Transaxle Disassembly & Assembly
The NV T350 (A-578) transaxle internal components can be serviced only by separating the gear case from the bellhousing 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.
Case Bolts:
2. Remove shift levers. Remove transaxle case half bolts.
Transaxle Case Halves:
Separate Case Halves:
3. Place two screwdrivers into the slots provided in the case halves near the dowels. Separate the case halves.
Bellhousing Case Half Removal:
4. Remove bellhousing half from gear case half.
5. Remove output shaft roller bearing from output shaft.
Differential Assembly Removal:
6. Remove differential assembly.
Reverse Idler Shaft Bolt Removal:
Reverse Idler Gear Removal:
7. Remove reverse idler shaft bolt. Remove reverse idler gear.
Screws Retaining Reverse Fork Bracket:
Remove Reverse Fork Bracket:
8. Remove two screws retaining reverse fork bracket. Remove reverse fork bracket and reverse cam block-out assembly.
Remove Selector Shaft Spacer:
9. Using snap-ring pliers, remove selector shaft spacer.
Selector Shaft:
10. Pull the selector shaft shift pin out of the slot in the blocker assembly. Turn selector shaft up and out of the way.
Transaxle Cover Removal:
End Cover:
11. Remove transaxle end cover.
Snap Rings Retaining Bearings:
12. Remove two snap rings retaining the output shaft and the input shaft to the bearings.
Bench Fixture:
13. Using bench fixture and shims provided (Miller tools # 6785, 6785-1, and 6785-2), turn transaxle over. Install transaxle onto bench fixture. Verify shim spacers are in position on bench fixture. Install transaxle into shop press.
Bearing Fixture:
14. Install bearing fixture Miller tool # 6768 onto transaxle end bearings. 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.
Pressing Gears Out Of Case:
15. Install transaxle gear case into shop press. Press output and input shaft assemblies out of case.
16. Remove transaxle from press.
Transaxle Case Removal:
Oil Feed Through:
17. Carefully remove transaxle case from the shaft assemblies and bench fixture. Be sure the oil-feed trough to the end bearings is not damaged.
Reverse Brake Shim:
Reverse Brake Friction Cone:
Reverse Brake Blocking Ring:
Reverse Brake Needle Bearing:
Reverse Brake Race:
18. TRANSAXLE W/ REVERSE BRAKE: Remove the reverse brake blocking ring, shim, reverse brake friction cone, bearing and race from the input shaft assembly. TRANSAXLE W/O REVERSE BRAKE: Remove plastic spacer from the input shaft assembly.
Shift Blocker Removal:
19. Remove the shift blocker assembly from the bench fixture.
Shift Fork Removal:
20. Remove the 1-2 shift fork from the output shaft.
Gear Train Removal:
21. Remove input and output shaft assemblies from bench fixture.
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 falls, it is necessary to replace the complete output shaft assembly.
ASSEMBLY
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:
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 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 gear-train removed from the case.
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 0.18 mm (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 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-pound 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 0.05 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 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.).