Manual Transmission/Transaxle - Assembly Part - 2

ASSEMBLY

FINAL ASSEMBLY





1. Turn front housing (1) with fixture (2) over onto the front housing and remove fixture.




2. Install intermediate plate (1) and two dowels (2).




3. Install intermediate plate (1) bolts (2) and tighten to 22 Nm (16 ft. lbs.).




4. Install interlock plate washers (1) on support (2).




5. Install interlock plate (2) and tighten bolts (1) to 10 Nm (88 in. lbs.).




6. Install second gear bearing (1) on mainshaft (2).




7. Install second gear (1) on mainshaft (2).




8. Install second gear inner friction ring (1) on second gear (2).




9. Install second gear outer friction ring (1) on second gear (2).




10. Install second gear blocker ring (1) on second gear (2).




11. Align 1-2 synchronizer hub (1) with blocker ring on mainshaft and install hub with Installer D-389 (2).

NOTE: If 1-2 synchronizer hub is installed incorrectly the snap ring groove will not be visible.





12. Install 1-2 synchronizer hub (1) snap ring (2).




13. Install 1-2 synchronizer hub (1) detents (2).




14. Install 1-2 synchronizer sleeve (2) on 1-2 hub (1).

NOTE: Align grooves in the sleeve with detents in hub.





15. Install first gear blocker ring (1) on 1-2 hub (2).




16. Install first gear outer friction ring (1) on 1-2 hub (2).




17. Install first gear inner friction ring (1) on 1-2 hub (2).




18. Install first gear bearing (1) on mainshaft (2).




19. Install first gear (1) on mainshaft (2).




WARNING: Use welding gloves or tongs when handling heated components. Failure to follow these instructions will result in personal injury.

CAUTION: A bearing heater is used to heat reverse bearing race (1). Use only a bearing heater/hot plate and follow manufacturer's instructions. Heat components to 100 - 177 Celsius (212° Min. - 350° Max Fahrenheit). Never use an open flame to heat components. Never leave components on heater for an extended amount of time. If component is discolored after heating, the component has been overheated and must not be used. Failure to follow these instructions will result in component damage.

20. Heat reverse bearing race (1) with bearing heater (2) to a maximum of 177 Celsius (350° Fahrenheit).




21. With welding gloves or tongs install reverse bearing race (1) on mainshaft (2).




22. Install reverse gear bearing (1) on bearing race (2).




23. Install reverse gear (1) on mainshaft (2).




24. Install reverse gear friction/blocker ring (1) on reverse gear (2).




25. Install reverse synchronizer detents (1) in reverse hub (2).




26. Install reverse synchronizer sleeve (1) on reverse hub (2).

NOTE: Align grooves in the sleeve with detents in hub.





27. Install reverse gear synchronizer hub (1) with Installer D-389 (2).




28. Install main shift rail (1) bearings (2) on main shift rail.




29. Install main shift rail (1) through rail support (2) and housing, then rotate counterclockwise into place.




30. Install 1-2 shift fork then, install 1-2 shift rail (2) into shift fork and housing. Install shift fork roll pin (1).




31. Install reverse shift rail (1) into the housing. Then install reverse shift fork (2) and pull shift rail (1) up into the shift fork.




32. Install reverse shift fork roll pin (1).




WARNING: Use tongs when handling heated components. Failure to follow these instructions will result in personal injury.

CAUTION: A bearing heater (2) is used to heat Plug 9619-2 (1). Use only a bearing heater/hot plate and follow manufacturer's instructions. Heat components to 100 - 177 Celsius (212° Min. - 350° Max Fahrenheit). Never use an open flame to heat components. Never leave components on heater for an extended amount of time. If component is discolored after heating, the component has been overheated and must not be used. Failure to follow these instructions will result in component damage.

33. Heat Plug 9619-2 (1) with bearing heater (2) to a maximum of 177 Celsius (350° Fahrenheit).




34. With tongs place Plug 9619-2 in rear housing mainshaft bearing (2). Allow plug to heat bearing for two minutes.




35. Apply a bead of Mopar(R) Gasket Maker or equivalent to the front housing sealing surface.
36. Remove plug and install rear housing (1) on front housing (2).
37. Install housing bolts and tighten to 22 Nm (16 ft. lbs.).




38. Install output shaft seal in rear housing (1) with Installer 9629 (2).




39. Install 4x4 transmission output shaft nut with Socket 9584 and tighten to 200 Nm (147 ft. lbs.). Then loosen nut and tighten to 170 Nm (125 ft. lbs.).




40. Drive output shaft flange onto the output shaft with Installer D-389.
41. Install 4x2 transmission output shaft flange (1) and tighten bolt (2) to 200 Nm (147 ft. lbs.). Then loosen bolt and tighten to 170 Nm (125 ft. lbs.). Remove Wrench 9586 from input shaft.




42. Install two detent plugs in the top of the rear housing.
43. Install large detent plunger (1) and spring (2) in the side of the rear housing.




44. Install large detent plug (1) in the side of the rear housing (2).




45. Install back up lamp switch (1) and tighten bolt (2) to 10 Nm (88 in. lbs.). Then lay transmission down on bench.




46. Install input shaft (1) snap ring (2).




47. Install input shaft seal in front housing with Installer 9620 (1) and Tube C-3717 (2).




48. Install clutch bearing release support (1) and tighten bolts (2) to 10 Nm (88 in. lbs.).




49. Install Wrench 9586 (1) on input shaft (2).




50. Install countershaft bolt (1) in front housing. Tighten bolt (1) to 90 Nm (66 ft. lbs.).




51. Install countershaft plug in front housing (1) with Installer 9622 (2) and Handle C-4171.




52. Install the cover plate for the second shift tower location, if necessary.
53. Apply Mopar(R) Lock & Seal or equivalent to shifter socket threads and install shifter socket (1).