Transaxle Case Overhaul
OVERVIEWThe 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.
The components that are left in the gear cases when the gear train is pulled out are the:
- Axle shaft seals
- Output bearing race and retainer
- Input bearing and sleeve
- Differential bearing cones
- Shift rail bushings
- Shift shafts
- Shift shaft seals
- Shift shaft bushings
- Rear bearing oil feed trough
AXLE SHAFT SEALS
REMOVAL
Fig. 129:
1. Insert a flat-blade pry tool at outer edge of axle shaft seal (Fig. 129).
2. Tap on the pry tool with a small hammer and remove axle shaft seal.
INSTALLATION
1. Clean axle shaft seal bore of any excess sealant.
2. Align axle shaft seal with axle shaft seal bore.
3. Install axle seal on tool #6709 with C-4171 and insert into axle shaft seal bore.
Fig. 130:
4. Tap seal into position (Fig. 130).
OUTPUT BEARING
REMOVAL
CAUTION: THE POSITION OF THE OUTPUT SHAFT BEARING IS CRITICAL. THE BEARING IS NOT IDENTICAL END-TO-END. INSTALL BEARING WITH LARGER DIAMETER CAGE RING FACING OUT.
Fig. 131:
1. Remove caged roller bearing from output bearing race (Fig. 131).
Fig. 132:
2. Remove screws at output bearing retainer strap (Fig. 132).
Fig. 133:
3. Install tool #6787 and slide hammer (Fig. 133). Tighten tool to output bearing race.
4. Using slide hammer, remove output bearing race.
INSTALLATION
1. Line up output bearing race to race bore.
Fig. 134:
2. Insert tool #4628 with C-4171 into output bearing race (Fig. 134). Tap race into bore. Install output bearing into race. Verify that the larger diameter cage is facing outward. Position bearing retaining strap. Tighten bolts to 11 Nm (96 inch lbs.).
INPUT BEARING AND SLEEVE
Fig. 135:
The input bearing is a one-piece bearing and sleeve unit (Fig. 135). The sleeve is the slide point for the clutch-release bearing and lever.
REMOVAL
1. Install tool #6342 over input bearing on the gear case side of the transaxle clutch housing.
Fig. 136:
2. Press the input bearing out of the housing (Fig. 136).
INSTALLATION
1. Apply coating of Loctite sealant on bearing outer diameter. Position sleeve and bearing assembly at input bearing bore.
Fig. 137:
2. Install tool #C-4680-1 over input bearing (Fig. 137).
Fig. 138:
3. Using the spacer tool #4894 and shop press, install input bearing into bore until it is fully seated (Fig. 138).
DIFFERENTIAL BEARING CUPS
REMOVAL
1. Remove differential assembly from gear case.
Fig. 139:
2. Install Miller tool #L-4518 into the differential bearing cup (Fig. 139).
Fig. 140:
3. Install the tool cup over the tool (Fig. 140).
4. Tighten the tool until the race is removed from the case.
INSTALLATION
1. Position the bearing cup into the case.
2. Install the bearing cup onto Miller tool #L-4520.
3. Using Miller tool #L-4520 and C-4171 driver, install differential bearing cup into the transaxle case.
SHIFT RAIL BUSHINGS
REMOVAL
1. Thread tool #6786 into shift rail bushing.
2. Install slide hammer #3752 onto tool.
Fig. 141:
3. Remove bushing using slide hammer and tool assembly (Fig. 141).
INSTALLATION
1. Line up replacement bushing in bore.
2. Using tool #MD998343, tap bushing into bore until flush with the chamfer in the case.
SHIFT SHAFT SEALS
It is not necessary to remove the shift shafts from the transaxle to service the shift shaft seals.
REMOVAL
1. Using a pick tool, pry up on the shift shaft seal and remove seal from bore.
INSTALLATION
1. Position new shift shaft seal in bore.
2. Install shift shaft seal into bore using an appropriate size deep-well socket.
SHIFT SELECTOR SHAFT
REMOVAL
1. Disassemble transaxle.
2. With the transaxle disassembled, remove the selector shaft by pushing on the shaft from the outside. Pull shaft out from the inside.
INSTALLATION
1. Reverse removal procedure to install selector shaft.
SHIFT CROSSOVER SHAFT
REMOVAL
1. Disassemble transaxle.
2. With the transaxle disassembled, remove the crossover shaft seal.
Fig. 142:
3. Using snap-ring pliers, remove the snap ring at the crossover shaft bore (Fig. 142).
4. Push the crossover shaft in the case and remove the crossover assembly.
INSTALLATION
1. Reverse removal procedure to install crossover shaft.
SHIFT SELECTOR SHAFT BUSHING
REMOVAL
1. Remove selector shaft.
2. Thread tool #6786 into bushing.
Fig. 143:
3. Install slide hammer #3752 onto tool and remove bushing using slide hammer (Fig. 143).
INSTALLATION
1. Position replacement bushing over selector shaft bore.
Fig. 144:
2. Using an appropriate size deep-well socket, install bushing in selector shaft bore (Fig. 144).
SHIFT CROSSOVER SHAFT BUSHING
REMOVAL
1. Install slide hammer #3752 through the crossover bushing.
2. Thread nut and washer onto slide hammer.
Fig. 145:
3. Using the slide hammer, remove the crossover shaft bushing (Fig. 145).
INSTALLATION
1. Position the replacement crossover shaft bushing over the crossover shaft bushing bore.
2. Using an appropriate size deep-well socket, install the crossover shaft bushing into the bushing bore.
REAR BEARING OIL FEED TROUGH
Fig. 146:
The bearing oil feed trough is retained in the case by a pin that is molded into the case and clips that are part of the trough (Fig. 146).
REMOVAL
1. Using light plier pressure, squeeze the clips together at the rear of the trough.
2. Slide the trough over the retaining pin that locates the trough in the case.
INSTALLATION
1. Reverse removal procedure to install oil feed trough.