Part 2

ASSEMBLY




63. Install the transmission case half (1) onto the clutch housing (2).





CAUTION: Insure snap rings are fully seated in bearings before installing case bolts.

64. Using suitable snap-ring pliers (3), expand the transmission shaft bearing snap-rings (1, 2) at the rear of the transmission case to allow the bearings fall into place.





NOTE: Always use a new washer anti-rotation bolt.

NOTE: Add MOPAR(R) Gasket Maker, Loctite(R) 518, or equivalent around inside flat of plug.

65. Install the new 27 mm shaft plug (2) into the rear of the case.
66. Install a 27 mm (1 1/16 in.) hex adapter (1) into the shaft plug (2) at the rear of the transmission case (3) and tighten to 55 Nm (41 ft. lbs.).





NOTE: Always use a new washer anti-rotation bolt.

NOTE: Next step only to be used on final assembly.

67. Install anti-rotation bolt (2) and washer (3) tighten to 80 Nm (59 ft. lbs.).




68. Install the bolts (1) holding the transmission case (2) to the clutch housing (3) on the transmission case side and tighten to 29 Nm (257 in. lbs.).




69. Install the bolts (1) holding the transmission case to the clutch housing on the inside of the clutch housing and tighten to 29 Nm (257 in. lbs.).




70. Add MOPAR(R) Gasket Maker, Loctite(R) 518, or equivalent around inside of all holes and on mating flange.




71. Install the shift lever assembly (1) into the transmission case (2).




72. Install thenew bolts (1) holding the shift lever assembly (2) to the transmission and tighten to 19 Nm (168 in. lbs.)




73. Install new shift tower lock ball for shift detent (5) and tighten to 29 Nm (277 in. lbs.).
74. Install new shift lock ball for the select detent (3) and tighten to 39 Nm (29 ft. lbs.).
75. Install new shift tower shift guide pin (2) and tighten to 30 Nm (257 in. lbs.).




76. Install the shift bracket (2) and bolts, tighten to 19 Nm (168 in. lbs.)




77. Install the crossover (1) onto the transmission.
78. Install the crossover bolts (1) and tighten to 19 Nm (168 in. lbs.)




79. Apply a light coating of white grease on crossover bushing (1).
80. Install the crossover bushing (1) onto the crossover shaft (2).




81. Install the nut (4) holding the crossover rod (2) to the shift lever. Be sure to use a wrench (1) to hold the ball stud to prevent it from rotating in the shift lever tighten to 12 Nm (106 in. lbs.).





CAUTION: Be sure to verify bracket position after installation.

82. Install the shift cable bracket (1) to the transmission case.
83. Install the bolts (2) holding the shift cable bracket (1) to the transmission case and tighten to 19 Nm (168 in. lbs.).




84. Install the backup lamp switch (1) with anew washer and tighten to 40 Nm (29 ft. lbs.).




85. Install the drain plug (1) with a new gasket and tighten to 39 Nm (29 ft. lbs.).

BEARING ADJUSTMENT PROCEDURE

86. 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.
87. 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.
88. 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.
89. 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.
90. Bearing cones must not be reused if removed.
91. 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 geartrain removed from the case.

92. Remove bearing cup and existing shim from clutch bellhousing case.
93. 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).
94. Press in new bearing cup into gear case side.
95. Oil differential bearings with transmission fluid. Install differential assembly in transaxle gear case. Install clutch bellhousing over gear case. Install and tighten case bolts to 29 Nm (257 in. lbs.).
96. Position transaxle with bellhousing facing down on workbench with C-clamps. Position dial indicator.

NOTE: The dial indicator should be parallel to T-Handle to obtain the most accurate reading.

97. Apply a medium load to differential with Torque Tool C-4995 - A (3) 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 (2). To obtain end play readings, apply a medium load in an upward direction while rolling differential assembly back and forth. Record end play.
98. The shim required for proper bearing preload is the total of end play, plus (constant) preload of 0.18mm (0.007 in.). Never combine shims to obtain the required preload.
99. Remove case bolts. Remove clutch bellhousing differential bearing cup. Install shim(s) selected, then press the bearing cup into clutch bellhousing.
100. Install clutch bellhousing. Install and tighten case bolts to 29 Nm (257 in. lbs.).
101. Using Torque Tool C-4995 A (2) and an inch-pound torque wrench (1), check turning torque of the differential assembly. The turning torque should be 80 to 195 Nm (9 to 22 in. 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.
102. Recheck turning torque (1). Repeat until the proper turning torque is obtained.
103. Once proper turning torque has been established for the differential separate case halves, install output shaft #2 assembly into case with the differential and recheck differential turning torque. The turning torque should be 327 to 460 Nm (37 to 52 in. 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.
104. Recheck total turning torque (1). Repeat 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(R) Gasket Maker, Loctite(R) 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 (257 in. lbs.).





105. Install axle seal (case side) on Seal Installer 9928 and Handle C-4171 and insert into axle shaft seal bore.
106. Tap seal into position until seated against transaxle case.





107. Install axle seal (bellhousing side) on Seal Installer 9928 and Handle C-4171 and insert into axle shaft seal bore.
108. Tap seal into position until seated against transaxle case.