Home

W5MG1 W6MG1 AWD Trans Service - Searchable

1. IN Bearing retainer TFM0484 2200048 0041 9D amp Installation of spacer 1 Place solder length approximately 10 mm and diameter approximately 1 6mm into positions shown in illustration then install outer bearing race 2 Install the input shaft bearing retainer bolts and tighten to the specified torque 3 Remove the bearing and the solder Measure the thickness of the crushed solder with a micrometer and select and install a spacer of thickness that gives standard preload End Play 0 02 mm 0 05 mm 4 If the solder is not collapsed in step 2 select a solder with a thicker diameter and start over at step 1 BEA Installation of input shaft bearing retainer 1 Apply thread locking compound to the threads of the bolt and tighten to the specified torque Note Brand Loc tite 242 3M Threadlocker 4170 or equivalent Manual Transmission Rear Cover 22 61 0486 F4 Installation of reverse gear idler shaft 1 Align the bolt holes as shown in order to install the idler shaft bolt 9 G9 Installation of reverse gear shaft bolt lt WSMG1 gt Reverse gear carrier bolt lt W6MG1 gt 1 Apply thread locking compound to the threads of the bolt and tighten to the specified torque Note Brand Loc tite 242 3M Threadlocker 4170 or equivalent 22 62 Manual Transmission Front Differential Disassembly Reassemb
2. 0465 women 0998812 0998825 Inner TFM0548 Installation of inner bearing race 22 50 Manual Transmission 3 4 Synchronizer Disassembly Reassembly WSMG1 Coat all internal parts in gear oil before reassembly Disassembly Procedure 1 3rd gear synchronizer ring 2 4th gear synchronizer ring cAgwA 3 Synchronizer sleeve gie 4 Synchronizer ball gin 5 Synchronizer spring 6 Synchronizer hub TFM0549 Synchronizer hub Ball Synchronizer sleeve 0551 Disassembly service points CAD Removal of synchronizer sleeve 1 Because there is a tendency for the synchronizer springs to pop out cover the assembly with your hand during removal Assembly service points 44 Installation of synchronizer spring ball sleeve 1 Install the 4th gear synchronizer ring and sleeve on the synchronizer hub 2 Install the synchronizer springs and balls 3 positions Manual Transmission 5 6 Synchronizer 22 51 Disassembly Reassembly Ww6MG1 I Coat all internal parts in gear oil before reassembly Disassembly Procedure 1 5th gear synchronizer ring 2 6th gear synchronizer ring cAgwA 3 Synchronizer sleeve gie 4 Synchronizer ball 5 Synchronizer spring 6 Synchronizer hub TFM0549 Synchronizer hub Synchronizer sleeve TFM0556 Disassembly service p
3. SWEMGI gt MD998801 5th gear side lt TFMO450 OD2 Removal of inner bearing race GED Removal of bearing sleeve Assembly service points A4installation of 5 R synchronizer hub Manual Transmission Intermediate Shaft MD998812 amp 7 Install in direction of intermediate shaft TFMOS36 MD998812 0998813 MD998823 Synchronizer hub lt W5MG1 gt MD998820 i s MD998812 Bearing sleeve 0452 lt W6MG 1 gt MD998812 0998822 TFM0538 Note Adjust the synchronizer ring and hub to the illustrated position B4 Installation of reverse synchronizer hub C4 Installation of bearing sleeve 1 Using an electric heater or similar device heat the spacer ring Heating temperature 110 120 C 230 248 F Note Try not to heat the part too much Material will weaken under high temperature Manual Transmission Intermediate Shaft 22 45 5th gear side TFM0454 0455 TFMO456 0539 04 Installation of synchronizer key ball spring sleeve ring 1 Install the key and spring in the synchronizer hub 3 positions 2 Verify the direction of the synchronizer sleeve during installation 3 Align the spines of the synchronizer sleeve with the
4. Installation of 5th gear 1 Using an electric heater or similar device heat the gear Heating temperature 160 180 C 320 356 F Note Try not to heat the part too much Material will weaken under high temperature 164 Installation of spacer 1 Install the spring pin into the groove of the spacer 22 40 Manual Transmission Intermediate Shaft Disassembly Reassembly WB5IVIG1 SD Coat all internal parts in gear oil before reassembly 16 Inner synchronizer ring T 17 2nd gear Disassembly Procedure 18 Needle bearing 1 Snap ring 19 Snap ring 2 Inner bearing race ODO mF 20 Inner bearing race 3 1st gear 21 Reverse gear 4 Needle bearing 22 Needle bearing 5 Inner synchronizer ring 0 23 Synchronizer ring 6 Synchronizer friction ring 282 04 24 Synchronizer sleeve 4 7 Outer synchronizer ring 04 25 Synchronizer ball 89 9J4 8 Synchronizer sleeve 32 26 Synchronizer spring 4 9 Synchronizer ball D4 27 Synchronizer key 4 10 Synchronizer spring CEOBCA 28 Bearing sleeve 14 11 Synchronizer key A4 29 Synchronizer hub 14 12 Bearing sleeve 30 Synchronizer ring 9 4 43 Synchronizer hub 31 5th gear 14 Outer synchronizer ring 32 Needle bearing 64 15 Synchronizer friction ring 33 Intermediate shaft Manual Transmission Intermediate Shaft 22 41 Disassembly Reassembly W6MG1 SW Coat all internal parts in gear oil before reassembly
5. weu MB991591 0500 lt gt TFMO401 TFMOS01 TFMO413 B4 Installation of input shaft lock bolt 1 The rear cover input shaft and intermediate shaft are set into the special tool 2 Shift both forks in the direction shown in the illustration This will lock the shafts so that the input shaft lock bolt can be installed 3 Apply thread locking compound to the threads of the lock bolt and tighten to the specified torque Note Brand Loc tite 242 3M Threadlocker 4170 or equivalent Manual Transmission Transmission 0414 Towswerz 0415 lt WEMG I gt aud L 0505 0054 C Installation of input shaft rear seal cap 1 Install the seal cap with the groove facing upward Tap the seal down flush with the rear cover D4 Installation of poppet cover 1 Sealant is applied to the illustrated position on the poppet cover Note Brand Mitsubishi Genuine Sealant part number MD997740 or equivalent 2 Install the bolts in the poppet cover 3 Apply thread locking compound to the threads of the bolt and tighten to the specified torque Note Brand Loc tite 242 3M Threadlocker 4170 or equivalent SES Installation of spacer 1 Select and install the spacers in accordance with the results obtained in the section Adjustment before assembly Manual Transmission Tran
6. Sp Coat all internal parts in gear oil before reassembly Disassembly Procedure 1 Snap ring GDO9D 9 Bearing sleeve CAO Ka 2 Sth gear 84 10 3 4 Synchronizer hub 3 4th gear 11 Synchronizer ring 4 Needle bearing 12 3rd gear 44 5 Synchronizer ring 13 Bearing spacer OBOSHE 6 Synchronizer sleeve 14 Needle bearing g 7 Synchronizer ball 4 45 Spacer ring H 8 Synchronizer spring 16 Input shaft Manual Transmission Input Shaft 22 35 Disassembly Reassembly W6MG1 Coat all internal parts in gear oil before reassembly Disassembly Procedure 1 Snap ring F411 Spacer La 2 Spacer 12 Steel ball 3 Spring pin 13 4th gear 4 6th gear 14 Needle bearing 5 Needle bearing FOEU 15 Bearing sleeve ccosa 6 Bearing sleeve C9 16 3 4 Synchronizer hub 14 7 5 6 Synchronizer hub 17 3rd gear 8 5th gear 18 Needle bearing 9 Needle bearing 19 Input shaft CEOWG8 10 Bearing sleeve 22 36 Manual Transmission Input Shaft Disassembly service points OAD Removal of 5th gear MD998801 5th gear Em TFMO436 Removal of synchronizer sleeve 1 Because there is a tendency for the synchronizer springs to pop out cover the assembly with your hand during removal 000 Removal of bearing sleeve M0998801 C Bearing sleeve j wy t ANN EG ODO Removal of bearing sleeve 0998801 Removal of bearing sleeve M099
7. TFMO04B9 Assembly service points 46 Installation of oil seal 0998812 1 After installation of oil seal fill the lip section MD998824 with specified grease Specified grease Molykote TA 1 or 2 MD998304 2200081 DAIMLERCHRYSLER SAFETY RECALL TO INSPECT AND REPAIR YOUR VEHICLE S TRANSFER CASE Dear Stealth R T Owner This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act DaimlerChrysler Corporation has determined that a defect which relates to motor vehicle safety exists in some 1991 through 1996 model year Dodge Stealth R T Twin Turbo All Wheel Drive vehicles The problem is Oil leakage from the transfer case on your Stealth identified on the enclosed form may cause the transfer case to fail This could cause the wheels to lock up and result in an accident without warning What DaimlerChrysler DaimlerChrysler will repair your vehicle free of charge parts and and your dealer will labor To do this your dealer will inspect the transfer casc for indications do of oil leakage Vehicles that have no oil leakage will have the transfer case oil changed Vehicles that have oil leakage will have the transfer case resealed or replaced if necessary The inspection and oil change will take about Y hour to complete Resealing or replacing the transfer case will require another 1 2 hours However additional time may be necessa
8. Discard the nuts 4 Remove the two nuts that secure REMOVE the front catalytic converter to the DRAIN PLUG FRONT turbocharger outlet Figure 26 Discard the nuts noe e DISCONNECT DISCONNECT 5 Disconnect the front exhaust pipe FRONT CATALYST EXHAUST PIPE support Figure 26 Disconnect the front exhaust pipe and temporarily support the front exhaust pipe with a wire or bunjee cord 6 Remove and discard the two exhaust gaskets FRONT CATALYST Figure 26 Safety Recall No B17 Transfer Case Page 19 Service Procedure Continued es 10 IL Remove the five bolts that secure the transfer case to the transaxle Figure 27 NOTE The upper mounting bolt may be hidden from view CAS DISCONNECT TRANSFER CASE FROM DRIVESHAFT Separate the transfer case from the transaxle If necessary tap the transfer case with a plastic hammer to loosen it Remove the transfer case from the transaxle by the case downward then disconnect the REMOVE FIVE TRANSFER transler case from the drive shaft CASE TO TRANSAXLE BOLTS Figure 27 Set the transfer case aside for return to the Warranty Material Retum Center Figure 27 IMPORTANT Do NOT allow the drive shaft to hang as this could damage the universal joint or bend the shaft Support the drive shaft with a wire or bunjee cord For vehicles equipped with a 5 speed transfer case transfer the extension h
9. Measure the thickness of the crushed solder with a micrometer and select and install a spacer of thickness that gives standard preload Standard preload values Intermediate shaft 0 15 mm 0 25 mm W5MG1 0 20 mm 0 30 mm W6MG1 Center differential 0 10 mm 0 20 mm W5MG1 0 15 mm 0 20 mm W6MG1 Front output shaft 0 15 mm 0 25 mm W5MG1 0 10 mm 0 15 mm W6MG1 Front differential 0 15 mm 0 25 mm W5MG1 0 15 mm 0 20 mm W6MG1 8 If the solder is not collapsed in step 6 select a solder with a thicker diameter and start over at step 1 Manual Transmission Transmission 22 23 WSMGI MB991589 TFMO0409 lt W6MG I gt MB991591 TFM0504 TFMO amp IO TFMOAII 0412 Service points for working base 8A Rear cover installation 1 Place the intermediate shaft input shaft shift forks and rails into the special tool 2 Using an electric heater or similar device heat the special tool Heating temperature 110 120 C 230 248 F 3 The heated special tool is placed against the inner race section of the input shaft rear bearing in the rear cover for approximately 10 minutes 4 The special tool is removed and the rear cover is installed Note Do not touch the heated special tool with bare hands 22 24 Manual Transmission Transmission lt WSMGI gt MB991589 TFMO400
10. Bearing sleeve 0546 Installation of 1 2 synchronizer hub Note Orientation of hub is the same for W6MG1 Note Adjust the synchronizer ring and hub to the illustrated position 4 Installation of bearing sleeve 1 Using an electric heater or similar device heat the bearing sleeve Heating temperature 110 120 C 230 248 F Note Try not to heat the part too much Material will weaken under high temperature 22 48 Manual Transmission Intermediate Shaft WSMGI Key TFM0493 lt W6MG I gt 1st gear side lt pring y Key 0547 GH lind TFMO462 TFMO463 0464 J Installation of synchronizer ball spring sleeve ring 1 Install the keys and springs in the synchronizer hub 3 positons Note Install keys with chamfer facing outside 2 Verify direction of synchronizer sleeve during installation 3 Shift the synchronizer sleeve to the 2nd gear side 4 Install the synchronizer balls 3 positions 5 The synchronizer ring is installed 6 Hold down the synchronizer ring with a finger and slide the sleeve to the 1st gear side Note When moving the sleeve to the 1st gear side make certain the keys lock into the notch along the inside center of the sleeve Manual Transmission Intermediate Shaft 22 49 lt W5MGI gt 0998812 0998825 Inner
11. Center Differential 0998369 Needle bearing TFMO47I Inner race TFMO472 Spring pin hole TFM0473 Planetary gear cover i pring pin Case 474 B Installation of needle bearing 1 Press the needle bearing into the illustrated position C Installation of inner bearing race D4 Installation of inner bearing race 1 Align the spring pin holes of the cover and differential case using a plastic hammer PES Installation of spring pin 1 Drive the spring pins down flush with the surface of the differential case Manual Transmission Front Output Shaft 22 55 Disassembly Reassembly Disassembly Procedure llb Coat all internal OAOWB9 1 Inner bearing race parts in gear oil SAQBA 2 Inner bearing race before reassembly 3 Output shaft TFM0388 MD998801 Disassembly service points CAD Removal of inner bearing race 0475 Assembly service points MD998812 MD998813 A4 Installation of inner bearing race Inner race TFMO476 22 56 Manual Transmission Front Output Shaft B4 Installation of inner bearing race MD998825 Inner race TFM0477 Manual Transmission Rear Cover 22 57 Disassembly Reassembly W5MG1 SW Coat all internal parts in gear oil before reassembly Disassembly Procedure DR 1 Reverse shaft carrier bolt 8
12. Input shaft bearing 2 Washer 04 9 Spacer 3 Reverse shaft carrier cadaca 10 Outer bearing race 4 Reverse gear 89484 11 Outer bearing race 5 Needle bearings 44 12 Oil guide F 6 Reverse gear shaft 13 Rear cover 7 Input shaft bearing retainer 22 58 Manual Transmission Rear Cover Disassembly Reassembly W6MG1 SW Coat all internal parts in gear oil before reassembly Disassembly Procedure G4 1 Reverse shaft carrier bolt 2 Washer 3 Reverse shaft carrier 4 Reverse gear 5 Needle bearings E4 6 Input shaft bearing retainer 18 ft lbs 25Nm 12 7 Input shaft bearing 04 8 Spacer C9 9 Outer bearing race CBOW89 10 Outer bearing race BAM 11 Oil guide 12 Rear cover Manual Transmission Rear Cover 22 59 Disassembly service points CAD Removal of outer bearing race 2 MA Hl A 478 M BD Removal of outer bearing race Assembly service points 46 Installation of oil guide 1 When installing the oil guide align the channels of the guide with the notches in the rear cover Note If the oil guide is damaged or broken replace 7 it with a new one C TFM0480 es B4 Installation of outer bearing race 990938 TFMOABI 8C Installation of outer bearing race Manual Transmission Rear Cover er 9 irn E le Hog SE e FS NI 7 7
13. Reverse 3 076 Transfer Case 0 814 Manual Transmission Standards and Sealants 22 5 Maintenance Standards Item Standard Value in mm Model Input shaft bearing end play 0 02 0 05 0 15 0 25 W5MG1 Intermediate shaft preload 0 20 0 30 W6MG1 e 0 10 0 20 W5MG1 Center differential preload 015 020 W6MG1 0 15 0 25 W5MG1 Front output shaft preload 010 015 W6MG1 0 15 0 25 W5MG1 Front differential preload 015 020 WGMG1 Sealants Item Input shaft lock bolt Rear cover to center case installation bolt Stopper plate installation bolt Center case to clutch housing installation bolt Shift shaft to clutch housing installation bolt Shift shaft guide bolt Loc tite 242 Select lever installation bolt Poppet cover installation bolt Reverse idler gear shaft bolt Reverse shift damper Mating surface of rear cover and center case Loc tite 17430 or Mitsubishi Geunine Sealant MD997740 Mating surface of center case and clutch housing Mating surface of clutch housing and shift shaft Mating surface of poppet cover and rear cover 22 6 Manual Transmission Lubricants Lubricants Item Type Spline section of center output shaft and mating sleeve of transfer case lip section of all oil seals Molykote TA 1 or 2 API Classification GL 4 or higher Synchronizer friction s
14. and output shaft splines with Mopar White Lithium Grease Mopar P N 04318066 or equivalent Coat the transaxle output shaft and the driveshaft splines with Mopar White Lithium Grease or equivalent Insert the driveshaft into the transfer case and then mount the transfer case onto the transaxle Figure 3 Install the transfer case mounting bolts and tighten the mounting bolts to 65 ft lbs 87 N m Figure 3 Remove the temporary driveshaft support Remove the temporary exhaust pipe support and then using the supplied exhaust gaskets and nuts reconnect the front exhaust pipe to the front turbocharger outlet and rear catalytic converter Figure 2 Tighten the exhaust nuts to 37 ft lbs 50 N m Connect the front exhaust pipe support Figure 2 Lower the vehicle Test drive the vehicle and verify that there are no leaks Safety Recall No B17 Transfer Case Page 18 B Replace Transfer Case NOTE Only transfer cases that are cracked or that have an input and or output gear that does NOT turn smoothly or that has damaged teeth as determined by the inspection in Section A require replacement Very few vehicles are expected to require transfer case replacement 1 Remove the transfer case filler plug N Remove the transfer case drain plug Figure 25 and drain the fluid from the transfer case 3 Remove the two nuts that secure the exhaust pipe to the rear turbocharger mounted catalytic converter Figure 26
15. grooves in the synchronizer hub 4 Shift the synchronizer sleeve to the 5th gear side 5 Install the synchronizer balls 3 positions 6 Install the synchronizer ring 7 While holding down the synchronizer ring slide the sleeve to the reverse gear side Note When moving the sleeve to the reverse gear side make sure the keys lock into the notch along the inside center of the sleeve BEA Installation of synchronizer key ball spring sleeve ring 1 Install the springs in the synchronizer hub 3 positions 22 46 Manual Transmission Intermediate Shaft Install in direction of reverse synchronizer hub lt gt Z E TFMO540 Ball TFMOS41 lt WSMGI gt MD998812 MD998820 Inner race 0457 lt W6MG1 gt MD9988 12 Inner race TFM0543 u TFMO458 2 Verify direction of synchronizer sleeve during installation 3 Install the synchronizer balls 3 positions WER Installation of inner bearing race 06 Installation of synchronizer friction ring 1 Apply specified gear oil gear oil to the faces of the friction ring Specified oil API GL 4 or higher 75W 90 to 75W 85W Manual Transmission Intermediate Shaft 22 47 lt WSMG I gt 1st gear side TFM0459 WSMGI MD998812 MD998825 TFMO461 lt W6MG1 gt MD9988 2 MD998825 MD998801
16. the gear housing over the shaft Figure 18 Make sure that the shaft slides easily into the input shaft seal and that the seal lip 1s not twisted SOME COVERS DO NOT HAVE AN O RING GROOVE DO NOT INSTALL AN O RING ON THESE COVERS Figure 17 TO INSTALL INPUT GEAR PLACE GEAR ON WORK SURFACE AND Figure 18 Safety Recall No B17 Transfer Case Service Procedure Continued 40 Place your thumb into the mput 4 shaft opening to hold the gear in position and then turn the gear housing over Figure 19 Put a bead of sealant Mopar Axle RTV P N 05013477A4A or equivalent on the gear housing cover flange Figure 20 Page 13 TO TURN HOUSING OVER PLACE THUMB IN INPUT SHAFT OPENING TO HOLD GEAR IN CE Figure 19 PUT A BEAD OF GEAR HOUSING ge COVER FLANGE INPUT GEAR ASSEMBLY Figure 20 Safety Recall No B17 Transfer Case Page 14 42 Carefully install the gear housing 43 45 Apply Mopar Lock amp Seal Mopar cover onto the gear housing Position the cover by loosely installing two of the cover bolts Figure 21 and then seat the cover by tapping it with a plastic hammer or using a press Remove the two bolts used to position the cover P N 04318031 to the threads of the cover bolts Install the cover bolts and tighten to 220 in Ibs 25 N m Figure 21 Lubricate the supplied gear housing to adapter housing O ring with Mopar
17. 5 ft lbs 9 Nm Lubricants Item Specified lubricant Clutch release bearing sleeve diameter Clutch release bearing and shift fork contact section Molykote TA 2 Shift fork and fulcrum contact section Clutch release cyliner pushrod tip Inside splines of clutch disk Molykote TA 1 or 2 Clutch release cylinder piston and piston cup SAE J1703 DOT3 Clutch damper O ring Clutch Special Tool 21 3 Tool Part Number Name Use Clutch disk PUT MD998126 centering guide Positioning the clutch disk 21 4 Clutch Clutch Assembly Removal Installation 27 ft lbs 36 Nm 22 Removal Procedure Clutch cylinder release tube Clutch cylinder release tube Clutch cylinder release tube Clip Bracket Clutch damper 9 way junction block Insulator Bracket 10 Insulator 11 Banjo bolt 12 Crush washer eonanpunm N 9 20 N s i we Ibs 23 d Nm ae Ibs 19Nm m 11 13 14 15 0 16 aCA 17 Ca 18 CAZWBa 19 BAG 20 21 22 23 at e Yu 14 ft Ibs 19 Nm 11 ft lbs 15Nm S 6 14 ft lbs N 19Nm T i 19 Nm 9 8 H 41 te 5 9 Qi 7 Bi Nm amp 10 ER 80 47 ft lbs 23Nm Union Release cylinder valve Release cylinder spring Clutch release cylinder Clutch cover Clutch disk Clutch release fork Throw out bearing Boot Release fork fulcrum Clutch housing C
18. 75W 90 GL 5 Gear Lube Install the O ring onto the adapter housing S speed or into the gear housing 6 speed Figure 10 Make sure that the O ring is not twisted IMPORTANT There are two different gear housing to adapter housing O rings contained in the repair kit Make sure that the correct O ring is used for the vehicle being serviced Refer to the Seal Repair Kit packaging for correct O ring identification Safety Recall No B17 Transfer Case Page 15 Service Procedure Continued 46 EN ds 49 L c Place the adapter housing assembly FOR 6 SPEED TRANSFER PUT A BEAD OF CASES ONLY Put a bead of sealant Mopar Axle RTV P N 05013477AA or equivalent on rg the gear housing flange Figure 22 SEALANT GEAR HOUSING TO ADAPTER IMPORTANT Do NOT use sealant on the 5 speed gear housing to adapter housing joint vertically on the work surface and then install the gear housing assembly onto the adapter housing Seat the gear housing by lightly lapping it with a plastic hammer Figure 22 Apply Mopar Lock amp Seal Mopar P N 04318031 to the threads of the adapter housing to gear housing bolts and then install the bolts and tighten to 220 in Ibs 25 N m IMPORTANT For 6 speed transfer cases the bolts are not all the same length Make sure that the one longer bolt is used in the position with the raised boss Place the transfer case on the work surtace with the output shaft facing upwa
19. 8917 1 TFMOS21 Manual Transmission Input Shaft 22 37 0998801 0998812 0998814 0998827 439 M0998812 A MD9988 12 MD998814 0998829 0998813 0998824 TFMOA4 Assembly service points 9A98 Installation of spacer ring 1 Using an electric heater or similar device heat the spacer ring Heating temperature 110 120 C 230 248 F Note Try not to heat the part too much Material will weaken under high temperature 9B Installation of 3 4 synchronizer hub Note Adjust the synchronizer ring and hub to the illustrated position 8C Installation of 3 4 synchronizer 06 Installation of bearing sleeve 1 Using an electric heater or similar device heat the spacer ring Heating temperature 110 120 C 230 248 F Note Try not to heat the part too much Material will weaken under high temperature 2 38 Manual Transmission Input Shaft 0998801 MD998812 0998813 0998826 MD998812 MD998813 MD998826 MD998801 Spring all TFM0442 TFMO443 PES Installation of bearing sleeve 1 Using an electric heater or similar device heat the bearing sleeve Heating temperature 110 120 C 230 248 F Note Try not to heat the part too much Material will weaken under high te
20. Disassembly Procedure CAO MK A ace ae OBO mda DP ae ae OCaml a DT Ka 1 Inner bearing race 2 1st gear 3 Needle bearing 4 Inner synchronizer ring 5 Synchronizer friction ring 6 Outer synchronizer ring 7 Synchronizer sleeve 8 Synchronizer ball 9 Synchronizer spring 10 Synchronizer key 11 Bearing sleeve 12 Synchronizer hub 13 Outer synchronizer ring 14 Synchronizer friction ring 15 Inner synchronizer ring 16 17 OD era 18 19 20 MEt 21 oBZ WES 22 23 BER 24 KSE 984 26 27 28 29 2nd gear Needle bearing Inner bearing race Reverse gear Needle bearing Synchronizer ring Synchronizer sleeve Synchronizer ball Synchronizer spring Bearing sleeve Synchronizer hub Snap ring Stopper plate Intermediate shaft 22 42 Manual Transmission Intermediate Shaft lt WSMGI gt Disassembly service points MD998801 GAD Removal of inner bearing race lt W6MG I gt MD998917 0532 080 Removal of synchronizer sleeve 1 Because there is a tendency for the synchronizer springs to pop out cover the assembly with your hand during removal San CO Removal of bearing sleeve MD998917 W6MGI MD998917 i TFM0533 Manual Transmission Intermediate Shaft 22 43 lt WS5MGI gt 0998801 lt W6MGI gt MD998917 WSMGI 0998801
21. E GEAR HOUSING COVER BOLTS Figure 11 5 Speed Vehicle Shown REMOVE GEAR HOUSING COVER THEN REMOVE INPUT GEAR FROM HOUSING Figure 12 Safety Recall No B17 Transfer Case Service Procedure Continued 28 30 31 32 33 Remove the O ring from the gear housing cover Figure 13 IMPORTANT Some early built 5 speed transfer cases do NOT have a cover O ring Clean the gear housing cover flange and the cover O ring seat and surface Remove any sealant from the gear housing and cover bolt holes Using a brass drift and a plastic hammer remove the input shaft seal from the gear housing Set the adapter housing extension housing assembly on the work surface with the output shaft facing upward Carefully remove the output shaft seal To remove the seal place a flat bladed screwdriver under the seal with the screwdriver shaft resting on the extension housing cuff Remove the seal by quickly hitting the screwdriver handle and popping the seal from its seat Figure 14 NOTE Protect the end of the output shaft by placing a shop rag over it prior to the seal removal Figure 14 Page 10 Safety Recall No B17 Transfer Case Service Procedure Continued 34 Place the supplied input shaft seal into the seal seat on the input gear housing 35 For 5 speed transfer cases Use a E Ilat seal installation tool to press the seal into the housing with an arbor press unti
22. MANUAL TRANSMISSION Service manual A 1991 1996 Dodge Stealth R T Turbo 1990 1999 Mitsubishi GTO Twin Turbo 1991 1999 Mitsubishi SO00GT WSMG1 WEMG1 MANUAL TRANSMISSION Preface This book was translated from the original Japanese language service manual published by Mitsubishi Motors Corporation of Japan Translation was performed by volunteers from 3000GT Stealth International an owners and enthusiast group focused on the Mitsubishi 3000GT Dodge Stealth and Mitsubishi GTO Great care has been taken to ensure the accuracy of the information contained in this manual but errors may still be possible due to the nature of the translation Therefore this manual is presented as a guide only and repair procedures should not be undertaken by unskilled individuals who do not posess a thorough understanding of the subject material The authors of this manual will not be held responsible for any personal injury or damage to property incurred while performing the procedures described within All tasks in this manual are undertaken at your own risk Group Index Clutch Manaul Transmission Transfer Case Recall Applicable Models This book covers the Getrag W5MG1 and W6MG1 all wheel drive manual transaxles found in the following models 1991 1996 Dodge Stealth R T Turbo 1991 1999 Mitsubishi 3000GT VR4 1990 1999 Mitsubishi GTO Twin Turbo This bo
23. Reassembly 2 fi ld er Q L a ei m 5 J Disassembly Procedure 1 Pushrod 2 Boot 8 3 Piston cup OAOA 4 Piston 5 Conical spring Coat all internal 6 Cap parts in brake fluid 7 Bleeder screw 8 before reassembly Release cylinder TFMO494 Disassembly service points GAD Removal of piston cup piston 1 Remove the corrosion from the piston removal port of the release cylinder 2 Remove the piston from the release cylinder using compressed air Caution 6cL035 1 Cover with rags to prevent the piston from popping out 2 Apply compressed air slowly to prevent brake fluid from splashing Clutch Clutch Release Cylinder 21 9 7CL0007 Apply Apply Piston cup Noon Piston 6CL0003 Inspection 1 Remove any rust or corrosion from the inside of the release cylinder 2 Measure the inside diameter of the cylinder at 3 places bottom middle and top If the diameter of the cylinder exceeds the outside diameter of the piston by more than the limit value replace the release cylinder assembly Limit value 0 15 mm Assembly service points A4 Installation of piston piston cup 1 Apply specified brake fluid to the release cylinder inside and outer surface of the piston and piston cup and push the piston cup assembly in the cylinder Specified brake fluid SAE J1703 DOT3 21 10 Clutch Clutch Dampe
24. T ait 3 DAIMLERCHRYSLER November 2002 Dealer Service Instructiens fer Safety Recall No B17 Transfer Case 1991 1996 B7 Stealth R T Twin Turbo All Wheel Drive AWD IMPORTANT Some of the involved vehicles may be in dealer used vehicle es before Minsk X Realemshontd winw perform this Tccalren vehicles in for service Involved vehicles can be determined by using the DIAL VIP System Oil leakage from the transfer case on about 9 100 of the above vehicles may cause the transfer case to fail This could cause the wheels to lock up and result in an accident without warning The transfer case must be irispetted 1f the transfer case is not leaking the transfer case oil must be changed 1f the transfer case is leaking it must be resealed If the transfer case is cracked Ur if the internal gears are damaged then the transfer case must be replaced Dealers should attempt to migimize customer inconvenience by placing the owner in a loafier vehicle if itiepcktion determines that transfer case replacement is required and the vehicle mist be held overnight Copyright 9802 DaimlerChrysler Corporation All Rights Reserved Safety Recall No B17 Transfer Case Page 2 A Transfer Case Seal Package Part Number Description CBATB170 Oil Seal Repair Kit Each package contains the following components Quantity Description 1 Input Shaft Seal 1 Output Shaft Seal 2 Gear Housing to Adapter O Ring
25. cking compound to the threads of the bolt and tighten to the specified torque Note Brand Loc tite 242 3M Threadlocker 4170 or equivalent 0419 T4 Installation of shift shaft 1 Apply sealant to the illustrated position on the rear cover Sealant Brand Loc tite 17430 or Mitsubishi Genuine Sealant MD997740 Note Squeeze out sealant from tube uniformly without excess or discontinuity 0512 Manual Transmission Transmission 22 31 lt WSMGI gt Return spring TFM0431 lt W6MGI gt Return spring 0513 TFMOA32 lt WEMGI gt k 0514 u N AY 2 Apply a coating of grease to the shift shaft to prevent the return spring from falling off during installation 3 The shift shaft must be kept in the position shown during installation 4 While keeping the shift shaft in the position shown in Step 3 install the shaft into the shift rail lugs 22 32 Manual Transmission Transmission lt WEMGI gt Jo O fn lug 0515 5 Apply thread locking compound to the threads of the bolt and tighten to the specified torque Note Brand Loc tite 242 3M Threadlocker 4170 or equivalent TFM0054 l4 Installation of reverse shift detent 1 Apply thread locking compound to the threads of the bolt and tigh
26. e cord p Remove and discard the aluminum gaskets from the transfer case filler and drain plugs Clean the filler and drain plugs 14 Remove the transfer case breather Figure 4 Clean the breather and set it aside for later re use BREATHER Figure 4 Safety Recall No B17 Transfer Case Page 6 Service Procedure Continued 15 Remove the bolts that secure the transfer case gear housing to the adapter housing Figure 5 NOTE There are five 5 bolts on 5 speed equipped vehicles and seven 7 bolts on 6 speed equipped vehicles 16 Position the transfer case vertically HAMMER P on a soft pad and separate the gear ADAPTER jr HOUSING FROM housing from the adapter housing rs ADAPTER HOUSING by tapping the gear housing with a 3 plastic hammer Figure 6 Safety Recall No B17 Transfer Case Page 7 Service Procedare Continued NOTE Be careful to not bend or damage the oil guide pipe when separating the housings on BEND OIL 6 speed equipped vehicles GUIDE PIRE Figure 7 GEAR HOUSING 6 SPEED Figure 7 17 While holding the gear housing ROTATE INPUT GEAR rotate the input gear and note its TO INSPECT condition Figure 8 FOR BINDING Figure 8 Safety Recall No B17 Transfer Case Page 8 Service Procedure Continued ROTATE OUTPUT GEAR KEN CH 18 While holding the adapter housing CHIPPED TEETH rotate the output gear and note its condition Figu
27. ear cover 35 Center differential 44 Input shaft F 36 Outer bearing race 45 Intermediate shaft WER 37 Spacer 46 Shift forks and rails 22 16 Manual Transmission Transmission Disassembly Reassembly A WSMG1 amd 7 ft lbs 5 10 Nm v v os 14 ft lbs 7 E 19Nm 52 ft lbs 7 24 ft lbs 33Nm n 12 22 ft lbs 30 Nm 4 1 6 d 10 15 ft lbs 20 Nm Coat all internal parts in gear oil before reassembly Disassembly procedure giel Transfer case gief Vent tube B 2 Speedometer gear nya 9 Gear select lever 3 Transmission mount 14 10 Shift detent 4 Gearshift cable bracket ewe 11 Guide bolt 5 Reverse light switch gue 12 Reverse shift detent 6 Gasket 13 Spring 929 7 Vent tube A 14 Shift shaft Manual Transmission Transmission 22 17 Disassembly procedure 15 Dowel 54 16 Clutch housing 17 Snap ring OCORA 18 Input shaft bearing 90 19 Oil seal P 20 Oil seal 21 Oil tank 22 Front differential 23 ODINO 24 RER 25 28926 ODO OMe 27 BEM 28 Wl DEZ MES 30 Coat all internal parts in gear oil before reassembly Front output shaft Outer bearing race Spacer Oil guide Outer bearing race Spacer Outer bearing race Spacer 22 18 Manual Transmission Transmission 7 5 ft lbs a 43A 44 amd 70 ft lbs 95Nm 18 ft lbs 25Nm Coat all internal parts in gear oil before reassembly Disass
28. embly Procedure 31 Stopper plate OE 32 Dowel gie 33 Poppet cover Spacer Rear seal cap Input shaft lock bolt 34 Spring CHO A 45 Rear cover 35 Ball 46 Input shaft 4 36 Center case 47 Intermediate shaft 14 37 Outer bearing race 48 5 6 shift fork and rail HA 38 Outer bearing race 49 3 4 shift fork and rail Ga 39 Oil seal 50 1 2 shift fork and rail 40 Center differential 51 Reverse shift fork and rail F 44 Outer bearing race Manual Transmission Transmission 22 19 Va D Shift shaft TFM0394 weveo Nik TFM0397 Disassembly service points GAD Removal of shift shaft 1 Place the shift shaft in the neutral position and pull to remove Removal of dowel pin 1 The dowel pin is driven out in the direction illustrated 069 Removal of input shaft front bearing OD Removal of bearing outer race Manual Transmission Transmission TFM0398 lt W5MG1 gt MB991589 TFMO400 lt WEMG gt 991591 0500 Wem 157 lt gt 0401 Removal of dowel pin 1 The dowel pin is driven out in the direction illustrated Removal of input shaft rear seal cap 1 Drive a nail or similar pointed object into seal cap and pull to remove CGO Removal of input shaft lock boit 1 Set the rear c
29. ent through the DCMMS and the MDS2 will be updated to include this recall in the near future Each dealer to whom involved vehicles were invoiced will receive a list of their involved vehicles The vehicle list is arranged in Vehicle Identification Number VIN sequence Owners known to Da are also listed The lists are for dealer reference in arranging for service of involved vehicles a Safety Recall No B17 Transfer Case Page 22 DIAL System Functions 53 and VIP All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed Function 3 provides involved dealers with an updated VIN list of their incomplete vehicles The customer name address and phone number are listed if known Completed vehicles are removed from Function 53 within several days of repair claim submission To use this system type 53 at the ENTER FUNCTION prompt then type ORDB17 All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail They are requested to schedule appointments for this service with their dealers A copy of the owner letter is attached Enclosed with each owner letter is an Owner Notification Form The involved vehicle and recall are identified on the form for owner or dealer reference as ll If a vehicle is not available for service let us know by filling out the pre addressed Owner Notification Form or describe the reason on a
30. l the seal is flush wath the housing surface Figure 15 For 6 speed transfer cases Use a 36mm socket to press the seal into the housing with an arbor press until the seal contacts the seat Figure 15 FOR 5 SPEED TRANSFER CASES ONLY remove the seal installation tool and place the supplied 2 5 mm spacer on top of the input shaft seal Figure 16 Place the tool on top of the spacer and press the seal further into the housing with the arbor press until the spacer is tush with the housing surface Remove the tool and spacer Lubricate the input shaft seal lip with a small amount of Mopar White Lithium Grease or equivalent Page 11 SEAL INSTALLATION TOOL Figure 16 GEAR HOUSING Safety Recall No B17 Transfer Case Service Proce Continued 38 Lubricate the supplied gear housing cover O ring with Mopar 75W 90 GL 5 Gear Lube and then install the O ring into the groove on the gear housing cover Make sure that the O ring is not twisted IMPORTANT Some early built 5 speed transfer cases did NOT have a cover O ring Figure 17 However some of these covers do have an O ring groove A new cover O ring MUST be installed if the cover has an O ring groove If the cover does NOT have an O ring groove DO NOT install a cover O ring Install the input gear into the gear housing by placing the input gear assembly on the work surface with the shaft tacing upward and then placing
31. lutch Clutch Assembly 21 5 Removal service points QAD Release fork removal Fulcrum Clip 1 Slide release fork in direction of arrow and disengage fulcrum from clip to remove release fork Be careful not to cause damage to clip by pushing release fork in the direction SE other than that of arrow and removing it with force octo Inspection Clutch cover assembly 1 Check the diaphragm spring end for wear and uneven height Replace if wear is evident or height difference exceeds the limit Limit 0 5 mm 020 in 2 Check the pressure plate surface for wear cracks and seizure 3 Check the strap plate rivets for looseness and replace the clutch cover assembly if loose Clutch disk 1 Check the facing for loose rivets uneven contact deterioration due to seizure adhesion of oil or grease p and replace the clutch disc if defective 2 Measure the rivet sink and replace the clutch disc if it is out of specification Limit 0 3 mm 012 in 3 Check for torsion spring play and damage and if defective replace the clutch disc 601003 4 Combine the clutch disc with the input shaft and check sliding condition and play in the rotating direction If it does not slide smoothly or the play is excessive check after cleaning and reassembling If the play is excessive replace the clutch disc and or the input shaft Rivet sink Clutch release bearing Caution Release bearing is packed with grease Therefore do not wash i
32. ly Disassembly Procedure D Coat all internal parts in gear oil before reassembly CAOBA 1 Inner bearing race 4 Ring gear bolt CAO94A8 2 Inner bearing race 3 Differential TFM0393 Disassembly service point GAD Removal of inner bearing MD998812 Assembly service point MD998823 Inner race A Installation of inner bearing race 0040 Manual Transmission Front Differential 22 63 MD998812 0998825 Inner 049 B4 Installation of inner bearing race 22 64 Manual Transmission Speedometer Gear Disassembly Reassembly ll Coat all internal parts in gear oil before reassembly Disassembly Procedure 1 O Ring 9682 Spring pin 94984 Oil seal 5 Sleeve 843 Speedometer driven gear 0381 Oil seal 0369 Assembly service points 4 Installation of oil seal 1 Press the oil seal into position as illustrated 84 Installation of speedometer driven gear 1 Apply gear oil to the shaft of the driven gear during installation sC installation of spring pin 1 Install the spring pin with the slit facing away from the shaft of the driven gear Manual Transmission Transfer Case 22 65 Disassembly Reassembly is 4 5 5 me 7 5 Nm Disassembly Procedure A 1 Oil seal gin 2 Oil seal 3 Washer 4 Oil fill bolt 5 Transfer case
33. mperature BER Installation of spacer 1 Install the steel ball into the groove of the spacer 06 Installation of bearing sleeve 1 Using an electric heater or similar device heat the bearing sleeve Heating temperature 110 120 C 230 248 F Note Try not to heat the part too much Material will weaken under high temperature Installation of spring ball sleeve ring 1 Install the sleeve on the synchronizer hub and shift it towards the 3rd gear side 2 Install the synchronizer balls and springs 3 positions 3 Install the synchronizer ring 4 While holding the synchronizer ring with a finger move the sleeve to the 4th gear side Note When moving the sleeve to the 4th gear side make certain the balls lock into the notch along the inside center of the sleeve Manual Transmission Input Shaft 22 39 Sth gear side TFM0527 MD998801 j Synchronizer A TFMOS28 MD998812 MD998813 0529 MD998812 MD998813 MD998824 0444 2 Spring m TFM0530 Installation of 5th and 6th gear synchronizers IR Installation of bearing sleeve 1 Using an electric heater or similar device heat the bearing sleeve Heating temperature 110 120 C 230 248 F Note Try not to heat the part too much Material will weaken under high temperature
34. n of needle bearings MD998801 Bearing remover Removal of taper bearings MD998803 Differential Installation of output shaft seal oil seal installer MD998812 Installer cap Use with installer adapter Use with installer cap and MD998813 Installer 100 adapter Cer Manual Transmission Special Tools 22 11 Tool Number Name Usage p MD998814 nstaller 200 Use with installer cap and adapter MD998820 nstaller Installation of bearing sleeve adapter 42 and inner bearing race MD998821 nstaller Installation of 5 R synchronizer adapter 44 hub MD998822 nstaller Installation of bearing sleeve adapter 46 and inner bearing race MD998823 Installer Installation of reverse synchronizer adapter 48 hub and inner bearing race Installer Installation of 3 4 synchronizer hub WS adapter 50 a sleeve 5th gear and oil MD998825 Installer Installation of bearing sleeve adapter 52 and inner bearing race Installer Installation of bearing sleeve MD998826 adapter 54 5 6 synchronizer hub 1 2 synchronizer hub MD998827 Installer Installation of spacer ring adapter 56 and inner bearing race MD998829 Installer Installation of 3 4 synchronizer ring adapter 60 22 12 Manual Transmission Special Tools Tool Number Name Usage MD998917 Bearing Removal of taper bearings remover MD999566 Claw Removal of outer bearing races Ma
35. nstallation of outer bearing race Installation of outer bearing race N4 Installation of oil guide 1 The notch in the oil guide is installed in the illustrated position Note If the oil guide is broken or damaged replace it with a new one 08 Installation of outer bearing race P Installation of oil seal 1 After installation of oil seal fill the lip section with specified grease Specified grease Molykote TA 1 or 2 Manual Transmission Transmission 22 29 TFMO446 12 0510 06 Installation of oil seal 1 After installation of oil seal fill the lip section with specified grease Specified grease Molykote TA 1 or 2 R Installation of input shaft front bearing 1 Install the bearing with the hole facing downward 56 Installation of clutch housing 1 Apply sealant to the illustrated position on the rear cover Sealant Brand Loc tite 17430 or Mitsubishi Genuine Sealant MD997740 Note Squeeze out sealant from tube uniformly without excess or discontinuity 2 Install the clutch housing Note Do not scar the center shaft oil seal when installing the clutch housing 22 30 Manual Transmission Transmission lt W5MGI gt 3 The dowel is driven down into the position illustrated W5MG1 4 The dowel is driven down into the position illustrated W6MG1 S pt 0511 5 Apply thread lo
36. nual Transmission Transmission 22 13 Disassembly Reassembly W5MG1 ad 7 ft lbs 10Nm 52 ft lbs 9 70 Nm d 10 17 ft lbs 23 Nm lb Coat all internal parts in gear oil before reassembly Disassembly Procedure gin 1 Transfer case 214 8 Vent tube B 2 Speedometer gear ya 9 Gear select lever 3 Transmission mount 10 Guide bolt 4 Gearshift cable bracket 11 Spring 5 Reverse light switch OAGMTA 12 Shift shaft 6 Gasket 24 7 Venttube A 22 14 Manual Transmission Transmission 17 lt Disassembly Procedure 54 13 Clutch housing 14 Dowel 15 Snap ring OCORA 16 Input shaft bearing 904 17 Oil seal 18 Oil seal 19 Oil tank 20 Front differential 21 Front output shaft det WE HE 24 25 BEM 26 0050 4 27 BEM 5g lb Coat all internal parts in gear oil before reassembly Outer bearing race Spacer Oil guide Outer bearing race Spacer Outer bearing race Spacer Manual Transmission Transmission 22 15 7 5 ft lbs 30 md 40 42 70 ft lbs 29 7 5 ft lbs 10 Nm cd Coat all internal 36 parts in gear oil before reassembly Disassembly Procedure Ka 29 Stopper plate 04 38 Poppet cover GEO 30 Dowel 39 Spring 4 31 Center case 40 Ball 32 Outer bearing race CFOMCH 41 Real seal cap Ha 33 Outer bearing race CGOSBA 42 Input shaft lock bolt 964 34 Oil seal OHOMA 43 R
37. of component parts or on the page following the component parts page E E Grease multipurpose unless there is a brand or type specifed Brake fluid or automatic transmission fluid DEREN Eee ER PETER Sealant or adhesive Wenns Gear oil Removal procedures The part designation number corresponds to the number in the illustration to indicate removal procedures Disassembly procedures The part designation number corresponds to the number in the illustration to indicate disassembly procedures Installation procedures Specified in case installation is impossible in reverse order of removal procedures Omitted if installation is possible in reverse order of removal procedures Reassembly procedures Specified in case reassembly is impossible in reverse order of disassembly procedures Omitted if reassembly is possible in reverse order of disassembly procedures Classification of major maintenance or service points IER Indicates that there are essential points for removal or disassembly BA Indicates that there are essential points for installation or reassembly Introduction Group number and page number Group title Section title 21 8 Clutch Clutch Release Cylinder Disassembly Reassembly Torque specification 2 i d Ss NX Besur 9 S w J Disassembly Procedure Denotes non pou 2 Eer 8 Siss Ain 3 Piston cup CAQMA 4 Pist
38. oints CAD Removal of synchronizer sleeve 1 Because there is a tendency for the synchronizer springs to pop out cover the assembly with your hand during removal Assembly service points 44 Installation of synchronizer spring ball sleeve 1 Install the 6th gear synchronizer ring and sleeve on the synchronizer hub 2 Install the synchronizer springs and balls 3 positions 22 52 Manual Transmission Center Differential Disassembly Reassembly Coat all internal parts in gear oil before reassembly Disassembly Procedure sta Dowel 2 End cover GBO C 3 Inner bearing race OCO9WB 4 Needle bearing 5 Planetary gear set 6 Viscous coupling 7 Sun gear 8 Center output shaft 0707 9A 9 Inner bearing race 10 Center differential case Manual Transmission Center Differential 22 53 Planetary gear cover T Spring Case m TFMO466 MD998801 Inner race TFM0467 TFMO469 Inner race TFM0470 Disassembly service points GAD Removal of planetary gear cover 1 Drive the spring pin down into the illustrated position GBS Removal of inner bearing race OCO Removal of needle bearing 1 Using a screwdriver or similar tool remove the needle bearing 0 5 Removal of inner bearing race Assembly service points BAM Installation of inner bearing race 22 54 Manual Transmission
39. ok would not be possible without the contributions of the following people Translation and layout Jeff VanOrsdal Additional Translation Frank Chen Kotaru Yamaguchi Corumisri Technical Assistance Bret Brinkmann Jeff Lucius Financial assistance Many generous members of 3000GT Stealth International Visit 3000GT Stealth International on the web at www 3si org Introduction Introduction Scope of this manual This book explains the main service points regarding the transmission itself However please utilize the relevant service manual for the car model and year in question when concerns arise regarding onboard inspection and service Important points 1 Component diagrams are published at the beginning of each section so that you may more easily visualize the assembled state of the component or sub assembly 2 Numbered service procedures are displayed in the component diagrams along with indications of non reusable parts and torque specifications 3 Main service points and maintenance points are explained in detail along with usage and descriptions of special tools About inspection Descriptions are provided for procedures to be taken when defective or damaged parts are discovered during inspection Symbols for lubricants sealants and adhesives Information concerning the locations of lubricarion and for application of sealants and adhesives is provided by using symbols in the diagram
40. on A 5 Conical spring gt 1 Coat all internal 6 Cap parts in brake fluid 7 Bleeder screw before reassembly 8 Release cylinder TFMO494 Disassembly service points CAD Removal of piston cup piston 1 Remove the corrosion from the piston removal port of the release cylinder 2 Remove the piston from the release cylinder using compressed air Caution 1 Cover with rags to prevent the piston from 6CLO35 popping out 2 Apply compressed air slowly to prevent brake fluid from splashing 21 CLUTCH Special Tools Clutch Assembly 21 2 Clutch Standards Torque and Lubrication Maintenance Standards Item Limit Value mm Clutch disk facing rivet sink Below 0 3 Diaphragm spring end height difference Within 0 5 Opening of release cylinder bore and piston major diameter Above 0 15 Torque Specifications Item Torque Clutch damper bracket attachment bolt 6 5 ft lbs 9 Nm Clutch damper installation bolt 14 ft lbs 19 N m Clutch oil tube filling nut 11 ft lbs 15 Nm Release fork fulcrum 26 ft lbs 38 Nm Clutch oil line bracket attachment bolt 14 ft lbs 19 N m 3 way type connector mounting bolt 14 ft lbs 19 N m Clutch release cylinder mounting bolt 14 ft lbs 19 N m Union bolt 17 ft lbs 23 Nm Clutch cover installation bolt 14 ft lbs 19 N m Clutch release cylinder air breather 8 ft lbs 11 Nm Clutch damper air breather 6
41. ousing support bracket from the old transfer to the new transfer case Coat the output shaft seal of the new transfer case with a small amount of Mopar 75W 90 GL 5 Gear Lube Tighten the transfer case filler and drain plugs to 300 in Ibs 35 N m Safety Recall No B17 Transfer Case Page 20 Service Procedure Continued 13 Coat the transfer case input shaft Fill the transfer case through the output shaft opening with Mopar 75W 90 GL 5 Gear Lube Mopar P N 05010320A A Figure 28 TRASEER CASE WITH NOTE 5 speed transfer cases CORRECT require 9 25 oz 270 cc of gear 75490 GEAR lube 6 speed transfer cases LUBE THROUGH require 20 25 oz 600 cc of gear OUTP lube UART OPENING WARNING Overfilling the transfer case can cause extensive powertrain damage Make sure that the transfer case is filled to the correct level Figure 28 and output shaft splines with Mopar White Lithium Grease Mopar P N 04318066 or equivalent Coat the transaxle output shaft and the driveshaft splines with Mopar White Lithium Grease or equivalent Insert the driveshaft into the transfer case and then mount the transfer case onto the transaxle Figure 27 Install the transfer case mounting bolts and tighten the mounting bolts to 65 fi Ibs 87 N m Figure 27 Remove the temporary driveshaft support Remove the temporary exhaust pipe support and then using the supplied exhaust gaske
42. over and shaft assembly into the special tool 2 Shift both forks in the direction shown in the illustration This will lock the shafts so that the input shaft lock bolt can be removed Manual Transmission Transmission 22 21 TFMOSO1 3 Lock bolt is removed 402 W5MGI Removal of rear cover MB991578 TFM0403 lt W6MG 1 gt MB991580 Adjustment before assembly Selection of spacers for adjustment 1 Place solder length approximately 10 mm and diameter approximately 1 6mm into positions shown in illustration then install outer bearing race 0404 Manual Transmission Transmission Outer bearing i Front 7 Front output shaft HATA TFM0407 Center differential Intermediate shaft 408 2200048 2 Install outer bearing races into the transmission case in the positions shown in the illustration 3 Place solder length approximately 10 mm and diameter approximately 1 6mm into positions shown in illustration then install outer bearing race 4 The front output shaft and front differential are installed on the clutch housing 5 The center differential intermediate shaft and center case are installed at the same time 6 The rear cover is installed and the bolts are tightened to the specifed torque 7 Remove each outer race and remove the solder
43. postcard and mail to DaimlerChrysler Corporation CIMS 482 00 85 800 Chrysler Drive Fast Auburn Hills Michigan 48326 2757 If you have any questions or need assistance in completing this action please contact your Zone Service Office Customer Services Field Operations DaimlerChrysler Corporation
44. r Disassembly Reassembly 8 6 5 ft lbs 9 Nm 5 3 lt J Disassembly Procedure 1 2 Bleeder screw 3 Clutch damper 4 O Ring 6 5 ft lbs 5 Clutch damper bracket 9Nm 0392 Inspection Clutch damper Se 1 Check that there are no scratches on the parts indicated in the illustration 2 Clean completely the inside of the clutch damper and confirm that there is no foreign material left Scratches 0292 Clutch damper bracket 1 Check that there are no scratches of cracks on the part indicated in the drawing and cracks TFM0373 Clutch Clutch Damper 21 11 a I3 TFMO294 Assembly service point BAM Installation of O ring 1 Apply the specified brake fluid onto the O ring and securely install it onto the position of the clutch damper indicated in the illustration Specified brake fluid SAE J1703 DOT3 MANUAL eu TRANSMISSION Maintenance _ Standards Sealants Lubrication Adjustment Spacers Torque Specifications Special Tools Transmission Input Shaft Intermediate Shaf 3rd 4th Gear Synchronizers lt W6MG1 gt 5th 6th Gear Synchronizers lt W6MG1 gt Center Differential Front Output Shaft Rear Cover Speedometer Gear 22 64 Transfer Case 22 2 Manual Tran
45. rd Place the supplied output shaft seal into the extension housing seat Safety Recall No B17 Transfer Case Pape 16 Service Procedure 51 Using a 36mm socket press the output shaft seal into the housing with an arbor press until the new seal contacts the seal seat Figure 23 52 Coat the output shaft seal with a small amount of Mopar 75W WGL 3 Gear Lube EXTENSION HOUSING tA Lui Install a new aluminum gasket onto the drain plug Install the drain plug into the transfer case and ughten the plug to 300 in Ibs 35 N m 54 Clean the transfer case breather and seat apply Mopar Weatherstrip Adhesive Mopar P N 04773774 or equivalent around the breather hole and then install the breather 55 Install a new aluminum gasket onto the tiller plug Install the filler plug into the transfer case and tighten the plug to 300 n Ibs 35 un e Fill the transfer case through the output shaft opening with Mopar 75W 90 GL 5 Gear Lube Mopar P N 05010320AA Figure 24 Figure 24 NOTE 5 speed transfer cases require 9 25 oz 270 cc of gear lube 6 speed transfer cases require 20 25 oz 600 cc of gear lube WARNING Overfilling the transfer case can cause extensive powertrain damage Make sure that the transfer case is filled to the correct level Safety Recall No B17 Transfer Case Page 17 57 58 59 60 6 62 63 Coat the transfer case input shaft
46. re 9 19 If either the input gear or output gear do not rotate smoothly or appear to be damaged then the transfer case must be replaced Continue with Step 10 of Section B Replace Transfer Case 20 Remove the gear housing to adapter housing O ring Figure 10 Use care to not damage the O ring seat 5 SPEED NOTE The O ring is located on the adapter housing for 5 speed equipped vehicles and in the gear housing for 6 speed equipped vehicles 21 Clean the adapter housing tlange and O ring seat 5 speed REMOVE GEAR HOUSING TO 22 Clean the gear housing flange and 6 SPEED a RING O ring seat 6 speed Figure 10 Safety Recall No B17 Transfer Case Service Procedure Continued n2 v Remove the six bolts that secure the gear housing cover to the gear housing Figure 11 IMPORTANT On 5 speed vehicles do NOT remove the bolt in the center of the cover Figure 11 Set the gear housing on the work surface with the cover facing upward While holding the gear housing tap one of the cover bolt bosses until the cover has turned sufficiently Set the gear housing on the work surface with the cover on the side While holding the gear housing with your thumb in the input gear shaft cavity tap the gear housing cover with a plastic hammer until it is separated from the housing Remove the input gear from the gear housing Figure 12 Page 9 REMOVE TH
47. ry depending on how dealer appointments are scheduled and processed What you must do to gt Simply contact your dealer right away to schedule a service ensure your safety appointment Ask the dealer to hold the parts for your vehicle or to order them before your appointment gt Bring the enclosed form with you to your dealer It identifies the required service to the dealer if you need help If you have questions or concerns which thc dealer is unable to resolve please contact the DaimlerChrysler Customer Assistance Center at 1 800 853 1403 A representative will assist you If you have already experienced the problem described above and have paid to have it repaired you may scnd your original receipts and or other adequate proof of payment to the following address for reimbursement DaimlerChrysler Customer Assistance Center P O Box 1040 St Charles MO 63302 1040 Attention Reimbursement If your dealer fails or is unable to remedy this defect without charge and within 2 reasonable time you may submit a written complaint to the Administrator National Highway Traffic Safety Administration 400 Seventh Street S W Washington DC 20590 or call the toll free Auto Safety Hotline at 1 888 327 4236 We re sorry for any inconvenience but we are sincerely concerned about your safety Thank you for your attention to this important matter 54 _ Customer Services Field Operations DaimlerChrysler Corporation BI
48. s 1 Gear Housing Cover O Ring 1 Input Shaft Seal Spacer 2 Filler Drain Plug Gaskets 3 Exhaust Pipe Gaskets 4 Exhaust Pipe Nuts Each dealer to whom vehicles in the recall were invoiced will receive enough Seal Packages to service about 10 of those vehicles B Transfer Case Due to the small number of involved vehicles expected to requirc transfer case replacement no parts will be distributed initially Transfer cases should be ordered only after inspection determines that replacement is required Very few vehicles are expected to require transfer case replacement Inspect the current transfer case serial number to ensure the correct replacement part is ordered The serial number is located on the bottom of the transfer case extension housing 2 er 5 Speed 1991 1992 built through 10 15 91 CBATBI71 Speed 1992 built after 10 15 91 1993 Nxxaxxxx CBATBI72 Speed 1994 1995 1996 CBATBI73 Each package contains a transfer case two exhaust gaskets and four nuts IMPORTANT The P N CBATB171 5 Speed Transfer Case will not be available until late December 2002 Safety Recall No B17 Transfer Case Page 3 A Inspec Tr er 1 Raise vehicle on an appropriate hoist 2 Inspect the transfer case for indications of oil leakage gt Ifevidence of oil leakage is noted continue with Step 3 gt oil leakage is noted a Remove the transfer case breather Figure 1 b Remove the tran
49. sfer case filler plug c Remove the transfer case drain plug and drain the fluid from the transfer case Figure 1 d Clean the drain plug and then install it into the transfer case DRAIN PLUG FRONT Tighten the drain plug to 300 in Ibs 35 N m Figure 1 Fill the transfer case with Mopar 75W 90 GL 5 Gear Lube Mopar P N 05010320AA NOTE 5 speed transaxle vehicles require 8 5 oz 250 cc of gear lube 6 speed transaxle vehicles require 18 5 oz 550 cc of gear lube WARNING Overfilling the transfer case can cause extensive powertrain damage Make sure that the transfer case is filled to the correct level f Clean the filler plug and then install it into the transfer case Tighten the filler plug to 300 in Ibs 35 N m Safety Recall No B17 Transfer Case Page Service Procedure Continoed g Clean the transfer case breather and seat apply Mopar Weatherstrip Adhesive Mopar P N 04773774 or equivalent around the breather hole and then install the breather h Lower the vehicle and return it to the customer no further action is necessary 3 Inspect the transfer case for signs of any cracks or breaks If cracks or breaks are found continue with Section B Replace Transfer Case If no cracks or breaks are found continue with Step 4 4 Remove the transfer case filler plug Remove the transfer case dram plug and drain the from the transfer case Figure 1 6 Remove the two nuts
50. smission MB990938 MB9909 TO N TFM0423 oF 0424 0418 Ft Installation of outer bearing race 04 Installation of oil seal 1 After installation of oil seal fill the lip section with specified grease Specified grease Molykote TA 1 or 2 BH Installation of outer bearing race Installation of outer bearing race 4 Installation of transmission case 1 Apply sealant to the illustrated position on the rear cover Sealant Brand Loc tite 17430 or Mitsubishi Genuine Sealant MD997740 Note Squeeze out sealant from tube uniformly without excess or discontinuity Manual Transmission Transmission 22 27 lt W6MGI gt TFMO419 TFM0054 TFM0507 3 The dowel pin is driven into place from the direction shown in the illustration 4 Apply thread locking compound to the threads of the bolt and tighten to the specified torque Note Brand Loc tite 242 3M Threadlocker 4170 or equivalent K4 Installation of stopper plate 1 Install the bolts into the stopper plate 2 Apply thread locking compound to the threads of the bolt and tighten to the specified torque Note Brand Loc tite 242 3M Threadlocker 4170 or equivalent 2 TFMO0420 MB990938 Manual Transmission Transmission Lg I
51. smission Summary nn Cross section W5MG1 Manual Transmission Summar 22 Cross section W6MG1 22 4 Manual Transmission Specifications Transmission types 1991 Model Year Ratio Speedometer 8 Transaxle model 561 gear ratio Final Drive Chassis Engine type W5MG1 0 FNBR A 27 36 3 972 Z15A 216 6G72 DOHC T C 1992 Model Year Ratio Speedometer Transaxle model set gear ratio Final Drive Chassis Engine type W5MG1 1 FNCR A 27 36 3 972 Z15A Z16A 6G72 DOHC T C 1993 Model Year Ratio Speedometer A R Transaxle model set gear ratio Final Drive Chassis Engine type W5MG1 2 FNCR A 27 36 3 972 Z15A 216 6G72 DOHC 1994 Model Year Asian Market Ratio Speedometer 3 Transaxle model st gear ratio Final Drive Chassis Engine type W6MG1 0 GNCR B 28 36 4 155 Z15A 216 6G72 DOHC T C 1994 Model Year North American Market Ratio Speedometer a gt Transaxle model sat gear ratio Final Drive Chassis Engine type W6MG1 0 FNBR B 28 36 3 869 215A 216 6G72 DOHC T C Gear ratio sets A 1st Gear 3 071 2nd Gear 1 739 3rd Gear 1 103 4th Gear 0 823 5th Gear 0 659 6th Gear NA
52. t 14 ft lbs 19 Nm Sen Oil fill plug 5 5 ft lbs 7 5 Nm Manual Transmission Special Tools e2 9 Tool Number Name Usage MB990934 Installer Installation of outer bearing race adapter MB990936 Installer Installation of outer bearing race adapter MB990037 Installer Installation of outer bearing race adapter MB990938 Handle For use with installer adapters MB991550 Outer bearing Installation of outer bearing race race installer MB991551 Outer bearing Installation of outer bearing race race installer MB991577 Outer bearing Installation of outer bearing race race installer MB991578 An Removal of rear cover 8 5 MIT W5MG1 W6MG1 Rear cover MB991580 puller adapter Removal of rear cover 6 MIT W6MG1 d Removal of input shaft lock bolt MB991559 ar and installation of rear cover W5MG1 W6MG1 22 10 Manual Transmission Special Tools Number Name Usage Removal of input shaft lock bolt W5MG1 W6MG1 Installation of rear cover W5MG1 W6MG1 MB991591 Working base adapter set MD998304 Oil seal installer Insta ation of transfer case tail housing oil seal MD998320 Oil seal installer Installation of output shaft oil seal MD998325 Differential Installation of axle shaft oil seal oil seal installer MD998349 Oil seal installer Removal and installation of input shaft front bearing MD998369 Oil seal installer Installatio
53. t in cleaning solvent or the like 1 Check bearing for seizure damage noise or improper rotation Check also diaphragm spring contact surface for wear 2 Replace bearing if its release fork contact surface is abnormally worn Release fork 1 Replace release fork if its bearing contact surface is abnormally worn 21 6 Clutch Clutch Assembly Installation service points 8A Installation of clutch release bearing 1 Fill the lip section with grease as illustrated Specified grease Molykote TA 2 NA AD de A 3 ten 84 Lubrication of release fork 1 Apply grease to release fork as illustrated Specified grease Molykote TA 2 3 1 0002 AE RN NOS AN 3CL0003 Clutch Clutch Assembly 21 7 Flywheel fh MD998 26 Clutch cover 6CL028 3CL0004 8C4 Installation of clutch disk cover 1 Apply specified grease to clutch disc splines and squeeze it in place with a brush Specified grease Molykote TA 1 or 2 2 Use the clutch disc guide to position clutch disc on flywheel 3 When installing the clutch cover tighten the bolts in a diagonal pattern 4 Remove clutch guide tool D4 Installation of clutch release cylinder 1 Apply grease to tip of release cylinder pushrod as illustrated Specified grease Molykote TA 2 21 8 Clutch Clutch Release Cylinder Disassembly
54. ten to the specified torque Note Brand Loc tite 242 3M Threadlocker 4170 or equivalent 4installation of guide bolt 1 Apply thread locking compound to the threads of the bolt and tighten to the specified torque Note Brand Loc tite 242 3M Threadlocker 4170 or equivalent TFM0434 W4 Installation of guide bolt 1 Apply thread locking compound to the threads of the bolt and tighten to the specified torque Note Brand Loc tite 242 3M Threadlocker 4170 or equivalent 0517 Manual Transmission Transmission 22 33 TFMOSI8 TFM0054 2 OX vll SE im X4 Installation of shift detent 1 Apply thread locking compound to the threads of the bolt and tighten to the specified torque Note Brand Loc tite 242 3M Threadlocker 4170 or equivalent 8Y4 Installation of gear select lever 1 Apply thread locking compound to the threads of the bolt and tighten to the specified torque Note Brand Loc tite 242 3M Threadlocker 4170 or equivalent 74 Installation of vents 1 Install the vent covers in the position shown in the installation AA4 Installation of transfer case 1 Apply specified grease to the splined sections of the center output shaft and the transfer case Specified grease Molykote TA 1 or 2 22 34 Manual Transmission Input Shaft Disassembly Reassembly W5MG1
55. that secure sn INNECT DISCONNECT the Piha pipe to x iih EROR Oa GT EXHAUST PIPE turbocharger mounted catalytic FROM FRONT EAR ya TURBOCHARGER CATALYST converter Figure 2 Discard he nuts Remove the two nuts that secure the front catalytic converter to the front turbocharger outlet Figure 2 Discard the nuts 8 Disconnect the front exhaust pipe su Fi 2 i EXHAUST pport Figure 2 Disconnect the FRONT PIPE front exhaust pipe and temporarily EXHAUST SUPPORT support the front exhaust pipe with CUNT a wire or bunjee cord 9 Remove and discard the two Figure 2 exhaust gaskets Safety Recall No B17 Transfer Case Page 5 e Procedure Continued 10 Remove the five bolts that secure gl the transfer case to the transaxle f N TRANSAXLE Figure 3 NOTE The upper mounting bolt may be hidden from view DISCONNECT TRANSFER CASE FROM DRIVESHAFT Separate the transfer case trom the transaxle If necessary tap the transfer case with a plastic hammer to loosen it P lt lt 12 Remove the transfer case from the transaxle by tilting the case downward then disconnect the RENOVERIVE TRANSFER transfer case from the drive shaft CASE TO TRANSAXLE BOLTS and set it on a clean work surface Figure 3 IMPORTANT Do NOT allow _ GE ADAPTER the drive shaft to hang as this HOUSING could damage the universal joint or bend the shaft Support the drive shaft with a wire or bunje
56. ts and nuts reconnect the front exhaust pipe to the front turbocharger outlet and the rear catalytic converter Figure 26 Tighten the exhaust nuts to 37 ft lbs 50 Nm Connect the front exhaust pipe support Figure 26 20 Lower the vehicle 21 Test drive the vehicle and verify that there are no leaks Safety Recall No B17 Transfer Case Page 21 Claims for vehicles that have been serviced must be submitted on the DIAL System Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments Use one of the following labor operation numbers and time allowances Labor Operation Time Number Allowance Inspect transfer case and change T C oil 21 BI 71 81 0 3 hours Inspect and reseal transfer case 21 1 71 82 1 4 hours Inspect and replace cracked transfer case 21 B1 71 83 0 8 hours Inspect disassemble T C inspect gears 21 1 71 84 1 1 hours and replace transfer case Add the cost of the recall parts package if necessary plus applicable dealer allowance to your claim Removed transfer cases must be returned to the Warranty Material Return Center Removed transfer cases must be drained and fully assembled NOTE Sce the Warranty Administration Manual Recall Claim Processing and Material Return Sections for complete recall claim processing instructions All dealers will receive a copy of this dealer recall notification letter by first class mail An additional copy will be s
57. urfaces and mating surfaces y 9 Viscosity 75W 90 to 75W 85W Manual Transmission Adjustment Spacers 22 7 Name Thickness in mm 0 15 Input shaft end bearing me adjustment spacers 0 40 0 50 0 20 Intermediate shaft preload 0 25 adjustment spacers 0 30 0 50 0 20 Center differential preload 0 25 adjustment spacers 0 30 0 50 0 10 0 15 Front output shaft preload 0 20 adjustment spacers 0 50 1 00 0 10 Front differential preload zem adjustment spacers 0 30 0 50 e2 8 Manual Transmission Torque Specifications Item Torque Remark Input shaft bearing retainer bolt 7 ft lbs 10 Nm Reverse gear shaft bolt 18 ft lbs 25 Nm W5MG1 Reverse gear carrier bolt 18 ft lbs 25 Nm W6MG1 Input shaft lock bolt 70 ft lbs 95 Nm Stopper plate bolt 7 ft bs 10 Nm TEN Center case to clutch housing bolt 18 ft lbs 25 Nm Center case to rear cover bolt 18 ft lbs 25 Nm Shift shaft bolt 7 ft lbs 10 Nm M Shift shaft guide bolt 17 ft lbs 23 Nm W5MG1 Detent 22 ft lbs 30 Nm W6MG1 Guide bolt 15 ft lbs 20 Nm W6MG1 Oil tank bolt 5 ft lbs 7 Nm W6MG1 Reverse shift damper 24 ft lbs 33 Nm W6MG1 Select lever bolt 18 ft lbs 25 Nm LL Poppet cover bolt 7 ft lbs 10 Nm Gg Reverse light switch 24 ft lbs 32 Nm EI Speedometer gear bolt 3 ft lbs 4 Nm n Transfer case bolt 63 ft lbs 86 Nm ya Transmission bracket mounting bolt 52 ft lbs 70 Nm Shift cable bracket bol

W5MG1 W6MG1 AWD Trans Service - Searchable

Contents

Download Pdf Manuals

Related Search

Related Contents