Assembly

NOTES:
- The sealant used to seal the transaxle case halves is MOPAR Gasket Maker, Loctite 518, or equivalent.

- The sealant used for the bearing end plate cover is MOPAR RTV.

Bench Fixture:

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

Shift Rail Installation:

2. Install shift rails and forks into bench fixture.

Shift Blocker Installation:

3. Install shift blocker assembly into bench fixture.

Reverse Brake Race Installation:

4. Install reverse brake race onto input shaft.

Reverse Brake Needle Bearing:

5. Install reverse brake needle bearing.

Reverse Brake Blocking Ring Installation:

6. Install reverse brake blocking ring.

Reverse Brake Friction Cone Installation:

7. Install reverse brake friction cone.

Reverse Brake Shim:

8. Install reverse brake shim. Apply petroleum jelly to shim to hold in place.

Gear Case Half:

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

Friction Cone Lugs:

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

Installing Input And Output Bearings:

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.

Snap Rings Retaining Bearings:

12. Install shaft snap rings at input and output bearings.

Transaxle End Cover:

13. Apply MOPAR 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.
14. Remove gear case from bench fixture.
15. Install gear case in a holding fixture with end cover facing down.

Selector Shaft:

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

Reverse Idler Gear:

Reverse Idler Shaft Bolt:

18. Install reverse idler gear and shaft. Install bolt into shaft. Tighten bolt on shaft to 26 Nm (19 ft. lbs.) torque.

Reverse Fork Bracket:

Reverse Fork Screws:

19. Install reverse fork bracket and reverse lockout. Tighten screws to 11 Nm (96 inch lbs.) torque.

Differential Assembly:

20. Install differential into gear case.

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 will give 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 their 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.

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

DIFFERENTIAL BEARING PRELOAD ADJUSTMENT
1. Remove bearing cup and existing shim from clutch bellhousing case.
2. Press in new bearing cup into bellhousing 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 type M.S. 9417 Manual Transaxle Fluid. Install differential assembly in transaxle gear case. Install clutch bellhousing over gear case. Install and torque case bolts to 29 Nm (21 ft. lbs.).
5. Position transaxle with bellhousing facing down on workbench with C-clamps. Position dial indicator.

Checking Differential Bearing End Play To Determine Shim Thickness:

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. Record end play.
7. The shim required for proper bearing preload is the total of end play, plus (constant) preload of 0.18mm (0.007 inch). Never combine shims to obtain the required preload.
8. Remove case bolts. Remove clutch bellhousing differential bearing cup. Install shim(s) selected in Step 7. Then press the bearing cup into clutch bellhousing.
9. Install clutch bellhousing. Install and torque case bolts to 26 Nm (19 ft. lbs.).

Checking Differential Bearing Turning Torque:

10. Using Special Tool C-4995 and an inch lb. torque wrench, check turning torque of the differential assembly. The turning torque should be 6 to 12 inch lbs. If the turning torque is too high, install a 0.05mm (0.002 inch) thinner shim. If the turning torque is too low, install a 0.05mm (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 Gasket Maker, Loctite 518, or equivalent, on the flat surface of the case mating flange. Install clutch bellhousing onto gear case. Install and tighten case bolts to 29 Nm (21 ft. lbs.).