Manual Transmission/Transaxle - Assembly

ASSEMBLY





The T350 transaxle internal components can be serviced only by separating the gear case from the bellhousing case.

CAUTION: The transaxle output shaft is serviced as a unit. No disassembly and reassembly is possible. Damage to the transaxle may result.

The sealant used to seal the transaxle case halves is Mopar(R) Gasket Maker, Loctite(R) 518, or equivalent. The sealant used for the bearing end plate cover is Mopar(R) RTV.

1. Verify bench fixture shims are removed from bench fixture (1).




2. Install output and input shafts into bench fixture 6785 (1).




3. Install shift blocker assembly into bench fixture (1).




4. Install reverse brake blocking ring (1).




5. Install reverse brake friction cone (1).




6. Install gear-case half (1) over bench fixture (2). Line up shift finger over 3-4 lug.




7. Line up reverse brake friction cone lugs (2) to the slots in the gear case (1). Verify reverse brake shim is in position.




8. Position input and output bearings (1) on the shafts. Using Seal Installer C-4992-1 (2), press on input and output shaft bearings (1) until they bottom into the case and against the shafts.




9. Install shaft snap rings (2) at input and output bearings.




10. Apply Mopar(R) RTV sealant to end-cover (2) outer edge and around bolt holes. Install end-cover onto gear case. Tighten end cover bolts to 29 Nm (21 ft. lbs.) torque.




11. Remove gear case from bench fixture.
12. Install gear case in a holding fixture with end cover facing down.
13. Turn selector shaft (2) into slot on blocker assembly.




14. Push selector shaft spacer clip onto selector shaft. Install shift levers.
15. Install reverse idler gear (2) and spacer (1).




16. Install reverse idler shaft (1).




17. Install bolt into shaft (2) and tighten to 29 Nm (19 ft. lbs.) torque.




18. Install reverse fork bracket (1).




19. Tighten reverse lockout (2) screws to 11 Nm (96 in. lbs.) torque.




20. Install differential (3) into gear case (4).
BEARING ADJUSTMENT PROCEDURE

1. Use extreme care when removing and installing bearing cups and cones. Use only an arbor press for installation, as a hammer may not properly align the bearing cup or cone. Burrs or nicks on the bearing seat gives a false end-play reading while gauging for proper shims. Improperly seated bearing cups and cones are subject to low-mileage failure.
2. Bearing cups and cones should be replaced if they show signs of pitting or heat distress. If distress is seen on either the cup or bearing rollers, both cup and cone must be replaced.
3. Bearing preload and drag torque specifications must be maintained to avoid premature bearing failures. Used (original) bearings may lose up to 50% of the original drag torque after break-in. All bearing adjustments must be made with no other component interference or gear intermesh.
4. Replace bearings as a pair: If one differential bearing is defective, replace both differential bearings, if one input shaft bearing is defective, replace both input shaft bearings.
5. Bearing cones must not be reused if removed.
6. Turning-torque readings should be obtained while smoothly rotating in either direction.

DIFFERENTIAL BEARING PRELOAD ADJUSTMENT

NOTE: True bearing turning-torque readings can be obtained only with the geartrain removed from the case.

1. Remove bearing cup and existing shim from clutch bellhousing case.
2. Press in new bearing cup into bellhousing case (or use a cup that has been ground down on the outer edge for ease of measurement).
3. Press in new bearing cup into gear case side.
4. Oil differential bearings with transmission fluid. Install differential assembly in transaxle gear case. Install clutch bellhousing over gear case. Install and torque case bolts to 29 Nm (21 ft. lbs.).
5. Position transaxle with bellhousing facing down on workbench with C-clamps. Position dial indicator.

NOTE: Position of dial indicator in is for illustrative purposes only. The dial indicator should be parallel to T-Handle to obtain the most accurate reading.





6. Apply a medium load to differential with Torque Tool C-4995 (3) and a T-handle (1), in the downward direction. Roll differential assembly back and forth a number of times. This will settle the bearings. Zero the dial indicator (2). To obtain end play readings, apply a medium load in an upward direction while rolling differential assembly back and forth. Record end play.




7. The shim required for proper bearing preload is the total of end play, plus (constant) preload of 0.18mm (0.007 in.). Never combine shims to obtain the required preload.
8. Remove case bolts. Remove clutch bellhousing differential bearing cup. Install shim(s) selected in STEP 7. Then press the bearing cup into clutch bellhousing.
9. Install clutch bellhousing. Install and torque case bolts to 26 Nm (19 ft. lbs.).
10. Using Torque Tool C-4995 (2) and an inch-pound torque wrench (1), check turning torque of the differential assembly. The turning torque should be 6 to 12 in. lbs. If the turning torque is too high, install a 0.05mm (0.002 inch) thinner shim. If the turning torque is too low, install a 0.05mm (0.002 inch) thicker shim.
11. Recheck turning torque (1). Repeat STEP 10 until the proper turning torque is obtained.

Once proper turning torque has been established, place gear case on the end plate. Draw a bead of Mopar(R) Gasket Maker, Loctite(R) 518, or equivalent, on the flat surface of the case mating flange. Install clutch bellhousing onto gear case. Install and tighten case bolts to 29 Nm (21 ft. lbs.).