Part 2 of 2
REASSEMBLY SERVICE POINTSA - SYNCHRONIZER SPRING INSTALLATION
Assemble the synchronizer spring so that its projection may be engaged in the groove of the synchronizer key. Take care to prevent the projections of the front and rear spring from sitting in the groove of the same key.
B - 3RD-4TH SPEED SYNCHRONIZER ASSEMBLY INSTALLATION
1. Install the synchronizer assembly so that the part that has the small round indentation is in the oil groove at the hub end.
NOTE: If the installation is in the opposite way, press-in might not be possible. This is because the edge of the hub inner diameter spline at the part that has the small round indentation is made to facilitate pressing in.
2. Press the 3rd-4th speed synchronizer assembly onto the input shaft using the special tool as illustrated.
CAUTION: When installing the synchronizer assembly, make sure that three synchronizer keys are seated correctly in respective grooves of the synchronizer ring.
3. Check the 3rd speed gear rotates smoothly.
C - BEARING SLEEVE INSTALLATION
Use the special tool as illustrated.
D - SUB GEAR/CONE SPRING/SNAP RING INSTALLATION
Install the sub gear and cone spring to 4th gear, and then install the snap ring.
NOTE: Be sure that the cone spring is installed so that it is facing in the correct direction.
E - TAPER ROLLER BEARING INSTALLATION
Install the taper roller bearing over the input shaft using the special tool.
F - SNAP RING INSTALLATION
1. Select thickest possible snap ring which can enter the snap ring groove.
Standard value: 0.01-0.09 mm (0.0004-0.0035 in.)
2. Using a special tool, attach the snap ring to the input shaft.
CAUTION:
- Don't reuse the old snap ring.
- If snap ring pliers are used, the snap ring may sometimes be expanded excessively. This will prevent proper mounting of the sleeve.
G - BEARING SLEEVE INSTALLATION
1. Using a special tool, fit the bearing sleeve to the input shaft.
CAUTION: After fitting, check that the sleeve flange is closely fit to the bearing.
H - TAPER ROLLER BEARING INSTALLATION
Install the taper roller bearing over the input shaft using the special tool.
INTERMEDIATE GEAR DISASSEMBLY AND REASSEMBLY
DISASSEMBLY SERVICE POINTS
A - TAPER ROLLER BEARING/1ST SPEED GEAR REMOVAL
Remove the taper roller bearing, 1st speed gear and bearing sleeve using the special tool as illustrated.
CAUTION:
- Do not reuse the bearing removed from the shaft.
- Replace the inner and outer races of the taper roller bearing as a set.
B - 1ST-2ND SPEED SYNCHRONIZER HUB/2ND SPEED GEAR REMOVAL
Remove the 1st-2nd speed synchronizer assembly and 2nd speed gear together using the special tool as illustrated.
C - TAPER ROLLER BEARING REMOVAL
Use the special tool as illustrated.
CAUTION:
- Do not reuse the bearing removed from the shaft.
- Replace the inner and outer races of the taper roller bearing as a set.
INSPECTION
INTERMEDIATE GEAR
- Check the outer surface of the intermediate gear where the needle bearing is mounted for damage, abnormal wear and seizure [portion A].
- Check the splines for damage and wear.
NEEDLE BEARING
- Combine the needle bearing with the shaft or bearing sleeve and gear and check that it rotates smoothly without abnormal noise or play.
- Check the needle bearing cage for deformation.
SYNCHRONIZER RING
- Check the clutch gear teeth for damage and breakage.
- Check paper lining on synchronizer outer ring l.D. and synchronizer inner ring 0.0. for damage, wear, and flaking.
- Force the synchronizer outer ring toward the clutch gear and check clearance "A". Replace if it is out of specification.
Limit: 0.5 mm (0.02 in.)
SYNCHRONIZER SLEEVE AND HUB
- Combine the synchronizer sleeve and hub and check that they slide smoothly.
- Check that the sleeve is free from damage at its inside front and rear ends.
- Check for wear of the hub end surfaces (in contact with each speed gear).
CAUTION: When replacing, replace the synchronizer hub and sleeve as a set.
SYNCHRONIZER KEY AND SPRING
- Check for wear of the synchronizer key center protrusion.
- Check the spring for weakness, deformation and breakage.
SPEED GEARS
- Check the bevel gear and clutch gear teeth for damage and wear.
- Check the synchronizer cone for rough surface, damage and wear.
- Check the gear bore and front and rear ends for damage and wear.
REASSEMBLY SERVICE POINTS
A - TAPER ROLLER BEARING INSTALLATION
Install the taper roller bearing over the intermediate gear using the special tool.
CAUTION: When installing the bearing, push the inner race only.
B - 1ST-2ND SPEED SYNCHRONIZER HUB/SYNCHRONIZER KEY/1ST-2ND SPEED/SYNCHRONIZER SLEEVE/SYNCHRONIZER/SPRING INSTALLATION
1. Combine the 1st-2nd speed synchronizer hub and sleeve as illustrated.
2. Assemble the synchronizer spring so that its projection may be engaged in the groove of the synchronizer key. Take care to prevent the projections of the front and rear spring from sitting in the groove of the same key.
NOTE: A synchronizer spring of a different shape from what is shown may be installed; however, there is no difference in installation procedure.
3. Install the 1st-2nd speed synchronizer assembly over the intermediate gear using the special tool.
CAUTION:
- When installing the synchronizer assembly, make sure that three synchronizer keys are seated correctly in respective grooves of the synchronizer ring.
- After installation of the synchronizer assembly, check that the 3rd speed gear rotates smoothly.
C - BEARING SLEEVE INSTALLATION
Install the 1st speed gear and bearing sleeve together Over the intermediate gear using the special tool.
D - TAPER ROLLER BEARING INSTALLATION
Install the taper roller bearing over the intermediate using the special tool.
CAUTION: When installing the bearing, push the inner race only.
E - SNAP RING INSTALLATION
Select and install a snap ring that will result in an intermediate gear bearing end play that is the standard value.
Standard value: 0.01-0.14 mm (0.0004-0055 in.)
OUTPUT SHAFT DISASSEMBLY AND REASSEMBLY
DISASSEMBLY SERVICE POINT
A - TAPER ROLLER BEARINGS REMOVAL
Remove the taper roller bearing using the special tool as illustrated.
CAUTION:
- Do not reuse the bearings removed from the shaft.
- Replace the inner and outer races of the taper roller bearing as a set.
REASSEMBLY SERVICE POINT
A - TAPER ROLLER BEARINGS INSTALLATION
Install the taper roller bearing using the special tool.
CAUTION: When installing the bearing, push the inner race only.
SHIFT RAILS AND FORKS DISASSEMBLY AND REASSEMBLY
REASSEMBLY SERVICE POINT
A - INTERLOCK PLUNGER INSTALLATION
Insert the interlock plunger at illustrated position of the 3rd-4th speed shift rail.
DIFFERENTIAL DISASSEMBLY AND ASSEMBLY
DISASSEMBLY SERVICE POINTS
A - TAPER ROLLER BEARING REMOVAL
Remove the taper roller bearing using the special tool as illustrated.
CAUTION:
- Do not reuse the bearing removed from the differential case.
- Replace the inner and outer races of the taper roller bearing as a set.
B - LOCK PIN REMOVAL
Drive out the lock pin from the hole A using a punch.
REASSEMBLY SERVICE POINTS
A - SPACER/SIDE GEAR/WASHER/PINION/PINION SHAFT INSTALLATION
1. Install the spacer on the back of the side gear and then install the gear in the differential case.
CAUTION: When installing a new side gear, use a spacer of medium thickness of 0.93-1.00 mm (0.0366-0.0394 in.)
2. Set the washer on the back of each pinion and insert the two pinions to specified position while engaging them with the side gears and turning them.
3. Insert the pinion shaft.
4. Measure the backlash between the side gears and pinions.
Standard value: 0.025-0.150 mm (0.001-006 in.)
5. If the backlash is out of specification, disassemble again and using correct spacer, reassemble and adjust.
CAUTION: Adjust for same backlash of both side gears.
B - LOCK PIN INSTALLATION
Align the pinion shaft lock pin hole with the case lock pin hole and insert the lock pin.
CAUTION:
- Do not reuse the lock pin.
- The lock pin head must be sunk from the flange surface of the differential case.
C - TAPER ROLLER BEARING INSTALLATION
Install the taper roller bearings on both sides of the differential case.
CAUTION: When press-fitting the bearings, push the inner race only.
D - BOLTS INSTALLATION
Apply MOPAR Part No.4318031 or No.4318032 or equivalent adhesive to the entire threads of the bolts and quickly tighten in the order shown to specified torque.
CAUTION: If a bolt is reused, remove traces of oil adhesive completely from the threads.
SPEEDOMETER DRIVEN GEAR DISASSEMBLY AND REASSEMBLY
REASSEMBLY SERVICE POINTS
A - SPEEDOMETER DRIVEN GEAR INSTALLATION
Apply gear oil sparingly to the speedometer driven gear shaft and insert the shaft.
B - SPRING PIN INSTALLATION
Install the spring pin in such a way that its slit does not face the gear shaft.
CLUTCH HOUSING DISASSEMBLY AND REASSEMBLY
DISASSEMBLY SERVICE POINTS
A - LOCK PIN REMOVAL
Drive out the lock pin from the control finger.
CAUTION: When removing the lock pin, turn the control lever to such position that the lock pin will not contact the clutch housing.
B - SPRING PIN REMOVAL
Drive out the spring pin from the stopper body.
CAUTION: When removing the spring pin, pull the control shaft in the direction illustrated so that the spring pin will not contact the clutch housing.
REASSEMBLY SERVICE POINTS
A - NEEDLE BEARINGS INSTALLATION
Install the needle bearing flush with the surface A of the clutch housing.
B - OIL SEAL INSTALLATION
Install the control shaft oil seal using a socket wrench.
C - SPRING PIN/LOCK PIN INSTALLATION
1. Install new spring pin and lock pin using the special tool.
CAUTION: Do not reuse the spring pin and lock pin.
2. Install the spring pin with its slit at right angle to the control shaft center.