Part 3

ASSEMBLY

Special Tools:























NOTE:
Remote pinion gear must NOT be installed while checking turning torque.

60. Using the Turning Torque Tool (9735) (1) and an inch pound torque wrench (2) check the differential turning torque, it should be 1.0-2.5 Nm (10 to 22 in-lbs drag). If turning torque is more than 2.5 Nm (22 in-lbs drag) decrease shim size behind the end cover and recheck. If turning torque is less than 1.0 Nm (10 in-lbs drag) increase shim size.

61. After proper turning torque is achieved for the differential remove the differential from the case and set aside keeping the correct shim with the differential.





62. Install the remote pinion bearing cup in the case (small cup) using Installer (9730) and Handle (C-4171).

63. Install the remote pinion bearing cup in the cover using Installer (9729) and Handle (C-4171).

64. Install the remote pinion (2) into the transaxle case.





65. Install the remote pinion cover (2) into transaxle case.





66. Install the bolts (1) at the remote pinion cover (2) and tighten to 16 Nm (140 in. lbs.).





NOTE:
Differential assembly must not be installed when checking for pinion drag torque.

67. Check turning torque using Differential Bearing Torque Tool (C-4995A) (2) and an inch pound torque wrench (1). Turning torque for the remote pinion gear should be 0.2-1.0 Nm (2 to 8 in-lbs drag). If more than 1.0 Nm (8 in-lbs drag) decrease shim size under the remote pinion bearing cover cup. If turning torque is less than 0.2 Nm (2 in-lbs drag) increase the shim size under the remote pinion bearing cover cup.





68. Install Holder (9908) (2) onto the compounder bearing retainer to help in installation.

69. Install the compounder bearing retainer into the transaxle case.





70. Remove Holder (9908) from the compounder bearing retainer.

71. Install all the bolts at the compounder bearing retainer and tighten to 12 Nm (105 in. lbs.).





72. Install snap ring (1) at top of the compounder bearing retainer.





NOTE:
Insure End Play Tool (9951) is not binding in support plate that is bolted to the case.

NOTE:
Always use original shim to determine end play.

73. Remove plug at case (3).

74. Install compounder End Play Tool (9951) (2) through the hole in the front case.

75. Install Dial Indicator (C-3339A) (1) onto End Play Tool (9951).

76. Use moderate downward pressure on End Play Tool (9951) and zero Dial Indicator (C-3339A).

77. Use moderate upward pressure on End Play Tool (9951) and take reading from Dial Indicator (C-3339A).

78. Remove End Play Tool (9951) and zero Dial Indicator (C-3339A).

79. Adjust shim thickness in the underdrive unit to 0.010 to 0.020".

80. Install the correct (select) helical shim and assemble the underdrive compounder Underdrive Compounder Assembly - Assembly and retest.

81. Using Mopar lock AND seal adhesive install plug back into case and tighten to 24 Nm (18 ft. lbs.).










82. Install the transfer gear (underdrive compounder side) cone using Installer (6756) (3).





83. Install Holder (9739) (1) onto the transfer gear (underdrive compounder side) (2).

84. Install a new transfer gear (underdrive compounder side) nut and tighten to 271 Nm (200 ft. lbs.).

85. Use Staking Tool (9721) and stake the new nut.





86. Install the differential, bearing cups, shim and oil slinger into case.





87. Use a bead of MOPAR(R) ATF RTV (MS-GF41).

88. Install the differential cover.





89. Install the differential cover bolts (1) and tighten to 61 Nm (45 ft. lbs.).