C514 Manual Transaxle - Assembly

ASSEMBLY

Special Tools:










1. Clean all sealing surfaces prior to assembling the transaxle





2. Install differential assembly to the transaxle case.





3. Apply a uniform bead of Mopar / Fiat Case Sealer or the equivalent to the case side of the transaxle.

4. Install the differential housing cover.





5. Install the differential housing bolts and tighten the larger bolts (1) to 40 Nm (30 ft. lbs.).





6. Install the differential housing bolts and tighten the smaller bolts (2) to 23 Nm (17ft. lbs.).





7. Prior to final installation of the seal plate, determine the correct shim for setting differential bearing preload Adjustments

8. Replace the O-ring seal and install the differential shim plate to the case. Tighten the bolts to 23 Nm (17ft. lbs.)





9. Install the left side differential seal using Universal Driver Handle (C-4171) (1) and Seal Installer (10284) (2).





10. Install the right side differential seal using Universal Driver Handle (C-4171) (1) and Seal Installer (10297) (2).





11. Install input shaft seal using Seal Installer (C-4698).





12. Install the reverse gear engagement fork (1) and bolts (2) to the transmission case. Tighten the bolts to 17 Nm (13ft. lbs.).





13. Install the reverse idler gear and shaft to the case, engage the reverse fork (1).





14. Install the input and output shafts to the transaxle case.

15. Install the shift fork assemblies. Ensure that the stud (1) and keyed lever (2) are engaged





16. Apply a uniform bead of Mopar / Fiat Case Sealer or the equivalent to the bellhousing side of the transaxle.

17. Install the transaxle case to the bellhousing. Tighten the bolts to 20 Nm (15 ft. lbs.).





18. Install new snap rings (2) at input and output bearings.

19. Install the bearing retaining plate





20. Install the bolts and tighten to 23 Nm (17ft. lbs.)





21. Install the reverse idler shaft retention bolt. Tighten to 29 Nm (21ft. lbs.).





22. Install fifth gear to the shaft using Bearing Installer (C-3095-A).





23. Install the fifth driven gear and synchronizer assembly to the shaft.





24. Install the fifth gear shifter fork to the synchronizer hub assembly. Tighten the retention bolt (1) to 14 Nm (10 ft. lbs.).





NOTE:
Engage two gears, locking the transmission, prior to removing the shaft nuts.

25. Install new ring nuts to the shafts. Tighten to 118 Nm (87 ft. lbs.)

26. Using a suitable punch stake both nuts to the shaft.





27. Align the shifter forks.





28. Apply a uniform bead of Mopar / Fiat Case Sealer or the equivalent to the case side of the transaxle.

29. Install the Gear Selector assembly. Tighten the bolts to 20 Nm (15 ft. lbs.)





30. Apply a uniform bead of Mopar / Fiat Cover Sealer or the equivalent to the case side of the transaxle.

31. Install the rear gear cover. Tighten the bolts to 11 Nm (97 in. lbs.)





32. Install the inner release bearing fork bushing.

33. Install the inner release bearing fork.





34. Install the outer release bearing fork bushing.





35. Install the clutch actuation lever and new retention clip.
36. Install the release bearing Installation.