, use the thickest shim available. Refer to Output Shaft Rear Shim Chart for available sizes.

Fig. 308:

5. Install output shaft/rear carrier into rear bearing. The shaft must be pressed into position. Use special tool MD-998911 (Disc) and C- 4171 and C4171-2 (Handle) to press shaft into rear bearing (Fig. 308).

CAUTION: Do not reuse old transfer shaft nut or output shaft nut because the removed stake weakens the nut flange.

6. Using special tools 6497 and 6498, install new output shaft nut. Do not reuse old output shaft nut.

Fig. 309:

Tighten new output shaft nut to 271 Nm (200 ft. lbs.).
7. Check the turning torque of the output shaft (Fig. 309). The shaft should have 1 to 8 in. lbs. of turning torque. If the turning torque is higher than 8 in. lbs., install a thicker shim. If the turning torque is less than 1 in. lbs., install a thinner shim. Make sure there is no end play.

CAUTION: Failure to stake shaft nuts could allow the nuts to back-off during use.

Fig. 310:

Fig. 311:

8. The new nut must be staked after the correct turning torque is obtained (Fig. 310). Use special tool 6639 to stake output shaft nut and special tool 6689 to stake transfer shaft.

Fig. 312:

When reinstalling main sump baffle apply Mopar Silicone Sealant as shown in (Fig. 312).

Fig. 313:

Install main sump baffle to transaxle case (Fig. 313).

CAUTION: When reinstalling drive chains, the blue link must face outward.

CAUTION: The chain sprockets have a slip fit onto the shafts. Apply only a slight amount of pressure to the chain spreader to release the chain pressure. If chain sprockets are not spread slightly, installation will be difficult.

Fig. 314:

Fig. 315:

CAUTION: Be sure to reinstall the chain snubber and chain oiler when reassembling.

Fig. 316:

Fig. 317:

Fig. 318:

Fig. 319:

Stand trans upright on bellhousing

Chain cover must be free of old sealant, dirt and oil before applying new sealant. Apply a 1/8 inch bead of sealant to flange of cover.

Fig. 320:

Fig. 321:

Fig. 322:

Fig. 323:

Fig. 324:

Fig. 325:

Fig. 326:

Fig. 326:

Press down clutch pack with finger and zero dial indicator. Low/Reverse clutch pack clearance is 0.86 to 1.52 (0.034 to 0.060 inch).

Low Reverse Reaction Plate Chart:

Select the proper low/reverse reaction plate to achieve specifications:

Fig. 328:

Fig. 329:

Fig. 330:

NOTE: When installing the 2-4 clutch plates and discs, the orientation should be alternated so the pilot pads of adjacent plates do not align, refer to (Fig. 330).

Fig. 331:

Fig. 332:

Fig. 333:

Fig. 334:

Fig. 335:

Press down clutch pack with finger and zero dial indicator. The 2/4 clutch pack clearance is 0.76 to 2.64 mm (0.030 to 0.104 inch). If not within specifications, the clutch is not assembled properly. There is no adjustment for the 2/4 clutch clearance.

Fig. 336:

The number 7 needle bearing has three anti reversal tabs and is common with the number 5 and number 2 position. The orientation should allow the bearing to seat flat against the rear sun gear (Fig. 336). A small amount of petrolatum can be used to hold the bearing to the rear sun gear.

Fig. 337:

Fig. 338:

Fig. 339: