T355 Manual Transmission (Service Information): Assembly: Assembly: Notes

Fig 1: Bench Fixture T355

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The T355 transaxle internal components can be serviced only by separating the gear case from the bellhousing case.

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

1. Load Bench Fixture (special tool #6785, Assembly, Pallet) (4) with adaptors (special tool #9761-1, Pad, Shift Rail Support) (1), (special tool #9761-2, Spacer) (3), (special tool #9761-3, Spacer) (2), (special tool #9761-4, Stand Off) (5) and (special tool #9761-5, Stand Off) (6).
   Fig 2: Shift Rail Assy

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2. Install the output (1) and input (2) shafts onto Bench Fixture (special tool #6785, Assembly, Pallet).
3. Install shift blocker assembly and the 1-2 shift fork (5) onto the Bench Fixture (special tool #6785, Assembly, Pallet) (4).
   NOTE:

   Adaptor (special tool #9761-1, Pad, Shift Rail Support) will slide shift blocker assembly and the 1-2 shift fork into the input and output shafts.

4. Align all shift forks and slide into place.
   Fig 3: Shift Shaft Assy

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5. Install reverse brake blocking ring (2).
6. Install reverse brake friction cone (1).
   Fig 4: Trans On Fixture T355

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   NOTE:

   One shift fork bolt may need to be installed to align assembly.

7. Install gear-case half (1) over Bench Fixture (special tool #6785, Assembly, Pallet) (2). Line up shift finger over 3-4 lug.
8. Line up reverse brake friction cone lugs to the slots in the gear case. Verify reverse brake shim is in position.
   Fig 5: Installing Input And Output Bearings

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   1 - INPUT AND OUTPUT BEARINGS

   2 - SEAL INSTALLER 4992-1

9. Position input and output bearings (1) on the shafts. Refer to Fig 5. Using Seal Installer (special tool #C-4992-1, Installer) (2), install input and output shaft bearings (1) until they bottom into the case and against the shafts.
   Fig 6: Snap Rings Retaining Bearings

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   1 - SNAP RING PLIERS

   2 - SNAP RINGS

10. Install new  snap rings (2) at input and output bearings.
    Fig 7: End Cover And Shaft Bolts

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11. Apply MOPAR® RTV sealant to end-cover outer edge and around bolt holes. Install end-cover onto gear case. Tighten end cover bolts to 25 N.m (225 in. lbs.).
    NOTE:

    Install new O-rings on shift blocker assembly bolts.

12. Install the three shift blocker assembly bolts (1) and tighten to 25 N.m (225 in. lbs.).
    Fig 8: Selector Shaft

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    1 - SHIFT ASSEMBLY

    2 - SELECTOR SHAFT

13. Remove gear case from Bench Fixture (special tool #6785, Assembly, Pallet).
14. Install gear case in a holding fixture with end cover facing down.
15. Turn selector link (2) into slot on blocker assembly. Refer to Fig 8.
    Fig 9: Reverse Idler Gear & Spacer

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    1 - SPACER

    2 - REVERSE IDLER GEAR

16. Push selector link spacer clip onto selector shaft. Install shift levers.
17. Install reverse idler gear (2) and spacer (1). Refer to Fig 9.
    Fig 10: Removing/Installing Reverse Idler Shaft

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    1 - REVERSE IDLER SHAFT

    2 - SPACER

18. Install reverse idler shaft (1). Refer to Fig 10.
    Fig 11: Reverse Idler Shaft

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    1 - CASE

    2 - REVERSE IDLER SHAFT

    3 - REVERSE IDLER SHAFT BOLT

    NOTE:

    Install a new O-ring on reverse idler shaft bolt.

19. Install bolt into reverse idler shaft (2) and tighten to 26 N.m (19 ft. Refer to Fig 11. lbs.).
    Fig 12: Remove Reverse Fork Bracket

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    1 - REVERSE FORK BRACKET

    2 - REVERSE CAM BLOCKOUT

    3 - SHIFT BLOCKER ASSEMBLY

20. Install reverse fork bracket (1). Refer to Fig 12.
    Fig 13: Screws Retaining Reverse Fork Bracket

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    1 - SCREWS (2)

    2 - REVERSE FORK BRACKET

21. Tighten reverse fork bracket (1) bolts to 11 N.m (96 in. Refer to Fig 13. lbs.).
    Fig 14: Linkage Tie Bar

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22. Install the linkage tie bar (1).
    Fig 15: Linkage Tie Bar Clips

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23. Install the linkage tie bar clips (1).
    Fig 16: Removing/Installing Differential

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    1 - INPUT SHAFT

    2 - OUTPUT SHAFT

    3 - DIFFERENTIAL ASSEMBLY

    4 - GEARTRAIN HOUSING

24. Install differential (3) into gear case (4). Refer to Fig 16.