M/T - High Shift Effort and/or Gear Clash

83chrysler4

Models

All Domestic 1981, 1982 & 1983 Front-Wheel Drive Cars & Trucks Equipped With Four-Speed (A-460) (Built After 5-11-81) or Five-Speed (A-465) Manual Transmission

Subject


High Shift Effort, and/or Clash


Index


TRANSMISSION


Date

April 18, 1983


No..

21-11-83


P-1195-C
SYMPTOM/CONDITION

Customer concern of high 1-2, 2-1 and/or 3-4, 4-3 shift effort and/or gear clash.

DIAGNOSIS

Road test the car and verify the shift condition. Refer to Technical Service Bulletin relating to shift linkage effort. Check clutch assembly for proper releasing. If shift linkage and clutch releasing are proper, proceed as follows:

REPAIR PROCEDURE

Parts Required: 1 - Fork PN 4295651 2 - Synchronizer PN 4269234 Rings

1. Remove the intermediate shaft assembly from the transaxle and disassemble it per service manual procedures.

NOTE: IF THE 5TH INPUT GEAR ON THE A465 TRANSAXLE CANNOT BE REMOVED FROM THE INPUT SHAFT EASILY BY HAND, REFER TO TECHNICAL SERVICE BULLETIN #21-12-83 COVERING PROPER SERVICE PROCEDURES FOR TRANSAXLES WITH PRESS FIT 5TH INPUT GEARS.

2. Check all synchronizer sleeves and gears for excessive clutch tooth pointing damage and replace parts as required.

3. Check all synchronizer assemblies for proper operation. The synchronizer sleeve must slide freely on the hub. Replace any sychronizer assembly that does not slide freely.
4. Inspect the shift rail for gouging or scoring caused by the shift forks. Replace the shift rail if it is excessively gouged or scored.

5. For hard shifting or clash in 1st or 2nd gear:

a. Replace the synchronizer ring for the gear that exhibited the problem with a new Synchronizer Ring, PN 4269234.

b. Replace the 1-2 fork with a new Cast Iron Fork, PN 4295651.

6. For hard shifting or clash into 3rd or 4th gear:

a. Replace the synchronizer ring for the gear that exhibited the problem with a new Synchronizer Ring, PN 4269234.

b. Replace the 3-4 fork with a new fork.

7. For hard shifting or clash into 5th gear:

a. Replace 5th synchronizer ring with a new Synchronizer Ring, PN 4269234.

8. Reinstall intermediate shaft assembly in transaxle per service manual procedures (note Technical Service Bulletin #21-12-83 on press fit 5th input gear).

Evaluate car for proper shifting and absence of gear clash.


This bulletin is released in advance of parts availability. The parts listed in this bulletin will be available in late June, 1983.


POLICY: Reimbursable within the provisions of the warranty

TIME ALLOWANCE: Refer to Labor Operation Time Schedule