Disassembly and Reassembly

DISASSEMBLY











1. Remove clutch release lever and bearing (Fig. 10). Inspect release lever pivot balls and replace if necessary (Fig. 11). Use slide hammer C-3752 and remover/installer 6891 (Fig. 12) if pivot ball replacement is necessary.





2. Remove input shaft bearing retainer (Fig. 13).

NOTE: Place transaxle in neutral before shift cover removal.





3. Remove shift cover-to-case bolts and remove shift cover assembly (Fig. 14).
4. Place transaxle with bellhousing surface down.





5. Remove backup lamp switch (Fig. 15).





6. Remove end plate (Fig. 16).





7. Set up lifting bar (tool 8489) as shown in (Fig. 17).
8. Lift up on bar (input shaft bearing side) and remove input shaft bearing snap ring.
9. Lift up on bar (intermediate shaft side) and remove intermediate shaft bearing snap ring.
10. Remove lifting bar 8489.





11. Remove end cover-to-case bolts (12) (Fig. 18).





12. Remove end cover from transaxle (Fig. 19).





13. Remove 3/4 shift rail bushing from end cover using slide hammer C-3752 and remover 6786 (Fig. 20).





14. Remove reverse idler bolt (Fig. 21). Remove reverse idler gear, washers, and shaft upon geartrain removal.





15. Remove 1-2/5-R shift rail (Fig. 22).
16. Install lifting bar 8489.





17. Lift geartrain ("/reverse idler gear assy.) out of transaxle and install on fixture 8487 (Fig. 23).
18. Remove remaining shift rail and forks from geartrain (Fig. 23).
19. Remove lifting bar from geartrain.

NOTE: At this point, differential bearing turning torque should be measured to ensure proper shim selection upon reassembly.

20. Measure differential turning torque.





21. Using a suitable screwdriver, remove extension housing axle oil seal (Fig. 24).





22. Remove bearing plate-to-case and differential cover bolts (Fig. 25).
23. Remove differential cover bolts.
24. Remove differential cover and bearing plate. If necessary, use a soft tipped hammer to aid in removal.





25. Remove differential assembly. Note orientation of shim, oil slinger, and differential side bearing races (Fig. 26).





26. Remove differential chip collector magnet and clean (Fig. 27). Magnet is adhered with RTV, and may require force to remove.





27. Remove intermediate shaft bearing race with puller 8472 (Fig. 28).





28. Remove shift rail bushing from case with remover 6786 and slide hammer C-3752 (Fig. 29).





29. Remove input shaft bearing using an arbor press and tool 8474 (Fig. 30).

ASSEMBLY

NOTE: When assembling this transaxle, always use NEW snap rings.

NOTE: Before assembling transaxle, differential turning torque must be measured and adjusted. Differential turning torque must be measured with geartrain out of case.





1. Install input shaft bearing using an arbor press and remover/installer 8474 (Fig. 31).





2. Install shift shaft bushing to case using installer 8475 (Fig. 32).





3. Install intermediate shaft bearing race to case with an arbor press, driver handle C-4 171, and installer 8471 (Fig. 33). Press until installer 8471 bottoms on transaxle case.
4. Roll transaxle assembly on side.





5. Install differential chip collector magnet (Fig. 34). Retain to case with a dab of Mopar Gear Lube RTV.





6. Install differential assembly with bearing races and select shim (Fig. 35). Shim selection was determined before transaxle assembly.
7. Install a 1 mm (0.04 inch) bead of Mopar Gasket Maker to differential cover and install to case. Torque differential cover-to-case bolts to 54 Nm (40 ft. lbs.).





8. Install a 1 mm (0.04 inch) bead of Mopar Gasket Maker to bearing plate. Install bearing plate to differential cover and case and torque bolts to 28 Nm (250 in. lbs.) (Fig. 36).
9. Verify proper differential turning torque.





10. Install both axle output shaft seals using driver handle C-4171 and installer 8473 (Fig. 37).

NOTE: If input shaft assembly was not disassembled, it is necessary to remove input shaft sealed ball bearing before assembling transaxle.





11. Install assembled input and intermediate shafts to fixture 8487 (Fig. 38).





12. Install shift forks and 3/4 rail assembly to geartrain as shown in (Fig. 39).

NOTE: Before installing geartrain, make sure that input shaft sealed roller bearing is not installed, otherwise reverse idler assembly installation will be difficult.

13. Install lifting bar 8489 to geartrain. Install geartrain to case. When installing geartrain to case, use care not to damage bearing surfaces.
14. Remove lifting bar 8489 from geartrain.





15. Install shift 1/2-5/R rail as shown in (Fig. 40).





16. Install reverse idler shaft into position (Fig. 41). Install and torque shaft-to-case bolt to 54 Nm (40 ft. lbs.).





17. Install reverse idler gear bearing (Fig. 42).





18. Install reverse idler gear with hub down as shown in (Fig. 43).





19. Install flat washer (Fig. 44).





20. Install wave washer (Fig. 45).





21. Install input shaft sealed roller bearing using installer 8482 (Fig. 46).





22. Install new input shaft bearing snap ring (Fig. 47).





23. Install shift rail bushing to end cover using installer 8475 (Fig. 48).











24. Apply a 1 mm (0.04 inch) bead of Mopar Gasket Maker to transaxle end cover and install to transaxle case (Fig. 49). While installing end cover, be sure to guide oil trough into pocket (Fig. 50). Torque end cover-to-case bolts to 28 Nm (250 in. lbs.) (Fig. 51).
25. Install lifting bar 8489 to geartrain.





26. Lift up on bar (input shaft side) and install input shaft bearing snap ring (Fig. 52).
27. Lift up on bar (intermediate shaft side) and install intermediate shaft bearing snap ring.
28. Remove lifting bar 8489.





29. Install a bead of Mopar Gear Lube RTV to end plate and immediately install to case. Install and torque bolts to 28 Nm (250 in. lbs.) (Fig. 53).





30. Install back up lamp switch and torque to 23 Nm (17 ft. lbs.) (Fig. 54).





31. Apply a 1 mm (0.04 inch) bead of Mopar Gasket Maker to shift cover assembly. Place shift cover and transaxle geartrain into neutral and install shift cover (Fig. 55) and torque bolts to 28 Nm (250 in. lbs.).





32. Install input shaft bearing retainer (Fig. 56). Torque bolts to 12 Nm (105 in. lbs.).








33. If previously removed, install clutch release lever pivot ball(s) using slide hammer C-3752 and remover/installer 6891 (Fig. 57) (Fig. 58).





34. Install clutch release bearing to lever. Apply grease to interface (contact) points. Make sure release bearing retainers engage lever pocket as shown in (Fig. 59).
35. Apply grease to pivot ball, and on release lever at slave cylinder contact point.





36. Install clutch release bearing/lever assembly into position by sliding bearing onto input bearing retainer, and using moderate hand pressure to seat release lever to pivot ball (Fig. 60). A "pop" sound should be heard. Verify proper engagement by lightly pulling outward on lever at pivot ball location, and then actuating lever and bearing to ensure proper operation.