Assembly
ASSEMBLY1. Install input and output shaft oil troughs to transaxle housing as shown in.
2. Install output shaft roller bearing to clutch bellhousing (Fig. 59).
3. Install differential assembly (Fig. 60).
4. Using heat gun, heat reverse shaft bearing boss in transaxle case to expand for reverse shaft/ bearing installation (Fig. 61).
5. Install reverse shaft and fork/rod as shown in (Fig. 62).
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.
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 bolts by hand (Fig. 65) (Fig. 66) (Fig. 67).
9. Torque twenty (18 short, 2 long) geartrain housing-to-clutch bellhousing bolts to 28 Nm (21 ft. lbs.) torque (Fig. 68).
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).
11. Engage fifth and reverse gears as shown in (Fig. 71) (Fig. 72).
12. Install new bearing retainer screws and torque to 90 - 100 Nm (66 - 74 ft. lbs.) (Fig. 73).
13. Install input and output shaft oil diverters as shown in (Fig. 74) (Fig. 75).
14. Install a bead of Mopar Gear Sealant RTV to geartrain housing as shown in (Fig. 76).
15. Install a bead of Mopar Gear Sealant RTV to end cover as shown in (Fig. 77).
16. Immediately install end cover to geartrain housing. Install and torque nine (9) bolts to 20 - 25 Nm (15 - 18 ft. lbs.) (Fig. 78).
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.
19. Install crossover lever assembly and four (4) bolts (Fig. 80). Torque shift shaft-to-geartrain housing bolts to 20 - 25 Nm (15 - 18 ft. lbs.).
20. Install shift shaft crossover detent pin, spring, and plug. Torque plug to 20 Nm (15 ft. lbs.) (Fig. 81).
21. Install shift shaft selector detent assembly with Mopar Lock 'n Seal (Fig. 82). Torque detent assembly 20 - 25 Nm (15 - 18 ft. lbs.).
22. Install back-up lamp switch (Fig. 83). Torque switch to 24 Nm (18 ft. lbs.).
23. Install four (4) shift rod detent plugs. Install new plugs as necessary Tap into place using a soft-tipped hammer (Fig. 84).
24. Install input shaft seal using Tool 8864 (Fig. 85).
25. Install output (axle) shaft seals (Fig. 86) using Tool 8916.
26. Install concentric slave cylinder (Fig. 87). Torque bolts in three passes to specified torque.