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1. 34055344 183 22 N M N N YOLVINWNDDV N PL TRANSAXLE SCHEMATICS AND DIAGRAMS Continued 148 21 9 i s ER 7 SCH NONE IS Ge m 5 i d VENERE aaddinoa an EE JILVIMS3HOS DITINVYGAH 3X TXVSNVHL HLLE JILLONHI 835012 1V0NVW MOT 177764 0 JILLOYHL BERA 066 Nouvomam 3 X awnd 555504 sss waan ise INIT saunssadd TIO TIO N N 5 eege ee CSS SS 7 TOXLNOD 34055384 YALYIANOD ER 1NO33 vJ OAN3S 1 44 35 YONYIAOO 149 21 TRANSAXLE PL SCHEMATICS AND DIAGRAMS Continued YWaILYFANOD 30301 ER RE SS 001 06 3AIVA 555 2 SE 3 gl 529 me S 2 JATVA 55 4 48 SE D ro JILVIMS3HOS DITINVYGAH FIXVSNVEL HLLE asuaaau 431115 10 FILIOSHL OL INN 00 0 ouni 54 001 09 55 Nouons awna Feu 0819 coc 2 41 534065344 CC CC r L zZ4 6 9 NMOQDIDDI NN NN NS m
2. N3382S 8 2 xX SCH HILMO geng HOLNID LINOJ Nei OA 3S Lo1NOM4 143 21 TRANSAXLE PL SCHEMATICS AND DIAGRAMS Continued LLDOpOOg aaddinoa JAYA SSVd Ad JILVISHOS DITINVYGAH FIXVSNVEL HLLE JILLONHI 5 10 NS 54 89 9 33133ANOO 300301 ZZZ S 0 ISd 06 5 NOuvonani F awna 1 11 54896 maan 54 29 514055344 10 e e e I f Le V3ATVA NAAOQXODI 12 52 55 4 8 ry d E LE 3 1 1 2 t 217172 Gi 211 4 L A N 3ILLONHL 2 N JAVA N 33155344 YBLYIANOD S HAUT LNO EZ Seel MA ch P NS dme Fel Ja m N YOLVINWNDDV Ham Sen 3AlVA AUS L OAAS NONNJA09 1 44 PL TRANSAXLE SCHEMATICS AND DIAGRAMS Continued 144 21 5 41 JATVA SSVd Ad JILVIM3HOS DITINVYGAH 3X TXVSNVHL HLLE 03201 LON 30301 280 dwnd Aa SE uod does F Nouons awnd
3. 48 SERVICE PROCEDURES ADJUSTMENTS FLUID DRAIN AND 4 GEARSHIFT CROSSOVER CABLE 49 REMOVAL AND INSTALLATION BEARING ADJUSTMENT PROCEDURE 50 GEARSHIFT KNOB 4 DIFFERENTIAL BEARING PRELOAD GEARSHIFT BOOT 5 5 50 GEARSHIFT CABLE ASSEMBLY 6 SPECIFICATIONS GEARSHIFT MECHANISM REPLACEMENT 9 T350 A 578 SPECIFICATIONS 51 VEHICLE SPEED SENSOR AND DRIVE SPECIAL TOOLS PINION oe ee eee bed ph E 11 T350 A 578 MANUAL TRANSAXLE 52 BACK UP LAMP 5 12 GENERAL INFORMATION NV T350 A578 MANUAL TRANSAXLE The NV T350 A 578 transaxle is a fully synchro nized except reverse constant mesh transaxle The transaxle case is constructed of die cast aluminum and is a two piece design bell housing case half and rear housing case half with a steel end plate bearing cover All forward gears are in constant mesh with each other which eliminates the need to move gears together for engagement This feature improves response and eliminates gear clash noises The reverse idler gear is supported and rotates on a spin dle idler shaft Depending on application a reverse gear brake blocking ring is available on some units for shifting ease The NV 350 A 578 transaxle also incorporates an open differential
4. ce 3NIT 530055344 TIO KSE f 331005 an SE See e e e e SSVd Ad CTS 5 NNUS Ke E EE cl 105 e OF ER 1 In wees y ATYA LIHS 8 6 35155349 YALYIJANOD 33425 d 4 JAVA HOLATD AVAA Lounen NSSSSSSSSS goivinwn2ov OA33S 1 41 44 HOLMIO AYIA 147 21 TRANSAXLE SCHEMATICS AND DIAGRAMS Continued PL JILVIMS3HOS DITINVYGAH 3X TXVSNVHL HLLE 31L1O3HL 036012 IVANYW 5 RAN iSd 777184 0 3ILLOSHL 54 066 Nouvomaem E j Nouons awna WEE E 2264 aalaaANo gt EMG SS ss 1118 21 aava NY Ted 534156344 WO 1 200009 331114 UO INDAOL aa 29646 aaddinoa 20 LE 55555227 KO eC SSVd Ad 5 x eM n BAN 1417 4 gs _anwa d Lu fe Nod 21 11 SSL NERDS AE _ H d PANN vr 36 4 INOW OMNIS AVI HOHTID eva eens EL AIVA Lag ez AE A aa o re
5. 5 21 123 DISASSEMBLY AND ASSEMBLY Continued Fig 166 Stirrup and Strap Removed From Output Gear 1 OUTPUT GEAR RETAINING NUT 2 OUTPUT GEAR 80bdbd28 OUTPUT GEAR AND SHAFT Fig 168 Remove Output Shaft Gear using L 4407A 1 OUTPUT GEAR 2 TOOL L 4407A Fig 167 Remove Output Shaft Retaining Nut and Washer 1 SPECIAL TOOL L 4434 2 TPUT SHAFT GEAR G PR22888 Fig 169 Output Shaft Gear and Select Shim 1 BEARING CUP 2 SHIM SELECT 3 BEARING CONE 4 OUTPUT SHAFT GEAR 5 OUTPUT SHAFT 21 14 TRANSAXLE DISASSEMBLY AND ASSEMBLY Continued PR2289 PR2292C Fig 170 Remove Output Shaft Gear Bearing Cone Fig 172 Remove Output Shaft 1 SPECIAL TOOL L 4406 1 WITH ADAPTERS L 4406 2 1 ARBOR PRESS RAM 2 OUTPUT SHAFT GEAR 2 CAUTION SUPPORT ANNULUS GEAR UNDERNEATH NEAR GEAR CENTER 3 BEARING CONE 4 REAR ANNULUS GEAR 5 OUTPUT SHAFT N PR2291B Fig 171 Remove Output Shaft and Rear Annulus Gear Assembly 1 BEARING CUP 2 REAR ANNULUS GEAR Fig 173 Remove Rear Planetary Annulus Gear 3 OUTPUT SHAFT Bearing Cone 1 SPECIAL TOOL L 4406 1 WITH ADAPTERS L 4406 2 2 REAR PLANETARY ANNULUS GEAR 5 21 125 DISASSEMBLY AND ASSEMBLY Continued ASSEMBLY PR2296 PR2290A
6. 129 CLEANING AND INSPECTION VALVE BODY RR IRR 135 ADJUSTMENTS GEARSHIFT 135 THROTTLE VALVE CABLE ADJUSTMENT PROCEDURE s esed ERR 136 BRAKE TRANSMISSION SHIFT INTERLOCK gt deed Saw d PEE 137 BAND ADJUSTMENT 138 HYDRAULIC CONTROL PRESSURE ADJUSTMENTS 138 BEARING ADJUSTMENT PROCEDURES 138 OUTPUT SHAFT BEARING 139 DIFFERENTIAL BEARING 139 TRANSFER SHAFT BEARING 140 SCHEMATICS AND DIAGRAMS 31TH TRANSAXLE HYDRAULIC SCHEMATIC 142 SPECIFICATIONS 31TH AUTOMATIC TRANSAXLE 150 31TH TRANSAXLE TORQUE SPECIFICATIONS 150 SPECIAL TOOLS 31TH AUTOMATIC TRANSAXLE 151 PL GENERAL INFORMATION IN VEHICLE SERVICE The following components are serviceable in the vehicle without transaxle removal e Valve Body Assembly Converter Clutch Solenoid Governor Vehicle Speed Sensor amp Pinion Park Neutral amp Back up Lamp Switch Transfer Gears and Transfer Shaft Low Reverse Servo Kickdown Servo Accumulator FLUID REQUIREMENTS NOTE The transmission and differential have a common oil sump with an opening between the two TRANSMISSION DIFFERENTIAL ATF 4 Automatic Transmission Fluid Type 9602 is required in this transaxle Substitute fluids must meet fluid specification MS 9602 FL
7. Ca ME KS A o D Es KAN Om A 22 2 Du 80504443 Fig 52 Starter Motor Removal Installation 1 BOLT 2 GROUND 3 STARTER 4 BOLT 3 80bbdad4 Fig 53 Transaxle Upper Mount and Bracket 1 MOUNT BRACKET 2 BOLT 3 MOUNT PL REMOVAL AND INSTALLATION Continued TRANSAXLE 21 87 80bbe370 Fig 54 Transaxle Removal Installation 3 TRANSAXLE 4 CONVERTER BOLT 4 80bbdad9 Fig 55 Transaxle Upper Mount and Bracket 1 MOUNT 2 TRANSAXLE INSTALLATION 1 Install torque converter into front pump Rotate converter until the hub fully engages front pump gear lugs 2 Install transaxle to engine mounting bolts Fig 54 and tighten to 95 N m 70 ft Ibs torque 3 Raise engine and transaxle with screw jack until through hole in upper mount aligns with hole in mount bracket Install mount bolt and tighten to 108 N m 80 ft Ibs torque Fig 53 4 Remove screwjack 5 Install converter to drive plate bolts and torque to 88 N m 65 ft Ibs torque 6 Install starter motor and tighten bolts to 54 N m 40 ft Ibs torque Make sure to fasten ground cable to upper starter bolt as shown in Fig 52 7 Connect starter electrical harness and tighten positive cable nut to 10 N m 90 in Ibs torque 8 Install bellhousing dust cover Fig 51 9 Install left engine to transaxle bending brace Fig 51 10 Instal
8. 5 21 119 DISASSEMBLY AND ASSEMBLY Continued 9521 111 Fig 151 Transfer Shaft and Bearing Retainer O RING TRANSFER SHAFT BEARING CONE TRANSFER SHAFT BEARING RETAINER PR2276A Fig 153 Install Transfer Shaft Bearing Cone PRESS 1 2 SPECIAL TOOL L 4411 3 BEARING CONE 4 TRANSFER SHAFT PR2275 Fig 152 Remove Transfer Shaft Bearing Cone 1 TOOL C 293 52 2 TRANSFER SHAFT 3 TOOL C 293 PA 4 4 VISE 2279 Fig 154 Remove Transfer Shaft Bearing Cup 1 SPECIAL TOOL L 4518 2 TRANSFER SHAFT BEARING RETAINER 3 O RING 4 BEARING CUP 21 120 TRANSAXLE DISASSEMBLY AND ASSEMBLY Continued PR2280C Fig 155 Install Transfer Shaft Bearing Cup 1 PRESS 2 HANDLE C 4171 3 SPECIAL TOOL L 4520 4 TRANSFER SHAFT BEARING RETAINER 5 O RING PL Fig 156 Tighten Transfer Shaft Gear Retaining Nut to 271 N m 200 ft Ibs 1 TRANSFER SHAFT GEAR 2 TORQUE WRENCH 3 SPECIAL TOOL L 4434 AND ADAPTER C 4658 DETERMINING SHIM THICKNESS Shim thickness need be determined only if any of the following parts are replaced Transaxle case Transfer shaft Transfer shaft gear Transfer shaft bearings Governor support retainer Transfer shaft bearing retainer Retainer snap ring Governor support Refer to Bearing Adjustment Procedure in rear of this section to determine proper sh
9. 9521 21 Fig 117 Install Differential Bearing Cone SPECIAL TOOL C 4171 SPECIAL TOOL L 4410 BEARING CONE SPEED SENSOR DRIVE GEAR Co 21 37 TRANSAXLE RP456 Fig 119 Install Differential Bearing Cone 1 ARBOR PRESS RAM 2 BEARING CONE 3 SPECIAL TOOL HANDLE C 4171 4 SPECIAL TOOL L 4410 5 DIFFERENTIAL ASSEMBLY RP455 Fig 118 Remove Differential Bearing Cone 1 SPECIAL TOOL C 293 2 SPECIAL TOOL ADAPTER C 293 45 USE 4 PIECES 3 DIFFERENTIAL ASSEMBLY 4 DIFFERENTIAL BEARING CONE 5 SPECIAL TOOL C 4996 NOTE POSITION RING GEAR lt gt FJ9521 84 Fig 120 Remove or Install Ring Gear Bolts and Ring Gear 1 SPEEDOMETER DRIVE GEAR 2 BEARING 3 RING GEAR 4 RING GEAR BOLTS CAUTION Always install new ring gear bolts Tighten ring gear bolts to 81 N m 60 ft Ibs torque 21 38 TRANSAXLE DISASSEMBLY AND ASSEMBLY Continued SPEEDOMETER DRIVE GEAR NOTE The plastic speedometer drive gear must be removed from the differential case in order to ser vice the differential gears REMOVAL 1 Pry the plastic speedometer drive gear off of the differential case using a flat blade pry tool Fig 121 Fig 122 B S 52777774 80468470 Fig 121 Pry Off Soeedometer Drive Gear 1 SPEEDOMETER DRIVE GEAR 2 DIFFERENTIAL ASSEMBLY PL
10. isd 75 55 81455344 10 La KSE B f 7 LL AA 10 o o 6 44 y AL sch SIE MASS 1 34055184 YALYIANOD z E7 oo 33425 1 44 1 em HDLNID JAIVA YONAIAOD ANN NN NN 145 21 TRANSAXLE PL SCHEMATICS AND DIAGRAMS Continued 20 3ATVA 55 4 et 2 5 o o o GION31OS YALYAANOD 3nO301 4066 Nouvommm ES wouons awna sa ces MEME SS 2555 3ATVA 4 553 44 33133ANOO YOLVINWNIIV JILVIMS3HOS DIINVYGAH FIXVSNVEL HLLE dfi 201 NNNIISd 280 90 JILLONHL 534055349 722 Y Java 10 aA OAM3S INOX Dam INON OMNIS SS NONEIAD A 772222727 J5 22 77 PL TRANSAXLE SCHEMATICS AND DIAGRAMS Continued 146 21 5 DITINVYGAH FIXVSNVEL HLLE 8311 110 LuVd NMOQXDDI 3133ANOD Isa 65 9 Ss eee 066 7 awnd Frit 15 zs
11. REAR CLUTCH RETAINER 2 CLUTCH PLATES 3 THICK STEEL PLATE 4 SNAP RING SELECTIVE 5 DRIVING DISCS 6 PRESSURE PLATE TRANSAXLE 21 109 2 PR2237A Fig 114 Piston Spring Waved Snap Ring 1 REAR CLUTCH RETAINER 2 PISTON SPRING 3 SCREWDRIVER 4 WAVED SNAP RING PR2238A Fig 115 Rear Clutch Piston and Piston Spring 1 INPUT SHAFT 2 REAR CLUTCH RETAINER 3 PISTON SPRING 4 WAVED SNAP RING 5 PISTON 6 PISTON SEALS 21 110 TRANSAXLE PL DISASSEMBLY AND ASSEMBLY Continued ASSEMBLY To reassemble reverse the above procedure MEASURING PLATE CLEARANCE 4 PR2239 Fig 116 Remove or Install Input Shaft Snap Ring 1 INPUT SHAFT 2 REAR CLUTCH RETAINER 3 SNAP RING PLIERS 4 SNAP RING Fig 118 Measuring Rear Clutch Plate Clearance 1 REAR CLUTCH ASSEMBLY 2 FEELER GAUGE 3 SELECTIVE SNAP RING FRONT PLANETARY AND ANNULUS GEAR RECONDITION PR2240 Fig 117 Input Shaft Snap Ring 1 INPUT SHAFT 2 REAR CLUTCH RETAINER 3 SNAP RING Press out input shaft if required Fig 119 Front Planetary Gear Snap Ring and No 4 Thrust Washer Always Install a New Snap Ring 1 SNAP RING 2 4 THRUST WASHER 3 SNAP RING 4 FRONT PLANETARY GEAR ASSEMBLY BL 5 21 111 DISASSEMBLY AND ASSEMBLY Continued 80524 5 Fig 120 Front Planeta
12. d 92274 7 4 1 M 202 2 1 EH BEEN 144 2222 oaks NN JAIVA mcs anid YONATAOD egood EIT n 2444 340155344 YILYJANOD 11 ges HAUT Jv3 OAM3S LA INO3J JON3JAOO 21 150 TRANSAXLE SPECIFICATIONS 31TH AUTOMATIC TRANSAXLE Automatic three speed with torque converter and integral differential Torque Converter Diameter 241 millimeters 9 48 in Oil Type Mopar ATF 4 Automatic Transmission Fluid Type 9602 Cooling Method Water Heat Exchanger and or air to oil heat exchanger Lubrication Pump internal external gear type Transmission Gear Ratios First Geal 2 69 Second 1 55 1 00 Reverse Gear 2 10 Band Adjustment Kickdown Backed Off From 8 Nem 72 165 2 1 4 Turns Low Reverse Backed Off From 5 Nem 41 165 iae ER 1 2 Turns Clutch Pack Clearances Front Clutch Not Adjustable 1 27 2 79mm 0 050 0 110 in Rear Clutch 0 71 1 10mm 0 028 0 043 in End Play Input Shaft 0 19 1 50 mm 008 060 in Front Clutch Retainer 0 76 2 69 mm 030 106 in
13. 2 277 d O 7 80114854 Seal Installer C 4992 4995 PL SPECIAL TOOLS Continued Adapter C 4996 Installer L 4410 Special Jaw Set L 4518 1136 80109a03 Bearing Splitter 1130 Driver 6342 TRANSAXLE Seal Installer 6709 Bearing Remover 6768 Bench Fixture 6785 RS Remover 6786 Remover 6787 21 53 21 54 TRANSAXLE 31TH AUTOMATIC TRANSAXLE TABLE OF CONTENTS page GENERAL INFORMATION IN VEHICLE 55 FLUID REQUIREMENTS 55 DESCRIPTION AND OPERATION 31TH GENERAL INFORMATION 55 FLUID LEVEL AND CONDITION 56 TORQUE CONVERTER CLUTCH 56 HYDRAULIC CONTROL 5 5 56 PRESSURE SUPPLY SYSTEM 56 PRESSURE REGULATING VALVES 56 FLOW CONTROL VALVES 56 CLUTCHES BAND SERVOS AND 57 BRAKE TRANSMISSION SHIFT INTERLOCK SYSTEM ie ieee elie toe e Nie 57 GEARSHIFT AND PARKING LOCK CONTROLS 57 COOLER BYPASS VALVE 57 TORQUE CONVERTER CLUTCH SOLENOID WIRING CONNECTOR 58 GOVERNOR 25555 55 Gos nem ek ee 58 DIAGNOSIS AND TESTING TRANSAXLE PRELIMINARY DIAGNOSIS 58 ROAD LES Pk pees 65 HYDRAULIC PRESSURE 5 5 66 CLUTCH AND SERVO AIR PRESSURE TESTS 68 FLUI
14. 3 Stake pinion shaft retaining pin with a suitable chisel Fig 132 80468473 Fig 132 Staking Retaining Pin 1 PINION SHAFT RETAINING PIN 2 SPEEDOMETER DRIVE GEAR 4 Rotate the assembly two full revolutions both clockwise and counterclockwise 4 Set up dial indicator as shown and record end play Fig 133 Fig 134 Rotate side gear 90 degrees and record another end play Again rotate side gear 90 degrees and record a final end play MOVE SIDE GEAR UP AND DOWN Fig 133 Checking Side Gear End Play Typical 1 SPECIAL TOOL C 4996 NOTE POSITION 2 DIAL INDICATOR SET 3 DIFFERENTIAL ASSEMBLY 4 SIDE GEAR 5 Using the smallest end play recorded shim that side gear to within 0 001 to 0 013 inch The other side gear should be checked using the same procedure TRANSAXLE 21 41 MOVE SIDE GEAR UP AND DOWN Fig 134 Checking Side Gear End Play Typical 1 SPECIAL TOOL C 4996 NOTE POSITION 2 DIAL INDICATOR SET 3 DIFFERENTIAL ASSEMBLY CAUTION Side gear end play musi be within 0 001 to 0 013 inch Five select thrust washers avail able 0 027 0 032 0 037 0 042 and 0 047 inch 6 After the end play is measured and adjusted replace speedometer drive gear with a new one Install drive gear lip downward For service informa tion refer to Speedometer Drive Gear service in this section SYNCHRONIZER DISASSEMBLY Place synchronizer in a dean shop
15. Fig 105 Oil Pump Assembly 1 REACTION SHAFT SUPPORT 2 INNER GEAR 3 PUMP BODY 4 PUMP BUSHING 5 OUTER GEAR 1 Remove reaction shaft support to pump body bolts 2 Remove reaction shaft support and the inner and outer pump gears Fig 105 3 Visually inspect gears for excessive wear 4 Inspect pump bushing for excessive wear 5 Reinstall gears and measure outer gear to pocket clearance Clearance should be within 0 045 0 141 mm 0 0018 0 0056 in 6 Measure both inner and outer gear side clear ance using a straight edge and feeler gauge across the pump face Inner and outer gear side clearance should be within 0 020 0 046 mm 0 0008 0 0018 in 80040400 Measuring Pump Outer Gear to Pocket Clearance 1 FEELER GAUGE 2 OUTER GEAR 5 21 105 DISASSEMBLY AND ASSEMBLY Continued FRONT CLUTCH 7 80545440 Front Clutch Assembly 1 SNAP RING WAVE 7 SEAL 2 REACTION PLATE 8 PISTON 3 CLUTCH DISC 9 SPRING 4 CLUTCH PLATE 10 SNAP RING 5 SEAL 11 SPRING RETAINER 6 CLUTCH RETAINER 21 106 TRANSAXLE DISASSEMBLY AND ASSEMBLY Continued DISASSEMBLY 9521 109 nee Fig 108 Front Clutch 4 Disc Shown Fig 106 Front Clutch Waved Snap Ring 1 FRONT CLUTCH RETAINER 1 WAVED SNAP RING 2 CLUTCH PLATES 2
16. Front Carrier 0 89 1 45 mm 007 057 in Front Annulus Gear 0 09 0 50 mm 0035 020 in Planet Pinion 0 15 0 59 mm 006 023 Reverse Drum 0 76 3 36 mm 030 132 in Oil Pump Clearances Outer Gear To Pocket 0 045 0 141mm 0 0018 0 0056 in Outer Gear Side 0 020 0 046mm 0 0008 0 0018 in Inner Gear Side Clearance 0 020 0 046mm 0 0008 0 0018 in Tapered Roller Bearing Settings Differential Assembly 610 12 lbs Drag Torque Output Hub 0 to 3 in Ibs Drag Torque Transfer Shaft 0 002 to 0 010 in End Play Overall Drag At Output Eltre gates dans to 16 in 165 Drag Torque PL Thrust Washers Reaction Shaft Support 1 1 55 1 60 mm 061 063 in Rear Clutch Retainer No 2 1 55 1 60 mm 061 063 in Output Shaft No 3 Select 1 98 2 03 mm 077 080 in Output Shaft No 3 Select 2 15 2 22 mm 085 087 in Output Shaft No 3 Select 2 34 2 41 mm 092 095 in Front Annulus No 4 2 95 3 05 mm 116 120 in Front Carrier Nos 5 amp 6 1 22 1 28 mm 0948 050 in Sun Gear Front No 7 0 85 0 91 mm 033 036 in Sun Gear Rear 8 0 85 0 91 mm 033 036 in Rear Carrier Nos 9 amp 10 1 22 1 28 mm 0948 050 in Rev Drum 11 1 55 1 60 mm 061 063 in 31TH TRANSAXLE TOR
17. INSTALLATION NOTE A new speedometer drive gear must be installed on differential assembly The lip on the speedometer drive gear must be positioned down ward when installing onto differential assembly 1 Position speedometer drive gear onto differen tial assembly Fig 123 80448 0 Fig 123 Speedometer Drive Gear 1 SPEEDOMETER DRIVE GEAR 2 DIFFERENTIAL ASSEMBLY 80468d71 Fig 122 Speedometer Drive Gear Removed 1 SPEEDOMETER DRIVE GEAR 2 DIFFERENTIAL ASSEMBLY 2 Using Miller Tool L 4440 and steel stock press speedometer drive gear onto differential Fig 124 Fig 125 Do not use a hammer 804d8ea3 Fig 124 Press Gear onto Diferential 1 STEEL STOCK 2 PRESS RAM 3 SPECIAL TOOL L 4440 4 DIFFERENTIAL ASSEMBLY 5 SPEEDOMETER DRIVE GEAR PL DISASSEMBLY AND ASSEMBLY Continued 804d8ea4 Fig 125 Drive Gear Pressed onto Differential 1 PRESS RAM 2 SPEEDOMETER DRIVE GEAR 3 DIFFERENTIAL ASSEMBLY DIFFERENTIAL GEARS NOTE The plastic speedometer drive gear must be removed from the differential case in order to ser vice the differential gears Refer to Speedometer Drive Gear for service information REM OVAL 1 Remove pinion shaft retaining pin Fig 126 Fig 127 80468d72 Fig 126 Remove Pinion Shaft Retaining Pin 1 RING GEAR 2 PINION SHAFT RETAINING PIN 3 SPEEDOMETER DRIVE GEAR 21 39 TRANS
18. 1 Install bearing splitter behind 5th speed gear Remove snap ring at 5th synchronizer hub on input shaft Fig 97 E X FJ9521 21 Fig 97 5th Synchro and Hub Snap Ring Removal 1 SNAP RING PLIERS 2 INPUT SHAFT 3 BEARING SPLITTER 4 SNAP RING 2 Remove synchronizer and gear using shop press Fig 98 7 FJ9521 22 Fig 98 Remove Synchronizer Using Shop Press 1 PRESS RAM 2 INPUT SHAFT 3 BEARING SPLITTER 4 SYNCHRONIZER ASSEMBLY 21 32 3 Remove caged needle bearing Fig 99 FJ9521 23 Fig 99 Caged Needle Bearing Removal 1 INPUT SHAFT 2 CAGED NEEDLE BEARING TRANSAXLE DISASSEMBLY AND ASSEMBLY Continued 4 Remove 4 5 gears split thrust washer ring Fig 100 2 Sa ILL EE 1 290 Dm A FJ9521 24 Fig 100 Split Thrust Washer Ring Removal 1 SPLIT THRUST WASHER RING 2 INPUT SHAFT PL 5 Remove split thrust washer Fig 101 E 2 9 LPR EXTUS 4 27 ps FJ9521 25 Fig 101 Split Thrust Washer Removal 1 INPUT SHAFT 2 SPLIT THRUST WASHER 6 Remove split thrust washer separation pin Fig 102 FI9S21 26 Fig 102 Split Thrust Washer Separation Pin 1 SEPARATION PIN 2 INPUT SHAFT 3 PLIERS PL TRANSAXLE 21 33 DISASSEMBLY AND AS
19. Fig 57 Selector Shaft 1 SHIFT ASSEMBLY 2 SELECTOR SHAFT 15 Remove transaxle end cover Fig 58 Fig 59 FJ9521 12 Fig 58 Transaxle Cover Removal 1 TRANSAXLE CASE 2 END COVER TRANSAXLE 21 21 Fig 59 End Cover 1 END COVER 2 CASE 16 Remove two snap rings retaining the output shaft and the input shaft to the bearings Fig 60 5 Fig 60 Snap Rings Retaining Bearings 1 SNAP RING PLIERS 2 SNAP RINGS 21 22 TRANSAXLE DISASSEMBLY AND ASSEMBLY Continued 17 Using bench fixture and shims provided Mill 19 Install transaxle gear case into shop press er tools 6785 6785 1 and 6785 2 turn transaxle Press output and input shaft assemblies out of case over Install transaxle onto bench fixture Fig 61 Fig 63 Verify shim spacers are in position on bench fixture Install transaxle into shop press 9521 12 Fig 63 Pressing Gears Out of Case 1 BEARING FIXTURE 2 PRESS RAM 3 TRANSAXLE CASE 4 BENCH FIXTURE Fig 61 Bench Fixture 1 SHIMS 2 TRANSAXLE 3 6785 BENCH FIXTURE 20 Remove transaxle from press 18 Install bearing fixture Miller tool 6768 onto 21 Carefully transaxle Cape from the transaxle end bearings Fig 62 Verify tool is prop shaft assemblies and bench fixture Fig 64 Be sure erly aligned to input
20. If air powered lubrication equipment is used to fill a transaxle be sure the equipment is properly cali brated Equipment out of calibration can lead to an underfill condition FLUID LEAKS Fluid leaks can occur around the input shaft seal axleshaft seals case split lines and the end cover Be careful not to misdiagnose an input shaft seal leak for an engine rear main seal leak Also the transaxle case sealer split line will accumulate dirt and look like an oil leak CLUTCH PROBLEMS Worn damaged or misaligned clutch components can cause difficult shifting gear clash and noise A worn or damaged clutch disc pressure plate or release bearing can cause hard shifting and gear clash SERVICE PROCEDURES FLUID DRAIN AND FILL All NV T350 A 578 transaxles are equipped with a fill plug The fill plug is located on the left side of the transaxle differential area Fig 3 The fluid level should be within 3 16 inch from the bottom of the transaxle fill hole vehicle must be level when check ing Fig 3 Fill Plug Location 1 RUBBER FILL PLUG 2 LEFT DRIVESHAFT SEAL PL NV T350 A 578 transaxles are equipped with a drain plug The drain plug is located on the lower right side of the transaxle differential housing Fig 4 Tighten drain plug to 28 N m 250 in Ibs 9421 8 Fig 4 Drain Plug Location 1 RIGHT DRIVESHAFT SEAL 2 DRAIN PLUG Dry fill lubricant capacity is approximately 1
21. NOTE Remove old sealant before applying new sealant Use Mopar RTV sealant or equivalent when installing cover STIRRUP AND STRAP REMOVAL NOTE A stirrup and retaining strap is attached to the transfer gear The stirrup prevents the transfer gear retaining nut from turning and backing off the transfer shaft The strap is used to hold the stirrup to the transfer gear and prevent the stirrup retain ing bolts from backing out 1 Using a punch bend tabs on strap flat against transfer gear 2 Remove bolts holding retaining strap to stir Fig 138 Transfer Shaft Gear Nut and Washer rup OUTPUT SHAFT GEAR 3 Remove strap from transfer gear and stirrup TRANSFER SHAET GEAR 4 Remove stirrup from transfer gear WASHER NUT Go 21 116 TRANSAXLE DISASSEMBLY AND ASSEMBLY Continued PR2264 Fig 141 Using Tool L 4406 1 with Adapter L 4406 3 Remove Transfer Shaft Gear Bearing Cone 1 SPECIAL TOOL L 4406 1 2 TRANSFER SHAFT GEAR 80040429 Fig 139 Remove Transfer Shaft Gear using L 4407A 1 TRANSFER GEAR 1 2 TOOL L 4407A PR2265A Fig 142 Install Transfer Shaft Gear Bearing Cone 1 PRESS See 2 HANDLE 4171 3 SPECIAL TOOL L 4410 Fig 140 Transfer Shaft Gear and Select Shim Soe GEAR 1 TRANSFER SHAFT GEAR 7 2 OUTPUT SHAFT GEAR 3 SHIM SELECT 4 BEARING CONE PL DISASSEMBL
22. PARK NOTE Any failure to meet these expected responses requires system adjustment or repair 13 Install shifter bezel Fig 31 14 Install center console assembly Fig 30 15 Install gearshift knob and tighten set screw to 2 N m 15 in 165 torque Fig 29 INTERLOCK MECHANISM REMOVAL 1 Remove the steering column lower cover Fig 39 2 Remove the steering column upper and lower shrouds Fig 40 3 Turn the ignition key to the OFF or ON RUN position Fig 41 4 Grasp the interlock cable and connector firmly Remove the interlock cable Fig 42 PL 80bc4ee5 Fig 39 Steering Column Lower Cover 1 LOWER COVER 80bc4ee6 Fig 40 Steering Column Shrouds 1 UPPER SHROUD 2 LOWER SHROUD 5 Remove the two interlock mechanism to steer ing column attaching screws Fig 43 Remove the interlock housing INSTALLATION 1 Position the interlock housing at steering col umn Install the two interlock mechanism to steering column attaching screws Torque screws to 3 N m 21 in 165 2 Snap the interlock cable into the housing PL REMOVAL AND INSTALLATION Continued 80b89922 Fig 41 Ignition Key Switch Positions 1 ACC 2 LOCK 3 OFF 4 ON RUN 5 START Ay 9 E 2815 NS g 9521 74 Fig 42 Interlock Cable 1 IGNITION LOCK CYLINDER 2 INTERLOCK CABLE 3 Install steer
23. 1 INPUT SHAFT 2 OUTPUT SHAFT 3 DIFFERENTIAL 4 CASE TRANSAXLE 21 19 9 Remove reverse idler shaft bolt Fig 51 AW mm 7 Fig 51 Reverse Idler Shaft Bolt Removal 1 CASE 2 REVERSE IDLER SHAFT 3 REVERSE IDLER SHAFT BOLT 10 Remove reverse idler shaft Fig 52 80046423 Fig 52 Reverse Idler Shaft Removal 1 REVERSE IDLER SHAFT 21 20 TRANSAXLE DISASSEMBLY AND ASSEMBLY Continued 11 Remove reverse idler gear and spacer Fig 53 Fig 55 Remove Reverse Fork Bracket 1 REVERSE FORK BRACKET 2 REVERSE CAM BLOCKOUT 3 SHIFT BLOCKER ASSEMBLY 80bdbd24 13 Using snap ring pliers remove selector shaft Fig 53 Reverse Idler Gear and Spacer Removal spacer Fig 56 1 SPACER 14 Pull the selector shaft shift pin out of the slot 2 REVERSE IDLER GEAR in the blocker assembly Turn selector shaft up and out of the way Fig 57 12 Remove two screws retaining reverse fork bracket Fig 54 Remove reverse fork bracket and reverse cam blockout assembly Fig 55 Fig 56 Remove Selector Shaft Spacer 1 SHIFT BLOCKER ASSEMBLY 2 SELECTOR SHAFT SPACER PLASTIC 3 SNAP RING PLIERS Fig 54 Screws Retaining Reverse Fork Bracket 1 SCREWS 2 2 REVERSE FORK BRACKET PL DISASSEMBLY AND ASSEMBLY Continued OL 9521 11
24. 2 SHIFTER Typical 3 CROSSOVER CABLE 1 CONSOLE 4 CLIP 2 SCREW 4 3 SCREW 2 4 Separate shifter boot from shifter assembly Fig 25 Boot is retained to shifter by three push pin retainers 80bc4d62 Fig 27 Selector Cable at Shifler Assembly 1 SHIFTER 2 CLIP 3 SELECTOR CABLE 80bc4d60 Fig 25 Gearshift Boot Removal Installation INSTALLATION 1 BOOT 1 Install shifter assy to floor pan Fig 28 2 SHIFTER ASSEMBLY Install and tighten four nuts to 12 N m 105 in Ibs torque 2 Install selector cable to shifter lever and secure cable to shifter bracket Install dip Fig 27 3 Install crossover cable to shifter lever and secure cable to shifter bracket Install clip Fig 26 4 Install boot to the shifter assembly Fig 25 Fasten boot with the three retainers 5 Remove crossover cable retaining dip and dis connect from shift lever Fig 26 Remove selector cable retaining clip and dis connect from shift lever Fig 27 7 Remove four shifter assy to floor pan nuts and remove shifter from vehicle Fig 28 PL REMOVAL AND INSTALLATION Continued 80bc4d66 Fig 28 Shifter Assy Removal Installation 1 SHIFTER ASSEMBLY 5 Install center console assembly Fig 24 Verify that boot is not pinched at console opening before tightening 6 Install knob to shifter lever align knob to three o clock position push knob dow
25. 66 Measure Input Shaft End Play using End Play Set 8266 1 TOOL 8266 8 2 TOOL 8266 2 3 TOOL C 3339 TRANSAXLE 21 91 Fig 67 Loosen Lock Nut and Tighten Kickdown Band Adjusting Screw 1 KICKDOWN BAND ADJUSTING SCREW Fig 68 Pump Attaching Bolts 1 SEAL 2 PUMP ATTACHING BOLTS 7 3 PUMP HOUSING ASSEMBLY When rebuilding reverse the above procedure VALVE BODY NOTE Tighten all valve body screws to 5 N m 40 Ibs CAUTION Do not clamp any portion of valve body or transfer plate in a vise Any slight distortion of the aluminum body or transfer plate will result in sticking valves excessive leakage or both When removing or installing valves or plugs slide them in or out carefully Do not use force NOTE TAG ALL SPRINGS AS THEY ARE REMOVED FOR REASSEMBLY IDENTIFICATION PL 21 92 TRANSAXLE DISASSEMBLY AND ASSEMBLY Continued Fig 69 Install Tool C 3752 with Adapters L 4437 Fig 71 Oil Pump Gasket 1 PUMP 1 SPLIT IN GASKET DIFFERENTIAL OIL FEED 2 PULLERS TOOL C 3752 2 PUMP GASKET 3 ADAPTERS TOOL L 4437 3 PUMP GASKET DIFFERENTIAL OIL FEED CUTOUT 17 PR2206A Fig 70 Oil Pump with No 1 Thrust Washer Fig 72 Loosen Kickdown Band Adjusting Screw 1 FRONT CLUTCH 1 KICKDOWN BAND ADJUSTING SCREW 2 OIL PUMP ASSEMBLY pL TRANSAXLE 21 93 DISASSEMBLY AND ASSEMBLY Continued _ H gt PR2211A Fig 75 No 2 T
26. ASSEMBLY To assemble reverse the above procedure KICKDOWN SERVO CONTROLLED LOAD RECONDITION DISASSEMBLY Fig 131 Kickdown Servo Snap Ring 1 SNAP RING 2 SNAP RING PLIERS 3 ACCUMULATOR PLATE 4 KICKDOWN LEVER 5 KICKDOWN PISTON ROD GUIDE 21 114 TRANSAXLE DISASSEMBLY AND ASSEMBLY Continued RB742A Fig 132 Kickdown Servo Rod Guide and Snap Ring Fig 134 Controlled Load Kickdown Servo 1 SNAP RING 1 KICKDOWN PISTON 2 ACCUMULATOR PLATE 2 O RING 3 RETURN SPRING 3 SNAP RING 4 O RING 4 PISTON ROD GUIDE 5 PISTON ROD GUIDE 5 SNAP RING 6 O RING 7 PISTON RETURN SPRING 8 PISTON ROD 9 SEAL RINGS ASSEMBLY To assemble reverse the above procedure TRANSFER SHAFT REPAIR DISASSEM BLY a Fig 133 Kickdown Piston Return Spring and Piston 1 RETURN SPRING 2 KICKDOWN LEVER 3 PISTON ROD 4 KICKDOWN SERVO PISTON PR2258B Fig 135 Rear Cover Bolts 1 REAR COVER 2 REAR COVER BOLTS 10 PR TRANSAXLE 21 115 DISASSEMBLY AND ASSEMBLY Continued Fig 137 Remove Transfer Shaft Gear Retaining Nut 1 TRANSFER SHAFT GEAR 2 SCREW 2 3 OUTPUT SHAFT GEAR 4 SPECIAL TOOL L 4434 Fig 136 Remove or Install Rear Cover OUTPUT SHAFT GEAR USE MOPAR SILICONE RUBBER ADHESIVE SEALER REAR COVER TRANSFER SHAFT GEAR
27. End Plate Cover Bolts 29 N m 21 ft Ibs Lateral Bending Strut toEngine 81 Nm 60 ft Ibs Lateral Bending Strut to Trans 81 60 ft Ibs Left Mount Through Bolt 108 N m 80 ft Ibs Left Mount to Transaxle 68 N m 50 ft Ibs Output Bearing Race Ret Strap 11 96 in Ibs Reverse Fork Bracket 11 N m 96 in Ibs Reverse Idler Shaft Bolt 26 N m 19 ft Ibs Shift Cable Bracket to Transaxle 28 250 in Ibs Transaxle Case Bolts 29 N m 21 ft Ibs Transaxle to Engine Bolt 95 N m 70 ft Ibs Trans to Eng Intake Bkt Bolts 95 N m 70 ft Ibs Vehicle Speed Sensor 7 N m 60 in Ibs Vertical Bending Strut toEngine 81 N m 60 ft Ibs Vertical Bending Strut to Trans 81 Nem 60 ft Ibs NOTE Bolts that have thread sealer or torque lock patches should not be reused Always install new bolts in these applications NV T350 A 578 MANUAL TRANSAXLE FLUID FILL U S MEASURE TRANSAXLE METRIC MEASURE NV T350 1 9 2 2 Liters 2 0 2 3 Quarts 21 52 TRANSAXLE SPECIAL TOOLS NV T350 A 578 MANUAL TRANSAXLE SS Adapter Blocks 293 45 0 293 45 00114408 90114420 Dial Indicator C 3339 Sleeve C 3717 ER Slide Hammer C 3752 80714499 Universal Handle 4171 0 Bearing Installer 4628 lt lt Seal Remover 4680
28. Fig 174 Remove Output Shaft Gear Bearing Cup 1 OUTPUT SHAFT GEAR BEARING CUP Fig 176 Install Output Shaft Gear Bearing Cone 2 SPECIAL TOOL L 4518 PRESS 1 2 HANDLE C 4171 3 SPECIAL TOOL L 4408 4 5 OUTPUT SHAFT GEAR BEARING CONE Fig 175 Remove Rear Planetary Annulus Gear Bearing Cup 1 REAR PLANETARY ANNULUS GEAR BEARING CUP 2 SPECIAL TOOL L 4518 RB744 Fig 177 Install Rear Planetary Annulus Gear Bearing Cone 1 ARBOR PRESS RAM 2 SPECIAL TOOL C 4637 3 REAR PLANETARY ANNULUS GEAR 4 CUP FROM TOOL L 4518 5 BEARING CONE 21 126 TRANSAXLE DISASSEMBLY AND ASSEMBLY Continued PR2299 B Fig 180 Install Rear Planetary Annulus Gear Bearing Cup 1 SPECIAL TOOL L 4429 3 PR2295A Fig 178 Install Output Shaft into Rear Planetary Annulus Gear PRESS DETERMINING SHIM THICKNESS 1 2 INCH SOCKET Shim thickness need be determined only if any of OUTPUT SHAFT the following parts are replaced REAR ANNULUS GEAR e Transaxle case COBPROER e Output shaft Rear planetary annulus gear e Output shaft gear e Rear annulus and output shaft gear bearing cones e Overrunning clutch race cups Refer to Bearing Adjustment Procedure at the rear of this section to determine proper shim thickness Check output shaft bearing turning torque using an inch pound torque wrench If turning torque is 3 to 8 inch pound
29. Fig 45 and partially remove air cleaner assembly d Disconnect accelerator transaxle kickdown and speed control if equipped cables after the assy is removed from position Remove air cleaner assembly from vehicle PL 80bbdadd Fig 45 Air Cleaner Assembly Removal installation 1 AIR CLEANER ASSY 2 THROTTLE BODY DUCT 4 Remove battery tray from bracket 5 Disconnect torque converter clutch solenoid and neutral safety back up lamp switch connectors 6 Disconnect and plug transaxle oil cooler lines Fig 46 80004566 Fig 46 Transaxle Oil Cooler Lines 1 RETURN 2 CLAMPS 3 PRESSURE 7 Disconnect shifter cable from shift lever and remove from bracket Fig 47 Secure cable out of the Way PL REMOVAL AND INSTALLATION Continued 80bbdad5 Fig 47 Gear Shift Cable at Transaxle 1 SHIFT LEVER 2 SHIFT CABLE 8 Disconnect kick down cable and remove from bracket Secure cable out of the way Fig 48 Fig 48 Kickdown Cable at Transaxle 1 LEVER 2 BRACKET 3 KICKDOWN CABLE 9 Raise vehicle on hoist 10 Remove transaxle oil pan and drain ATF into a suitable container 11 Remove both axle shafts Refer to Group 3 Differential and Driveline for the correct procedures TRANSAXLE 21 85 12 Remove the right engine to transaxle lateral bending brace Fig 49 80bbdad Fig 49 Right Lateral Bending Brace Removal Install
30. recheck the turning torque of the differen tial The turning torque should be between 5 and 18 inch pounds PL DIFFERENTIAL BEARING SHIM CHART TRANSFER SHAFT BEARING 1 Use tool L 4434 to remove the retaining nut and washer Remove the transfer shaft gear using tool L 4407 2 Install a 2 29 mm 0 090 inch and a 1 39 mm 0 055 inch gauging shims on the transfer shaft behind the governor support 3 Install transfer shaft gear and bearing assem bly and torque the nut to 271 N m 200 ft Ibs To measure bearing end play a Attach tool L 4432 to the transfer gear b Mount a steel ball with grease into the end of the transfer shaft c Push and pull the gear while rotating back and forth to insure seating of the bearing rollers d Using a dial indicator measure transfer shaft end play Refer to the Transfer Bearing Shim Chart for the required shim combination to obtain the proper bearing setting f Use tool L 4434 to remove the retaining nut and washer Remove the transfer shaft gear using tool L 4407 PL USTMENTS Continued g Remove the two gauging shims and install the correct shim combination Install the transfer gear and bearing assembly h Install the retaining nut and washer and torque to 271 N m 200 ft Ibs Measure transfer shaft end play end play should be 0 05 to 0 25 mm 0 002 to 0 010 inch i Measure bearing end play End play should be between 05 mm and 25 mm 002 to
31. which converts power from the output shaft pinion gear to the differential ring gear The dif 21 2 TRANSAXLE GENERAL INFORMATION Continued ferential case transfers torque from the ring gear to the drive axles by means of differential side gears The NV 350 A 578 transaxle internal components can only be serviced by separating the case halves CAUTION The transaxle output shaft is serviced as a unit No disassembly and reassembly is possible Damage to the transaxle may result TRANSAXLE IDENTIFICATION The transaxle model part number build sequence and date are shown on a bar code label that is attached to the front of the transaxle This informa tion is also shown on a metal tag that is attached to the end cover of the transaxle Fig 1 NOTE Transaxles use various final drive gear ratios in different vehicle applications Therefore it is necessary that the correct transaxle assembly number is used when ordering service parts NOTE There are three different versions of this transaxle There are external differences between the models Refer to the identification tag on the transaxle to determine which transaxle the vehicle is equipped with FLUID REQUIREMENTS NV T350 A 578 transaxles use Mopar Manual Transaxle Lubricant MS 9417 Hypoid gear lube engine oil and or automatic transmission fluid should not be used in this transaxle Hard shift ing effort bearing gear and or synchronizer failu
32. 3 21 154 TRANSAXLE SPECIAL TOOLS Continued Bearing Puller L 4435 Du Differential Tool L 4436A Housing Remover Adapter L 4437 PL Starter Nut L 4439 Transfer Shaft Remover Installer L 4512 Bearing Cup Remover L 4517 E Special Jaw Set L 4518 Installer L 4520 5 21 155 SPECIAL TOOLS Continued Bearing Installer 6536 A Bearing Installer 5052 Bearing Cup Remover 6062 A End Play Set 8266
33. 4436A and an inch pound torque wrench check the turning torque of the differential 21 140 TRANSAXLE USTMENTS Continued The turning torque should be between 5 and 18 inch pounds EX m A H 80477390 Fig 223 Checking Differential Bearings Turning Torque 1 SPECIAL TOOL L 4436 A 2 TORQUE WRENCH 5 If the turning torque is within specifications remove tools Setup is complete 6 If turning torque is not within specifications proceed with the following steps a Remove differential bearing retainer from the transaxle case b Remove the bearing cup from the differential bearing retainer using Tool 6062A Remove the existing shim from under the cup d Measure the existing shim e NOTE If the turning torque was too high when measured install a 05 mm 002 inch thinner shim If the turning torque is was too low install 05 mm 002 inch thicker shim Repeat until 5 to 18 inch pounds turning torque is obtained Oil Baffle is not required when making shim selection f Install the proper shim under the bearing cup Make sure the oil baffle is installed properly in the bearing retainer below the bearing shim and cup g Install the differential bearing retainer using Tool 5052 and C 4171 Seal the retainer to the housing with MOPAR Adhesive Sealant and torque bolts to 28 N m 250 in 165 7 Using Tool L 4436A and an inch pound torque wrench
34. 6786 2 SHIFT SHAFT BUSHING 3 SLIDE HAMMER C 3752 INSTALLATION 1 Position shaft bore 2 Using an appropriate size deep well socket install bushing in selector shaft bore Fig 154 replacement bushing over selector Fig 154 Selector Shaft Bushing Installation 1 DEEP WELL SOCKET 2 SHIFTER SHAFT BUSHING 21 48 TRANSAXLE DISASSEMBLY AND ASSEMBLY Continued SHIFT CROSSOVER SHAFT BUSHING REMOVAL 1 Install slide hammer 3752 through the cross over bushing 2 Thread nut and washer onto slide hammer 3 Using the slide hammer remove the crossover shaft bushing Fig 155 Fig 155 Crossover Shaft Bushing Removal 1 SLIDE HAMMER 2 SHIFTER SHAFT BUSHING INSTALLATION 1 Position the replacement crossover shaft bush ing over the crossover shaft bushing bore 2 Using an appropriate size deep well socket install the crossover shaft bushing into the bushing bore REAR BEARING OIL FEED TROUGH The bearing oil feed trough is retained in the case by a pin that is molded into the case and clips that are part of the trough Fig 156 REMOVAL 1 Using light plier pressure squeeze the clips together at the rear of the trough 2 Slide the trough over the retaining pin that locates the trough in the case INSTALLATION 1 Reverse removal procedure to install oil feed trough PL 9521 16 Fig 156 Oil Feed Trough 1 OIL FEED TROUGH CLEANING AND INSPEC
35. Differential and Extension 1 EXTENSION HOUSING Fig 199 Extension Bolts 1 EXTENSION HOUSING BOLTS 4 2 O RING 2 EXTENSION HOUSING 3 DIFFERENTIAL ASSEMBLY 3 OIL SEAL 21 132 TRANSAXLE PL DISASSEMBLY AND ASSEMBLY Continued WARNING HOLD ONTO DIFFERENTIAL ASSEMBLY TO PREVENT IT FROM ROLLING OUT OF HOUSING Use Mopar Silicone Rubber Adhesive Sealant or equivalent when installing extension housing 8056d9dd Fig 204 Install Differential Bearing Cone 1 SPECIAL TOOL C 4171 2 SPECIAL TOOL 6536 80524 3 DIFFERENTIAL ASSEMBLY ERA lt i Fig 202 Remove Differential Bearing Cone Extension Housing Side 1 SPECIAL TOOL 293 2 SPECIAL TOOL C 293 36 3 SPECIAL TOOL C 293 3 8056d9de Fig 205 Position Button and Collets Onto Differential and Bearing Ring Gear Side 1 SPECIAL TOOL L 4539 2 2 SPECIAL TOOL 5048 3 SPECIAL TOOL 5048 4 80524 77 Fig 203 Position Bearing Cone Onto Differential 1 DIFFERENTIAL ASSEMBLY 2 DIFFERENTIAL BEARING PL DISASSEMBLY AND ASSEMBLY Continued 80524 6 Fig 206 Position Tool 5048 Over Button Collets at Differential Bearing 1 SPECIAL TOOL 5048 2 DIFFERENTIAL 3 SPECIAL TOOL 5048 4 80524e6d Fig 207 Remove Differential Bearing Cone 1 SPECIAL TOOL 5048 2 RING GEAR To install the differential bearing cup and cone on
36. IN 2 1 Attach one gauge to line pressure port and tee another gauge into lower cooler line fitting This will allow lubrication pressure readings to be taken 2 Operate engine at 1000 rpm for test 3 Move selector lever on transaxle one detent for ward from full rearward position This is selector 2 position 4 Read pressures on both gauges as throttle lever on transaxle is moved from full clockwise position to full counterclockwise position 5 Line pressure should read 52 to 58 psi with throttle lever clockwise Pressure should gradually increase to 80 to 88 psi as lever is moved counter clockwise 6 Lubrication pressure should be 10 to 25 psi with lever clockwise and 10 to 35 psi with lever at full counterclockwise 7 This tests pump output pressure regulation and condition of rear clutch and lubrication hydraulic circuits TEST THREE SELECTOR IN D 1 Attach gauges to line and kickdown release ports 2 Operate engine at 1600 rpm for test 3 Move selector lever on transaxle two detents forward from full rearward position This is selector D position 4 Read pressures on both gauges as throttle lever on transaxle is moved from full clockwise to the full counterclockwise position 5 Line pressure should read 52 to 58 psi with throttle lever clockwise Pressure should gradually increase to 80 to 88 psi as lever moved counter clockwise 6 Kickdown release is pressurized only in direct d
37. LINE PRESSURE VALVE 8 KICKDOWN VALVE 3 SPRING 9 SPRING 4 ADJUSTING SCREW 10 MANUAL VALVE 5 SCREW 11 THROTTLE VALVE 6 GUIDE PL TRANSAXLE 21 101 DISASSEMBLY AND ASSEMBLY Continued 1 SHUTTLE VALVE SECONDARY SPRING 2 SHUTTLE VALVE 3 1 2 SHIFT VALVE GOVERNOR PLUG 4 END COVER 714 Fig 102 Governor Plugs 5 SCREW 4 6 END COVER 7 2 3 SHIFT VALVE GOVERNOR PLUG 8 E CLIP 21 102 TRANSAXLE DISASSEMBLY AND ASSEMBLY Continued 80bdbd32 Fig 103 Torque Converter Clutch Solenoid and Regulator Control Valves 1 CONVERTER PRESSURE CONTROL VALVE 4 REGULATOR VALVE THROTTLE PRESSURE PLUG SPRING 2 END COVER 5 REGULATOR VALVE THROTTLE PRESSURE PLUG 3 SCREW 3 6 SWITCH VALVE BL E TRANSAXLE 21 103 DISASSEMBLY AND ASSEMBLY Continued 80bdbd30 Fig 104 Shift Valves and Shuttle Valve 1 SHUTTLE VALVE E CLIP 9 BY PASS VALVE SPRING 2 SHUTTLE VALVE SECONDARY SPRING 10 1 2 SHIFT VALVE SPRING 3 SHUTTLE VALVE 11 1 2 SHIFT VALVE 4 2 3 SHIFT VALVE 12 BY PASS VALVE 5 SHUTTLE VALVE PRIMARY SPRING 13 TORQUE CONVERTER CLUTCH SOLENOID 6 2 3 SHIFT VALVE SPRING 14 VALVE BODY 7 SHUTTLE VALVE PLUG 15 SPRING GUIDES 2 8 SCREWS 21 104 TRANSAXLE DISASSEMBLY AND ASSEMBLY Continued OIL PUMP PL 80bdbd50
38. SEAL 2 PRY TOOL INSTALLATION 1 Clean axle shaft seal bore of any excess seal ant 2 Align axle shaft seal with axle shaft seal bore 3 Install axle seal on tool 6709 with C 4171 and insert into axle shaft seal bore 4 Tap seal into position Fig 140 OUTPUT BEARING REMOVAL NOTE The position of the output shaft bearing is critical The bearing is not identical end to end Install bearing with larger diameter cage ring facing out 1 Remove caged roller bearing from output bear ing race Fig 141 2 Remove screws at output bearing retainer strap Fig 142 3 Install tool 6787 and slide hammer Fig 143 Tighten tool to output bearing race 4 Using slide hammer remove output bearing race 27 80a6769b Fig 141 Output Roller Bearing 1 INPUT BEARING 2 OUTPUT BEARING 3 LARGER DIAMETER CAGE RING 21 44 TRANSAXLE DISASSEMBLY AND ASSEMBLY Continued INSTALLATION 1 Line up output bearing race to race bore 2 Insert tool 4628 with C 4171 into output bear ing race Fig 144 Tap race into bore Install output bearing into race Verify that the larger diameter cage is facing outward Position bearing retaining strap Tighten bolts to 11 N m 96 in Ibs Fig 142 Output Bearing Strap w 1 BEARING RETAINER 2 OUTPUT BEARING RACE dps 1 e AN Fig 144 Output Bearing Race Instal
39. SPECIAL TOOL 6062A 2 DIFFERENTIAL BEARING RETAINER To remove the differential bearing cup from the extension housing adapter side use Special Tool 6062A Remover To install the differential bearing cup on the extension housing adapter side use Spe cial Tool 6536 Driver and Special Tool C 4171 Han dle 80524676 Fig 213 Install Bearing Cup 1 SPECIAL TOOL 4171 2 SPECIAL TOOL 5052 3 DIFFERENTIAL BEARING RETAINER PL CLEANING AND INSPECTION VALVE BODY Allow all parts to soak a few minutes in a suitable clean solvent Wash thoroughly and blow dry with compressed air Be sure all passages are clean and free from obstructions Inspect manual and throttle valve operating levers and shafts for being bent worn or loose If a lever is loose on its shaft it should be replaced Do not attempt to straighten bent levers Inspect all mating surfaces for burrs nicks and scratches Minor blemishes may be removed with cro cus cloth using only a very light pressure Using a straightedge inspect all mating surfaces for warpage or distortion Slight distortion may be corrected using a surface plate Be sure all metering holes in steel plate are open Using a penlight inspect bores in valve body for scores scratches pits and irregu larities Inspect all valve springs for distortion and col lapsed coils Inspect all valves and plugs for burrs nicks and scores Small nicks and scores may be removed
40. Using a pick tool pry up on the shift shaft seal and remove seal from bore INSTALLATION 1 Position new shift shaft seal in bore 2 Install shift shaft seal into bore using an appropriate size deep well socket PL DISASSEMBLY AND ASSEMBLY Continued SHIFT SELECTOR SHAFT REMOVAL 1 Disassemble transaxle using the procedure out lined in this group 2 With the transaxle disassembled remove the selector shaft by pushing on the shaft from the out side Pull shaft out from the inside INSTALLATION 1 Reverse removal procedure to install selector shaft SHIFT CROSSOVER SHAFT REMOVAL 1 Disassemble transaxle using the procedure out lined in this group 2 With the transaxle disassembled remove the crossover shaft seal 3 Using snap ring pliers remove the snap ring at the crossover shaft bore Fig 152 692330 Fig 152 Crossover Shaft Snap Ring 1 SELECTOR SHAFT 2 CROSSOVER SHAFT 3 SNAP RING 4 Push the crossover shaft in the case and remove the crossover assembly INSTALLATION 1 Reverse removal procedure to install crossover shaft TRANSAXLE 21 47 SHIFT SELECTOR SHAFT BUSHING REMOVAL 1 Remove selector shaft using procedure in this group 2 Thread tool 56786 into bushing 3 Install slide hammer 8752 onto tool and remove bushing using slide hammer Fig 153 SAO Y 9521 6 Fig 153 Selector Shaft Bushing Removal 1 SPECIAL TOOL
41. cable core end to the plastic cam of the shifter mechanism Snap the shifter ignition interlock cable end fitting into the groove in the gear shift mechanism as shown in Fig 32 11 Adjust interlock cable system as follows If interlock cable is being replaced it will come with an adjustment pin Remove the pin from the cable and allow the cable to self adjust Lock cable adjustment by pressing down on the adjuster lock until bottomed at the cable housing If interlock cable is being re used no pin will be provided Pry up on cable adjuster lock to release and allow cable to self adjust Lock cable adjustment by pressing down on the adjuster lock until bottomed at the cable housing 12 Connect battery negative cable and ver ify interlock system operation as follows ACTION EXPECTED RESPONSE 1 Turn key to the OFF 1 Shifter CAN be shifted position out of park 2 Turn key to the 2 Shifter CANNOT be shifted out of park 3 Shifter CAN be shifted out of park ON RUN position 4 Key cannot be 3 Turn key to the ON RUN position and returned to the LOCK or ACC position depress the brake pedal 4 Leave shifter in any gear and try to return key to the LOCK or ACC position 5 Return shifter to PARK and try to remove the key 6 With the key removed try to shift out of PARK 5 Key can be removed after returning to LOCK position 6 Shifter cannot be shifted out of
42. case Fig 83 Verify reverse brake bearings Fig 85 shim is in position R 1 3 EE 2 0 SS Sep A A FJ9521 14 FJ9521 43 Fig 85 Snap Rings Retaining Bearings Fig 83 Friction Cone Lugs 1 SNAP RING PLIERS 2 SNAP RINGS 1 CASE 2 FRICTION CONE LUGS 3 INPUT SHAFT 13 Apply Mopar RTV sealant to end cover outer ME edge and around bolt holes Install end cover onto 11 Position input and output bearings on the gear case Tighten end cover bolts to 29 N m 21 ft shafts Using Miller tool 4992 1 press on input torque Fig 86 and output shaft bearings until they bottom into the case and against the shafts Fig 84 7 4 Ed 9521 73 Fig 86 Transaxle End Cover 1 TRANSAXLE CASE Fig 84 Installing Input and Output Bearings 2 END COVER 1 INPUT AND OUTPUT BEARINGS 2 SPECIAL TOOL C 4992 1 21 28 TRANSAXLE DISASSEMBLY AND ASSEMBLY Continued 14 Remove gear case from bench fixture 19 Install reverse idler shaft Fig 89 15 Install gear case in a holding fixture with end cover facing down 16 Turn selector shaft into slot on blocker assem bly Fig 87 Fig 87 Selector Shaft 1 SHIFT ASSEMBLY 2 SELECTOR SHAFT Fig 89 Reverse Idler Shaft 80bdbd23 1 REVERSE IDLER SHAFT 17 Push selector shaft spacer dip onto selector shaft Install shift leve
43. frequently the end result of insufficient improper lubricant Refer to Fluid Requirements in this group Transaxle noise is most often a result of worn or damaged components Chipped pitted spalled and broken gears or synchronizer teeth can cause noise Brinnelled or spalled bearings will generate noise Improperly assembled missing loose or improp erly installed parts etc transaxles are likely to gen erate abnormal noise Squealing noises are commonly caused by defective dutch release bearings and the reverse brake if equipped Inspect the bearing cage and reverse cone for signs of heat damage Gear rattle gear clash hard shifts and premature dutch disc wear can result from misalignment of the transmission to the engine Inspect for excessive dutch dust in the dutch housing and oblonged mushroomed dowel holes SLIPS OUT OF GEAR Transaxle disengagement may be caused by mis aligned or damaged shift components manufacturing burrs on the gear teeth or worn teeth on the drive gears or synchronizer components Incorrect assem bly such as missing snap rings also causes gear dis engagement 21 4 TRANSAXLE DIAGNOSIS AND TESTING Continued LOW LUBRICANT LEVEL Insufficient transaxle lubricant is usually the result of leaks or inaccurate fluid level check or refill method Leakage is evident by the presence of oil around the leak point If leakage is not evident the condition is probably the result of an underfill
44. hub weld e Torque converter impeller shell cracked adjacent to hub e At drive lug welds NOTE Hub weld is inside and not visible Do not attempt to repair Replace torque converter BRAKE TRANSMISSION SHIFT INTERLOCK The following chart describes the normal operation of the Brake Transmission Shift Interlock BTSI sys tem If the expected response differs from the vehi de s response then system repair and or adjustment is necessary Refer to Brake Transmission Interlock Removal and Installation or Adjustment in this Group PL ACTION EXPECTED RESPONSE 1 Turn key to the OFF 1 Shifter CAN be shifted position out of park 2 Turn key to the 2 Shifter CANNOT be shifted out of park ON RUN position 3 Turn key to the 3 Shifter CAN be shifted ON RUN position and out of park depress the brake pedal 4 Leave shifter in any 4 Key cannot be returned to the LOCK or ACC position gear and try to return key to the LOCK or ACC position 5 Return shifter to PARK and try to remove the key 5 Key can be removed after returning to LOCK position 6 With the key removed 6 Shifter cannot be try to shift out of PARK shifted out of PARK NOTE Any failure to meet these expected responses requires system adjustment or repair SERVICE PROCEDURES TRANSAXLE FLUID AND FILTER SERVICE NOTE Refer to Group 0 Lubrication and Mainte nance or the vehicle owner s manu
45. in 3 Inspect servo and repair as required Bore 4 Front Band Linkage Malfunction 4 Inspect linkage and look for bind in linkage NO KICKDOWN OR 1 Throttle Linkage Misadjusted 1 Adjust linkage NORMAL DOWNSHIFT 2 Accelerator Pedal Travel 2 Floor mat under pedal accelerator cable Restricted worn or brackets bent 3 Governor Valve Body Hydraulic 3 Perform hydraulic pressure tests to Pressures Too High or Too Low Due determine cause and repair as required to Sticking Governor Valve Body Correct valve body pressure adjustments as Malfunction or Incorrect Hydraulic required Control Pressure Adjustments 4 Valve Body Malfunction 4 Perform hydraulic pressure tests to determine cause and repair as required Correct valve body pressure adjustments as required 5 Valve Body Malfunction 5 Sticking 1 2 2 3 shift valves governor plugs 3 4 solenoid 3 4 shift valve 3 4 timing valve STUCK IN LOW GEAR 1 Throttle Linkage Misadjusted 1 Adjust linkage and repair linkage if worn WILL NOT UPSHIFT Stuck or damaged Check for binding cable 2 Gearshift Linkage Misadjusted 2 Adjust linkage and repair linkage if worn or damaged 3 Governor Valve Body Governor 3 Check line and governor pressures to Valve Stuck Closed Loose Output determine cause Correct as required Shaft Support or Governor Housing Bolts Leaking Seal Rings or Valve Body Problem i e Stuck 1 2 Shift Valve Gov Plug 4 Front Band Out of A
46. repair as Seized required 4 Overrunning Clutch Worn Broken 4 Inspect and check for debris in oil pan Repair as required 5 Oil Pump Components Scored 5 Remove inspect and repair as required Binding 6 Output Shaft Bearing or Bushing 6 Remove inspect and repair as required Damaged 8 Front and Rear Bands 8 Adjust bands Misadjusted 4 Case Leaks Internally 4 Check for leakage between passages in case 5 Servo Band or Linkage 5 Air pressure check servo operation and Malfunction repair as required 6 Overrunning Clutch Worn 6 Remove and inspect clutch Repair as required 7 Clutch Operation Faulty 7 Perform air pressure check and repair as required 7 Planetary Gears Broken 7 Remove inspect and repair as required look for debris in oil pan 3 Front or Rear Band Misadjusted 3 Adjust bands DRAGS OR LOCKS UP 1 Fluid Level Low 1 Check and adjust level 2 Clutch Dragging Failed 2 Air pressure check clutch operation and repair as required WHINE NOISE RELATED 1 Fluid Level Low 1 Add fluid and check for leaks TO ENGINE SPEED 2 Shift Cable Incorrect Routing 2 Check shift cable for correct routing Should not touch engine or bell housing TORQUE CONVERTER Lockup Solenoid Relay or Wiring Test solenoid relay and wiring for LOCKS UP IN SECOND Shorted Open continuity shorts or grounds Replace AND OR THIRD GEAR solenoid and relay if faulty Repair wiring and connectors as necessary HARSH 1 2
47. servo operation and repair as required 7 Band Linkage Binding 7 Inspect and repair as required SLIPS IN FORWARD 1 Fluid Level Low 1 Add fluid and check for leaks DRIVE RANGES 2 Fluid Foaming 2 Check for high oil level bad pump gasket or seals dirt between pump halves and loose pump bolts Replace pump if necessary 3 Throttle Linkage Misadjusted 3 Adjust linkage 4 Gearshift Linkage Misadjusted 4 Adjust linkage 5 Rear Clutch Worn 5 Inspect and replace as needed 6 Low Hydraulic Pressure Due to 6 Perform hydraulic and air pressure tests Worn Pump Incorrect Control to determine cause Pressure Adjustments Valve Body Warpage or Malfunction Sticking Governor Leaking Seal Rings Clutch Seals Leaking Servo Leaks Clogged Filter or Cooler Lines 7 Rear Clutch Malfunction Leaking 7 Air pressure check clutch servo operation Seals or Worn Plates and repair as required 8 Overrunning Clutch Worn Not 8 Replace Clutch Holding Slips in 1 Only SLIPS IN LOW GEAR D Overrunning Clutch Faulty Replace overrunning clutch ONLY BUT NOT IN 1 POSITION 21 64 TRANSAXLE DIAGNOSIS AND TESTING Continued CONDITION POSSIBLE CAUSES CORRECTION GROWLING GRATING OR 1 Drive Plate Broken 1 Replace SCRAPING NOISES 2 Torque Converter Bolts Hitting 2 Dust shield bent Replace or repair Dust Shield 3 Planetary Gear Set Broken 3 Check for debris in oil pan and
48. sizes Use the thickest snap ring that fits in each snap ring groove 1 Place input shaft into shop press 2 Install 3rd gear caged needle bearing on input shaft 3 Install 3rd gear and 3 4 synchronizer onto input shaft Install Tool 4C 3717 over input shaft and press on synchronizer hub and 3rd gear Fig 108 The synchronizer hub has the letter U stamped on the top face of the hub This designates that the hub must be installed with the U facing upward Fig 108 Press On 3rd Gear Synchronizer Hub 1 PRESS RAM 2 SPECIAL TOOL C 3717 3 BEARING SPLITTER 4 3RD GEAR SYNCHRONIZER ASSEMBLY PL 4 Install 3 4 synchronizer snap ring into slot on input shaft 5 Install blocking ring into 3 4 synchronizer Install 4th gear caged needle bearing 6 Install 4th gear onto input shaft 7 Install 4 5 split thrust washer separation pin Fig 109 zwar dE Ns FJ9521 26 Fig 109 Split Thrust Washer Separation Pin Installation 1 SEPARATION PIN 2 INPUT SHAFT 3 PLIERS 8 Install split thrust washer onto input shaft Fig 110 DRE Ze ES 27799729 FJ9521 25 Fig 110 Split Thrust Washer Installation 1 INPUT SHAFT 2 SPLIT THRUST WASHER PL DISASSEMBLY AND ASSEMBLY Continued 9 Install split thrust washer retaining ring Fig 111 bs SCH Si m oU GE 7 9521
49. to Gearshift Cable Removal and Installation in this Group 2 Using a pin punch remove both roll pins from the lever 3 Pull up and remove the selector lever from the transaxle selector shaft PL REMOVAL AND INSTALLATION Continued Fig 33 Shift Cables at Transaxle 1 CROSSOVER LEVER 2 CROSSOVER CABLE 3 SELECTOR CABLE 4 SELECTOR LEVER INSTALLATION 1 Install the selector lever to the shaft and fasten with two NEW roll pins Refer to Fig 34 for correct roll pin orientation 2 Install selector cable to cable bracket and install clip Install cable to selector lever D 9521 65 Fig 34 Correct Orientation of Roll Pins 1 OUTER ROLL PIN 2 INNER ROLL PIN TRANSAXLE 21 13 AXLE SHAFT SEALS REM OVAL 1 Remove axle shaft Refer to Group 3 Differen tial and Driveline for the correct procedures 2 Insert a flat blade pry tool at outer edge of axle shaft seal Fig 35 3 Tap on the pry tool with a small hammer and remove axle shaft seal FJ9521 99 Fig 35 Axle Shaft Seal Removal 1 AXLE SEAL 2 PRY TOOL INSTALLATION 1 Clean axle shaft seal bore of any excess seal ant 2 Align axle shaft seal with axle shaft seal bore 3 Install axle seal on tool 6709 and C 4171 and insert into axle shaft seal bore 4 Tap seal into position until seated against tran saxle case 5 Install axle shaft Refer to Group 3 Differen tial and Driveline f
50. valve body Replace assembly if any valves or bores are damaged 5 Transmission Overrunning Clutch 5 Remove and disassemble transmission Broken Replace overrunning clutch 6 Input Shaft Seal Rings Worn 6 Remove and disassemble transmission Damaged Replace seal rings and any other worn or damaged parts 7 Front Planetary Failed Broken 7 Remove and repair NO DRIVE OR REVERSE 1 Fluid Level Low 1 Add fluid and check for leaks if drive is VEHICLE WILL NOT restored MOVE 2 Gearshift Linkage Cable 2 Inspect adjust and reassemble linkage Loose Misadjusted as needed Replace worn damaged parts 3 Filter Plugged 3 Remove and disassemble transmission Repair or replace failed components as needed Replace filter If filter and fluid contained clutch material or metal particles an overhaul may be necessary Perform lube flow test Flush oil Replace cooler as necessary 4 Oil Pump Damaged 4 Perform pressure test to confirm low pressure Replace pump body assembly if necessary 5 Valve Body Malfunctioned 5 Check press and inspect valve body Replace valve body as assembly if any valve or bore is damaged Clean and reassemble correctly if all parts are in good condition 6 Transmission Internal Component 6 Remove and disassemble transmission Damaged Repair or replace failed components as needed Remove and disassemble transmission Repair or replace failed components as needed 7 Park Sprag not Re
51. 010 inch NOTE If end play is too high install a 0 05 mm 0 002 inch thinner shim combination If end play is too low install a 0 05 mm 0 002 inch thicker shim combination Repeat until 0 05 to 0 25 mm 0 002 to 0 010 inch end play is obtained TRANSAXLE 21 141 TRANSFER BEARING SHIM CHART End Play with 2 29 mm and 1 39 mm gauging shims installed Required Shim Total Combination Thickness MO R2 NO ND IO PO RO IO RO PO BO 2 09999999999 PL TRANSAXLE 142 21 SCHEMATICS AND DIAGRAMS 31TH TRANSAXLE HYDRAULIC SCHEMATIC 20 JAVA SSVd Ad 33143ANOD 300301 4 9 amp 6 e 9 s e e E 5 EE 3ATVA 1 81 34155384 33143ANOD Isa 99s 2 MEN GS e 090000 9 02522220723 Za 5 DITNVYGAH FIXVSNVEL HLLE 110 15414 JAINA Sd 89 0 77771164 JILLONHL FPH Nouo ns dwnd 524055244 WO N A ARAS 18 1 eet SE EE 1 S UN N zzz Uu per Tl E L eg 1 5 wcklan Ae
52. 19 Shift Cable Assembly at Floor 1 CABLE ASSEMBLY 2 GROMMET PLATE NOTE Only the crossover cable is adjustable The selector cable does not have any adjustment capa bilities 11 Adjust crossover cable as follows a Loosen adjusting screw on crossover cable at shifter Fig 20 b Pin transaxle crossover lever in 3 4 N tion using a 1 4 inch drill bit Align hole in cross over lever with the hole in the boss on the transaxle case Fig 21 Be sure drill bit goes into transaxle case at least one half inch c The shifter is spring loaded and self center ing Allow shifter to rest in its neutral position Torque adjustment screw to 8 N m 70 in Ibs Care must be taken to avoid moving the shift mechanism off center during screw tightening d Remove drill bit from transaxle case and per form functional check by shifting transaxle into all gears 12 Install boot to the shifter assembly Fig 13 Fasten boot with the three retainers 13 Install center console assembly Fig 12 Ver ify that boot is not pinched at console opening before tightening 14 Install knob to shifter lever align knob to three o clock position push knob down to engage spring and rotate counter clockwise Fig 22 15 Return shifter boot to its original position seated around knob lip 16 Install the air cleaner throttle body assy Fig 16 as follows 5 21 9 REMOV
53. 1st 1 04 1 72 mm 0 041 0 069 2nd 0 94 1 72 mm 0 038 0 069 in e 3rd 1 37 1 93 mm 0 054 0 076 in e 4th 1 41 1 97 mm 0 056 0 078 in e 5th 1 37 1 93 mm 0 054 0 076 in If a stop ring gap does not fall within the specifi cations it must be inspected for wear and replaced If the 1st or 2nd synchronizer stop ring is worn beyond specifications the complete output shaft assembly must be replaced The output shaft incorporates the 1st and 2nd gears and synchronizers on the assembly Fig 115 o 22 22 PAE Ze FJ9521 80 Fig 115 Output Shaft 1 1ST GEAR 2 SLEEVE 3 STOP RING 4 OUTPUT SHAFT 5 2ND SPEED GEAR 6 REVERSE GEAR 7 STOP RING PL DIFFERENTIAL Shim thickness need be determined only if any of the following parts are replaced e Transaxle gear case e Clutch bellhousing case Differential case Differential bearings Refer to Bearing Adjustment Procedure in the Adjustments section at the end of this section to determine proper shim thickness This will provide correct bearing preload and proper bearing turning torque DIFFERENTIAL BEARINGS D Ka 2 9521 20 Fig 116 Remove Differential Bearing Cone 1 SPECIAL TOOL C 293 PA 2 SPECIAL TOOL C 4996 3 DIFFERENTIAL ASSEMBLY 4 SPECIAL TOOL C 293 45 PL DISASSEMBLY AND ASSEMBLY Continued
54. 22 f M ep 26 80004965 Fig 35 Interlock Cable Steering Column 1 IGNITION SWITCH 2 CLIP 3 INTERLOCK CABLE 4 BTSI SOLENOID 80b89922 Fig 36 Ignition Key Switch Positions 1 ACC 2 LOCK 3 OFF 4 ON RUN 5 START INSTALLATION CAUTION When installing interlock cable assem bly care must be taken not to bend exposed cable wire and slug at shifter end of cable 21 81 TRANSAXLE 9521 74 Fig 37 Interlock Cable and Connector 1 IGNITION LOCK CYLINDER 2 INTERLOCK CABLE 1 Route interlock cable through hole in instru ment panel below steering column and around to gear shifter assembly 2 Turn the ignition key to the OFF or ON RUN position Fig 36 3 Install the interlock cable into the interlock housing at the steering column Fig 38 Verify the cable snaps into the housing and is fully seated 9521 72 Fig 38 Interlock Cable at Interlock Housing 1 IGNITION SWITCH 2 INTERLOCK CABLE 4 Return the ignition key to the LOCK position Fig 36 5 Connect the BTSI solenoid connector Fig 35 Install cable into retaining clips as shown Fig 35 7 Install steering column upper shrouds Fig 34 8 Install steering column lower cover Fig 33 and lower 21 82 TRANSAXLE REMOVAL AND INSTALLATION Continued 9 Verify that shifter is in gated PARK 10 Install the
55. 31 Fig 111 Retaining Ring Installation 1 SPLIT THRUST WASHER RING 2 INPUT SHAFT 10 Install 5th gear caged needle bearing Fig 112 Sar a 2 FJ9521 23 Fig 112 Caged Needle Bearing Installation 1 INPUT SHAFT 2 CAGED NEEDLE BEARING TRANSAXLE 21 35 0 vi 9521 4 Fig 113 5th Speed Gear Installation 1 PRESS RAM 2 SPECIAL TOOL C 3717 3 SYNCHRONIZER ASSEMBLY 4 BEARING SPLITTER 5 5TH SPEED GEAR 11 Using special tool C 3717 install 5th speed gear and synchronizer Fig 113 The 5th gear syn chronizer hub has the letter S stamped on the top face of the hub This designates that the hub must be installed with the S facing upward 12 Install 5th gear synchronizer snap ring Fig 114 E A WC Sie FJ9521 21 Fig 114 5th Gear Synchronizer Snap Ring Installation 1 SNAP RING PLIERS 2 INPUT SHAFT 3 BEARING SPLITTER 4 SNAP RING 21 36 TRANSAXLE DISASSEMBLY AND ASSEMBLY Continued OUTPUT SHAFT CAUTION The output shaft is serviced as an assembly Do not try to repair any component on the output shaft If the 1 2 synchronizer or gear fails it is necessary to replace the output shaft assembly It is necessary to check the synchronizer stop ring gap Use a feeler gauge to measure the gaps between the stop rings and the speed gears The correct gaps are listed below
56. 9 2 2 liters 4 0 4 6 pints Wipe the outside of the tran saxle if any lubricant spills REMOVAL AND INSTALLATION GEARSHIFT KNOB REMOVAL 1 Pull shifter boot down and away from shifter knob 2 Push down on knob and rotate clockwise to remove Fig 5 gt 80bdbd21 Fig 5 Gearshift Knob Removal 1 GEARSHIFT KNOB PL TRANSAXLE 21 5 REMOVAL AND INSTALLATION Continued INSTALLATION 1 Install knob to shifter lever align knob to three o clock position push knob down to engage spring and rotate counter clockwise Fig 6 2 Return shifter boot to its original position seated around knob lip 80004567 Fig 8 Center Console Removal Installation Typical 1 CONSOLE 2 SCREW 4 3 SCREW 2 80595022 4 Separate shifter boot from shifter assembly Fig 9 Boot is retained to shifter by three push pin retainers Fig 6 Gearshift Knob Installation 1 GEARSHIFT KNOB 2 SPRING GEARSHIFT BOOT REMOVAL 1 Pull shifter boot down and away from shifter knob 2 Push down on knob and rotate clockwise to remove Fig 7 80bc4d60 Fig 9 Gearshift Boot Removal Installation 1 BOOT 2 SHIFTER ASSEMBLY INSTALLATION Ew 1 Install boot to the shifter assembly Fig 9 Fasten boot to shifter with the three retainers 2 Install center console assembly Fig 8 Verify 80090421 that boot is not pinched at console opening before Fig 7 Gearshift Kn
57. AL AND INSTALLATION Continued 80be4d63 Fig 20 Crossover Cable Adjustment Screw 1 CROSSOVER ADJUSTMENT SCREW 80000422 Fig 22 Gearshift Knob Installation 1 GEARSHIFT KNOB 2 SPRING d Connect the Throttle Position Sensor TPS and Idle Air Control connectors e Connect proportional purge solenoid PPS and crankcase vent hose from throttle body 17 Connect battery negative cable GEARSHIFT MECHANISM REPLACEMENT REMOVAL 1 Pull shifter boot down and away from shifter knob 2 Push down on knob and rotate clockwise to Fig 21 Crossover Lever Pin Procedure remove Fig 23 1 DRILL BIT 2 SELECTOR CABLE 4 3 CROSSOVER CABLE Connect the accelerator and speed control if NU equipped cables to the air deaner throttle body assy b Install assy into position making sure the air cleaner locating slot is engaged to the battery bracket tab and tighten fasteners to 14 N m 120 in Ibs torque c Verify throttle body duct is fully seated to intake manifold and tighten clamp to 5 N m 40 in Ibs torque 80bdbd21 Fig 23 Gearshift Knob Removal 1 GEARSHIFT KNOB 21 10 TRANSAXLE PL REMOVAL AND INSTALLATION Continued 3 Remove the center console assembly as shown in Fig 24 80bc4d61 80059587 Fig 26 Crossover Cable Shifter Assembly 1 GROMMET PLATE NUT Fig 24 Center Console Removal Installation
58. ANSAXLE DESCRIPTION AND OPERATION Continued OTTO 80040426 Fig 2 Cooler Bypass Valve 1 BYPASS VALVE 2 TUBE 80bdbd19 Fig 3 Bypass Valve Location If Equipped 1 TRANSFER PLATE 2 BYPASS VALVE 3 SEAL PL TORQUE CONVERTER CLUTCH SOLENOID WIRING CONNECTOR If the solenoid wiring connector is unplugged the torque converter will not engage Fig 4 80a77392 Fig 4 Torque Converter Clutch Solenoid Wiring Connector 1 TCC SOLENOID WIRING CONNECTOR GOVERNOR The governor can be serviced by removing the transaxle oil pan and valve body assembly The gov ernor can be unbolted from the governor support and removed from the transaxle for reconditioning or replacement When cleaning or assembling the governor be sure the governor valves move freely in the bores of the governor body DIAGNOSIS AND TESTING TRANSAXLE PRELIMINARY DIAGNOSIS Automatic transaxle malfunctions are usually caused by the following general conditions e fluid level condition e Poor engine performance e Improper engine or transaxle adjustments e Transaxle hydraulic malfunctions e Transaxle mechanical malfunctions Diagnosis of transaxle problems should always begin with checking the easily accessible variables e Fluid level and condition e Gearshift cable adjustment e Throttle valve cable adjustment After verifying or adjusting these varia
59. AXLE DISASSEMBLY AND ASSEMBLY Continued D PR2190 Fig 93 Transfer Plate and Separator Plate 1 SEPARATOR PLATE Fig 95 Remove or Install Throttle Shaft E Clip 2 TRANSFER PLATE 1 MANUAL VALVE LEVER ASSEMBLY 3 OIL SCREEN 2 THROTTLE VALVE LEVER ASSEMBLY 4 VALVE BODY 3 SCREWDRIVER 4 E CLIP 9 Fig 94 Steel Ball Locations 1 MANUAL VALVE Fig 96 Throttle Shaft E Clip Washer and Seal 2 STEEL BALLS 8 1 MANUAL VALVE LEVER ASSEMBLY 3 STEEL BALLS 2 SEAL O 3 E CLIP 4 THROTTLE VALVE LEVER ASSEMBLY 5 WASHER pL 5 21 99 DISASSEMBLY AND ASSEMBLY Continued Fig 97 Manual Valve Lever Assembly Fig 99 Manual Valve 1 THROTTLE VALVE LEVER ASSEMBLY 1 MANUAL VALVE 2 MANUAL VALVE LEVER ASSEMBLY 2 VALVE BODY 3 VALVE BODY PR2193 3 Fig 100 Pressure Regulator and Adjusting Screw Fig 98 Throttle Valve Lever Assembly Bracket 1 THROTTLE VALVE LEVER ASSEMBLY 1 SCREWDRIVER HANDLE 2 MANUAL VALVE 2 PRESSURE REGULATOR SPRING RETAINER AND 3 VALVE BODY ADJUSTING SCREW BRACKET 3 VALVE BODY 4 SCREWS 21 100 TRANSAXLE DISASSEMBLY AND ASSEMBLY Continued PR2196A Fig 101 Pressure Regulators and Manual Controls 1 VALVE BODY 7 SPRING 2
60. AXLE 80468473 Fig 127 Retaining Pin Removed 1 DIFFERENTIAL ASSEMBLY 2 SPEEDOMETER DRIVE GEAR 3 PINION SHAFT RETAINING PIN 2 Remove pinion shaft Fig 128 AUTEN OG 2 0 80468474 Fig 128 Pinion Shaft Removal 1 DIFFERENTIAL ASSEMBLY 2 PINION SHAFT 3 SPEEDOMETER DRIVE GEAR 4 PINION SHAFT RETAINING PIN 21 40 3 Rotate side gears to opening in differential Fig 129 3 80448 9 Fig 129 Remove Pinion Gears Side Gears and Thrust Washers by Rotating Side Gears to Opening in Case 1 DIFFERENTIAL ASSEMBLY 2 PINION SHAFT 3 SPEEDOMETER DRIVE GEAR 4 PINION SHAFT RETAINING PIN 5 PINION GEAR 2 TRANSAXLE DISASSEMBLY AND ASSEMBLY Continued PL INSTALLATION 1 Assemble the differential side gears pinion gears and pinion gears with the pinion gear washers 2 Install pinion shaft retaining pin Fig 131 80408 9 Fig 131 Install Retaining Pin 1 PINION SHAFT RETAINING PIN 2 SPEEDOMETER DRIVE GEAR 4 Remove differential gears Fig 130 804d8e9d Fig 130 Differential Gears 5 PINION GEAR THRUST WASHERS 6 PINION GEARS 7 SIDE GEARS 8 PINION SHAFT RETAINING PIN 1 DIFFERENTIAL ASSEMBLY 2 PINION SHAFT 3 SPEEDOMETER DRIVE GEAR 4 SIDE GEAR THRUST WASHERS SELECT THICKNESS PL DISASSEMBLY AND ASSEMBLY Continued
61. CABLE 80004567 5 Road test vehicle to verify proper transaxle Fig 30 Center Console Removal Installation operation 1 CONSOLE 2 SCREW 4 3 SCREW 2 21 80 TRANSAXLE REMOVAL AND INSTALLATION Continued 4 Remove shifter bezel Fig 31 80504568 Fig 31 Shifter Bezel 1 BEZEL 2 SCREW 4 5 Disconnect the shifter ignition interlock cable from the shifter lever and bracket as shown in Fig 32 Remove the cable core end from the plastic cam of the shifter mechanism and release cable from shifter bracket 80be4ee3 Fig 32 Interlock Cable at Shifter Assembly 1 INTERLOCK CABLE 2 SHIFTER ASSEMBLY PL V 80bc4ee5 Fig 33 Steering Column Lower Cover 1 LOWER COVER 80bc4ee6 Fig 34 Steering Column Shrouds 1 UPPER SHROUD 2 LOWER SHROUD 6 Remove the steering column lower cover Fig 33 7 Remove the steering column upper and lower shrouds Fig 34 8 Disconnect the Brake Transmission Shift Inter lock BTSI solenoid connector from the interlock cable Fig 35 9 Rotate the ignition key to the OFF or ON RUN position Fig 36 10 Squeeze the interlock cable locking tab Remove the cable from the interlock housing Fig 37 11 Release cable from retaining dips and remove through opening under steering column PL REMOVAL AND INSTALLATION Continued 122
62. D LEAKAGE TRANSAXLE TORQUE CONVERTER HOUSING 70 BRAKE TRANSMISSION SHIFT INTERLOCK 70 SERVICE PROCEDURES TRANSAXLE FLUID AND FILTER SERVICE 70 ALUMINUM THREAD REPAIR 71 FLUSHING COOLERS AND TUBES 72 OIL PUMP VOLUME CHECK 72 REMOVAL AND INSTALLATION GEARSHIFT 73 GEARSHIFT 76 THROTTLE VALVE KICKDOWN 77 BRAKE TRANSMISSION SHIFT INTERLOCK CABLE osse E ied ars 79 INTERLOCK 5 82 VEHICLE SPEED SENSOR PINION GEAR 83 PARK NEUTRAL STARTING AND BACK UP LAMP SWITCH PL page TRANSAXLE AND TORQUE CONVERTER 84 PUMP OILSEAL 88 DISASSEMBLY AND ASSEMBLY TRANSAXLE 89 VALVE BODY nx ge pirs wale nw oats ene 91 OIL PUMP 25 86 eee 104 asain 105 REAR CLUTCH ASSEMBLY 108 FRONT PLANETARY AND ANNULUS GEAR RECONDITION 110 LOW REVERSE REAR SERVO RECONDITION 112 ACCUMULATOR RECONDITION 113 KICKDOWN SERVO CONTROLLED LOAD RECONDITION 113 TRANSFER SHAFT REPAIR 114 PARKING PAWL een 121 OUTPUT SHAFT 121 DIFFERENTIAL
63. D RETAINING STRAP INSTALLATION Once bearing turning torque and shim selection has been adjusted install stirrup and strap assembly onto output gear NOTE Once the stirrup assembly is positioned onto the output gear it is necessary to clock the stirrup against the flats of the output gear retaining nut 1 Position the stirrup on the output gear 2 Position strap 3 Install retaining bolts into output gear Finger tighten bolts 4 Turn stirrup dockwise against the flats of the output gear retaining nut Fig 188 5 Tighten retaining bolts to 23 N m 200 in 165 Fig 189 6 Bend tabs of strap up against flats of retain ing bolts PL 80524e68 Fig 188 Turn Stirrup Clockwise Against Flats Of Retaining Nut 1 TURN STIRRUP CLOCKWISE 2 STRAP i 80524e6f Fig 189 Tighten Strap Retaining Nuts 1 STRAP 2 OUTPUT GEAR 3 STIRRUP 21 129 DISASSEMBLY AND ASSEMBLY Continued DIFFERENTIAL REPAIR NOTE The transfer shaft should be removed for differential repair and bearing turning torque check ing RB747A Fig 192 Differential Cover Bolts 1 DIFFERENTIAL COVER 2 DIFFERENTIAL COVER BOLT Fig 190 Remove Extension Seal EXTENSION HOUSING SMALL CHISEL HAMMER OIL SEAL ook al 7 RB748 Fig 193 Remove or Install Differential Cover GOVERNOR PRESSURE PLUG DIFFERENT
64. EST ONE SELECTOR IN 1 1 Attach gauges to line and low reverse ports 2 Operate engine at 1000 rpm for test 3 Move selector lever on transaxle all the way rearward 1 position 4 Read pressures on both gauges as throttle lever on transaxle is moved from full dockwise position to full counterclockwise position 5 21 67 DIAGNOSIS AND TESTING Continued 2 se EI 0 e lt gt LLL 2 Led LU 8 7 Fig 5 Test Port Locations 8050053 1 ACCUMULATOR VENT 8 TO COOLER 2 MANUAL THROTTLE LEVER SHAFT 9 KICKDOWN RELEASE FRONT CLUTCH 3 MANUAL SHIFT LEVER SHAFT 10 KICKDOWN APPLY 4 LOW REVERSE PRESSURE 11 CONVERTER CLUTCH SOLENOID CONNECTOR 5 GOVERNER PRESSURE BELOW DIFFERENTIAL COVER 12 FROM COOLER ON RIGHT SIDE 13 KICKDOWN BAND ADJUSTING SCREW LINE PRESSURE 7 KICKDOWN APPLY AT ACCUMULATOR 5 Line pressure should read 52 to 58 psi with throttle lever clockwise Pressure should gradually increase to 80 to 88 psi as lever is moved counter clockwise 6 Low reverse pressure should read the same as line pressure within 3 psi 7 This tests pump output pressure regulation and condition of rear clutch and rear servo hydraulic circuits Fig 6 Governor Pressure Tap 1 GOVERNOR PRESSURE PLUG 21 68 TRANSAXLE DIAGNOSIS AND TESTING Continued TEST TWO SELECTOR
65. IAL COVER 1 8 INCH BEAD OF SEALANT DIFFERENTIAL ASSEMBLY 2307 Fig 191 Install New Seal into Extension SPECIAL TOOL L 4520 INVERTED HANDLE C 4171 HAMMER EXTENSION HOUSING Co 21 130 TRANSAXLE DISASSEMBLY AND ASSEMBLY Continued NOTE Use Mopar RTV sealant or equivalent when installing differential cover 80524e71 Fig 194 Remove Bearing Retainer Axle Seal 1 SPECIAL TOOL 7794 2 SPECIAL TOOL C 637 3 DIFFERENTIAL BEARING RETAINER Fig 195 Install Bearing Retainer Axle Seal 1 SPECIAL TOOL L 4520 2 SPECIAL TOOL C 4171 PR2310 Fig 196 Differential Bearing Retainer Bolts 1 DIFFERENTIAL BEARING RETAINER 2 DIFFERENTIAL BEARING RETAINER BOLTS 6 PR2311 Fig 197 Remove or Install Bearing Retainer 1 GOVERNOR PRESSURE PLUG 2 DIFFERENTIAL BEARING RETAINER 3 SPECIAL TOOL L 4435 5 21 131 DISASSEMBLY AND ASSEMBLY Continued 22 80524e70 Lu RB749A Fig 198 Differential Bearing Retainer Typical 1 DIFFERENTIAL BEARING CUP Fig 200 Remove or Install Extension Housing 2 DIFFERENTIAL 1 EXTENSION HOUSING 3 DIFFERENTIAL BEARING RETAINER 2 DIFFERENTIAL ASSEMBLY 3 SPECIAL TOOL L 4435 NOTE Use Mopar RTV sealant or equivalent when installing differential bearing retainer RB750A Fig 201
66. MENTS Continued Fig 161 Crossover Lever Pin Procedure 1 4 DRILL BIT 2 SELECTOR CABLE 3 CROSSOVER CABLE 10 Install center console assembly Fig 158 Ver ify that boot is not pinched at console opening before tightening 11 Install knob to shifter lever align knob to three o dock position push knob down to engage spring and rotate counter clockwise Fig 162 12 Return shifter boot to its original position seated around knob lip 80606022 Fig 162 Gearshift Knob Installation 1 GEARSHIFT KNOB 2 SPRING BEARING ADJUSTMENT PROCEDURE GENERAL RULES ON SERVICING BEARINGS 1 Use extreme care when removing and install ing bearing cups and cones Use only an arbor press PL for installation as a hammer may not properly align the bearing cup or cone Burrs or nicks on the bear ing seat will give a false end play reading while gauging for proper shims Improperly seated bearing cups and cones are subject to low mileage failure 2 Bearing cups and cones should be replaced if they show signs of pitting or heat distress If distress is seen on either the cup or bearing rollers both cup and cone must be replaced 3 Bearing preload and drag torque specifications must be maintained to avoid premature bearing fail ures Used original bearings may lose up to 50 of their original drag torque after break in All bearing adjustments must be made with no other component interference
67. OR 2 3 Lockup Solenoid Malfunction Remove valve body and replace solenoid SHIFTS assembly NO START IN PARK OR 1 Gearshift Linkage Cable 1 Adjust linkage cable NEUTRAL Misadjusted 2 Neutral Switch Wire Open Cut 2 Check continuity with test lamp Repair as required 3 Neutral Switch Faulty 3 Refer to service section for test and replacement procedure 4 Neutral Switch Connect Faulty 4 Connectors spread open Repair 5 Valve Body Manual Lever 5 Inspect lever assembly and replace if Assembly Bent Worn Broken damaged PL DIAGNOSIS AND TESTING Continued CONDITION POSSIBLE CAUSES CORRECTION 1 Disassemble unit and rebuild clutch pack 2 Rear Band Misadjusted 2 Adjust band NO REVERSE OR SLIPS IN REVERSE Worn OIL LEAKS ITEMS LISTED REPRESENT POSSIBLE LEAK POINTS AND SHOULD ALL BE case Leaks Damaged CHECKED 4 Pan Gasket Leaks 1 Direct Clutch Pack front clutch TRANSAXLE 21 65 3 Front Clutch Malfunctioned Burnt 3 Air pressure test clutch operation Remove and rebuild if necessary 1 Fluid Lines and Fittings Loose 1 Tighten fittings If leaks persist replace Leaks Damaged fittings and lines if necessary 2 Filler Tube where tube enters 2 Replace tube seal Inspect tube for cracks in tube 3 Pressure Port Plug Loose 3 Tighten to correct torque Replace plug Loose Damaged or reseal if leak persists 4 Tighten pan screws to 150 inch pounds If leaks persist replace ga
68. OUND TORQUE WRENCH 2 SPECIAL TOOL C 4995 11 Recheck turning torque Repeat Step 10 until the proper turning torque is obtained Once proper turning torque has been established place gear case on the end plate Draw a bead of Mopar Gasket Maker Loctite 518 or equivalent on the flat surface of the case mating flange Install dutch bellhousing onto gear case Install and tighten case bolts to 29 N m 21 ft Ibs PL DISASSEMBLY AND ASSEMBLY Continued INPUT SHAFT DISASSEMBLY Before disassembly of the input shaft it is neces sary to check the synchronizer stop ring gap Use a feeler gauge to measure the gaps between the stop rings and the speed gears The correct gaps are listed below 151 1 04 1 72 mm 0 041 0 069 2nd 0 94 1 72 mm 0 038 0 069 in 3rd 1 37 1 93 mm 0 054 0 076 in 4th 1 41 1 97 mm 0 056 0 078 5th 1 37 1 93 mm 0 054 0 076 in If a stop ring gap does not fall within the specifi cations it must be inspected for wear and replaced If the 1st or 2nd synchronizer stop ring is worn beyond specifications the complete output shaft assembly must be replaced The input shaft incorporates the 3rd 4th and 5th speed gears and synchronizers on the assembly Fig 96 Fig 96 Input Shaft 1 INPUT SHAFT 2 STOP RING 3 SLEEVE 4 5TH SPEED GEAR 5 STOP RING 6 SLEEVE 7 4TH SPEED GEAR 8 STOP RING 9 3RD SPEED GEAR TRANSAXLE 21 31
69. PL TRANSAXLE 21 1 TRANSAXLE TABLE OF CONTENTS page page NV T350 A 578 MANUAL TRANSAXLE 1 31TH AUTOMATIC TRANSAXLE 54 NV T350 A 578 MANUAL TRANSAXLE TABLE OF CONTENTS page page GENERAL INFORMATION CROSSOVER 12 T350 A578 MANUAL TRANSAXLE 1 SELECTOR LEVER 12 TRANSAXLE 2 AXLE SHAFT 5 13 FLUID REQUIREMENTS 2 SHIFT SHAFT 5 5 13 SPECIAL ADDITIVES 2 TRANSAXLE 14 SEALANTS RA E s 2 DISASSEMBLY AND ASSEMBLY GEAR RATIOS iig ca cR Rt De eR et E 2 TRANSAXLE ue E RR 18 GEARSHIFT 3 INPUT SHAFT gek 08442858 31 DIAGNOSIS AND TESTING OUTPUT SHAFT nates nena sin ox 36 COMMON PROBLEM CAUSES 3 DIFFERENTIAL 55 5 da eg betes oe eked 36 HARD SHIFTING gee stave eee eee 3 SYNCHRONIZER pea ERR ERR 41 NOISY 3 SHIFT RAILS OVERHAUL 42 SLIPS OUT OF GEAR 3 TRANSAXLE CASE OVERHAUL 42 LOW LUBRICANT LEVEL 4 CLEANING AND INSPECTION FLUID LEAKS RE Re 4 TRANSAXLE 255 224 44 2 4 4 48 CLUTCH 5 4 2
70. QUE SPECIFICATIONS DESCRIPTION TORQUE Bell Housing Cover Bolts 12 N m 105 in Ibs Cooler Line Clamps 2 N m 18 in Ibs Diff Bear Ret To Case Bolt 34 N m 300 in Ibs Diff Cover To Case Bolt 19 N m 165 in Ibs Exten Hous To Case Bolt 28 N m 250 in Ibs Drive Plate To Crankshaft 6 52 eae 95 N m 70 ft Ibs Drive Plate To Torque Conv 88 N m 65 ft Ibs Fluid Filter Screw 5 N m 45 in Ibs Governor Counterweight SOW wax 28 N m 250 in Ibs Governor To Support Bolt 7 N m 60 in Ibs Kickdown Band Adj Lock Nut 47 N m 35 ft Ibs Left Motor Mount Bolts 54 N m 40 ft Ibs Manual Cable To Trans Case Bolt 28 250 in Ibs Manual Control Lever Screw 12 105 in Ibs Oil Pan To Trans Case SOOW 19 N m 165 in Ibs Output Gear Strap Bolts 23 N m 17 ft Ibs Output Shaft Nut 271 200 ft Ibs Park Neutral Switch 34 N m 25 ft Ibs Pressure Check Plug 5 N m 45 in Ibs Pump To Case Bolts 31 N m 275 in Ibs Reaction Shaft Assembly Bolt 28 250 in 165 Rear Cover To Case Screw 19 N m 165 in Ibs Reverse Band Adj Lock Nut 14N m 125 in Ibs PL SPECIFICATIONS Continued DESCRIPTION Reverse Band Shaft Plug Ring Gear Screw Spee
71. R2220A Fig 84 Overrunning Clutch Cam Assembly 1 OUTPUT SHAFT 2 OVERRUNNING CLUTCH CAM ASSEMBLY 21 96 TRANSAXLE DISASSEMBLY AND ASSEMBLY Continued PR2221A Fig 85 Overrunning Clutch Rollers and Spring 1 LOW REVERSE BAND Fig 87 Low Reverse Band and Strut 2 OVERRUNNING CLUTCH ROLLERS 8 1 11 THRUST WASHER 3 OVERRUNNING CLUTCH SPRINGS 8 2 LOW REVERSE BAND 3 STRUT PR2223A Fig 86 Loosen or Adjust Low Reverse Band 1 LOW REVERSE BAND LEVER 2 ADJUSTING SCREW Fig 88 No 11 Thrust Washer 1 11 THRUST WASHER 2 OUTPUT SHAFT 3 STRUT 4 LOW REVERSE BAND 5 LOCK NUT 6 LEVER SHORT PL PR2224 Fig 89 Install Overrunning Clutch Rollers and Springs 1 TOOL L 4440 2 ROLLER 8 3 OVERRUNNING CLUTCH CAM ASSEMBLY 4 SPRING 8 5 DISASSEMBLY AND ASSEMBLY Continued 80bdbd31 Fig 90 Detent Spring Attaching Screw and Spring 1 SPECIAL TOOL L 4553 2 DETENT SPRING SCREW 3 SCREWDRIVER HANDLE 21 97 Fig 91 Using Tool L 4553 on Valve Body Screw 1 SCREWDRIVER HANDLE 2 VALVE BODY ASSEMBLY 3 SPECIAL TOOL L 4553 PR2186A PR2187B Fig 92 Remove or Install Valve Body Screws 1 SCREWDRIVER HANDLE 2 VALVE BODY SCREWS 16 3 VALVE BODY 4 SPECIAL TOOL L 4553 21 98 TRANS
72. Reverse Brake Race 1 REVERSE BRAKE RACE 23 Remove the shift blocker assembly from the bench fixture Fig 71 9521 17 Fig 71 Shift Blocker Removal 1 6785 BENCH FIXTURE 2 SHIFT BLOCKER ASSEMBLY PL 9521 18 Fig 72 1 2 Shift Fork Removal 1 6785 BENCH FIXTURE 2 1 2 SHIFT FORK 9521 19 Fig 73 Gear Train Removal 1 6785 BENCH FIXTURE 2 INPUT AND OUTPUT SHAFTS 24 Remove the 1 2 shift fork from the output shaft Fig 72 25 Remove input and output shaft assemblies from bench fixture Fig 73 CAUTION The output shaft assembly is serviced as an assembly Do not try to repair any component on the output shaft If the 1 2 synchronizer or gear fails it is necessary to replace the complete output shaft assembly PL DISASSEMBLY AND ASSEMBLY Continued ASSEMBLY 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 Verify bench fixture shims are removed from bench fixture Install output and input shafts into bench fixture Miller tool 6785 Fig 74 Fig 74 Bench Fixture 1 BENCH FIXTURE 2 GEARTRAIN 2 Install shift rails and forks into bench fixture Fig 75 9521 18 Fig 75 Shift Rail Installation 1 6785 BENCH FIXTURE 2 1 2 SHIFT FORK 3 Install shift blocker assembly
73. S and Idle Air Control connectors d Connect proportional purge solenoid PPS and crankcase vent hose from throttle body 22 Fill transaxle with a suitable amount of ATF 44 23 Road test vehicle 24 Check for leaks inspect fluid level and adjust as necessary PUMP OIL SEAL The pump oil seal can be replaced without remov ing the pump and reaction shaft support assembly from the transaxle case REMOVAL 1 Screw seal remover Tool C 3981 B into seal Fig 56 then tighten screw portion of tool to with draw the seal PL 9521 154 Fig 56 Remove Pump Oil Seal 1 PUMP OIL SEAL 2 OIL SEAL REMOVER TOOL C 3981 B 3 OIL PUMP INSTALLATION 1 To install a new seal place seal in opening of the pump housing lip side facing inward Using Tool C 4193 and Handle Tool C 4171 drive new seal into housing until tool bottoms Fig 57 RB718B Fig 57 Install Pump Oil Seal 1 OIL PUMP 2 OIL SEAL INSTALLER TOOL C 4193 3 SPECIAL TOOL HANDLE C 4171 PL 21 89 DISASSEMBLY AND ASSEMBLY TRANSAXLE DISASSEMBLY Fig 60 Oil Filter Screws 1 SCREWDRIVER HANDLE 2 SPECIAL TOOL L 4553 3 OIL FILTER SCREWS 2 PR2176B 4 OILFILTER Fig 58 Transaxle Oil Pan Bolts 1 TRANSAXLE OIL PAN 2 OIL PAN BOLTS Remove all old sealant before applying new seal ant Use only Mopar Silicone Rubber Sealant or equiv alent when installing
74. SCREWDRIVER 3 DRIVING DISCS 3 FRONT CLUTCH ASSEMBLY 9 8 PR2232 PR2230 Fig 107 Thick Steel Plate and Waved Snap Ring Fig 109 Front Clutch Return Spring Snap Ring 1 WAVED SNAP RING 1 COMPRESSOR TOOL C 3575 A 2 THICK STEEL PLATE 2 FRONT CLUTCH RETAINER 3 FRONT CLUTCH RETAINER 3 SNAP RING 4 SNAP RING PLIERS BL 5 21 107 DISASSEMBLY AND ASSEMBLY Continued ASSEMBLY To reassemble reverse the above procedure MEASURING PLATE CLEARANCE Fig 110 Front Clutch Return Spring and Piston 1 LIP SEALS 2 PISTON 3 RETURN SPRING RETAINER PR2234 4 SNAP RING 5 PISTON RETURN SPRING Fig 111 Measuring Front Clutch Plate Clearance 6 FRONT CLUTCH RETAINER 1 FEELER GAUGE 2 FRONT CLUTCH ASSEMBLY PL TRANSAXLE DISASSEMBLY AND ASSEMBLY Continued REAR CLUTCH ASSEMBLY 21 108 80540441 Rear Clutch Assembly 8 SNAP RING 9 PISTON 10 SPRING 1 SNAP RING SELECT 2 REACTION PLATE 3 CLUTCH DISC 4 CLUTCH PLATE 11 SNAP RING WAVE 12 SEAL 13 SEAL 5 REACTION PLATE 6 CLUTCH RETAINER 7 INPUT SHAFT PL DISASSEMBLY AND ASSEMBLY Continued DISASSEMBLY Fig 112 Rear Clutch Outer Snap Ring 1 SCREWDRIVER 2 SNAP RING 3 REAR CLUTCH ASSEMBLY 9521 105 Fig 113 Rear Clutch 4 Disc Shown 1
75. SEMBLY 21 46 TRANSAXLE DISASSEMBLY AND ASSEMBLY Continued DIFFERENTIAL BEARING CUPS REMOVAL 1 Remove differential assembly from gear case using the procedure outlined in this group 2 Install Miller tool _ 4518 into the differential bearing cup Fig 149 FJ9521 47 Fig 149 Tool Installed in Bearing 1 SPECIAL TOOL L 4518 2 GEAR CASE 3 Install the tool cup over the tool Fig 150 SS 9521 48 Fig 150 Installed 1 GEAR CASE 2 SPECIAL TOOL L 4518 3 WRENCH 4 Tighten the tool until the race is removed from the case PL INSTALLATION 1 Position the bearing cup into the case 2 Install the bearing cup onto Miller tool 34 4520 3 Using Miller tool 4520 and C 4171 driver install differential bearing cup into the transaxle case SHIFT RAIL BUSHINGS REMOVAL 1 Thread tool 76786 into shift rail bushing 2 Install slide hammer 8752 onto tool 3 Remove bushing using slide hammer and tool assembly Fig 151 9521 7 Fig 151 Shift Rail Bushing Removal 1 SPECIAL TOOL 6786 2 SLIDE HAMMER C 3752 3 SHIFTER RAIL BUSHING 4 INPUT BEARING INSTALLATION 1 Line up replacement bushing in bore 2 Using tool M 0998343 tap bushing into bore until flush with the chamfer in the case SHIFT SHAFT SEALS It is not necessary to remove the shift shafts from the transaxle to service the shift shaft seals REMOVAL 1
76. SEMBLY Continued 9 Remove blocking ring Remove 3 4 synchronizer 7 Remove 4th gear Fig 103 hub retaining snap ring Fig 105 N 4 il c r 031181 72773777 9 FJ9521 27 2 FJ9521 29 Fig 103 4th Gear Removal 1 INPUT SHAFT Fig 105 3 4 Synchronizer Hub Snap Ring 2 4TH GEAR 1 SNAP RING PLIERS 2 SYNCHRO SNAP RING 3 SYNCHRONIZER ASSEMBLY 8 Remove 4th gear caged needle bearing Fig 104 Check the caged needle bearing for a broken retention spring e 10 Install input shaft in shop press Using ing splitter remove 3 4 synchronizer and 3rd gear Fig 106 Fig 104 Caged Needle Bearing Removal 1 INPUT SHAFT SE Fig 106 3rd Gear Removal 1 PRESS RAM 2 INPUT SHAFT 3 3RD GEAR 4 SYNCHRONIZER ASSEMBLY FJ9521 28 11 Remove 3rd gear caged needle bearing Fig 107 Check the caged needle bearing for a broken retention spring 12 Inspect the input shaft for worn or damaged bearing races or chipped gear teeth Replace as essary 21 34 TRANSAXLE DISASSEMBLY AND ASSEMBLY Continued FJ9521 31 Fig 107 3rd Gear Caged Needle Bearing 1 INPUT SHAFT 2 3RD GEAR CAGED NEEDLE BEARING ASSEMBLY The snap rings that are used on the input shaft are available in select fit
77. TION TRANSAXLE Clean the gears bearings shafts synchronizers thrust washers oil feeder shift mechanism gear case and bellhousing with solvent Dry all parts except the bearings with compressed air Allow the bearings to either air dry or wipe them dry with clean shop towels Inspect the gears bearings shafts and thrust wash ers Replace the bearings and cups if the rollers are worn chipped cracked flat spotted or brinnelled or if the bearing cage is damaged or distorted Replace the thrust washers if cracked chipped or worn Replace the gears if the teeth are chipped cracked or worn thin Inspect the synchronizers Replace the sleeve if worn or damaged in any way Replace the stop rings if the friction material is burned flaking off or worn Check the condition of the synchro keys and springs Replace these parts if worn cracked or distorted SYNCHRONIZER CLEAN Do not attempt to clean the blocking rings in sol vent The friction material will become contaminated Place synchronizer components in a suitable holder and clean with solvent Air dry INSPECT Proper inspection of components involve e Teeth for wear scuffed nicked burred or bro ken teeth e Keys for wear or distortion e Balls and springs for distortion cracks or wear If any of these conditions exist in these compo nents replace as necessary PL ADJ USTMENTS GEARSHIFT CROSSOVER CABLE 1 Pull shifter boot down and away from s
78. TION METHOD 1 When performing the fluid suction method make sure the transaxle is at full operating temper ature 2 To perform the dipstick tube fluid suction method use a suitable fluid suction device Vacula or equivalent 3 Insert the fluid suction line into the dipstick tube NOTE Verify that the suction line is inserted to the lowest point of the transaxle oil pan This will ensure complete evacuation of the fluid in the pan 4 Follow the manufacturers recommended proce dure and evacuate the fluid from the transaxle 5 Remove the suction line from the dipstick tube 6 Pour four quarts of Mopar ATF 4 Automatic Transmission Fluid Type 9602 through the dipstick opening 7 Start engine and allow to idle for at least one minute Then with parking and service brakes applied move selector lever momentarily to each position ending in the park or neutral position 8 Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to 3mm 1 8 in below the ADD mark on the dip stick Fig 8 9 Recheck the fluid level after the transaxle has reached normal operating temperature 180 F 10 To prevent dirt from entering transaxle make certain that dipstick is fully seated into the dipstick opening ALUMINUM THREAD REPAIR Damaged or worn threads in the aluminum tran saxle case and valve body can be repaired by the use of Heli Coils This repair consists of dri
79. TTENTION COOLER FLUSH USING TOOL 6906A 1 Remove cover plate filler plug on Tool 6906A Fill reservoir 1 2 to 3 4 full of fresh flushing solution Flushing solvents are petroleum based solutions gen erally used to clean automatic transmission compo nents DO NOT use solvents containing acids water gasoline or any other corrosive liquids 2 Reinstall filler plug on Tool 6906A 3 Verify pump power switch is turned OFF Con nect red alligator clip to positive battery post Connect black alligator clip to a good ground 4 Disconnect the cooler lines at the transmission NOTE When flushing transmission cooler and lines ALWAYS reverse flush 5 Connect the BLUE pressure line to the OUT LET From cooler line 6 Connect the CLEAR return line to the INLET To cooler line 7 Turn pump ON for two to three minutes to flush cooler s and lines Monitor pressure readings PL and clear return lines Pressure readings should sta bilize below 20 psi for vehicles equipped with a sin gle cooler and 30 psi for vehicles equipped with dual coolers If flow is intermittent or exceeds these pres sures replace cooler 8 Turn pump OFF 9 Disconnect CLEAR suction line from reservoir at cover plate Disconnect CLEAR return line at cover plate and place it in a drain pan 10 Turn pump ON for 30 seconds to purge flush ing solution from cooler and lines Turn pump OFF 11 Place CLEAR suction line into a one q
80. UID ADDITIVES Chrysler Corporation strongly recommends against the addition of any fluids to the transmission other than those automatic transmission fluids listed above Exceptions to this policy are the use of special dyes to aid in detecting fluid leaks Various special additives and supplements exist that claim to improve shift feel quality and converter clutch operation inhibit overheating oxidation var nish and sludge These claims have not been sup ported to Chrysler s satisfaction and these additives must not be used The use of transmission sealers should also be avoided since they may adversely affect the integrity of tranmission seals DESCRIPTION AND OPERATION 31TH GENERAL INFORMATION NOTE Safety goggles should be worn at all times when working on these transaxles This transaxle combines torque converter three speed transmission final drive gearing and differen tial into a front wheel drive system NOTE Transaxle operation requirements are differ ent for each vehicle and engine combination Some internal parts will be different to provide for this TRANSAXLE 21 55 Therefore when replacing parts refer to the seven digit part number stamped on rear of the transaxle oil pan flange Within this transaxle there are three primary areas 1 Main center line plus valve body 2 Transfer shaft center line includes governor and parking sprag 3 Differential center line Center distan
81. Y AND ASSEMBLY Continued Fig 143 Governor Support Retainer 1 TRANSFER SHAFT 2 OUTPUT SHAFT GEAR 3 BEARING CUP 4 GOVERNOR SUPPORT RETAINER PR2267A Fig 144 Remove Governor Support Retainer Bearing Cup 1 PRESS 2 HANDLE C 4171 WITH SPECIAL TOOL L 4517 3 GOVERNOR SUPPORT RETAINER 9521 113 TRANSAXLE 21 117 PR2268A Fig 145 Install Governor Support Retainer Bearing Cup PRESS HANDLE C 4171 SPECIAL TOOL L 4520 GOVERNOR SUPPORT RETAINER BEARING CUP _ 9821 110 Fig 146 Low Reverse Band Anchor Pin 1 LOW REVERSE BAND ANCHOR PIN 2 OUTPUT SHAFT GEAR 21 118 TRANSAXLE DISASSEMBLY AND ASSEMBLY Continued AMEN a 9 ee y 1 gt 9521 117 SEI Fig 149 Remove Transfer Shaft and Bearing Fig 147 Governor Assembly 1 TRANSFER SHAFT Retainer Assembly 2 OUTPUT SHAFT GEAR 1 SPECIAL TOOL L 4512 3 GOVERNOR ASSEMBLY 2 SPECIAL TOOL L 4437 3 SPECIAL TOOL C 3752 NOTE Remove or install both governor valves and governor body 9521 112 9521 118 X Fig 150 Remove or Install Transfer Shaft and Fig 148 Transfer Shaft Bearing Snap Ring Bearing Retainer Assembly Using Tool L 4512 1 OUTPUT SHAFT GEAR 1 SNAP RING PLIERS 2 SNAP RING es 3 SPECIAL TOOL L 4512 3 OUTPUT SHAFT GEAR 4 BEARING RETAINER ASSEMBLY BL
82. al for the rec ommended maintenance fluid filter change intervals for this transaxle NOTE Only fluids of the type labeled Mopar ATF 4 Automatic Transmission Fluid Type 9602 should be used A filter change should be made at the time of the transmission oil change The magnet on the inside of the oil pan should also be cleaned with a clean dry cloth NOTE If the transaxle is disassembled for any rea son the fluid and filter should be changed FLUID FILTER SERVICE RECOMMENDED 1 Raise vehicle on a hoist See Lubrication Group 0 Place a drain container with a large open ing under transaxle oil pan 2 Loosen pan bolts and tap the pan at one corner to break it loose allowing fluid to drain then remove the oil pan 3 Install a new filter and o ring on bottom of the valve body and tighten retaining screws to 5 N m 40 Ibs PL SERVICE PROCEDURES Continued 4 Clean the oil pan and magnet Reinstall pan using new Mopar Silicone Adhesive sealant Tighten oil pan bolts to 19 N m 165 in Ibs 5 Pour four quarts of Mopar ATF 44 Automatic Transmission Fluid Type 9602 through the dipstick opening 6 Start engine and allow to idle for at least one minute Then with parking and service brakes applied move selector lever momentarily to each position ending in the park or neutral position 7 Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid le
83. alve is operated by a cam on the valve body throttle lever The throttle lever is actuated by a cable connected to the engine throttle body lever The throttle valve is located within the transaxle valve body and is responsible for transaxle shift speed shift quality and part throttle downshift sen sitivity Proper cable adjustment is essential for proper transaxle operation NOTE The air cleaner throttle body assembly must be installed into position before making this adjust ment pL 5 21 79 REMOVAL AND INSTALLATION Continued 1 Verify cable is routed properly with no kinked BRAKE TRANSMISSION SHIFT INTERLOCK or binding conditions CABLE 2 Release adjustment locking dip on cable at throttle body It is not necessary to remove clip REMOVAL 3 Grab cable conduit near adjustment body push 1 Disconnect the battery negative cable in towards throttle body then release grip Fig 27 2 Loosen set screw and remove knob from shifter This allows cable to self adjust handle Fig 29 0 80 4 Fig 27 Throttle Valve Cable Adjustment 1 TAB UNLOCKED 80bc4ee2 4 Press locking clip to secure cable position Fig Fig 29 Gearshift Knob Removal Installation 28 1 SHIFTER KNOB 2 SET SCREW 3 Remove the center console assembly as shown in Fig 30 5 80bc4ee7 Fig 28 Cable Locking Clip 1 TAB LOCKED 2 THROTTLE VALVE
84. and output shafts 277 to the end bearings is not dam 80 773 8 9521 15 Fig 62 Bearing Fixture 1 BEARING FIXTURE Fig 64 Transaxle Case Removal 2 TRANSAXLE CASE 1 TRANSAXLE CASE 2 BENCH FIXTURE CAUTION The oil dams in the input and output GEARTRAIN shafts can be damaged while pressing on the shafts if the bearing fixture is not used properly BL TRANSAXLE 21 23 DISASSEMBLY AND ASSEMBLY Continued 9521 16 FJ9521 40 Fig 65 Oil Feed Trough Fig 67 Reverse Brake Friction Cone 1 OIL FEED TROUGH 1 REVERSE BRAKE FRICTION CONE 22 TRANSAXLE W REVERSE BRAKE Remove the reverse brake blocking ring shim reverse brake friction cone bearing and race from the input shaft assembly Fig 66 Fig 67 Fig 68 1 Fig 69 Fig 70 TRANSAXLE W O REVERSE BRAKE Remove plastic spacer from the input shaft assembly 2 S 72 gt d FJ9521 39 Fig 68 Reverse Brake Blocking Ring 1 REVERSE BRAKE BLOCKING RING 4 d 2 FJ9521 41 Fig 66 Reverse Brake Shim 1 REVERSE BRAKE SHIM 2 REVERSE BRAKE FRICTION CONE FJ9521 38 Fig 69 Reverse Brake Needle Bearing 1 REVERSE BRAKE NEEDLE BEARING 21 24 TRANSAXLE DISASSEMBLY AND ASSEMBLY Continued 2 NS ANN Ce 5 FJ9521 37 Fig 70
85. at does not use one of those units the unit that is slip ping can be determined If the transaxle also slips in reverse the front clutch is slipping If the transaxle does not slip in reverse the rear clutch is slipping The process of elimination can be used to detect any unit that slips and to confirm proper operation of good units Road testing can usually diagnose slip ping units although the actual cause of the problem may not be detected Practically any condition can be caused by leaking hydraulic circuits or sticking valves Therefore unless the condition is obvious the tran saxle should never be disassembled until hydraulic pressure tests have been performed HYDRAULIC PRESSURE TESTS Pressure testing is a very important step in the diagnostic procedure These tests usually reveal the cause of most transaxle problems Before performing pressure tests check fluid level and condition as well as control cable adjustments Fluid must be at operating temperature 150 to 200 degrees F Install an engine tachometer Raise vehide on a hoist that allows front wheels to turn and position tachometer so it can be read Disconnec throttle cable and shift cable from tran saxle levers so they can be controlled from outside the vehide Attach 150 psi gauges to ports required for test being conducted A 300 psi gauge C 3293 is required for reverse pressure test at rear servo Test port locations are shown in Fig 5 T
86. ation 1 TRANSAXLE 2 ENGINE 3 LATERAL BENDING BRACE 13 Disconnect the vehicle speed sensor connector Fig 50 9 80004562 Fig 50 Vehicle Speed Sensor Connector 1 CONNECTOR 2 SPEEDO PINION 3 O RING 4 SENSOR 21 86 TRANSAXLE REMOVAL AND INSTALLATION Continued 14 Remove structural collar Fig 51 15 Remove the left engineto transaxle lateral bending brace Fig 51 16 Remove bellhousing dust cover Fig 51 80bbdad2 Fig 51 Left Lateral Bending Brace and Structural Collar 1 LATERAL BENDING BRACE 2 STRUCTURAL COLLAR 3 DUST COVER 17 Remove starter motor Fig 52 18 Remove drive plate to converter bolts Fig 54 19 Support engine at pan with screw jack wood block 20 Remove transaxle upper mount thru bolt Gain access to this bolt through the driver s side wheel house Fig 53 21 Carefully lower engine and transaxle on screw jack until proper removal dearance is obtained 22 Obtain a helper to assist in holding transaxle while removing transaxle to engine mounting bolts Fig 54 23 Remove transaxle from vehide Fig 54 24 Remove torque converter from front pump 25 If installing a new or replacement transaxle remove the upper mount and bracket as shown in Fig 55 and transfer to the replacement unit and torque all bolts to 68 50 ft Ibs torque PL ix a ges DC Dy AN
87. bles road test the vehicle to determine if the problem has been cor rected or that further diagnosis is necessary If the prob lem still exists refer to the following diagnosis charts to aid in determining the source or cause of failure pL TRANSAXLE 21 59 DIAGNOSIS AND TESTING Continued Hydraulic pressure tests should be performed when a transaxle internal failure is suspected The hydraulic flow charts in the Schematics and Dia grams section of this group outline fluid flow and hydraulic circuitry Circuit operation is provided for all gear ranges Normal working pressures are also supplied for each of the gear ranges TRANSAXLE DIAGNOSIS CHARTS CONDITION POSSIBLE CAUSES CORRECTION HARSH ENGAGEMENT 1 Fluid Level Low 1 Add Fluid FROM NEUTRAL TO 2 Throttle Linkage Misadjusted 2 Adjust linkage setting may be too long DRIVE OR REVERSE 3 Excessive Pinion Backlash 3 Check per Service Manual Correct as needed 4 Hydraulic Pressure Incorrect 4 Check pressure Remove overhaul or adjust valve body as needed 5 Adjust rear band 5 Band Misadjusted 6 Valve Body Check Balls Missing 6 Inspect valve body for proper check ball installation 7 Clutch band or planetary 7 Remove disassemble and repair component Damaged transmission as necessary 8 Converter Clutch if equipped 8 Replace converter and flush cooler and Faulty line before installing new converter DELAYED ENGAGEMENT 1 Fluid Level Low 1 Cor
88. cables after the assy is removed from position Remove air cleaner assembly from vehi de 80004445 Fig 14 Gear Shift Cable at Transaxle 1 SHIFT LEVER 2 SHIFT CABLE Wy 255144 80bbdadd Fig 13 Air Cleaner Assembly Removal Installation 1 AIR CLEANER ASSY 2 THROTTLE BODY DUCT 80bc4d68 8 Remove battery tray from bracket 9 Disconnect shifter cable from shift lever Fig 15 Catalytic Converter Heat Shield remove from bracket Fig 14 1 CONVERTER HEAT SHIELD 10 Raise vehide on hoist 11 Remove catalytic converter heat shield Fig 15 12 Remove intermediate pipe heat shield front bolts 13 Remove remaining grommet plate screw and remove cable assembly from vehicle Fig 16 PL REMOVAL AND INSTALLATION Continued 806 4965 Fig 16 Grommet Plate Shift Cable at Floor 1 GROMMET PLATE 2 SHIFT CABLE INSTALLATION 1 Install cable assembly through floor pan open ing and secure to floor pan with grommet plate and one screw Fig 16 Make sure the three grommet plate studs protrude through cable assembly and floor pan and tighten screw to 7 N m 60 in Ibs 2 Route transaxle end of cable assembly into engine compartment and over transaxle assembly 3 Install and tighten intermediate pipe heat shield front screws 4 Install catalytic converter heat shield Fig 15 5 Install gear shift cable to bracke
89. cation at any throttle position BRAKE TRANSMISSION SHIFT INTERLOCK SYSTEM The Brake Transmission Shifter l gnition Interlock BTSI is a cable and solenoid operated system It interconnects the automatic transmission floor mounted shifter to the steering column ignition switch The system locks the shifter into the PARK position The interlock system is engaged whenever the ignition switch is in the LOCK or ACCESSORY position An additional electrically activated feature will prevent shifting out of the PARK position unless the brake pedal is depressed at least one half inch A magnetic holding device integral to the interlock cable is energized when the ignition is in the RUN position When the key is in the RUN position and the brake pedal is depressed the shifter is unlocked and will move into any position The interlock system TRANSAXLE 21 57 also prevents the ignition switch from being turned to the LOCK or ACCESSORY position unless the shifter is in the gated PARK position The following chart describes the normal operation of the Brake Transmission Shift Interlock BTSI sys tem If the expected response differs from the vehi de s response then system repair and or adjustment is necessary ACTION EXPECTED RESPONSE 1 Turn key to the OFF 1 Shifter CAN be shifted position out of park 2 Turn key to the 2 Shifter CANNOT be shifted out of park 3 Shifter CAN be shifted out of park ON RUN positi
90. ces between the main rotating parts in these three areas are held precise to maintain a low noise level The torque converter transaxle area and differen tial are housed in an integral aluminum die casting The differential oil sump is common with the transaxle sump Separate filling of the differen tial is NOT necessary The torque converter is attached to the crankshaft through a flexible driving plate Cooling of the con verter is accomplished by circulating the transaxle fluid through a remote cooler There are two types of coolers used An oil to water type cooler located in the radiator side tank and or an oil to air heat exchanger The torque converter assembly is a sealed unit that cannot be disassembled The transaxle fluid is filtered by an internal filter attached to the lower side of the valve body assembly Engine torque is transmitted to the torque con verter and then through the input shaft to multiple disc clutches in the transaxle The power flow depends on the application of the clutches and bands Refer to Elements in Use Chart in Diagnosis and Tests section The transaxle consists of Two multiple disc clutches An overrunning clutch Two servos A hydraulic accumulator Two bands e Two planetary gear sets This provides three forward ratios and a reverse ratio The common sun gear of the planetary gear sets is connected to the front clutch by a driving shell The driving shell is splined to the sun gear and fr
91. common to both the transfer shaft and out put shaft bearings 8 Use tool L 4434 to remove the retaining nut and washer To remove the output shaft gear use tool L 4407 9 Remove the two gauging shims and install the proper shim combination making sure to install the 12 65 13 15 or 13 65 mm shim first Use grease to hold the shims in place Install the output shaft gear and bearing assembly 10 Install the retaining nut and washer and torque to 271 N m 200 ft Ibs 11 Using an inch pound torque wrench check the turning torque The torque should be between 3 and 8 inch pounds 12 If the turning torque is too high install a 0 05mm 0 002 inch thicker shim If the turning torque is too low install a 0 05 mm 0 002 inch thin ner shim Repeat until the proper turning torque is 3 to 8 inch pounds DIFFERENTIAL BEARING 1 Position the transaxle assembly vertically on the support stand differential bearing retainer side up 2 Install Tool L 4436A into the differential and onto the pinion mate shaft 3 Rotate the differential at least one full revolu tion to ensure the tapered roller bearings are fully seated TRANSAXLE 21 139 OUTPUT SHAFT BEARING SHIM CHART and 1 34mm gauging shims installed Required Shim Combination Total Thickness 80a7738e Fig 222 Tool L 4436 and Torque Wrench 1 SPECIAL TOOL L 4436 A 2 TORQUE WRENCH 3 DIFFERENTIAL BEARING RETAINER 4 Using Tool L
92. d play 7 The shim required for proper bearing preload is the total of end play plus constant preload of 0 18mm 0 007 in Never combine shims to obtain the required preload PL USTMENTS Continued Determine Shim Thickness 1 T HANDLE 2 DIAL INDICATOR SET 3 SPECIAL TOOL 4995 8 Remove case bolts Remove clutch bellhousing differential bearing cup Install shim s selected in Step 7 Then press the bearing cup into dutch bell housing 9 Install dutch bellhousing Install and torque case bolts to 26 N m 19 ft Ibs 10 Using Spedial Tool C 4995 and an inch pound torque wrench check turning torque of the differen tial assembly Fig 164 The turning torque should be 6 to 12 in Ibs If the turning torque is too high install a 0 05mm 0 002 inch thinner shim If the turning torque is too low install a 0 05mm 0 002 inch thicker shim 9521 35 Fig 164 Checking Differential Bearing Turning Torque 1 INCH POUND TORQUE WRENCH 2 SPECIAL TOOL C 4995 TRANSAXLE 21 51 11 Recheck turning torque Repeat Step 10until the proper turning torque is obtained SPECIFICATIONS NV T350 A 578 SPECIFICATIONS DESCRIPTION TORQUE Back up Lamp Switch 24 N m 18 ft Ibs Crossover Cable Adj Screw 8 70 in Ibs Drain Plug 28 N m 250 in 105 Differential Ring Gear Bolts 81 60 ft Ibs Dust Shield to Transaxle 12 N m 105 in Ibs
93. dadd Fig 36 Air Cleaner Assembly Removal installation 1 AIR CLEANER ASSY 2 THROTTLE BODY DUCT 4 Remove battery tray from bracket 80904568 5 Disconnect ground cable at battery tray bracket Fig 38 Shift Cables at Transaxle 6 Disconnect back up lamp switch connector 1 SHIFT CABLES 2 CLIPS 7 Remove bellhousing Fig 37 8 Disconnect dutch cable from fork and remove 3 BRACKET from transaxle Fig 37 BL TRANSAXLE 21 15 REMOVAL AND INSTALLATION Continued 11 Disconnect the vehicle speed sensor connector Fig 39 80bbdad2 SMS Fig 40 Left Lateral Bending Brace and Structural Fig 39 Vehicle Speed Sensor Connector Collar Typical 1 CONNECTOR 1 LATERAL BENDING BRACE 2 SENSOR 2 STRUCTURAL COLLAR 3 O RING 3 DUST COVER 4 SPEEDO PINION 12 Raise vehide on hoist 13 Remove transaxle oil drain plug and drain oil into a suitable container 14 Remove both axle shafts Refer to Group 3 Differential and Driveline for the correct procedures 15 Remove structural collar Fig 40 16 Remove the left engine to transaxle lateral bending brace Fig 40 17 Remove bellhousing dust cover Fig 40 18 Remove the right engine to transaxle lateral bending brace Fig 41 19 Remove starter motor Fig 42 20 Remove drive plate to clutch module bolts 21 Support engine at oil pan with screw jack and wood block 22 Remove transa
94. djustment 4 Adjust Band 5 Clutch or Servo Malfunction 5 Air pressure check operation of clutches and bands Repair faulty component CREEPS IN NEUTRAL 1 Gearshift Linkage Misadjusted 1 Adjust linkage 2 Rear Clutch Dragging Warped 2 Disassemble and repair Welded 3 Valve Body Malfunction 3 Perform hydraulic pressure test to determine cause and repair as required BL TRANSAXLE 21 63 DIAGNOSIS AND TESTING Continued CONDITION POSSIBLE CAUSES CORRECTION BUZZING NOISE 1 Fluid Level Low 1 Add fluid and check for leaks 2 Shift Cable Misassembled 2 Route cable away from engine and bell housing 3 Valve Body Misassembled 3 Remove disassemble inspect valve body Reassemble correctly if necessary Replace assembly if valves or springs are damaged Check for loose bolts or screws 4 Pump Passages Leaking 4 Check pump for porous casting scores on mating surfaces and excess rotor clearance Repair as required Loose pump bolts 5 Cooling System Cooler Plugged 5 Flow check cooler circuit Repair as needed 6 Overrunning Clutch Damaged 6 Replace clutch SLIPS IN REVERSE ONLY 1 Fluid Level Low 1 Add fluid and check for leaks 2 Gearshift Linkage Misadjusted 2 Adjust linkage 3 Rear Band Misadjusted 3 Adjust band 4 Rear Band Worn 4 Replace as required 5 Hydraulic Pressure Too Low 5 Perform hydraulic pressure tests to determine cause 6 Rear Servo Leaking 6 Air pressure check clutch
95. do To Ext Hous Screw Sprag Ret To Transfer Case Starter To Trans Bell Bolts Stirrup Strap Ret Bolts Trans To Cyl Block Bolt Transfer Shaft Nut Transfer Gear Strap Bolts Valve Body Assy To Case Bolts cod CN d Valve Body Screw SPECIAL TOOLS TORQUE 7 60 in 95 N m 70 ft 7 N m 60 in 28 N m 250 in 54 N m 40 ft 23 N m 200 in 95 N m 70 ft 271 N m 200 ft 23 Ne m 17 ft 12 N m 105 in b 45 in 31TH AUTOMATIC TRANSAXLE SB Puller Press Extension C 293 3 450 450 Adapter Blocks 293 52 Ibs Ibs Ibs Ibs Ibs Ibs Ibs Ibs Ibs Ibs Ibs TRANSAXLE 21 151 90114420 Dial Indicator C 3339 21 152 TRANSAXLE SPECIAL TOOLS Continued C Band Adjusting Adapter ER Oil Pump Puller C 3752 Seal Puller C 3981B A Universal Handle C 4171 0 Seal Installer C 4193A L Bearing Installer 4637 Adapter C 4658 Se Torque Tool C 4995 4996 PL PL SPECIAL TOOLS Continued Remover Kit L 4406 Bearing Remover Cup L 4406 1 v Bearing Remover Jaws L 4406 2 Adapter 1 4406 3 Gear Puller L 4407A TRANSAXLE 21 153 i Puller L 4407 6 Bearing Installer L 4408 Bearing Installer L 4410 gt Bearing Installer L 4411 Installer Adapter L 4429
96. e the 5th shift fork Remove the shift lug roll pin and remove the shift lug Replace parts as necessary 3 To service the 3 4 shift rail remove the roll pin retaining the 3 4 shift fork Remove the shift fork Remove the shift lug roll pin and remove the shift lug Replace parts as necessary FJ9521 75 Fig 138 Keys in Hub 1 SNAP RING 2 CLUTCH 3 KEY 4 BALL 5 SPRING 4 To service the 1 2 shift rail remove the roll pin retaining the 1 2 shift fork Remove the shift fork and replace parts as necessary TRANSAXLE CASE OVERHAUL The sealant used to seal the transaxle case halves is Gasket Maker Loctite 518 or equivalent The sealant used for the bearing end plate cover is Mopar RTV The components that are left in the gear cases when the gear train is pulled out are the Axle shaft seals PL DISASSEMBLY AND ASSEMBLY Continued Output bearing race and retainer Input bearing and sleeve Differential bearing cones Shift rail bushings Shift shafts Shift shaft seals Shift shaft bushings Rear bearing oil feed trough AXLE SHAFT SEALS REMOVAL 1 Insert a flat blade pry tool at outer edge of axle shaft seal Fig 139 2 Tap on the pry tool with a small hammer and remove axle shaft seal FJ9521 99 Fig 139 Axle Shaft Seal Removal TRANSAXLE 21 43 Fig 140 Axle Seal Installation 1 TOOL C 4171 2 TOOL 6709 3 AXLE SEAL 1 AXLE
97. e turns Test adjusting screw for free turning in the transaxle case 2 Using wrench tighten adjusting screw to 8 N m 72 in Ibs 3 Back off adjusting screw the number of turns listed in Specifications Hold adjusting screw in this position and tighten locknut to 47 N m 35ft Ibs LOW REVERSE BAND REAR To adjust low reverse band proceed as follows 1 Loosen and back off locknut approximately five turns 2 Using an inch pound torque wrench tighten adjusting screw to 5 41 in Ibs true torque 3 Back off adjusting screw the number of turns listed under Specifications A chart is located at the rear of this section 4 Tighten locknut to 14 N m 10 ft Ibs HYDRAULIC CONTROL PRESSURE ADJUSTMENTS LINE PRESSURE An incorrect throttle pressure setting will cause incorrect line pressure readings even though line pressure adjustment is correct Always inspect and PL correct throttle pressure adjustment before adjusting the line pressure The approximate adjustment for line pressure is 1 5 16 inches measured from valve body to inner edge of adjusting nut However due to manufactur ing tolerances the adjustment can be varied to obtain specified line pressure The adjusting screw may be turned with an Allen wrench One complete turn of adjusting screw changes closed throttle line pressure approximately 1 2 3 psi Turning adjusting screw counterclockwise increases pressure and clockwise decreases pr
98. ear case from the bellhousing case CAUTION The transaxle output shaft is serviced as a unit No disassembly and reassembly is possible Damage to the transaxle may result DISASSEMBLY 1 Place transaxle on bench 2 Remove the clutch release bearing and fork Move the release fork and bearing to an in line posi tion Grasp the release lever with two hands in the pivot stud socket area Pull with even pressure to release the fork from the pivot stud CAUTION Do not use a screwdriver or pry bar to release the fork as this may cause damage to the fork and or clip 3 Remove shift levers by driving out the roll pins 4 Remove transaxle case half bolts Fig 46 FJ9521 1 Fig 46 Case Bolts 1 CASE BOLTS PL 80468d6d Fig 47 Transaxle Case Halves 1 BELLHOUSING HALF 2 GEAR CASE HALF ZAN Fig 48 Separate Case Halves 1 PRY TOOL 2 CASE HALVES 3 PRY SLOT 5 Place two screwdrivers into the slots provided in the case halves near the dowels Fig 47 Separate the case halves Fig 48 PL DISASSEMBLY AND ASSEMBLY Continued 6 Remove bellhousing half from gear case half Fig 49 FJ9521 4 Fig 49 Bellhousing Case Half Removal 1 BELLHOUSING CASE HALF 2 DIFFERENTIAL 3 GEAR CASE HALF 7 Remove output shaft roller bearing from output shaft 8 Remove differential assembly Fig 50 FJ9521 5 Fig 50 Differential Assembly Removal
99. ed Worn 2 Adjust band replace 3 Valve Body Malfunction 3 Remove and service valve body Replace valve body if any valves or valve bores are worn or damaged 4 Rear Servo Malfunction 4 Remove and disassemble transmission Replace worn damaged servo parts as necessary 5 Direct Clutch in Overdrive Worn 5 Disassemble overdrive Replace worn or damaged parts 6 Front Clutch Burnt 6 Remove and disassemble transmission Replace worn damaged clutch parts as required HAS FIRST REVERSE 1 Governor Valve Shaft Weights or 1 Remove governor assembly and clean or ONLY NO 1 2 OR 2 3 Body Damaged Stuck repair as necessary UPSHIFT 2 Valve Body Malfunction 2 Stuck 1 2 shift valve or governor plug 3 Front Servo Kickdown Band 3 Repair replace Damaged Burned MOVES IN 2ND OR 3RD 1 Valve Body Malfunction 1 Remove clean and inspect Look for GEAR ABRUPTLY stuck 1 2 valve or governor plug DOWNSHIFTS TO LOW 2 Governor Valve Sticking 2 Remove clean and inspect Replace faulty parts 21 62 TRANSAXLE DIAGNOSIS AND TESTING Continued CONDITION POSSIBLE CAUSES CORRECTION NO LOW GEAR MOVES 1 Governor Valve Sticking 1 Remove governor clean inspect and IN 2ND OR 3RD GEAR repair as required ONLY 2 Valve Body Malfunction 2 Remove clean and inspect Look for sticking 1 2 shift valve 2 3 shift valve governor plug or broken springs 3 Front Servo Piston Cocked
100. ely check output shaft bearing turning torque TRANSAXLE 21 121 T Fig 160 Parking Pawl Return Spring and Pivot Shaft 1 PARKING PAWL 2 RETURN SPRING 3 NOTE SMALL DIAMETER TO REAR 4 PIVOT SHAFT STIRRUP AND RETAINING STRAP NOTE A stirrup and retaining strap Fig 161 is attached to the output gear The stirrup prevents the output gear retaining nut from turning and backing off the output shaft The strap is used to hold the stirrup to the output gear and prevent the stirrup retaining bolts from backing out REMOVAL d Fig 161 Stirrup and Retaining Strap Assembly 1 STRAP 2 RETAINING BOLTS 2 3 OUTPUT GEAR 4 STIRRUP 21 122 TRANSAXLE DISASSEMBLY AND ASSEMBLY Continued 1 Using a punch bend tabs on strap flat against 3 Remove strap from output gear and stirrup output gear Fig 162 Fig 164 80524 61 Fig 162 Bend Strap Tabs Flat Fig 164 Remove Strap From Stirrup and Gear 1 RETAINING TABS 1 OUTPUT GEAR 2 STRAP 2 STRAP 2 Remove bolts holding retaining strap to stirrup 4 Remove stirrup from output gear Fig 165 Fig 163 Fig 166 80524662 lt lt A Fig 165 Remove Stirrup From Gear Fig 163 Remove Strap Bolts Be GEAR 1 RETAINING BOLTS 2 STIRRUP 2 STIRRUP 3 STRAP BL
101. er or a stuck pressure regulator valve GOVERNOR PRESSURE Test only if transaxle shifts at wrong vehicle speeds when throttle cable is correctly adjusted 1 Connect a 0 150 psi pressure gauge to governor pressure take off point It is located at lower right side of case below differential cover 2 Operate transaxle in third gear to read pres sures The governor pressure should respond smoothly to changes in mph and should return to 0 to 3 psi when vehicle is stopped High pressure above 3 psi at standstill will prevent the transaxle from downshifting THROTTLE PRESSURE No gauge port is provided for throttle pressure Incorrect throttle pressure should be suspected if part throttle upshift speeds are either delayed or occur too early in relation to vehicle speed Engine runaway on shifts can also be an indicator of low throttle pressure setting or misadjusted throttle cable In no case should throttle pressure be adjusted until the transaxle throttle cable adjustment has been verified to be correct CLUTCH AND SERVO AIR PRESSURE TESTS A no drive condition might exist even with correct fluid pressure because of inoperative clutches or bands The inoperative units clutches bands and servos can be located through a series of tests This is done by substituting air pressure for fluid pressure Fig 7 The front and rear clutches kickdown servo and low reverse servo be tested by applying air pres sure to their
102. essure THROTTLE PRESSURE Throttle pressures cannot be tested accurately therefore the adjustment should be measured if a malfunction is evident 1 Insert gauge pin of Tool C 3763 between the throttle lever cam and kickdown valve 2 By pushing in on tool compress kickdown valve against its spring so throttle valve is com pletely bottomed inside the valve body 3 While compressing spring turn throttle lever stop screw with adapter C 4553 Turn until head of screw touches throttle lever tang with throttle lever cam touching tool and throttle valve bottomed Be sure adjustment is made with spring fully com pressed and valve bottomed in the valve body BEARING ADJUSTMENT PROCEDURES 1 Take extreme care when removing and install ing bearing cups and cones Use only an arbor press for installation as a hammer may not properly align the bearing cup or cone Burrs or nicks on the bearing seat will give a false end play reading while gauging for proper shims Improperly seated bearing cup and cones are subject to low mile age failure 2 Bearing cups and cones should be replaced if they show signs of pitting or heat distress 3 If distress is seen on either the cup or bearing rollers both cup and cone must be replaced NOTE Bearing end play and drag torque specifica tions must be maintained to avoid premature bear ing failures 4 Used original bearing may lose up to 50 per cent of the original drag torque af
103. f pitting or heat distress If distress is seen on either the cup or bearing rollers both cup and cone must be replaced 3 Bearing preload and drag torque specifications must be maintained to avoid premature bearing fail ures Used original bearings may lose up to 5096 of the original drag torque after break in All bearing adjustments must be made with no other component interference or gear intermesh 4 Replace bearings as a pair If one differential bearing is defective replace both differential bear ings if one input shaft bearing is defective replace both input shaft bearings 5 Bearing cones must not be reused if removed 6 Turning torque readings should be obtained while smoothly rotating in either direction 21 30 TRANSAXLE DISASSEMBLY AND ASSEMBLY Continued DIFFERENTIAL BEARING PRELOAD ADJUSTMENT NOTE True bearing turning torque readings can be obtained only with the geartrain removed from the case 1 Remove bearing cup and existing shim from dutch bellhousing case 2 Press in new bearing cup into bellhousing case or use a cup that has been ground down on the outer edge for ease of measurement 3 Press in new bearing cup into gear case side 4 Oil differential bearings with Mopar type M S 9417 Manual Transaxle Fluid Install differential assembly in transaxle gear case Install clutch bell housing over gear case Install and torque case bolts to 29 N m 21 ft Ibs 5 Position tra
104. g the Transaxle Hydrau lic Pressure Test procedure pL TRANSAXLE 21 73 REMOVAL AND INSTALLATION 3 Remove shifter bezel Fig 11 GEARSHIFT CABLE REMOVAL 1 Loosen set screw and remove knob from shifter handle Fig 9 l l Fig 11 Shifler Bezel Removal Installation 1 BEZEL 2 SCREW 4 4 Disconnect shift cable from shifter assembly as shown in Fig 12 Fig 9 Gearshift Knob Removal Installation 5 Remove three grommet plate to floor pan nuts 1 SHIFTER KNOB as shown in Fig 12 2 SET SCREW 80504568 2 Remove the center console assembly as shown in Fig 10 80bc4d67 Fig 12 Gearshift Cable at Shifter Assembly 1 SHIFTER ASSEMBLY 2 GROMMET PLATE NUT 3 SHIFT CABLE Fig 10 Center Console Removal installation 1 CONSOLE 2 SCREW 4 3 SCREW 2 21 74 TRANSAXLE REMOVAL AND INSTALLATION Continued 6 Disconnect both battery cables remove battery hold down clamp and bolt and remove battery 7 Remove air cleaner throttle body assy Fig 13 as follows a Disconnect proportional purge solenoid PPS and crankcase vent hose from throttle body 0 Disconnect the Throttle Position Sensor TPS and Idle Air Control connectors c Remove mounting bolt and nut Fig 13 and partially remove air cleaner assembly d Disconnect accelerator and speed control if equipped
105. hifter knob 2 Push down on knob and rotate clockwise to remove Fig 157 Fig 157 Gearshift Knob Removal 1 GEARSHIFT KNOB 80040421 3 Remove the center console assembly as shown in Fig 158 80004567 Fig 158 Center Console Removal Installation Typical 1 CONSOLE 2 SCREW 4 3 SCREW 2 TRANSAXLE 21 49 80bc4d60 Fig 159 Gearshift Boot Removal Installation 1 BOOT 2 SHIFTER ASSEMBLY 4 Separate shifter boot from shifter assembly Fig 159 Boot is retained to shifter by three push pin retainers 5 Loosen crossover adjustment screw at shifter assembly Fig 160 80bc4de3 Fig 160 Crossover Adjustment Screw 1 CROSSOVER ADJUSTMENT SCREW 6 Pin transaxle crossover lever in 3 4 neutral position using a 1 4 inch drill bit Align hole in cross over lever with the hole in the boss on the transaxle case Fig 161 Be sure drill bit goes into transaxle case at least one half inch 7 The shifter is spring loaded and self centering Allow shifter to rest in its neutral position Torque adjustment screw to 8 N m 70 in 106 Care must be taken to avoid moving the shift mechanism off center during screw tightening 8 Remove drill bit from transaxle case and per form functional check by shifting transaxle into all gears 9 Install boot to the shifter assembly Fig 159 Fasten boot with the three retainers 21 50 TRANSAXLE UST
106. hrust Washer and Rear Clutch 1 REAR CLUTCH ASSEMBLY 2 2 THRUST WASHER Fig 73 Kickdown Band and Strut 1 FRONT CLUTCH 2 KICKDOWN BAND 3 OIL RETURN AND FEED HOLE TO DIFFERENTIAL 4 STRUT RB722A Fig 76 No 3 Thrust Washer 1 OUTPUT SHAFT Fig 74 Front Clutch Assembly 2 SUN GEAR DRIVING SHELL 1 REAR CLUTCH ASSEMBLY 3 3 THRUST WASHER SELECT FIT 2 FRONT CLUTCH ASSEMBLY 21 94 TRANSAXLE DISASSEMBLY AND ASSEMBLY Continued 80524e59 Fig 79 Sun Gear Driving Shell Fig 77 Front Planetary Gear Snap Ring 1 SUN GEAR DRIVING SHELL 1 FRONT PLANETARY GEAR SNAP RING 2 REAR PLANETARY GEAR 2 SNAP RING PLIERS 3 FRONT PLANETARY GEAR ASSEMBLY Fig 80 Sun Gear Driving Shell Components RB724A 1 8 THRUST WASHER STEEL 2 7 SPACER STEEL 3 SUN GEAR Fig 78 Front Planetary Gear Assembly 4 SUN GEAR DRIVING SHELL en 5 SNAP RING 2 FRONT PLANETARY GEAR ASSEMBLY 3 86 THRUST WASHER PL DISASSEMBLY AND ASSEMBLY Continued 80524 Fig 81 9 Thrust Washer 1 9 THRUST WASHER 2 OUTPUT SHAFT 3 REAR PLANETARY GEAR ASSEMBLY TRANSAXLE 21 95 PR2219A Fig 83 No 10 Thrust Washer 1 OVERRUNNING CLUTCH CAM ASSEMBLY 2 10 THRUST WASHER 80524e5b Fig 82 Rear Planetary Gear Assembly 1 REAR PLANETARY GEAR ASSEMBLY P
107. ift knob and tighten set screw to 2 N m 15 in 165 torque Fig 9 15 Connect battery cables 16 Verify that engine starter operates in both PARK P and NEUTRAL N Starter should not operate in any other gear position 21 76 TRANSAXLE REMOVAL AND INSTALLATION Continued GEARSHIFT MECHANISM REMOVAL 1 Disconnect battery negative cable and isolate 2 Loosen set screw and remove knob from shifter handle Fig 18 80bc4ee2 Fig 18 Gearshift Knob Removal Installation 1 SHIFTER KNOB 2 SET SCREW 3 Remove the center console assembly as shown in Fig 19 80004567 Fig 19 Center Console Removal installation 1 CONSOLE 2 SCREW 4 3 SCREW 2 PL 4 Remove shifter bezel Fig 20 80504568 Fig 20 Shifter Bezel Removal Installation 1 BEZEL 2 SCREW 4 5 Disconnect shift cable from shifter assembly as shown in Fig 21 80bc4d67 Fig 21 Gearshift Cable at Shifter Assembly 1 SHIFTER ASSEMBLY 2 GROMMET PLATE NUT 3 SHIFT CABLE PL REMOVAL AND INSTALLATION Continued 6 Disconnect the shifter ignition interlock cable from the shifter lever and bracket as shown in Fig 22 80bc4ee3 Fig 22 Shifter Ignition Interlock Cable 1 INTERLOCK CABLE 2 SHIFTER ASSEMBLY 7 Remove the four shifter assembly to floor pan nuts and remove shifter assembly from vehicle Fig 23 80bc4ee4 Fig 23 Gearshif
108. im thickness STIRRUP AND STRAP INSTALLATION Once bearing shim selection has been adjusted install stirrup and strap assembly onto transfer gear NOTE Once the stirrup assembly is positioned onto the transfer gear it is necessary to clock the stirrup against the flats of the transfer gear retain ing nut 1 Position the stirrup on the transfer gear 2 Position strap 3 Install retaining bolts into transfer gear Fin ger tighten bolts 4 Turn stirrup dockwise against the flats of the transfer gear retaining nut 5 Tighten retaining bolts to 23 200 in 165 9521 115 Fig 157 Checking Transfer Shaft End Play 1 SPECIAL TOOL L 4432 AND 4658 2 TRANSFER SHAFT GEAR 3 STEEL BALL USE GREASE TO HOLD IN PLACE 4 DIAL INDICATOR 5 SCREW 2 6 Bend tabs of strap up against flats of retain ing bolts ASSEMBLY To install transfer shaft reverse the above proce dure PL DISASSEMBLY AND ASSEMBLY Continued PARKING PAWL DISASSEMBLY 09 40 16 0873 d UR 2 9521 116 Fig 158 Parking Sprag Rod Support 1 PARKING SPRAG ROD SUPPORT 2 BOLT 2 3 OUTPUT SHAFT GEAR Fig 159 Support and Bolts 1 BOLT 2 2 PARKING SPRAG ROD SUPPORT ASSEMBLY To install reverse the above procedure OUTPUT SHAFT REPAIR NOTE Transfer shaft should be removed for repair of output shaft Planetary gear sets must be removed to accurat
109. ing column upper lower shrouds Fig 40 4 Install steering column lower cover Fig 39 VEHICLE SPEED SENSOR PINION GEAR REMOVAL 1 Remove harness connector from sensor Fig 44 Be sure weather seal stays on harness connector 2 Remove bolt securing the sensor in the exten sion housing Fig 44 3 Carefully pull sensor and pinion gear assembly out of extension housing 4 Remove pinion gear from sensor Fig 44 5 Inspect pinion gear for damage missing teeth etc and replace as necessary TRANSAXLE 21 83 118 9521 71 Fig 43 Interlock Mechanism 1 MOUNTING SCREW 2 INTERLOCK MECHANISM NOTE When removing vehicle speed sensor for any reason a new o ring MUST be used 80004562 Fig 44 Vehicle Speed Sensor Removal Installation 1 CONNECTOR 2 SPEEDO PINION O RING 4 SENSOR INSTALLATION 1 Install pinion gear to vehicle speed sensor as shown in Fig 44 2 Install sensor to extension housing using a NEW o ring 3 Tighten bolt to 7 N m 60 in Ibs 4 Connect harness connector 21 84 TRANSAXLE REMOVAL AND INSTALLATION Continued PARK NEUTRAL STARTING AND BACK UP LAMP SWITCH TEST The park neutral starting switch is the center ter minal of the three terminal switch It provides ground for the starter solenoid circuit through the selector lever in PARK and NEUTRAL positions only 1 To test switch remove wiring connect
110. into bench fix ture Fig 76 4 Install reverse brake race onto input shaft Fig 71 5 Install reverse brake needle bearing Fig 78 TRANSAXLE 21 25 9521 17 Fig 76 Shift Blocker Installation 1 6785 BENCH FIXTURE 2 SHIFT BLOCKER ASSEMBLY 2 2 FJ9521 37 Fig 77 Reverse Brake Race Installation 1 REVERSE BRAKE RACE FJ9521 38 Fig 78 Reverse Brake Needle Bearing 1 REVERSE BRAKE NEEDLE BEARING 21 26 TRANSAXLE DISASSEMBLY AND ASSEMBLY Continued 6 Install reverse brake blocking ring Fig 79 FJ9521 39 Fig 79 Reverse Brake Blocking Ring Installation 1 REVERSE BRAKE BLOCKING RING 7 Install reverse brake friction cone Fig 80 FJ9521 40 Fig 80 Reverse Brake Friction Cone Installation 1 REVERSE BRAKE FRICTION CONE PL 8 Install reverse brake shim Fig 81 Apply petroleum jelly to shim to hold in place FJ9521 41 Fig 81 Reverse Brake Shim 1 REVERSE BRAKE SHIM 2 REVERSE BRAKE FRICTION CONE 9 Install gear case half over bench fixture Fig 82 Line up shift finger over 3 4 lug 9521 15 Fig 82 Gear Case Half 1 TRANSAXLE CASE 2 BENCH FIXTURE 3 GEARTRAIN PL TRANSAXLE 21 27 DISASSEMBLY AND ASSEMBLY Continued 10 Line up reverse brake friction cone lugs to the 12 Install shaft snap rings at input and output slots the gear
111. itch is located on the top left front side of the transaxle case Fig 31 ep 9421 54 Fig 31 Back up Lamp Switch 1 CLUTCH CABLE 2 BACK UP LAMP SWITCH 3 LEFT FRAME RAIL REMOVAL 1 Lift vehicle on hoist 2 From bottom side of vehicle disconnect back up lamp switch connector 3 Unscrew switch from transaxle INSTALLATION 1 Install back up lamp switch Teflon tape or equivalent must be used on switch threads CAUTION Do not overtighten switch 2 Connect back up lamp switch connector 3 Lower vehicle 4 Verify back up lamp operation PL CROSSOVER LEVER REMOVAL 1 Disconnect crossover cable from crossover lever and cable bracket Refer to Gearshift Cable Removal and Installation in this Group 2 Using a pin punch remove the crossover roll pin from lever 3 Pull up and remove the crossover lever from the transaxle crossover shaft Fig 32 INSTALLATION 1 Install crossover lever to shaft and fasten with NEW roll pin 2 Install crossover cable to bracket Fasten with clip 3 Install crossover cable to crossover lever Fig 32 Crossover Lever 1 CROSSOVER LEVER 2 CROSSOVER CABLE 3 SELECTOR CABLE 4 SELECTOR LEVER SELECTOR LEVER The selector lever is retained to the shaft by two roll pins one inside the other REMOVAL 1 Disconnect the selector cable from the selector lever Fig 33 and remove from cable bracket Refer
112. l structural collar Fig 51 as follows a Position collar and install all bolts finger tight b Tighten the collar to oil pan bolts to N m 30 in 165 torque 21 88 TRANSAXLE REMOVAL AND INSTALLATION Continued Tighten the collar to transaxle bolts to 108 N m 80 ft Ibs torque d Final torque the collar to oil pan bolts to 54 N m 40 ft Ibs torque 11 Install both front axle driveshafts Refer to Group 3 Differential and Driveline for the correct procedures 12 Connect vehicle speed sensor connector Fig 50 13 Install right lateral bending brace and tighten bolts to 81 N m 60 ft Ibs torque 14 Lower vehicle 15 Connect transaxle cooler lines and tighten clamps Fig 46 16 Connect torque converter clutch solenoid and neutral safety back up lamp switch connectors 17 Install transaxle dipstick tube 18 Install gear shift cable to bracket and connect to shift lever Fig 47 19 Install transaxle kickdown cable to bracket and lever as shown in Fig 48 20 Install battery lower tray and battery and tighten battery hold down clamp to secure battery 21 Install the air cleaner throttle body assy as follows a Connect the accelerator transaxle kickdown and speed control if equipped cables to the air cleaner throttle body assy b Install assy into position and tighten fasten ers to 14 120 in Ibs torque c Connect the Throttle Position Sensor TP
113. lation 1 TOOL C 4171 b 2 TOOL C 4628 3 OUTPUT BEARING RACE d 5 Q 2 os SAC 2 ah Fig 143 Output Bearing Race Removal 1 3752 2 SPECIAL TOOL 6787 3 OUTPUT SHAFT BEARING RACE M PL DISASSEMBLY AND ASSEMBLY Continued INPUT BEARING AND SLEEVE The input bearing is a one piece bearing and sleeve unit Fig 145 The sleeve is the slide point for the clutch release bearing and lever FJ9521 101 Fig 145 Input Bearing And Sleeve 1 DIFFERENTIAL BEARING 2 OUTPUT BEARING 3 INPUT BEARING 4 BEARING RETAINER REM OVAL 1 Install tool 6342 over input bearing on the gear case side of the transaxle dutch housing 2 Press the input bearing out of the housing Fig 146 80468d6e Fig 146 Input Bearing Removal 1 SPECIAL TOOL 6342 2 BELLHOUSING HALF 3 INPUT BEARING AND SLEEVE TRANSAXLE 21 45 INSTALLATION 1 Apply coating of Loctite sealant on bearing outer diameter Position sleeve and bearing assembly at input bearing bore 2 Install tool C 4680 1 over input bearing Fig 147 3 Using the spacer tool 74894 and shop press install input bearing into bore until it is fully seated Fig 148 80468461 Fig 147 Input Bearing Tool 1 SPECIAL TOOL C 4680 1 2 SPECIAL TOOL 4894 3 BELLHOUSING HALF 2 2 Fig 148 Input Bearing Installed 1 SLEEVE AND BEARING AS
114. le Removal Installation 1 CONSOLE 2 SCREW 4 3 SCREW 2 3 Adjust gearshift cable as follows a Place gearshift lever in the PARK P posi tion b Loosen shift cable adjustment screw Fig 216 c Move transaxle manual lever to the PARK Verify transaxle is in PARK by attempting to roll vehide in either direction 21 136 TRANSAXLE USTMENTS Continued d Tighten shift cable adjustment screw to 8 N m 70 in 165 torque 80bc4ee1 Fig 216 Gearshift Cable Adjustment Screw 1 GEARSHIFT CABLE ADJUSTMENT SCREW 4 Verify proper cable adjustment Engine should start with the shifter lever in PARK P and NEU TRAL N positions ONLY 5 Install center console assembly Fig 215 6 Install gearshift knob and tighten set screw to 2 N m 15 in Ibs torque Fig 214 THROTTLE VALVE CABLE ADJUSTM ENT PROCEDURE The transmission throttle valve is operated by a cam on the valve body throttle lever The throttle lever is actuated by a cable connected to the engine throttle body lever The throttle valve is located within the transaxle valve body and is responsible for transaxle shift speed shift quality and part throttle downshift sen sitivity Proper cable adjustment is essential for proper transaxle operation NOTE The air cleaner throttle body assembly must be installed into position before making this adjust ment 1 Verify cable is routed properly with no kinked
115. le bushings must not be lubricated or the bushings will swell and split 80004840 Fig 16 Air Cleaner Assembly Removal installation 1 AIR CLEANER ASSY 2 THROTTLE BODY DUCT 1 Raise vehicle on hoist 2 Install cable assembly through floor pan open ing and secure to floor pan with grommet plate and one screw Fig 19 Make sure the three grommet plate studs protrude through cable assembly and floor pan and tighten screw to 7 N m 60 in Ibs 3 Route transaxle end of cable assembly into engine compartment and over transaxle assembly 4 Install converter heat shield Fig 18 5 Lower vehicle 21 8 TRANSAXLE REMOVAL AND INSTALLATION Continued 80004069 Fig 17 Shift Cables at Transaxle 1 SHIFT CABLES 2 CLIPS 3 BRACKET 2 80004468 Fig 18 Converter Heat Shield Removal Installation 1 CONVERTER HEAT SHIELD 6 Install gearshift cables to mounting bracket and fasten with NEW clips Fig 17 Make sure dips are installed flush to bracket 7 Connect gearshift selector and crossover cable to shift levers at transaxle Fig 17 8 Install and tighten the three grommet plate to floor pan nuts to 6 N m 50 in Ibs torque 9 Install selector cable to shifter lever and secure cable to shifter bracket Install clip Fig 15 10 Install crossover cable to shifter lever and secure cable to shifter bracket Install dip Fig 14 PL 2 80 4464 Fig
116. leaner Throttle Body 1 KICKDOWN CABLE 2 AIR CLEANER THROTTLE BODY ASSY 3 Disconnec throttle valve cable from lever on transaxle and remove from bracket Fig 26 80bbdad6 Fig 26 Throttle Valve Cable at Transaxle 1 LEVER 2 BRACKET 3 KICKDOWN CABLE PL INSTALLATION NOTE Route throttle valve cable in a manner that allows free unobstructed travel For proper tran saxle operation the cable must not bind 1 Install transaxle throttle valve cable to bracket and lever as shown in Fig 26 Make sure the cable snaps onto the lever 2 Install the throttle valve cable to the air er throttle body as shown in Fig 25 3 Install the air deaner throttle body assy as fol lows a Install assy into position making sure the air deaner locating slot is engaged to the battery bracket tab and tighten fasteners to 14 N m 120 165 torque b Verify throttle body duct is fully seated to intake manifold and tighten clamp to 5 N m 40 in lbs torque c Connect the Throttle Position Sensor TPS and Idle Air Control IAC connectors d Connect proportional purge solenoid PPS and crankcase vent hose from throttle body 4 Connect the battery negative cable 5 Perform the Throttle Valve Cable Adjustment Procedure found in this group 6 Road test vehicle and verify proper transaxle operation THROTTLE VALVE CABLE ADJUSTMENT PROCEDURE The transmission throttle v
117. leasing Check 7 Remove disassemble repair Stall Speed Worn Damaged Stuck 8 Torque Converter Damage 8 Inspect and replace as required pL TRANSAXLE 21 61 DIAGNOSIS AND TESTING Continued CONDITION POSSIBLE CAUSES CORRECTION SHIFTS DELAYED OR 1 Fluid Level Low High 1 Correct fluid level and check for leaks if ERRATIC ALSO SHIFTS low HARSH AT TIMES 2 Fluid Filter Clogged 2 Replace filter If filter and fluid contained clutch material or metal particles an overhaul may be necessary Perform lube flow test 3 Throttle Linkage Misadjusted 3 Adjust linkage as described in service section 4 Throttle Linkage Binding 4 Check cable for binding Check for return to closed throttle at transmission 5 Gearshift Linkage Cable 5 Adjust linkage cable as described in Misadjusted service section 6 Governor Valve Sticking 6 Inspect clean or repair 7 Governor Seal Rings Worn 7 Inspect replace Damaged 8 Clutch or Servo Failure 8 Remove valve body and air test clutch and band servo operation Disassemble and repair transmission as needed 9 Front Band Misadjusted 9 Adjust band 10 Pump Suction Passage Leak 10 Check for excessive foam on dipstick after normal driving Check for loose pump bolts defective gasket Replace pump assembly if needed NO REVERSE D RANGES 1 Gearshift Linkage Cable 1 Repair or replace linkage parts as OK Misadjusted Damaged needed 2 Rear Band Misadjust
118. lling out the worn out or damaged threads Then tap the hole with a Heli Coil tap and install a Heli Coil insert into the hole This brings the hole back to its original thread size Heli Coil tools and inserts are readily available from most automotive parts suppliers 21 72 TRANSAXLE SERVICE PROCEDURES Continued FLUSHING COOLERS AND TUBES When a transaxle failure has contaminated the fluid the transaxle oil cooler s must be flushed both radiator and remote The cooler bypass valve in the transaxle must be replaced also The torque con verter must also be replaced with an exchange unit This will ensure that metal particles or sludged oil are not later transferred back into the reconditioned or replaced transaxle The recommended procedure for flushing the cool ers and tubes is to use Tool 6906A Cooler Flusher WARNING WEAR PROTECTIVE EYEWEAR THAT MEETS THE REQUIREMENTS OF OSHA AND ANSI 287 1 1968 WEAR STANDARD INDUSTRIAL RUB BER GLOVES KEEP LIT CIGARETTES SPARKS FLAMES AND OTHER IGNITION SOURCES AWAY FROM THE AREA TO PREVENT THE IGNITION OF COMBUSTI BLE LIQUIDS AND GASES KEEP A CLASS B FIRE EXTINGUISHER IN THE AREA WHERE THE FLUSHER WILL BE USED KEEP THE AREA WELL VENTILATED DO NOT LET FLUSHING SOLVENT COME IN CON TACT WITH YOUR EYES OR SKIN IF EYE CONTAM INATION OCCURS FLUSH EYES WITH WATER FOR 15 TO 20 SECONDS REMOVE CONTAMINATED CLOTHING AND WASH AFFECTED SKIN WITH SOAP AND WATER SEEK MEDICAL A
119. n to engage spring and rotate counter clockwise Fig 29 7 Return shifter boot to its original seated around knob lip position 80bdbd2z Fig 29 Gearshift Knob Installation 1 GEARSHIFT KNOB 2 SPRING TRANSAXLE 21 11 VEHICLE SPEED SENSOR AND DRIVE PINION REM OVAL 1 Raise vehicle on hoist 2 Disconnect the speed sensor connector Fig 30 CAUTION Clean area around speed sensor before removing to prevent dirt from entering the transaxle during speed sensor removal 3 Remove speed sensor retaining bolt Fig 30 Fig 30 Speed Sensor and Pinion Removal 80554563 Installation 1 CONNECTOR 2 SENSOR 3 O RING 4 SPEEDO PINION 4 Remove speed sensor from transaxle CAUTION Carefully remove vehicle speed sensor 50 that sensor drive gear does not fall into tran saxle Should sensor drive gear fall into the tran saxle during sensor removal drive gear must be reattached to sensor 5 Remove speed sensor drive gear from speed sensor 21 12 TRANSAXLE REMOVAL AND INSTALLATION Continued INSTALLATION 1 Install pinion gear to speed sensor Fig 30 2 Using a NEW install the speed sensor to the transaxle Fig 30 3 Install the bolt and torque to 7 N m 60 in Ibs 4 Connect speed sensor connector Fig 30 5 Lower vehicle and road test to verify proper speedometer operation BACK UP LAMP SWITCH The back up lamp sw
120. nsaxle with bellhousing facing down on workbench with C clamps Position dial indicator 6 Apply a medium load to differential with Tool C 4995 and a T handle in the downward direction Roll differential assembly back and forth a number of times This will settle the bearings Zero the dial indicator To obtain end play readings apply a medium load in an upward direction while rolling differential assembly back and forth Fig 94 Record end play 9521 34 Fig 94 Checking Differential Bearing End Play To Determine Shim Thickness 1 T HANDLE 2 DIAL INDICATOR SET 3 SPECIAL TOOL C 4995 PL 7 The shim required for proper bearing preload is the total of end play plus constant preload of 0 18mm 0 007 in Never combine shims to obtain the required preload 8 Remove case bolts Remove dutch bellhousing differential bearing cup Install shim s selected in Step 7 Then press the bearing cup into clutch bell housing 9 Install dutch bellhousing Install and torque case bolts to 26 N m 19 ft Ibs 10 Using Special Tool C 4995 and an inch pound torque wrench check turning torque of the differen tial assembly Fig 95 The turning torque should be 6 to 12 165 If the turning torque is too high install a 0 05mm 0 002 inch thinner shim If the turning torque is too low install a 0 05mm 0 002 inch thicker shim 9521 35 Fig 95 Checking Differential Bearing Turning Torque 1 INCH P
121. ob Removal tightening 1 GEARSHIFT KNOB 3 Install knob to shifter lever align knob to three o clock position push knob down to engage spring and rotate counter clockwise Fig 10 3 Remove the center console assembly as shown in Fig 8 21 6 TRANSAXLE REMOVAL AND INSTALLATION Continued 4 Return shifter boot to its original position seated around knob lip 80bdbd2z Fig 10 Gearshift Knob Installation 1 GEARSHIFT KNOB 2 SPRING PL KS i Fig 11 Gearshift Knob Removal 1 GEARSHIFT KNOB GEARSHIFT CABLE ASSEMBLY NOTE The crossover and selector cables are man ufactured as a cable assembly and cannot be ser viced individually REMOVAL 1 Raise hood and disconnect battery negative cable 2 Pull shifter boot down and away from shifter knob 3 Push down on knob and rotate clockwise to remove Fig 11 4 Remove the center console assembly as shown in Fig 12 5 Separate shifter boot from shifter assembly Fig 13 Boot is retained to shifter by three push pin retainers 6 Remove crossover cable retaining clip and dis connect from shift lever Fig 14 7 Remove selector cable retaining clip and dis connect from shift lever Fig 15 8 Remove three grommet attaching nuts Fig 14 9 Remove air cleaner throttle body assy Fig 16 as follows a Disconnect proportional purge solenoid PPS and crankcase vent hose from thr
122. oil pan Put sealant on the oil pan flange Fig 59 and on all oil pan bolts underside of bolt head Fig 61 Oil Filter 1 OIL FILTER 2 GASKET 3 VALVE BODY Fig 59 Transaxle Oil Pan 1 TRANSAXLE OIL PAN 2 OIL FILTER 21 90 TRANSAXLE DISASSEMBLY AND ASSEMBLY Continued PR2180 Fig 62 Remove Parking Rod E Clip 1 VALVE BODY 2 SCREWDRIVER 8 E CLIP 4 PARKING ROD Remove neutral starting and back up lamp switch PR2181 Fig 63 Parking Rod 1 VALVE BODY 2 PARKING ROD PL 80bdbd19 Cooler Bypass Valve and Seat Jr Equipped 1 TRANSFER PLATE 2 BYPASS VALVE 3 SEAL Measuring input shaft end play before disassembly will usually indicate if a thrust washer change is required Fig 66 The 8 thrust washer is located between input and output shafts Move input shaft in and out to obtain end play reading End play specifications are 0 19 to 1 50 mm 0 008 to 0 060 inch Record indicator reading for reference when reas sembling the transaxle Remove Number 6 thrust washer from sun gear driving shell Fig 64 Valve Body Attaching Bolts 1 VALVE BODY 2 VALVE BODY ATTACHING BOLTS 7 3 GOVERNOR TUBES PL DISASSEMBLY AND ASSEMBLY Continued PR2183 Fig 65 Valve Body and Governor Tubes 1 VALVE BODY ASSEMBLY 2 GOVERNOR TUBES 80540418 Fig
123. on 4 Key cannot be returned to the LOCK or ACC position 3 Turn key to the ON RUN position and depress the brake pedal 4 Leave shifter in any gear and try to return key to the LOCK or ACC position 5 Return shifter to 5 Key can be removed PARK and try to remove after returning to LOCK the key position 6 With the key removed 6 Shifter cannot be try to shift out of PARK shifted out of PARK NOTE Any failure to meet these expected responses requires system adjustment or repair GEARSHIFT AND PARKING LOCK CONTROLS The transaxle is controlled by a lever type gear shift incorporated within the console The control has six selector lever positions P Park R Reverse Neutral and D Drive 2 Second and 1 First The parking lock is applied by moving the selector lever past a gate to the P position Do not apply the parking lock until the vehicle has stopped otherwise a severe banging noise will occur COOLER BYPASS VALVE Some 31TH transaxles are equipped with a cooler bypass valve Fig 2 The valve is designed to bypass the transaxle oil cooler circuit in cold weather condi tions or when circuit restriction exceeds 25 30 p s i The valve consists of an integrated check ball and spring and a return tube to carry bypassed oil back to the pump The bypass valve is mounted to the valve body transfer plate and is sealed with a rubber o ring seal Fig 3 21 58 TR
124. ont clutch retainer The hydraulic system consists of an oil pump and a single valve body which con tains all of the valves except the governor valves The transaxle sump and differential sump are both vented through the dipstick Output torque from the main center line is delivered through helical gears to the transfer shaft This gear set is a factor in the transaxle final drive axle ratio The shaft also car ries the governor and parking sprag An integral heli cal gear on the transfer shaft drives the differential ring gear 21 56 TRANSAXLE DESCRIPTION AND OPERATION Continued FLUID LEVEL AND CONDITION NOTE The transmission and differential sump have a common oil sump with a communicating opening between the two The torque converter fills in both the P Park and N Neutral positions Place the selector lever in P Park to be sure that the fluid level check is accu rate The engine should be running at idle speed for at least one minute with the vehicle on level ground This will ensure complete oil level stabilization between differential transmission The fluid should be at normal operat ing temperature approximately 82 C or 180 F The fluid level is correct if it is in the HOT region cross hatched area on the dipstick Fig 1 80bdbd25 Fig 1 Transaxle Dipstick 1 TRANSAXLE DIPSTICK Low fluid level can cause a variety of conditions because it allows the pump to take in air along wi
125. or binding conditions PL 2 Release adjustment locking dip on cable at throttle body It is not necessary to remove clip 3 Grab cable conduit near adjustment body push in towards throttle body then release grip Fig 217 This allows cable to self adjust 80bc4eec Fig 217 Throttle Valve Cable Adjustment 1 TAB UNLOCKED 4 Press locking dip to secure cable position Fig 218 5 80bc4ee7 Fig 218 Cable Locking Clip 1 TAB LOCKED 2 THROTTLE VALVE CABLE 5 Road test vehicle to verify proper transaxle operation PL USTMENTS Continued BRAKE TRANSMISSION SHIFT INTERLOCK SYSTEM VERIFICATION The following chart describes the normal operation of the Brake Transmission Shift Interlock BTSI sys tem If the expected response differs from the vehi cle s response then system repair and or adjustment is necessary ACTION EXPECTED RESPONSE 1 Turn key to the OFF 1 Shifter CAN be shifted position out of park 2 Turn key to the 2 Shifter CANNOT be shifted out of park ON RUN position 3 Turn key to the 3 Shifter CAN be shifted ON RUN position and out of park depress the brake pedal 4 Leave shifter in any 4 Key cannot be returned to the LOCK or ACC position gear and try to return key to the LOCK or ACC position 5 Return shifter to 5 Key can be removed PARK and try to remove after returning to LOCK the key p
126. or from switch and test for continuity between center pin of switch and transaxle case Continuity should exist only when transaxle is in PARK or NEUTRAL 2 Check gearshift cable adjustment before replac ing a switch that tests bad REMOVAL 1 Unscrew switch from transaxle case allowing fluid to drain into a container Move selector lever to PARK then to NEUTRAL position and inspect to see the switch operating lever fingers are centered in switch opening INSTALLATION 1 Screw the switch with a new seal into tran saxle case and tighten to 33 N m 24 ft Ibs Retest switch with the test lamp 2 Add fluid to transaxle to bring up to proper level 3 The back up lamp switch circuit is through the two outside terminals of the three terminal switch 4 To test switch remove wiring connector from switch and test for continuity between the two out side pins 5 Continuity should exist only with transaxle in REVERSE position 6 No continuity should exist from either pin to the case TRANSAXLE AND TORQUE CONVERTER REM OVAL 1 Raise hood 2 Disconnec both battery cables remove battery hold down clamp and bolt and remove battery 3 Remove air cleaner throttle body assy Fig 45 as follows a Disconnect proportional purge solenoid PPS and crankcase vent hose from throttle body b Disconnect the Throttle Position Sensor TPS and Idle Air Control IAC connectors c Remove mounting bolt and nut
127. or gear intermesh 4 Replace bearings as a pair If one differential bearing is defective replace both differential bear ings if one input shaft bearing is defective replace both input shaft bearings 5 Bearing cones must not be reused if removed 6 Turning torque readings should be obtained while smoothly rotating in either direction DIFFERENTIAL BEARING PRELOAD ADJUSTMENT NOTE True bearing turning torque readings can be obtained only with the geartrain removed from the case 1 Remove bearing cup and existing shim from clutch bellhousing case 2 Press in new bearing cup into bellhousing case or use a cup that has been ground down on the outer edge for ease of measurement 3 Press in new bearing cup into gear case side 4 Oil differential bearings with Mopar type M S 9417 Manual Transaxle Fluid Install differential assembly in transaxle gear case Install clutch bell housing over gear case Install and torque case bolts to 29 N m 21 ft Ibs 5 Position transaxle with bellhousing facing down on workbench with C clamps Position dial indicator 6 Apply a medium load to differential with Tool C 4995 and a T handle in the downward direction Roll differential assembly back and forth a number of times This will settle the bearings Zero the dial indicator To obtain end play readings apply a medium load in an upward direction while rolling differential assembly back and forth Fig 163 Record en
128. or the correct procedures SHIFT SHAFT SEALS It is not necessary to remove the shift shafts from the transaxle to service the shift shaft seals REMOVAL 1 Using a pick tool pry up on the shift shaft seal and remove seal from bore INSTALLATION 1 Position new shift shaft seal in bore 2 Install shift shaft seal into bore using an appropriate size deep well socket 21 14 TRANSAXLE REMOVAL AND INSTALLATION Continued TRANSAXLE REMOVAL 1 Raise hood 2 Disconnect both battery cables remove battery hold down clamp and bolt and remove battery 3 Remove air cleaner throttle body assy Fig 36 as follows a Disconnect proportional purge solenoid PPS and crankcase vent hose from throttle body 0 Disconnect the Throttle Position Sensor TPS and Idle Air Control connectors Disconnect throttle body air duc at intake manifold d Remove mounting bolt and nut Fig 36 and partially remove air deaner assembly e Disconnect accelerator and speed control if equipped cables after the assy is removed from position Remove air cleaner assembly from vehide 80bbdb64 Fig 37 Clutch Cable at Transaxle 1 CLUTCH CABLE 2 TRANSAXLE 3 BELLHOUSING CAP 9 Remove shift cable to bracket clips Fig 38 10 Disconnect shift selector and crossover cable from levers Fig 38 Remove cables and secure out of the way m ov a 80bb
129. osition 6 With the key removed 6 Shifter cannot be try to shift out of PARK shifted out of PARK NOTE Any failure to meet these expected responses requires system adjustment or repair ADJUSTMENT 1 Loosen set screw and remove knob from shifter handle Fig 219 2 Remove the center console assembly as shown in Fig 220 3 Remove shifter bezel Fig 221 4 Adjust interlock cable system as follows Pry up on cable adjuster lock to release and allow cable to self adjust Lock cable adjustment by press ing down on the adjuster lock until bottomed at the cable housing 5 Verify correct system operation Refer to verifi cation procedure 6 Install shifter bezel Fig 221 7 Install center console assembly Fig 220 8 Install gearshift knob and tighten set screw to 2 N m 15 in 165 torque Fig 219 TRANSAXLE D l pu Fig 219 Gearshift Knob Removal installation 1 SHIFTER KNOB 2 SET SCREW 21 137 80bc4ee2 80004567 Fig 220 Center Console Removal Installation 1 CONSOLE 2 SCREW 4 3 SCREW 2 21 138 TRANSAXLE USTMENTS Continued 80504568 Fig 221 Shifter Bezel Removal Installation 1 BEZEL 2 SCREW 4 BAND ADJUSTMENT KICKDOWN BAND FRONT The kickdown band adjusting screw is located on left side top front of the transaxle case 1 Loosen locknut and back off nut approximately fiv
130. ottle body b Disconnect the Throttle Position Sensor TPS and Idle Air Control IAC connectors plate to floor 80004567 Fig 12 Center Console Removal Installation Typical 1 CONSOLE 2 SCREW 4 3 SCREW 2 c Disconnect throttle body air duct from intake manifold d Remove mounting bolt and nut Fig 16 and partially remove air cleaner assembly e Disconnect accelerator and speed control if equipped cables after the assy is removed from position Remove air deaner assembly from vehi de 10 Disconnect cables from the shift levers at the transaxle Fig 17 CAUTION Pry up with equal force on both sides of shifter cable isolator bushings to avoid damaging cable isolator bushings PL REMOVAL AND INSTALLATION Continued 80bc4d60 Fig 13 Gearshift Boot Removal Installation 1 BOOT 2 SHIFTER ASSEMBLY 80bc4d61 Fig 14 Crossover Cable at Shifler Assembly 1 GROMMET PLATE NUT 2 SHIFTER 3 CROSSOVER CABLE 4 CLIP TRANSAXLE 21 7 80bc4d62 Fig 15 Selector Cable at Shifler Assembly 1 SHIFTER 2 CLIP 3 SELECTOR CABLE Remove cable retaining dips and remove cables from bracket Fig 17 11 Raise vehicle on hoist 12 Remove converter heat shield Fig 18 13 Remove remaining grommet plate to floor pan screw Fig 19 14 Remove cable assembly from vehicle INSTALLATION CAUTION Gearshift cab
131. racket Install mount bolt and tighten to 108 N m 80 ft 165 torque Fig 43 4 Remove screwjack 5 Install drive plate to clutch module bolts and torque to 88 N m 65 ft Ibs torque 6 Install starter motor and tighten bolts to 54 N m 40 ft Ibs torque Make sure to fasten ground cable to upper starter bolt as shown in Fig 42 7 Connect starter electrical harness and tighten positive cable nut to 10 N m 90 in Ibs torque 8 Install bellhousing dust cover Fig 40 9 Install left engine to transaxle bending brace Fig 40 10 Install structural collar Fig 40 as follows a Position collar and install all bolts finger tight b Tighten the collar to oil pan bolts to N m 30 165 torque c Tighten the collar to transaxle bolts to 108 N m 80 ft 165 torque d Final torque the collar to oil pan bolts to 54 N m 40 ft 106 torque 11 Install the right lateral bending brace and tighten bolts to 81 N m 60 ft Ibs torque Fig 41 12 Install both front axle driveshafts Refer to Group 3 Differential and Driveline for the correct procedures 13 Fill transaxle with suitable amount of Mopar Manual Transaxle Lubricant PN 04874465 14 Lower vehicle 15 Connect vehicle speed sensor connector Fig 39 16 Connect shift crossover and selector cables to shift lever Install cables to bracket install retaining clips Fig 38 17 Connect clutch cable to fo
132. re may occur if incorrect fluid is used SPECIAL ADDITIVES The addition of any fluids to the transaxle other than the fluid listed above is not recommended An exception to this policy is the use of special dyes to aid in detecting fluid leaks The use of transmission sealers should be avoided since they may adversely affect seals SEALANTS The sealant used to seal the transaxle case halves and input bearing is Mopar Gasket Maker Loctite 518 or equivalent The sealant used for the bearing end plate cover is Mopar RTV GEAR RATIOS CAUTION All gears and shafts must not be inter changed with other transaxles they will not func tion correctly PL o N 1731 0013 4 BAIT M el NV T350 003 350 P N 000 17370002 80bdbd20 Fig 1 NV T350 A 578 Transaxle Identification LAST 3 DIGITS OF PART DATE CODE PRODUCTION LINE SEQUENCE CODE FULL PART END COVER METAL TAG NVG MODEL LABEL 0 The differential is a conventional arrangement of gears that is supported by tapered roller bearings The final output gear turns the ring gear and differ ential assembly thereby turning the drive axle shafts All transaxles have a torque capacity of 136 Ib ft The gear ratios of each transaxle are shown in the following chart The chart also shows which transax les are available wi
133. rect level and check for leaks Ee Ge 2 2 Change filter 3 Gearshift Linkage Misadjusted 3 Adjust linkage and repair linkage if worn or damaged 4 Rear Band Misadjusted 4 Adjust band 5 Valve Body Filter Plugged 5 Replace fluid and filter If oil pan and old fluid were full of clutch disc material and or metal particles overhaul will be necessary 6 Oil Pump Gears Worn Damaged 6 Remove transmission and replace oil pump 7 Hydraulic Pressure Incorrect 7 Perform pressure test remove transmission and repair as needed 8 Reaction Shaft Seal Rings 8 Remove transmission remove oil pump Worn Broken and replace seal rings 9 Rear Clutch Input Shaft Rear 9 Remove and disassemble transmission Clutch Seal Rings Damaged and repair as necessary 10 Governor Valve Stuck 10 Remove and inspect governor components Replace worn or damaged parts 11 Regulator Valve Stuck 11 Clean 21 60 TRANSAXLE DIAGNOSIS AND TESTING Continued CONDITION POSSIBLE CAUSES CORRECTION NO DRIVE RANGE 1 Fluid Level Low 1 Add fluid and check for leaks if drive is REVERSE Ok restored 2 Gearshift Linkage Cable 2 Repair or replace linkage components Loose Misadjusted 3 Rear Clutch Burnt 3 Remove and disassemble transmission and rear clutch and seals Repair replace worn or damaged parts as needed 4 Valve Body Malfunction 4 Remove and disassemble
134. respective passages To make air pres sure tests proceed as follows PL DIAGNOSIS AND TESTING Continued TRANSAXLE 21 69 PU142A Fig 7 Air Pressure Tests PUMP SUCTION PUMP PRESSURE FRONT CLUTCH APPLY REAR CLUTCH APPLY TO TORQUE CONVERTER FROM TORQUE CONVERTER TO OIL COOLER KICKDOWN SERVO OFF P 9 KICKDOWN SERVO 10 ACCUMULATOR OFF 11 ACCUMULATOR ON 12 LOW REVERSE SERVO APPLY 13 GOVERNOR PRESSURE 14 LINE PRESSURE TO GOVERNOR 15 GOVERNOR PRESSURE PLUG 16 GOVERNOR PRESSURE NOTE Compressed air supply must be free of all dirt and moisture Use a pressure of 30 psi Remove oil pan and valve body Refer to Valve Body for removal procedure FRONT CLUTCH Apply air pressure to front clutch apply passage and listen for a dull thud which indicates that front clutch is operating Hold air pressure on for a few seconds and inspect system for excessive oil leaks REAR CLUTCH Apply air pressure to rear clutch apply passage and listen for a dull thud which indicates that rear clutch is operating Also inspect for excessive oil leaks If a dull thud cannot be heard in the clutches place finger tips on clutch housing and again apply air pressure Movement of piston can be felt as the clutch is applied KICKDOWN SERVO FRONT Direct air pressure into KICKDOWN SERVO ON passage Operation of servo is indica
135. rive and should be same as line pressure within 3 psi up to kickdown point 7 This tests pump output pressure regulation and condition of rear dutch front dutch and hydraulic circuits TEST FOUR SELECTOR IN REVERSE 1 Attach 300 psi gauge to low reverse port 2 Operate engine at 1600 rpm for test 3 Move selector lever on transaxle four detents forward from full rearward position This is selector R position 4 Low reverse pressure should read 180 to 220 psi with throttle lever clockwise Pressure should gradually increase to 260 to 300 psi as lever is moved counterclockwise 5 This tests pump output pressure regulation and condition of front dutch and rear servo hydraulic circuits PL 6 Move selector lever on transaxle to D position to check that low reverse pressure drops to zero 7 This tests for leakage into rear servo due to case porosity which can cause reverse band burn out TEST RESULT INDICATIONS 1 If proper line pressure minimum to maximum is found in any one test the pump and pressure reg ulator are working properly 2 Low pressure in D 1 and 2 but correct pres sure in R indicates rear clutch circuit leakage 3 Low pressure in D and R but correct pressure in 1 indicates front clutch circuit leakage 4 Low pressure in R and 1 but correct pressure in 2 indicates rear servo circuit leakage 5 Low line pressure in all positions indicates a defective pump a clogged filt
136. rk and secure to transaxle Fig 37 18 Install bellhousing cap Fig 37 19 Connect back up lamp switch connector 20 Connect ground strap to transaxle upper mount bracket 21 Install battery lower tray and battery and tighten battery hold down clamp to secure battery PL REMOVAL AND INSTALLATION Continued TRANSAXLE 21 17 80030661 Fig 44 Transaxle Removal Installation 3 TRANSAXLE 4 CLUTCH MODULE BOLT 4 1 MODULAR CLUTCH ASSEMBLY 2 CLIP 80bbdad8 Fig 45 Transaxle Upper Mount and Bracket 1 MOUNT 2 TRANSAXLE 22 Install the air deaner throttle body assy as follows a Connect the accelerator and speed control if equipped cables to the air cleaner throttle body assy 0 Install assy into position making sure the air cleaner locating slot is engaged to the battery bracket tab and tighten fasteners to 14 N m 120 in 165 torque c Verify throttle body duct is fully seated to intake manifold and tighten clamp to 5 N m 40 in lbs torque d Connect the Throttle Position Sensor TPS and Idle Air Control connectors e Connect proportional purge solenoid PPS and crankcase vent hose from throttle body 23 Connect the battery cables 24 Road test vehicle and inspect for leaks 21 18 TRANSAXLE DISASSEMBLY AND ASSEMBLY TRANSAXLE NV T350 A 578 transaxle internal compo nents can be serviced only by separating the g
137. rs 20 Install bolt into shaft and tighten to 26 N m 18 Install reverse idler gear and spacer as shown 19 ft Ibs torque Fig 90 in Fig 88 zd SAGO LY 16 FJ9521 6 Fig 90 Reverse Idler Shaft Bolt 1 CASE 2 REVERSE IDLER SHAFT 3 REVERSE IDLER SHAFT BOLT 80bdbd24 Fig 88 Reverse Idler Gear and Spacer 1 SPACER 2 REVERSE IDLER GEAR PL DISASSEMBLY AND ASSEMBLY Continued 21 Install reverse fork bracket and reverse lock out Tighten screws to 11 N m 96 in Ibs torque Fig 91 Fig 92 Fig 91 Reverse Fork Bracket 1 REVERSE FORK BRACKET 2 REVERSE CAM BLOCKOUT 3 SHIFT BLOCKER ASSEMBLY Em D 27 SECH Fig 92 Reverse Fork Screws 1 SCREWS 2 2 REVERSE FORK BRACKET TRANSAXLE 21 29 22 Install differential into gear case Fig 93 FJ9521 5 Fig 93 Differential Assembly 1 INPUT SHAFT 2 OUTPUT SHAFT 3 DIFFERENTIAL 4 CASE BEARING ADJUSTM ENT PROCEDURE 1 Use extreme care when removing and install ing bearing cups and cones Use only an arbor press for installation as a hammer may not properly align the bearing cup or cone Burrs or nicks on the bear ing seat gives a false end play reading while gauging for proper shims mproperly seated bearing cups and cones are subject to low mileage failure 2 Bearing cups and cones should be replaced if they show signs o
138. ry Gear 1 FRONT PLANETARY GEAR ASSEMBLY Fig 122 Front Annulus Gear Support and Snap Ring 1 FRONT ANNULUS GEAR 2 FRONT SNAP RING 3 FRONT ANNULUS GEAR SUPPORT 4 REAR SNAP RING Fig 121 Annulus Gear Support Front Snap Ring 1 ANNULUS GEAR SUPPORT 2 FRONT SNAP RING 3 SCREWDRIVER 4 FRONT PLANETARY ANNULUS GEAR Fig 123 Front Annulus Gear Support Snap Ring 1 FRONT ANNULUS GEAR 2 REAR SNAP RING 21 112 TRAN S AXLE DISASSEMBLY AND ASSEMBLY Continued LOW REVERSE REAR SERVO RECONDITION DISASSEM BLY Fig 126 Remove Retainer Spring and Servo 1 SERVO PISTON 80a77395 2 SPRING AND RETAINER Fig 124 Low Reverse Lever 1 LOW REVERSE LEVER ASSEM BLY 80a77398 Se Fig 127 Low Reverse Servo Assembly 1 SERVO PISTON 2 SPRING Fig 125 Low Reverse Servo Snap Ring 1 SNAP RING PLIERS To assemble reverse the above procedure PL DISASSEMBLY AND ASSEMBLY Continued ACCUMULATOR RECONDITION DISASSEMBLY PR2251C Fig 128 Accumulator Snap Ring 1 ACCUMULATOR PLATE SNAP RING 2 SNAP RING PLIERS 3 ACCUMULATOR PLATE 2252 Fig 129 Accumulator Plate and Snap Ring 1 SNAP RING 2 ACCUMULATOR PLATE 3 O RING TRANSAXLE 21 113 PR2253 Fig 130 Accumulator Spring and Piston 1 ACCUMULATOR SPRING 2 ACCUMULATOR PISTON 3 SEAL RINGS
139. s the proper shim has been installed PR2298A Fig 179 Install Output Shaft Gear Bearing Cup 1 OUTPUT SHAFT GEAR BEARING CUP 2 SPECIAL TOOL L 4429 3 RB746 Fig 181 Install Output Shaft Assembly OUTPUT SHAFT ASSEMBLY USE GREASE TO HOLD SHIMS IN POSITION BEARING CONE LUBRICATION HOLE SELECT SHIMS E BL E TRANSAXLE 21 127 DISASSEMBLY AND ASSEMBLY Continued PR2301 Fig 182 Output Shaft and Select Shims in Position 1 BEARING CUP 2 SELECT SHIM 3 OUTPUT SHAFT ASSEMBLY PR2304A Fig 185 Tighten Output Shaft Retaining Nut to 271 N m 200 ft Ibs 1 OUTPUT SHAFT GEAR 2 SPECIAL TOOL L 4434 AND C 4658 3 SCREW 2 Fig 183 Start Output Shaft Gear onto Output Shaft 1 OUTPUT SHAFT GEAR 2 OUTPUT SHAFT 3 SPECIAL TOOL L 4439 Fig 186 Checking Output Shaft End Play SPECIAL TOOL L 4432 AND 4658 SCREW 2 OUTPUT SHAFT GEAR STEEL BALL GREASE IN PLACE SPECIAL TOOL L 4438 DIAL INDICATOR Ek a aid 5 4 PR2303B Fig 184 Holding Output Shaft Gear OUTPUT SHAFT SCREW 2 SPECIAL TOOL L 4434 AND C 4658 WASHER NUT akon 21 128 TRANSAXLE DISASSEMBLY AND ASSEMBLY Continued RY295 Fig 187 Checking Bearing Turning Torque 1 OUTPUT SHAFT GEAR 2 TORQUE WRENCH STIRRUP AN
140. sic groups e Pressure supply system e Pressure regulating valves e Flow control valves e Clutches e Band servos Taking each of these basic groups or systems in turn the control system may be described as follows PRESSURE SUPPLY SYSTEM The pressure supply system consists of an oil pump driven by the engine through the torque converter The single pump furnishes pressure for all hydraulic and lubrication requirements Oil pump housing assemblies are available with preselected pump gears PRESSURE REGULATING VALVES The pressure regulating valve controls line pres sure dependent on throttle opening The governor valve transmits regulated pressure to the valve body in conjunction with vehicle speed to control upshift and downshift The throttle valve transmits regulated pressure to the transaxle dependent on throttle position to con trol upshift and downshift FLOW CONTROL VALVES The manual valve provides the different transaxle drive ranges selected by the vehicle operator The 1 2 shift valve automatically shifts the tran saxle from first to second or from second to first depending on the vehicle operation The 2 3 shift valve automatically shifts the tran saxle from second to third or from third to second depending on the vehicle operation PL DESCRIPTION AND OPERATION Continued The kickdown valve makes possible a forced down shift from third to second second to first or third to first depending on
141. sket Do no over tighten screws 5 Valve Body Manual Lever Shaft 5 Replace shaft seal Seal Leaks Worn 6 Rear Bearing Access Plate Leaks 6 Replace gasket Tighten screws 7 Gasket Damaged or Bolts are 7 Replace bolts or gasket or tighten both Loose 8 Adapter Extension Gasket Damaged Leaks Damaged 9 Neutral Switch Leaks Damaged 10 Converter Housing Area Leaks 8 Replace gasket 9 Replace switch and gasket 10 Check for leaks at seal caused by worn seal or burr on converter hub cutting seal worn bushing missing oil return oil in front pump housing or hole plugged Check for leaks past O ring seal on pump or past pump to case bolts pump housing porous oil coming out vent due to overfill or leak past front band shaft access plug 11 Pump Seal Leaks Worn 11 Replace seal Damaged 12 Torque Converter Weld Leak Cracked Hub 13 Case Porosity Leaks ROAD TEST Prior to performing a road test check the fluid level and throttle valve cable adjustments During the road test the transaxle should be oper ated in each position to check for slipping and any variation in shifting If vehicle operates at high speeds but has poor acceleration the converter s overrunning clutch may be slipping If acceleration is normal but high throt tle opening is needed for high speeds the stator clutch may have seized 12 Replace converter 13 Replace case Observe closely for slipping or engine
142. speed flare up Slipping or flare up in any gear usually indicates clutch band or overrunning clutch problems If the condition is far advanced an overhaul will probably be necessary to restore normal operation In most cases the clutch or band that is slipping can be determined by noting the transaxle operation in all selector positions and then comparing which internal units are applied in those positions The Ele ments in Use Chart provides a basis for road test analysis 21 66 TRANSAXLE DIAGNOSIS AND TESTING Continued PL CLUTCHES BANDS LEVER POSITION START SAFETY PARK SPRAG FRONT KICK DOWN LOW Lockup OVER REV RUNNING FRONT REAR P PARK R REVERSE N NEUTRAL D DRIVE First Second Third 2 SECOND First Second 1 Low The rear dutch is applied in both the D first gear and 1 first gear positions Also the overrunning dutch is applied in D first gear and the low reverse band is applied in 1 first gear position If the tran saxle slips in D range first gear but does not slip in 1 first gear the overrunning dutch is slipping Simi larly if the transaxle slips in any two forward gears the rear dutch is slipping Using the same procedure the rear clutch and front dutch are applied in D third gear If the tran saxle slips in third gear either the front dutch or the rear clutch is slipping By selecting another gear th
143. t Mechanism Removal Installation 1 SHIFTER ASSEMBLY 2 NUT 4 TRANSAXLE 21 77 INSTALLATION 1 Install gearshift mechanism and tighten the four nuts to 12 N m 105 in Ibs torque 2 Install gearshift cable as shown in Fig 21 3 Install shifter ignition interlock cable as shown in Fig 22 4 Install shifter bezel Fig 20 5 Install center console assembly Fig 19 6 Install gearshift knob and tighten set screw to 2 N m 15 in Ibs torque Fig 18 THROTTLE VALVE KICKDOWN CABLE REM OVAL 1 Remove air deaner throttle body assy Fig 24 as follows a Disconnect proportional purge solenoid PPS and crankcase vent hose from throttle body b Disconnect the Throttle Position Sensor TPS and Idle Air Control IAC connectors c Disconnect throttle body air duct at intake manifold d Remove mounting bolt and nut Fig 24 and partially remove air deaner assembly leave cables attached 80bbdadd Fig 24 Air Cleaner Assembly Removal Installation 1 AIR CLEANER ASSY 2 THROTTLE BODY DUCT NOTE Pay attention to throttle valve cable routing before removal so it can be re installed in the same manner For proper transaxle operation the cable must not bind 21 78 TRANSAXLE REMOVAL AND INSTALLATION Continued 2 Disconnect throttle valve cable from air clean er throttle body assembly as shown in Fig 25 80bbdad7 Fig 25 Throttle Valve Cable at Air C
144. t and connect to shift lever Fig 14 6 Install and tighten the three grommet plate to floor pan nuts Tighten to 6 N m 50 in Ibs torque 7 Connect gearshift cable to shifter assembly as shown in Fig 12 8 Install shifter bezel Fig 11 9 Adjust gearshift cable as follows a Place gearshift lever in the PARK P posi tion 0 Loosen shift cable adjustment screw Fig 17 c Verify transaxle is in the PARK P position and the shifter lever is in gated PARK d Tighten shift cable adjustment screw to 8 N m 70 in 1065 torque 10 Install battery tray 11 Install battery and hold down clamp 12 Install the air cleaner throttle body assy Fig 13 as follows TRANSAXLE 21 75 80bc4ee1 Fig 17 Gearshift Cable Adjustment Screw 1 GEARSHIFT CABLE ADJUSTMENT SCREW a Connect the accelerator and speed control if equipped cables to the air cleaner throttle body assy b Install assy into position making sure the air deaner locating slot is engaged to the battery bracket tab and tighten fasteners to 14 N m 120 106 torque c Verify throttle body duct is fully seated to intake manifold and tighten clamp to 5 N m 40 in Ibs torque d Connect the Throttle Position Sensor TPS and Idle Air Control IAC connectors e Connect proportional purge solenoid PPS and crankcase vent hose from throttle body 13 Install center console assembly Fig 10 14 Install gearsh
145. ted by a tighten ing of front band Spring tension on servo piston should release the band 21 70 TRANSAXLE DIAGNOSIS AND TESTING Continued LOW AND REVERSE SERVO REAR Direct air pressure into LOW REVERSE SERVO APPLY passage Operation of servo is indicated by a tightening of rear band Spring tension on servo pis ton should release the band If clutches and servos operate properly no upshift indicates that a malfunction exists in the valve body FLUID LEAKAGE TRANSAXLE TORQUE CONVERTER HOUSING AREA 1 Check for source of leakage 2 Since fluid leakage near the torque converter area may be from an engine oil leak the area should be checked closely Factory fill fluid is dyed red and therefore can be distinguished from engine oil 3 Prior to removing the transaxle perform the following checks 4 When leakage is determined to originate from the transaxle check fluid level prior to removal of the transaxle and torque converter 5 High oil level can result in oil leakage out the vent in the dipstick If the fluid level is high adjust to proper level 6 After performing this operation inspect for leakage If a leak persists perform the following operation on the vehide This will determine if the torque converter or transaxle is leaking TORQUE CONVERTER LEAKAGE Possible sources of torque converter leakage are e Torque converter weld leaks at the outside diam eter peripheral weld e Torque converter
146. ter break in NOTE All bearing adjustments must be made with no other component interference or gear inter mesh except the transfer gear bearing 5 Refer to the conversion chart in specifications to convert inches to millimeter measurements Refer to bearing shim chart for proper shim thicknesses PL USTMENTS Continued OUTPUT SHAFT BEARING With output shaft gear removed install a 13 65 mm 0 537 inch and a 1 34 mm 0 053 inch gauging shim on the planetary rear annulus gear hub using grease to hold the shim in place The 13 65 mm shim has a larger inside diameter and must be installed over the output shaft first The 1 34 mm shim pilots on the output shaft Install output shaft gear and bearing assembly torque to 271 N m 200 ft Ibs To measure bearing end play 1 Attach Tool L 4432 to the output shaft gear 2 Mount a steel ball with grease into the end of the output shaft 3 Push and pull the gear while rotating back and forth to insure seating of the bearing rollers 4 Using a dial indicator mounted to the transaxle case measure output shaft end play 5 Once bearing end play has been determined refer to the output shaft bearing shim chart 6 The 12 65 mm 0 498 inch 13 15 mm 0 518 inch or 13 65 mm 0 537 inch shims are always installed first These shims have lubrication slots that are necessary for proper bearing lubrica tion 7 Shims thinner than 12 65 mm listed in the chart are
147. th the fluid As in any hydraulic system air bubbles make the fluid spongy therefore pressures will be low and will build up slowly Improper filling also can raise the fluid level too high When the transaxle has too much fluid the gears churn up foam and cause the same conditions that occur with a low fluid level In either case the air bubbles can cause overheat ing fluid oxidation and varnishing This can inter fere with normal valve clutch and servo operation Foaming also can result in fluid escaping from the transaxle dipstick where it may be mistaken for a leak Along with fluid level it is important to check the condition of the fluid When the fluid smells burned or is contaminated with metal or friction material particles a complete transaxle overhaul is needed Be sure to examine the fluid on the dipstick closely If there is any doubt about its condition remove the oil pan and inspect PL TORQUE CONVERTER CLUTCH A torque converter clutch is standard on all vehi cles The torque converter clutch is activated only in direct drive and is controlled by the engine electron ics A solenoid on the valve body is powered by the powertrain control module to activate the torque con verter clutch HYDRAULIC CONTROL SYSTEM The hydraulic control system makes the transaxle fully automatic and has four important functions to perform The components of any automatic control system may be grouped into the following ba
148. th the reverse input shaft brake This brake allows easier shifting into reverse and helps eliminate reverse gear clash PL GENERAL INFORMATION Continued ENGINE 2 0 SOHC EUROPE AND U S GEAR TRANSAXLE 21 3 1 8 RIGHT HAND DRIVE ONLY 1 8 BUX or 2 0L SALES CODE ACR EE 9 28 28 o 888 88 REVERSE BRAKE BRAKE ROUTE RELERSE RELEASE r ea SYSTEM GEARSHIFT PATTERN The NV T350 A 578 transaxle shift pattern is a modified H pattern Fig 2 Overdrive fifth and reverse gears are in line and outboard of the first through fourth gear positions FJ9521 110 Fig 2 NV T350 A 578 Shift Pattern DIAGNOSIS AND TESTING COMMON PROBLEM CAUSES The majority of transaxle malfunctions are a result of e Insufficient lubrication e Incorrect lubricant e Misassembled or damaged internal components Improper operation HARD SHIFTING Hard shifting may be caused by a misadjusted crossover cable If hard shifting is accompanied by gear dash synchronizer dutch and stop rings or gear teeth may be worn or damaged Misassembled synchronizer components also cause shifting problems Incorrectly installed synchronizer sleeves struts or springs can cause shift problems NOISY OPERATION Before removing a transaxle to diagnose and repair a noisy condition verify the correct level and type of fluid is installed in the transaxle Abnormal wear and damage to the internal components is
149. the ring gear side use Special Tool 5052 and Special Tool C 4171 TRANSAXLE 21 133 NOTE The differential is serviced as an assembly The only parts that are serviceable within the differ ential are the differential bearing cups and cones If any other part fails within the differential you must replace the differential assembly along with the transfer shaft MOVE SIDE GEAR UP AND DOWN Fig 208 Checking Side Gear End Play 1 SPECIAL TOOL C 4996 NOTE POSITION 2 DIAL INDICATOR SET 3 DIFFERENTIAL ASSEMBLY 4 SIDE GEAR CAUTION Side gear end play must be BETWEEN 0 001 to 0 013 inch Q MOVE SIDE GEAR UP AND DOWN Fig 209 Checking Side Gear End Play Typical 1 SPECIAL TOOL C 4996 NOTE POSITION 2 DIAL INDICATOR SET 3 DIFFERENTIAL ASSEMBLY 21 134 TRANSAXLE PL DISASSEMBLY AND ASSEMBLY Continued 80524675 Fig 210 Differential Bearing Retainer Fig 212 Remove Bearing Cup 1 DIFFERENTIAL BEARING CUP Te Ee 2 DIFFERENTIAL BEARING RETAINER DETERMINING SHIM THICKNESS Shim thickness need be determined only if any of the following parts are replaced e Transaxle case e Differential carrier e Differential bearing retainer e Extension housing e Differential bearing cups and cones Refer to Bearing Adjustment Procedure in rear of this section to determine proper shim thickness 80524e74 Fig 211 Position Bearing Cup Remover Tool in Retainer 1
150. towel and wrap Press on inner hub Carefully open up shop towel and remove springs balls keys hub and sleeve ASSEMBLY 1 Position synchronizer hub onto a suitable hold ing fixture input shaft The synchronizer hubs are directional The hubs must be installed with the U facing upward 2 Install springs into hub slot Fig 135 3 Insert key into hub and spring 4 Apply petroleum jelly to the hole in the key Insert balls into each key Fig 136 5 Slide sleeve over the hub and depress balls as you carefully slip the sleeve into position Fig 137 6 Line up stop ring tang over the keys in the hub Fig 138 Install stop rings Center the keys and balls by pushing on both stop rings 21 42 TRANSAXLE DISASSEMBLY AND ASSEMBLY Continued 9521 69 Fig 135 Synchronizer Assembly 1 SLEEVE 2 BALL 3 KEY 4 SPRING 5 HUB PL 9 2 2 s ci Er 22 22 CI CELL FJ9521 76 Fig 137 Synchronizer Sleeve 1 SLEEVE 2 INPUT SHAFT 3 KEY eut dE 53 7 7 LI o7 7 77 122041 9521 9 Fig 136 Synchronizer Balls 1 INPUT SHAFT 2 HUB 3 KEY 4 BALL SHIFT RAILS OVERHAUL 1 Remove shift rails from the geartrain 2 To service the 5 R shift rail remove the C clip retaining the reverse shift lever arm Remove the 5th shift fork roll pin and remov
151. uart container of Mopar ATF 4 Automatic Transmission Fluid Type 9602 12 Turn pump ON until all transmission fluid is removed from the one quart container and lines This purges any residual cleaning solvent from the trans mission cooler and lines Turn pump OFF 13 Disconnect alligator clips from battery Recon nect flusher lines to cover plate and remove flushing adapters from cooler lines OIL PUMP VOLUME CHECK After the new or repaired transmission has been installed fill to the proper level with Mopar ATF 4 Automatic Transmission Fluid Type 9602 The vol ume should be checked using the following proce dure 1 Disconnect the From cooler line at the trans mission and place a collecting container under the disconnected line CAUTION With the fluid set at the proper level fluid collection should not exceed 1 quart or inter nal damage to the transmission may occur 2 Run the engine at curb idle speed with the shift selector in neutral 3 If fluid flow is intermittent or it takes more than 20 seconds to collect one quart of ATF discon nect the To Cooler line at the transaxle 4 Refill the transaxle to proper level and recheck pump volume 5 If flow is found to be within acceptable limits replace the cooler Then fill transmission to the proper level using Mopar ATF 44 Automatic Trans mission Fluid Type 9602 6 If fluid flow is still found to be inadequate check the line pressure usin
152. vehicle speed This can be done by depressing the accelerator pedal past the detent feel near wide open throttle The shuttle valve has two separate functions and performs each independently of the other The first is providing fast release of the kickdown band and smooth front dutch engagement when lift foot upshift from second to third is made The second function is to regulate the application of the kick down servo and band when making third to second kickdown The bypass valve provides for smooth application of the kickdown band on 1 2 upshifts The torque converter clutch solenoid allows for the electronic control of the torque converter clutch It also disengages the torque converter at closed throt tle This is done during engine warm up and part throttle acceleration The switch valve directs oil to apply the torque converter clutch in one position The switch valve releases the torque converter clutch in the other posi tion CLUTCHES BAND SERVOS AND ACCUMULATOR The front and rear clutch pistons and both servo pistons are moved hydraulically to engage the clutches and apply the bands The pistons are released by spring tension when hydraulic pressure is released On the 2 3 upshift the kickdown servo piston is released by spring tension and hydraulic pressure The accumulator controls the hydraulic pressure on the apply side of the kickdown servo during the 1 2 upshift thereby cushioning the kickdown band appli
153. vel to 3mm 1 8 in below the ADD mark on the dip stick Fig 8 80bdbd25 Fig 8 Dipstick Markings 1 TRANSAXLE DIPSTICK 8 Recheck the fluid level after the transaxle has reached normal operating temperature 180 F 9 To prevent dirt from entering transaxle make certain that dipstick is fully seated into the dipstick opening ALTERNATIVE MAINTENANCE METHODS TRANSAXLE FLUID EXCHANGER METHOD CAUTION The use of any fluid exchanger that introduces additives into the transaxle is not rec ommended 1 To perform the transaxle fluid exchange the transaxle must be at operating temperature Drive the vehide until it reaches full operating tempera ture 2 Obtain a suitable transaxle fluid exchanger and verify the tank is dean and dry 3 Fill the tank to the recommended fill capacity with Mopar ATF 44 Type 9602 4 Connect the machine to the vehicle following the manufacturers instructions Perform exchange procedure following the instructions pro vided with the machine TRANSAXLE 21 71 5 Once machine has completed the fluid exchange Check the fluid level and condition and fill to proper level with ATF 44 Type 9602 Refer to Fluid Level and Condition Check in this group for the proper fluid top off procedure NOTE Verify that the transaxle cooler lines are tightened to proper specifications Cooler line torque specification is 2 Nem 18 in Ibs DIPSTICK TUBE FLUID SUC
154. with crocus cloth providing extreme care is taken not to round off sharp edges The sharpness of these edges is vitally important It prevents foreign matter from lodging between valve and valve body This reduces the possibility of sticking Inspect all valves and plugs for freedom of operation in valve body bores When bores valves and plugs are clean and dry the valves and plugs should fall freely in the bores The valve body bores do not change their dimensions with use Therefore a valve body that was function ing properly when vehicle was new will operate cor rectly if it is properly and thoroughly cleaned There is no need to replace a valve body unless it is dam aged in handling 05 5 GEARSHIFT CABLE Normal operation of the Park Neutral Position Switch provides a quick check to confirm proper link age adjustment The engine starter should only oper ate when the transaxle shift lever is in the PARK P or NEUTRAL N positions If the engine starts in any other gear position or the vehicle rolls when the shifter is in gated PARK P a gearshift cable adjustment is necessary ADJUSTMENT 1 Loosen set screw and remove knob from shifter handle Fig 214 TRANSAXLE D l pu Fig 214 Gearshift Knob Removal installation 1 SHIFTER KNOB 2 SET SCREW 21 135 80bc4ee2 2 Remove the center console assembly as shown in Fig 215 80004567 Fig 215 Center Conso
155. xle upper mount thru bolt gt Gain access to this bolt through the driver s side wheel house Fig 43 Fig 41 Right Lateral Bending Brace Removal Installation Typical 1 TRANSAXLE 2 ENGINE 3 LATERAL BENDING BRACE 21 16 TRANSAXLE REMOVAL AND INSTALLATION Continued WW NS O 5 9 Ne A P el Zon es NBT A EE SN SR VS Ge Ge 74 7 d e 80bbdad3 Fig 42 Starter Motor Removal Installation Typical 1 BOLT 2 GROUND 3 STARTER 4 BOLT 3 80bbdad4 Fig 43 Transaxle Upper Mount Thru Bolt Typical 1 MOUNT BRACKET 2 BOLT 3 MOUNT 23 Carefully lower engine and transaxle on screw jack until proper removal clearance is obtained 24 Obtain a helper to assist in holding transaxle while removing transaxle to engine mounting bolts Fig 44 PL 25 Remove transaxle from vehicle Fig 44 26 If installing a new or replacement transaxle remove the upper mount as shown in Fig 45 trans fer to the replacement unit and torque all bolts to 68 N m 50 ft Ibs torque INSTALLATION 1 Install dutch module onto input shaft Install transaxle into position 2 Install transaxle to engine mounting bolts Fig 44 and tighten to 95 N m 70 ft Ibs torque 3 Raise engine and transaxle with screw jack until through hole in upper mount aligns with hole in mount b

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