Assembly
ASSEMBLY
NOTE: When assembling this transaxle, always use NEW snap rings.
NOTE: Before assembling transaxle, differential turning torque must be measured and adjusted. Differential turning torque must be measured with geartrain out of case.
1. Install input shaft bearing using an arbor press and remover/installer 8474 (Figure 1).
Figure 1 Input Shaft Bearing Installation
2. Install shift shaft bushing to case using installer 8475 (Figure 2).
Figure 2 Shift Shaft Bushing Installation
3. Install intermediate shaft bearing race to case with an arbor press, driver handle C-4171, and installer 8471 (Figure 3). Press until installer 8471 bottoms on transaxle case.
Figure 3 Install Intermediate Shaft Bearing Race
NOTE: If input shaft assembly was not disassembled, it is necessary to remove input shaft sealed ball bearing before assembling transaxle.
4. Install assembled input and intermediate shafts to fixture 8487 (Figure 4).
Figure 4 Install Geartrain to Fixture 8487
5. Install shift forks and 3/4 rail assembly to geartrain as shown in (Figure 5).
Figure 5 Shift Fork/Rail Orientation
NOTE: Before installing geartrain, make sure that input shaft sealed roller bearing is not installed, otherwise reverse idler assembly installation will be difficult.
6. Install lifting bar 8489 to geartrain. Install geartrain to case. When installing geartrain to case, use care not to damage bearing surfaces.
7. Remove lifting bar 8489 from geartrain.
8. Install shift 1/2-5/R rail as shown in (Figure 6).
Figure 6 Shift Rail Installation
1 - 1/2-5/R SHIFT RAIL
9. Install reverse idler shaft into position (Figure 7). Install and torque shaft-to-case bolt to 54 Nm (40 ft. lbs.).
Figure 7 Reverse Shaft Removal/Installation
10. Install inner pin (Figure 8).
Figure 8 Inner Pin Removal/Installation
1- PIN (2)
11. Install inner washer (Figure 9).
Figure 9 Inner Washer Removal/Installation
12. Install needle bearing and outer pin (Figure 10)
Figure 10 Outer Pin and Needle Bearing
13. Install reverse idler gear (Figure 11).
Figure 11 Reverse Idler Gear Removal/Installation
1 - REVERSE IDLER GEAR
14. Install outer washer (Figure 12).
Figure 12 Outer Washer Removal/Installation
15. Install input shaft sealed roller bearing using installer 8482 (Figure 13).
Figure 13 Install Input Shaft Sealed Roller Bearing
16. Install new input shaft bearing snap ring (Figure 14).
Figure 14 Input Shaft Bearing Snap Ring
1 - SNAP RING
17. Install shift rail bushing to end cover using installer 8475 (Figure 15).
Figure 15 Shift Rail Bushing Installation
1 - INSTALLER 8475
18. Apply a 1 mm (0.04 in.) bead of Mopar(R) Gasket Maker to transaxle end cover and install to transaxle case (Figure 16). While installing end cover, be sure to guide oil trough into pocket (Figure 17). Torque end cover-to-case bolts to 28 Nm (250 in. lbs.) (Figure 18).
Figure 16 End Cover Removal/Installation
Figure 17 Oil Trough Pocket
Figure 18 End Cover Bolts
1 - BOLT (12)
19. Install lifting bar 8489 to geartrain.
20. Lift up on bar (input shaft side) and install input shaft bearing snap ring (Figure 19).
21. Lift up on bar (intermediate shaft side) and install intermediate shaft bearing snap ring.
Figure 19 Input Bearing Snap Ring
22. Remove lifting bar 8489.
23. Install a bead of Mopar(R) Gear Lube RTV to end plate and immediately install to case. Install and torque bolts to 28 Nm (250 in. lbs.) (Figure 20).
Figure 20 End Cover Bolts
1 - BOLT (11)
24. Install back up lamp switch. Use Tool 8827 and torque to 23 Nm (17 ft. lbs.)(Figure 21).
Figure 21 Back-Up Lamp Switch - Typical
1 - BACK-UP LAMP SWITCH
25. Roll transaxle assembly on side.
26. Install differential chip collector magnet (Figure 22). Retain to case with a dab of Mopar(R) Gear Lube RTV.
Figure 22 Differential Magnet
1 - MAGNET
27. Install differential assembly with bearing races and select shim (Figure 23). Shim selection was determined before transaxle assembly.
Figure 23 Differential Shim/Slinger Orientation
28. Install a 1 mm (0.04 in.) bead of Mopar(R) Gasket Maker to differential cover and install to case. Torque differential cover-to-case bolts to 54 Nm (40 ft. lbs.).
29. Install a 1 mm (0.04 in.) bead of Mopar(R) Gasket Maker to extension housing. Install extension housing to differential cover and case and torque bolts to 28 Nm (250 in. lbs.) (Figure 24).
Figure 24 Extension Housing-to-Case Bolts
1 - EXTENSION HOUSING
30. Install both axle new output shaft seals using driver handle C-4171 and installer 8476 (Figure 25) (Figure 26).
Figure 25 Axle Seal Installation (Extension Housing Side)
Figure 26 Axle Seal Installation - Typical
31. Install impact blocker (If Equipped) (Figure 27).
Figure 27 Impact Blocker (SRT-4 Models)
32. Apply a 1 mm (0.04 in.) bead of Mopar(R) Gasket Maker to shift cover assembly. Place shift cover and transaxle geartrain into neutral and install shift cover (Figure 28) and torque bolts to 28 Nm (250 in. lbs.).
33. Reinstall shift selector lever if previously removed.
Figure 28 Shift Cover Removal/Installation
1 - SHIFT COVER ASSEMBLY
34. Install input shaft bearing retainer (Figure 29). Torque bolts to 12 Nm (105 in. lbs.).
Figure 29 Input Bearing Retainer
1 - INPUT BEARING RETAINER
35. If previously removed, install new clutch release lever pivot ball(s) using slide hammer C-3752 and remover/installer 6891 (Figure 30) (Figure 31).
Figure 30 Pivot Ball Removal/Installation
Figure 31 Pivot Ball Position
1 - PIVOT BALL (1)
36. Install clutch release bearing to lever. Apply grease to interface (contact) points. Make sure release bearing retainers engage lever pocket as shown in (Figure 32).
Figure 32 Release Bearing-to-Lever
37. Apply grease to pivot ball(s), and on release lever at slave cylinder contact point.
38. Install clutch release bearing/lever assembly into position by sliding bearing onto input bearing retainer, and using moderate hand pressure to seat release lever to pivot ball (Figure 33). A "pop" sound should be heard. Verify proper engagement by lightly pulling outward on lever at pivot ball location, and then actuating lever and bearing to ensure proper operation.
Figure 33 Release Bearing and Lever
