Part 2 of 3

REASSEMBLY SERVICE POINTS




A - 3RD-4TH SPEED SYNCHRONIZER HUB/3R-4TH SPEED SYNCHRONIZER SLEEVE INSTALLATION

B - SYNCHRONIZER SPRING-SYNCHRONIZER KEY INSTALLATION




Position each spring with respect to the keys as illustrated.




C - BEARING SLEEVE FOR 4TH SPEED GEAR INSTALLATION




D - SUB GEAR/CONE SPRING/S NAP RING INSTALLATION




E - REAR TAPER ROLLER BEARING INSTALLATION

F - SNAP RING INSTALLATION








Select the thickest snap ring that can be fitted in the snap ring groove.
Standard value: Input shaft rear bearing end play 0-0.09 mm (0-0.0035 in.)

CAUTION:
- Do not reuse the snap ring.
- Do not open the snap ring too wide by pliers, or the sleeve will be improperly installed.




G - BEARING SLEEVE FOR 5TH SPEED GEAR INSTALLATION

CAUTION: When press-fitting the sleeve to the input shaft, make sure that the sleeve flange is closely fitted to the bearing.




H - FRONT TAPER ROLLER BEARING INSTALLATION

INSPECTION

INPUT SHAFT




1. Check the outer surface of the input shaft where the needle bearing is mounted for damage, abnormal wear and seizure [portion A].
2. Check the splines for damage and wear.

NEEDLE BEARING




1. Combine the needle bearing with the shaft or bearing sleeve and gear, and check that it rotates smoothly without abnormal noise or play.
2. Check the needle bearing cage for deformation.

SYNCHRONIZER RING




1. Check the clutch gear teeth for damage and breakage.
2. Check the internal surface for damage, wear and broken threads.




3. Force the synchronizer ring toward the clutch gear and check clearance "A". Replace if it is out of the limit.
Limit: 0.5 mm (0.02 in.)

SYNCHRONIZER SLEEVE AND HUB




1. Combine the synchronizer sleeve and hub, and check that they slide smoothly.
2. Check that the sleeve is free from damage at its inside front and rear ends.
3. Check for wear of the hub end surfaces (in contact with each speed gear).

CAUTION: Replace the synchronizer hub and sleeve as a set.

SYNCHRONIZER KEY AND SPRING




1. Check for wear of the synchronizer key center protrusion.
2. Check the spring for weakness, deformation and breakage.

SPEED GEARS




1. Check the synchronizer cone for rough surface, damage and wear.
2. Check the gear bore and front and rear ends for damage and wear.




INTERMEDIATE GEAR DISASSEMBLY AND REASSEMBLY

DISASSEMBLY SERVICE POINTS




A - BALL BEARING/TAPER ROLLER BEARING/1ST SPEED GEAR REMOVAL

CAUTION: Do not reuse the bearing.




B - 1ST-2ND SPEED SYNCHRONIZER SLEEVE/2ND SPEED GEAR REMOVAL




C - TAPER ROLLER BEARING REMOVAL

CAUTION:
- Do not reuse the bearing.
- Replace the inner and outer races of the taper roller bearing as a set.

REASSEMBLY SERVICE POINTS




A - TAPER ROLLER BEARING INSTALLATION

CAUTION: Apply the special tool to the inner race only.

B - SYNCHRONIZER RINGS FOR 1ST AND 2ND SPEED GEARS INSTALLATION




The 1St speed gear and 2nd speed gear of synchronizer rings have an identification mark.

C - 1ST-2ND SPEED SYNCHRONIZER HUB/SYNCHRONIZER KEY/1ST-2ND SYNCHRONIZER/SLEEVE INSTALLATION




1. Combine the 1st-2nd speed synchronizer hub and sleeve as illustrated.




2. The synchronizer sleeve has tooth missing at six portions. Assemble the hub to the sleeve so that the center tooth "T"between two missing teeth will touch the synchronizer key.

D - SYNCHRONIZER SPRING INSTALLATION




Position each spring with respect to the keys as illustrated.




E - BEARING SLEEVE INSTALLATION




F - TAPER ROLLER BEARING INSTALLATION

CAUTION: Apply the special tool to the inner race only.

G - SNAP RING INSTALLATION




Select and install the snap ring that gives standard intermediate gear bearing end play.
Intermediate gear bearing end play: 0.01-0.14 mm (0.0004-0.0055 in.)

INSPECTION

INTERMEDIATE GEAR




1. Check the outer surface of the intermediate gear where the needle bearing is mounted for damage, abnormal wear and seizure [portion A].
2. Check the splines for damage and wear.

NEEDLE BEARING




1. Combine the needle bearing with the shaft or bearing sleeve and gear and check that it rotates smoothly without abnormal noise or play.
2. Check the needle bearing cage for deformation.

SYNCHRONIZER RING




1. Check the clutch gear teeth for damage and breakage.
2. Check the internal surface for damage, wear and broken threads.




3. Force the synchronizer ring toward the clutch gear and check clearance "A". Replace if it is out of the limit.
Limit: 0.5 mm (0.020 in.)

SYNCHRONIZER OUTER RING, INNER RING AND CONE




1. Check that there are no scratches or damage on the clutch gear teeth and cone surface.
2. Check that there are no scratches, wear or peeling on the paper lining surface.




3. Install the outer ring, inner ring and cone, and press them onto the clutch gear. Check clearance "A", and replace it "A" is below the limit value.
Limit: 0.5 mm (0.020 in.)

CAUTION: Replace the outer ring, inner ring and cone as a set.

SYNCHRONIZER SLEEVE AND HUB




1. Combine the synchronizer sleeve and hub and check that they slide smoothly.
2. Check that the sleeve is free from damage at its inside front and rear ends.
3. Check for wear of the hub end surface (in contact with each speed gear).

CAUTION: Replace the synchronizer hub and sleeve as a set

SYNCHRONIZER KEY AND SPRING




1. Check for wear of the synchronizer key center protrusion.
2. Check the spring for weakness, deformation and breakage.

SPEED GEARS




1. Check the bevel gear and clutch gear teeth for damage and wear.
2. Check the synchronizer cone for rough surface, damage and wear.
3. Check the gear bore and front and rear ends for damage and wear.




FRONT OUTPUT SHAFT DISASSEMBLY AND REASSEMBLY

DISASSEMBLY SERVICE POINT

A - TAPER ROLLER BEARINGS REMOVAL




Use the special tool to remove the taper roller bearings.

NOTE:
- Do not reuse the bearing.
- Replace the inner and outer races of the taper roller bearing as a set.

REASSEMBLY SERVICE POINTS

A - TAPER ROLLER BEARINGS INSTALLATION




Use the special tool to install the taper roller bearing.

NOTE: Apply the special tool to the inner race only.

B - TAPER ROLLER BEARINGS INSTALLATION




Use the special tool to install the taper roller bearing.

NOTE: Apply the special tool to the inner race only.




DIFFERENTIAL DISASSEMBLY AND REASSEMBLY





DISASSEMBLY SERVICE POINTS

A - BALL BEARINGS REMOVAL

CAUTION: Do not reuse the bearing.




B - TAPER ROLLER BEARING REMOVAL

CAUTION:
- Do not reuse the bearing.
- Replace the Inner and outer races of the taper roller bearing as a set.

C - LOCK PIN REMOVAL




Use a punch to drive out the lock pin from the hole A.

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 [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 (0.00098-0.00591 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




1. Align the pin ion 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 BEARINGS INSTALLATION

CAUTION: Apply the special tool to the Inner race only.




D - BALL BEARINGS INSTALLATION

E - BOLTS INSTALLATION




1. Apply the specified sealant to the bolt threads.
Specified sealant: MOPAR Part No.4318031 or MOPAR Part No. 4318032 or equivalent




2. Tighten to the specified torque while following the order given in the illustration.