Transfer Shaft Sub-Disassembly
STAND TRANSAXLE UPRIGHT ON BELLHOUSINGFig.114 Remove Chain Cover:
Fig.114 Remove Chain Cover
Chain cover must be free of old sealant dirt and oil before applying new sealant. Apply a 1/8 inch bead of sealant to flange of cover.
Fig.115 Remove Chain Oiler:
Fig.115 Remove Chain Oiler
CAUTION: Be sure to reinstall the chain snubber and chain oiler when reassembling.
Fig.116 Remove Chain Snubber:
Fig.116 Remove Chain Snubber
Fig.117 Remove Output Shaft Sprocket Snap Ring And Wave Washer:
Fig.117 Remove Output Shaft Sprocket Snap Ring And Wave Washer
Fig.118 Remove Transfer Shaft Sprocket Snap Ring And Wave Washer:
Fig.118 Remove Transfer Shaft Sprocket Snap Ring And Wave Washer
CAUTION: The chain sprockets have a slip fit onto the shafts. Apply only a slight amount of pressure to the chain spreader to release the chain pressure. If chain sprockets are not spread slightly, removal or installation will be difficult. Overspreading of the chain sprocket will also make sprocket removal difficult.
Fig.119 Install Chain Spreader:
Fig.119 Install Chain Spreader
CAUTION: When reinstalling drive chains, the blue link must face outward.
When reinstalling transaxle drive chains and sprockets, sprocket height must be checked. Refer to Drive Sprocket Height Adjustment Procedure.
Fig.120 Remove Chains And Both Sprockets As An Assembly:
Fig.120 Remove Chains And Both Sprockets As An Assembly
Fig.121 Output Sprocket Spacer:
Fig.121 Output Sprocket Spacer
Fig.122 Main Sump Vent Baffle Location:
Remove main sump baffle from transaxle case (Fig. 122).
CAUTION: Failure to grind and open stakes of the output shaft nut and transfer shaft nut will result in thread damage to the shafts during nut removal.
Fig.123 Correctly Applied Sealant:
When reinstalling main sump baffle apply MOPAR Silicone Sealant as shown (Fig. 123).
WARNING: WEAR SAFETY GOGGLES WHILE GRINDING STAKE NUTS.
Fig.124 Grinding Stakes:
Fig.124 Grinding Stakes
Fig.125 Stake Grinding Pattern:
Using a die grinder or equivalent, grind the stakes in the shoulder of the shaft nuts as shown (Fig. 124) and (Fig. 125). Do not grind all the way through the nut and into the shaft. There are two stakes on each nut.
Fig.126 Opening Nut Stakes:
Using a small chisel, carefully open stakes on nut (Fig. 126).
Fig.127 Remove Output Shaft Nut:
Use special tool 6497 and 6498 to remove the transfer shaft nut or the output shaft nut (Fig. 127). Note that your breaker bar will turn clockwise to remove the nut and counter clockwise to install the nut.
CAUTION: Do not reuse old transfer shaft nut or output shaft nut because the removed stake weakens the nut flange.
When installing new nuts use special tool 6639 to stake output shaft nut and special tool 6589 to stake transfer shaft nut.
Fig.128 Use Arbor Press To Remove Output Shaft From Case:
Fig.128 Use Arbor Press To Remove Output Shaft From Case
Fig.129 Remove Front Bearing Cup:
Use special tool 6596 to remove front output shaft bearing cup (Fig. 129).
Fig.130 Remove Rear Bearing Cup:
Use special tool 6597 and handle C-4171 and C-4171-2 to press rear output shaft bearing cup rearward (Fig. 130).
Fig.131 Bearing Cup Installation Special Tool 5050A:
Use special tool 5O5OA to install both front and rear bearing cups (Fig. 131).
CAUTION: When installing, be sure guide bracket and split sleeve touch the rear of the transaxle case.
Fig.132 Remove Rear Carrier Front Bearing Cone:
Fig.132 Remove Rear Carrier Front Bearing Cone
Fig.133 Low/Reverse Spring Compressor Tool:
Fig.133 Low/Reverse Spring Compressor Tool
Fig.134 Compressor Tool In Use:
Fig.134 Compressor Tool In Use
Fig.135 Remove Snap Ring:
Fig.135 Remove Snap Ring
Fig.136 Low/Reverse Piston Return Spring:
Fig.136 Low/Reverse Piston Return Spring
Fig.137 Remove Parking Sprag Pivot Retaining Screw:
Fig.137 Remove Parking Sprag Pivot Retaining Screw
Fig.138 Anchor Shaft Removal:
Fig.138 Anchor Shaft Removal
Fig.139 Guide Bracket Pivot Shaft:
Fig.139 Guide Bracket Pivot Shaft
Fig.140 Guide Bracket Assembled:
Fig.140 Guide Bracket Assembled
Fig.141 Guide Bracket Disassembled:
Fig.141 Guide Bracket Disassembled
Fig.142 Low/Reverse Clutch Piston:
Fig.142 Low/Reverse Clutch Piston
Fig.143 Piston Retainer Attaching Screws:
Fig.143 Piston Retainer Attaching Screws
Fig.144 Piston Retainer:
Fig.144 Piston Retainer
Fig.145 Piston Retainer Gasket:
Fig.145 Piston Retainer Gasket
Fig.146 Install Rear Carrier Front Bearing Cone:
Fig.146 Install Rear Carrier Front Bearing Cone
At this point the Centerline of the transaxle has been removed. If the condition for disassembly did not pertain to the differential, it's disassembly may not be required. Inspect the rear transfer shaft area and the transfer shaft seal area for contamination. If evidence of contamination is present, replace the rear transfer shaft bearing and/or the transfer shaft seal. Refer to the Transfer Shaft Seal Removal Section and the Differential Disassembly/Assembly section.
To assemble transaxle, reverse the above procedure. Be sure to check both grounded clutch clearances. Before installing the input clutches retainer, follow the instructions in Determining No. 4 Thrust Plate Thickness.