Disassembly And Assembly: Assembly
NOTE:
It is not necessary to reestablish preload shim thickness when new bearings are installed. It is only necessary to establish preload shim thickness when a transaxle housing component, gear shaft, or differential is replaced.
- Install the right and left side differential bearing races using (special tool #8866, Installer, Bearing Cup) and (special tool #C-4171, Driver Handle, Universal).
- Install the differential.
- Install the magnet.
- Install the bearing race plate and tighten the bolts in four steps using the sequence shown in illustration:
- Step 1 - Tighten bolts 9-10-6-8-1 to 20 N.m (15 ft. lbs.) in order.
- Step 2 - Tighten bolts 3-5-4 to 25 N.m (18 ft. lbs.) in order.
- Step 3 - Tighten bolts 2-7 to 80 N.m (59 ft. lbs.) in order.
- Step 4 - Tighten bolts 9-10-6-8-1 to 80 N.m (59 ft. lbs.) in order.
NOTE:The following tools are to be used in conjunction with (special tool #C-4171, Driver Handle, Universal)
- Install the new bearing races to the race plate using the following tools:
- For the shaft bearing race use (special tool #10302, Installer, Bearing Cup) (2).
- For the shaft bearing race use (special tool #D-111, Installer, Bearing Cup) (3).
- For the main shaft bearing race use (special tool #C-4198, Installer, Axle Bearing) (1).
- Install the lubricating duct (1).
- Ensure that the oil duct locating pin (1) is in the locating hole (2).
- Install the correct shim (1) to the case.
- Install output shaft the bearing races to the case using (special tool #L-4520, Installer, Seal/Cup) and (special tool #6446, Installer, Bearing).
- Install the gear shaft oil ducts. Using an appropriate drift (1) re-stake the ducts (2) to the case.
- Install the input shaft bearing race using (special tool #C-4171, Driver Handle, Universal) and (special tool #10305, Installer, Differential Bearing Cup).
- Install the gear side differential bearing race using (special tool #C-4171, Driver Handle, Universal) and (special tool #8866, Installer, Bearing Cup).
- Install the output and main shafts (1) as a group.
- Install the 3-4-R gear shifter fork assembly.
- Install the 1-2-5-6 gear shifter fork assembly.
- Install the reverse idler gear and the needle bearing.
- Using a hydraulic press, install the pin to the reverse gear mounting bracket.
- Install the reverse idler gear assembly (1).NOTE:
The case halves must be assembled within 15 minutes after the application of the anaerobic sealant. Do not allow transmission oil or any other lubricants to come in contact with the sealant for at least one hour after the case halves have been assembled.
- Apply a uniform bead of LOCTITE®509™ Sealer or equivalent to the sealing surface of the case.
- Install the gear side case half (1) to the bellhousing case half (2).
- Install the long case bolts (1) and the short case bolts (2) and tighten to 25 N.m (18 ft. lbs.) using a cross sequence.
- Patch and install the reverse gear idler retaining bolt using the following process. Tighten to 10 N.m (89 in. lbs.).
- Remove the remaining traces of the original locking patch with a wire brush or the equivalent.
- Clean the threads with denatured alcohol and allow to dry.
- Apply the locking patch using Mopar thread locker.
- Apply a uniform bead of LOCTITE®509™ Sealer or equivalent to the sealing surface of the case.
- Install the gear selector assembly, tighten the bolts to 20 N.m (15 ft. lbs.).
- Apply a uniform bead of Mopar® Threebond RTV Sealer or equivalent to the sealing surface of the NEW
input shaft sealing ring.
- Install the sealing ring to the transmission.
- Install the Concentric Slave Cylinder (CSC) and bolt to the transmission. Tighten the bolts to 10 N.m (89 in. lbs.) and engage the retention tabs.
- Connect the hydraulic fitting (2) to the plastic retainer (1).
- Connect the hydraulic connection at the case.
- Install the axle seals