Disassembly and Assembly

The NV T360 (A-578) transaxle internal components can be serviced only by separating the gear case from the bell housing case.

CAUTION: The transaxle output shaft is serviced as a unit. No disassembly and reassembly is possible. Damage to the transaxle may result.

DISASSEMBLY
1. Place transaxle on bench.
2. Remove the clutch release bearing and fork. Move the release fork and bearing to an in-line position. Grasp the release lever with two hands in the pivot stud socket area. Pull with even pressure to release the fork from the pivot stud.

CAUTION: Do not use a screwdriver or pry bar to release the fork as this may cause damage to the fork and/or clip.

3. Remove shift levers by driving out the roll pins.

Fig. 46:

4. Remove transaxle case half bolts (Fig. 46).

Fig. 47:

Fig. 48:

5. Place two screwdrivers into the slots provided in the case halves near the dowels (Fig. 47). Separate the case halves (Fig. 48).

Fig. 49:

6. Remove bell housing half from gear case half (Fig. 49).
7. Remove output shaft roller bearing from output shaft.

Fig. 50:

8. Remove differential assembly (Fig. 50).

Fig. 51:

9. Remove reverse idler shaft bolt (Fig. 51).

Fig. 52:

10. Remove reverse idler shaft (Fig. 52).

Fig. 53:

11. Remove reverse idler gear and spacer (Fig. 53).

Fig. 54:

Fig. 55:

12. Remove two screws retaining reverse fork bracket (Fig. 54). Remove reverse fork bracket and reverse cam blockout assembly (Fig. 55).

Fig. 56:

13. Using snap-ring pliers, remove selector shaft spacer (Fig. 56).

Fig. 57:

14. Pull the selector shaft shift pin out of the slot in the blocker assembly. Turn selector shaft up and out of the way (Fig. 57).

Fig. 58:

Fig. 59:

15. Remove transaxle end cover (Fig. 58) (Fig. 59)

Fig. 60:

16. Remove two snap rings retaining the output shaft and the input shaft to the bearings (Fig. 60).

Fig. 61:

17. Using bench fixture and shims provided (Miller tools # 6785, 6785-1, and 6785-2), turn transaxle over. Install transaxle onto bench fixture (Fig. 61). Verify shim spacers are in position on bench fixture. Install transaxle into shop press.

Fig. 62:

18. Install bearing fixture Miller tool #6768 onto transaxle end bearings (Fig. 62). Verify tool is properly aligned to input and output shafts.

CAUTION: The oil dams in the input and output shafts can be damaged while pressing on the shafts if the bearing fixture is not used properly.

Fig. 63:

19. Install transaxle gear case into shop press. Press output and input shaft assemblies out of case (Fig. 63).
20. Remove transaxle from press.

Fig. 64:

Fig. 65:

21. Carefully remove transaxle case from the shaft assemblies and bench fixture (Fig. 64). Be sure the oil-feed trough to the end bearings is not damaged (Fig. 65).

Fig. 66:

Fig. 67:

Fig. 68:

Fig. 69:

Fig. 70:

22. TRANSAXLE W/REVERSE BRAKE: Remove the reverse brake blocking ring, shim, reverse brake friction cone, bearing and race from the input shaft assembly (Fig. 66) (Fig. 67) (Fig. 68) (Fig. 69) (Fig. 70). TRANSAXLE W/O REVERSE BRAKE: Remove plastic spacer from the input shaft assembly.

Fig. 71:

23. Remove the shift blocker assembly from the bench fixture (Fig. 71).

Fig. 72:

24. Remove the 1-2 shift fork from the output shaft (Fig. 72).

Fig. 73:

25. Remove input and output shaft assemblies from bench fixture (Fig. 73).

CAUTION: The output shaft assembly is serviced as an assembly. Do not try to repair any component on the output shaft. If the 1-2 synchronizer or gear fails, it is necessary to replace the complete output shaft assembly.

ASSEMBLY
The sealant used to seal the transaxle case halves is Mopar(R) Gasket Maker, Loctite 518, or equivalent. The sealant used for the bearing end plate cover is Mopar(R) RTV.

Fig. 74:

1. Verify bench fixture shims are removed from bench fixture. Install output and input shafts into bench fixture (Miller tool #6785) (Fig. 74).

Fig. 75:

2. Install shift rails and forks into bench fixture (Fig. 75).

Fig. 76:

3. Install shift blocker assembly into bench fixture (Fig. 76).

Fig. 77:

4. Install reverse brake race onto input shaft (Fig. 77).

Fig. 78:

5. Install reverse brake needle bearing (Fig. 78).

Fig. 79:

6. Install reverse brake blocking ring (Fig. 79).

Fig. 80:

7. Install reverse brake friction cone (Fig. 80).

Fig. 81:

8. Install reverse brake shim (Fig. 81). Apply petroleum jelly to shim to hold in place.

Fig. 82:

9. Install gear-case half over bench fixture (Fig. 82). Line up shift finger over 3-4 lug.

Fig. 83:

10. Line up reverse brake friction cone lugs to the slots in the gear case (Fig. 83). Verify reverse brake shim is in position.

Fig. 84:

11. Position input and output bearings on the shafts. Using Miller tool C-4992-1, press on input and output shaft bearings until they bottom into the case and against the shafts (Fig. 84).

Fig. 85:

12. Install shaft snap rings at input and output bearings (Fig. 85).

Fig. 86:

13. Apply Mopar(R) RTV sealant to end-cover outer edge and around bolt holes. Install end-cover onto gear case. Tighten end cover bolts to 29 Nm (21 ft. lbs.) torque (Fig. 86).
14. Remove gear case from bench fixture.
15. Install gear case in a holding fixture with end cover facing down.

Fig. 87:

16. Turn selector shaft into slot on blocker assembly (Fig. 87).
17. Push selector shaft spacer clip onto selector shaft. Install shift levers.

Fig. 88:

18. Install reverse idler gear and spacer as shown in (Fig. 88)

Fig. 89:

19. Install reverse idler shaft (Fig. 89).

Fig. 90:

20. Install bolt into shaft and tighten to 26 Nm (19 ft. lbs.) torque (Fig. 90).

Fig. 91:

Fig. 92:

21. Install reverse fork bracket and reverse lockout. Tighten screws to 11 Nm (96 inch lbs.) torque (Fig. 91) (Fig. 92).

Fig. 93:

22. Install differential into gear case (Fig. 93).

BEARING ADJUSTMENT PROCEDURE
1. Use extreme care when removing and installing bearing cups and cones. Use only an arbor press for installation, as a hammer may not properly align the bearing cup or cone. Burrs or nicks on the bearing seat gives a false end-play reading while gauging for proper shims. Improperly seated bearing cups and cones are subject to low-mileage failure.
2. Bearing cups and cones should be replaced if they show signs of pitting or heat distress. If distress is seen on either the cup or bearing rollers, both cup and cone must be replaced.
3. Bearing preload and drag torque specifications must be maintained to avoid premature bearing failures. Used (original) bearings may lose up to 50% of the original drag torque after break-in. All bearing adjustments must be made with no other component interference or gear intermesh.
4. Replace bearings as a pair: If one differential bearing is defective, replace both differential bearings, if one input shaft bearing is defective, replace both input shaft bearings.
5. Bearing cones must not be reused if removed.
6. Turning-torque readings should be obtained while smoothly rotating in either direction.

DIFFERENTIAL BEARING PRELOAD ADJUSTMENT

NOTE: True bearing turning-torque readings can be obtained only with the geartrain removed from the case.

1. Remove bearing cup and existing shim from clutch bell housing case.
2. Press in new bearing cup into bell housing case (or use a cup that has been ground down on the outer edge for ease of measurement).
3. Press in new bearing cup into gear case side.
4. Oil differential bearings with Mopar(R) type M.S. 9417 Manual Transaxle Fluid. Install differential assembly in transaxle gear case. Install clutch bell housing over gear case. Install and torque case bolts to 29 Nm (21 ft. lbs.).
5. Position transaxle with bell housing facing down on workbench with C-clamps. Position dial indicator.

Fig. 94:

6. Apply a medium load to differential with Tool C-4995 and a T-handle, in the downward direction. Roll differential assembly back and forth a number of times. This will settle the bearings. Zero the dial indicator. To obtain end play readings, apply a medium load in an upward direction while rolling differential assembly back and forth (Fig. 94). Record end play.
7. The shim required for proper bearing preload is the total of end play, plus (constant) preload of 0.18 mm (0.007 inch). Never combine shims to obtain the required preload.
8. Remove case bolts. Remove clutch bell housing differential bearing cup. Install shim(s) selected in Step 7. Then press the bearing cup into clutch bell housing
9. Install clutch bell housing Install and torque case bolts to 26 Nm (19 ft. lbs.).

Fig. 95:

10. Using Special Tool C-4995 and an inch-pound torque wrench, check turning torque of the differential assembly (Fig. 95). The turning torque should be 6 to 12 inch lbs.. If the turning torque is too high, install a 0.05 mm (0.002 inch) thinner shim. If the turning torque is too low, install a 0.05 mm (0.002 inch) thicker shim.
11. Recheck turning torque. Repeat Step 10 until the proper turning torque is obtained.
Once proper turning torque has been established, place gear case on the end plate. Draw a bead of Mopar(R) Gasket Maker, Loctite(R) 518, or equivalent, on the flat surface of the case mating flange. Install clutch bell housing onto gear case. Install and tighten case bolts to 29 Nm (21 ft. lbs.).