Assembly
Fig. 57 Input Shaft Oil Trough:
Fig. 58 Output Shaft Oil Trough:
ASSEMBLY
1. Install input and output shaft oil troughs to transaxle housing as shown in (Fig. 57) (Fig. 58).
Fig. 59 Output Shaft Bearing Installation:
2. Install output shaft roller bearing to clutch bellhousing (Fig. 59).
Fig. 60 Differential Assembly:
3. Install differential assembly (Fig. 60).
Fig. 61 Heating Reverse Shaft Bearing Bore:
4. Using heat gun, heat reverse shaft bearing boss in transaxle case to expand for reverse shaft/ bearing installation (Fig. 61).
Fig. 62 Reverse Shaft and Fork Assembly:
5. Install reverse shaft and fork/rod as shown in (Fig. 62).
Fig. 63 Install Geartrain to Clutch Bellhousing:
Fig. 64 Propedy Installed Geartrain:
6. Install geartrain (with forks/rods) into case (Fig. 63). Verify proper installation of input and output shaft assemblies, as well as proper orientation of shift rod/fork assemblies (Fig. 64).
7. Install chip collector magnet to case and retain with grease.
Fig. 65 Install Geartrain Housing:
8. Apply a bead of Mopar Gasket Maker or Omnifit FD-40 to clutch bellhousing flange. Install geartrain housing and install transaxle housing-to-clutch bellhousing
Fig. 66 Geartrain Housing-to-Clutch Bellhousing Bolts (Short):
Fig. 67 Geartrain Housing-to-Clutch Bellhousing Bolts (Long):
Fig. 68 Torquing Transaxle Housing to Clutch Bellhousing Bolts:
9. Torque twenty (18 short, 2 long) geartrain housing-to-clutch bellhousing bolts to 28 N.m (21 ft. lbs.) torque (Fig. 68).
Fig. 69 Install Input Shaft Roller Bearing:
Fig. 70 Install Output Shaft Bearing:
10. Using an arbor press and Tools C-4171 and 8871, install input and output shaft roller bearings as shown in (Fig. 69) (Fig. 70).
Fig. 71 Engage Fifth Gear:
Fig. 72 Engage Reverse Gear:
11. Engage fifth and reverse gears as shown in (Fig. 71) (Fig. 72).
Fig. 73 Bearing Retaining Screws:
12. Install new bearing retainer screws and torque to 90-100 N.m (66-74 ft. lbs.) (Fig. 73).
Fig. 74 Input Shaft Oil Diverter:
Fig. 75 Output Shaft Oil Diverter:
13. Install input and output shaft oil diverters as shown in (Fig. 74) (Fig. 75).
Fig. 76 Proper Sealer Application:
14. Install a bead of Mopar Gear Sealant RTV to geartrain housing as shown in (Fig. 76).
Fig. 77 Apply Sealer to Cover:
15. Install a bead of Mopar© Gear Sealant RTV to end cover as shown in (Fig. 77).
Fig. 78 End Cover-to-Case Bolts:
16. Immediately install end cover to geartrain housing. Install and torque nine (9) bolts to 20-25 N.m (15-18 ft. lbs.) (Fig. 78).
Fig. 79 Apply Sealer to Shift Shaft Mounting Location:
17. Install bead of Mopar Gasket Maker or Omnifit FD-1664 to shift shaft assy mounting pad as shown in (Fig. 79).
NOTE: When installing shift shaft assembly, do not handle assembly by counterweight.
18. Install shift shaft assembly. Use caution when installing. It is necessary to guide slot in shaft assembly over locating pin which is pressed into case.
Fig. 80 Shift Shaft-to-Case Bolts:
19. Install crossover lever assembly and four (4) bolts (Fig. 80). Torque shift shaft-to-geartrain housing bolts to 20-25 N.m (15-18 ft. lbs.).
Fig. 81 Shift Shaft Crossover Detent Components:
20. Install shift shaft crossover detent pin, spring, and plug. Torque plug to 20 N.m (15 ft. lbs.) (Fig. 81).
Fig. 82 Shift Shaft Detent Assembly:
21. Install shift shaft selector detent assembly with Mopar Lock 'n Seal (Fig. 82). Torque detent assembly 20-25 N.m (15-18 ft. lbs.).
Fig. 83 Backup Lamp Switch:
22. Install back-up lamp switch (Fig. 83). Torque switch to 24 N.m (18 ft. lbs.).
Fig. 84 Seat with Soft-Tipped Hammer:
23. Install four (4) shift rod detent plugs. Install new plugs as necessary. Tap into place using a soft-tipped hammer (Fig. 84).
Fig. 85 Input Shaft Seal Installation:
24. Install input shaft seal using Tool 8864 (Fig. 85).
Fig. 86 Axle Seal Installation:
25. Install output (axle) shaft seals (Fig. 86) using Tool 9064 and Driver Handle C-4171.
Fig. 87 CSC Remova/Installation:
26. Install concentric slave cylinder (Fig. 87). Torque bolts in three passes to specified torque. (Refer to MANUAL TRANSMISSION SPECIFICATIONS)