Assembly
G288 MANUAL TRANSAXLEASSEMBLY
1. Install input shaft oil trough (1) to transaxle housing.
2. Install output shaft oil trough (1) to transaxle housing.
3. Install output shaft roller bearing to clutch bellhousing (1, 2).
4. Install differential assembly (1).
5. Using heat gun (1), heat reverse shaft bearing bore (2) in transaxle case to expand for reverse shaft/ bearing installation.
6. Install reverse shaft (2) and fork/rod (1).
7. Install geartrain (1) (with forks/rods) into case.
8. Verify proper installation of input (2) and output shaft (1) assemblies, as well as proper orientation of shift rod/fork assemblies.
9. Install chip collector magnet to case and retain with grease.
10. Apply a bead (3) of Mopar(R) Gasket Maker or Omnifit FD-40 to clutch bellhousing flange (2). Install geartrain housing (1).
11. Install transaxle housing-to-clutch bellhousing short bolts (1) by hand.
12. Install transaxle housing-to-clutch bellhousing long bolts (1) by hand.
13. Torque (1) twenty (18 short, 2 long) geartrain housing-to-clutch bellhousing bolts to 28 Nm (21 ft. lbs.) torque.
14. Using an arbor press and Handle C-4171 (1) and Installer 8871(2), install input shaft roller bearing (4).
15. Using an arbor press and Handle C-4171 (1) and Installer 8871(2), install output shaft roller bearing (3).
16. Engage fifth gear (1).
17. Engage reverse gear (1).
18. Install new bearing retaining screws (1) and torque to 90 - 100 Nm (66 - 74 ft. lbs.).
19. Install input shaft oil diverter (1).
20. Install output shaft oil diverter (1).
21. Install a bead (2) of Mopar(R) Gear Sealant RTV to geartrain housing.
22. Install a bead (1) of Mopar(R) Gear Sealant RTV to end cover.
23. Immediately install end cover (1) to geartrain housing. Install and torque nine (9) bolts (2) to 20 - 25 Nm (15 - 18 ft. lbs.).
24. Install bead (1) of Mopar(R) Gasket Maker or Omnifit FD-1664 to shift shaft assembly mounting pad.
NOTE: When installing shift shaft assembly, do not handle assembly by counterweight.
25. 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.
26. Install crossover lever assembly and four bolts (1). Torque Shift Mechanism-to-Case bolts to 20 - 25 Nm (15 - 18 ft. lbs.).
27. Install shift shaft crossover detent pin (1), spring (2), and plug (3). Torque plug to 20 Nm (15 ft. lbs.).
28. Install shift shaft selector detent assembly (1) with Mopar(R) Lock 'N Seal (TM). Torque detent assembly 20 - 25 Nm (15 - 18 ft. lbs.).
29. Install back-up lamp switch (1). Torque switch to 24 Nm (18 ft. lbs.).
30. Install four shift rod detent plugs (1). Install new plugs as necessary. Tap into place using a soft tipped hammer (2).
31. Install input shaft seal (2) using Installer 8864 (1).
32. Install output (axle) shaft seals using Installer 8916 (1).
33. Install concentric slave cylinder (1). Torque bolts in three passes to specified torque.