Part 2 of 3
INSPECTION
INPUT SHAFT
- Check the outer surface of the input shaft where the needle bearing is mounted for damage, abnormal wear and seizure [portion A].
- Check the splines for damage and wear.
NEEDLE BEARING
- Mate the needle bearing with the shaft or bearing sleeve and gear, and check to see if rotation is smooth with no binding, noise, or play.
- Check the needle bearing cage for possible deformation.
SYNCHRONIZER RING
- Check the clutch gear teeth for damage and breakage.
- Check the cone inside paper lining for damage, wear or peeling.
- Force the synchronizer ring toward the clutch gear and check clearance "A". Replace if the clearance is below the limit.
Limit: 0.5 mm (0.020 in.)
SYNCHRONIZER SLEEVE AND HUB
- Mate the synchronizer sleeve with the hub and check to see if they slide smoothly.
- Check to see if the sleeve is free from damage at its inside front and rear ends.
- Check the hub front and rear end faces (in contact with each speed gear) for wear.
CAUTION: When replacement is necessary, replace the synchronizer hub and sleeve as a set.
SYNCHRONIZER KEY AND SPRING
- Check the synchronizer key center protrusion for wear.
- Check the spring for proper tension, possible deformation and breakage.
SPEED GEARS
- Check the bevel and clutch gear teeth for damage and wear.
- Check the synchronizer cone for rough surfaces, damage and wear.
- Check the gear bore and front and rear ends for damage and wear.
REASSEMBLY SERVICE POINTS
A - SUB GEAR/CONE SPRING/SNAP RING INSTALLATION
Install the sub gear and cone spring to 3rd speed gear, and then install the snap ring.
NOTE: Be sure that the cone spring is installed so that it is facing in the correct direction.
B - SYNCHRONIZER SPRING INSTALLATION
Install the synchronizer springs so that its protrusion fits into the groove in the synchronizer key. Make sure that the protrusions in the front and rear springs are not in the groove of the same key.
C - BEARING SLEEVE INSTALLATION
Using the special tool, press-fit the bearing sleeve.
D - BALL BEARING INSTALLATION
Using the special tools, press-fit the bearing over the input shaft.
CAUTION: Apply the special tool to the inner race only when installing the bearing.
E - SNAP RING INSTALLATION
1. Select the thickest snap ring that fits the snap ring groove.
Standard value: 0-0.09 mm (0-0.0035 in.)
2. Using the special tool, fit the snap ring to the input shaft.
NOTE:
- Do not reuse the snap ring.
- The use of snap ring pliers can cause the snap ring to expand too much, making correct installation of the sleeve difficult.
F - BEARING SLEEVE INSTALLATION
Using the special tool, install the bearing sleeve over the input shaft.
CAUTION: When the sleeve has been press fitted over the input shaft, make sure that the sleeve flange is in tight contact with the bearing.
G - BALL BEARING INSTALLATION
Using the special tool, press-fit the ball bearing over the input shaft.
INTERMEDIATE GEAR DISASSEMBLY AND REASSEMBLY
DISASSEMBLY SERVICE POINTS
A - TAPER ROLLER BEARING/1ST SPEED GEAR REMOVAL
Using the special tool, remove the taper roller bearing, the 1st speed gear, and the bearing sleeve.
CAUTION:
- Do not reuse the bearing if it has been removed from the shaft.
- Replace the inner and outer races of the taper roller bearing as a set.
B - 1ST-2ND SPEED SYNCHRONIZER HUB/2ND SPEED GEAR REMOVAL
Using the special tool, remove the 1st-2nd speed synchronizer assembly and 2nd speed gear.
C - TAPER ROLLER BEARING REMOVAL
Using the special tool, remove the taper roller bearing.
CAUTION:
- Do not reuse the bearing if it has been removed from the shaft.
- Replace the inner and outer races of the taper roller bearing as a set.
INSPECTION
INTERMEDIATE GEAR
- Check the outer surface of the intermediate gear where the needle bearing is mounted for damage, abnormal wear, and seizure (portion A).
- Check splines for damage and wear.
NEEDLE BEARING
- Mate the needle bearing with the shaft or bearing sleeve and gear, and check to see if rotation is smooth with no binding, noise, or play.
- Check the needle bearing cage for possible deformation.
SYNCHRONIZER RING
- Check the clutch gear teeth for damage and breakage.
- Check the inside surface for damage, wear, and collapsed threads.
- Force the synchronizer ring toward the clutch gear and check clearance "A". Replace if the measurement is below the limit.
Limit: 0.5 mm (0.020 in.)
SYNCHRONIZER SLEEVE AND HUB
- Mate the synchronizer sleeve with the hub and check to see if they slide smoothly.
- Check to see if the sleeve is free from damage at its inside front and rear ends.
- Check the hub front and rear end faces (in contact with each speed gear) for wear.
CAUTION: When replacement is necessary, replace the synchronizer hub and sleeve as a set.
SYNCHRONIZER KEY AND SPRING
- Check the synchronizer key center protrusion for wear.
- Check the spring for proper tension, possible deformation and breakage.
SPEED GEARS
- Check the bevel and clutch gear teeth for damage and wear.
- Check the synchronizer cone for rough surface, damage, and wear.
- Check the gear bore and front and rear ends for damage and wear.
REASSEMBLY SERVICE POINTS
A - TAPER ROLLER BEARING INSTALLATION
Using the special tool No. MD998817(F5M22) MD998819(F5M31), press-fit the taper roller bearing over the intermediate gear.
CAUTION: Apply pressure with the special tool only to the inner race when installing the bearing.
B - SYNCHRONIZER RING INSTALLATION
Note the identification mark made on the 1st speed synchronizer ring.
C - 1ST-2ND SYNCHRONIZER HUB/SYNCHRONIZER KEY/1ST-2ND SYNCHRONIZER SLEEVE/SYNCHRONIZER SPRING INSTALLATION
1. Mate the 1st-2nd speed synchronizer hub and sleeve as shown.
2. Install the synchronizer spring so that its protrusion fits into the groove in synchronizer key.
CAUTION: Make sure that the protrusions in the front and rear springs are not in the groove of the same key.
NOTE: A synchronizer spring different from the one shown in the image may be used but the explanation is the same.
3. Using the special tool, press-fit the 1st-2nd speed synchronizer assembly over the intermediate gear.
CAUTION:
- When installing the synchronizer assembly, make sure that the three synchronizer keys are seated correctly in their respective grooves in the synchronizer ring.
- After installing the synchronizer assembly, check to see if the 3rd speed gear rotates smoothly.
D - BEARING SLEEVE INSTALLATION
Using the special tool, press-fit the 1st speed gear and bearing sleeve.
E - TAPER ROLLER BEARING INSTALLATION
Using the special tool, press-fit the taper roller bearing.
CAUTION: Apply pressure with the special tool only to the inner race when installing the bearing.
F - SNAP RING INSTALLATION
Select and install the snap ring so that the end play of the intermediate shaft is up to specification.
Standard value: 0.01-0.11 mm (0.0004-0.0044 in.)
SHIFT RAIL DISASSEMBLY AND REASSEMBLY
REASSEMBLY SERVICE POINT
A - INTERLOCK PLUNGER INSTALLATION
Insert the interlock plunger at illustrated position of the 3rd-4th speed shift rail.
DIFFERENTIAL DISASSEMBLY AND REASSEMBLY
DISASSEMBLY SERVICE POINTS
A - BALL BEARING REMOVAL
Using the special tool, remove the ball bearing.
CAUTION: Do not reuse the bearing if it has been removed from the differential case.
B - LOCK PIN REMOVAL
Drive out the lock pin from hole A using a punch.
ADJUSTMENT OF PINION BACKLASH
Measure the backlash between the side gears and pinions. Adjust for the same backlash of both side gears.
Standard Value: 0.025-0.150 mm (0.00098-0.00591 in.)
If backlash is out of specification, disassemble again and correct spacer, reassemble and adjust.
REASSEMBLY SERVICE POINTS
A - LOCK PIN INSTALLATION
Align the lock pin hole in the pinion shaft with that in the case and press the lock pin into position.
CAUTION:
- Do not reuse the lick pin.
- Make sure the lock pin head is lower than the differential case flange surface.
B - BALL BEARINGS INSTALLATION
Install the ball bearing in both sides of the differential case.
C - SEALANT TO BOLTS APPLICATION
Apply specified MOPAR Part No.4318031 or No.4318032 or equivalent sealant to the entire threads of the bolts and quickly tighten in the order shown to specified torque.
CAUTION: If a bolt is reused, remove traces of oil, adhesive completely from the threads.
SPEEDOMETER DRIVEN GEAR DISASSEMBLY AND REASSEMBLY
REASSEMBLY SERVICE POINTS
A - SPEEDOMETER DRIVEN GEAR INSTALLATION
Apply gear oil sparingly to the speedometer driven gear shaft and insert the shaft.
B - SPRING PIN INSTALLATION
Install the spring pin in such a way that its slit does not face the gear shaft.
CENTER DIFFERENTIAL DISASSEMBLY AND ASSEMBLY
DISASSEMBLY SERVICE POINTS
A - TAPER ROLLER BEARINGS REMOVAL
Using the special tool, remove the taper roller bearings.
CAUTION:
- Do not reuse the bearing if it has been removed from the shaft.
- Replace the inner and outer races of the taper roller bearing as a set.
REASSEMBLY SERVICE POINTS
PINION BACKLASH ADJUSTMENT
1. Install the spacer, side gear, pinion gear, washer, and pinion shaft into the center differential case.
2. Select and install the thickest spacer that ensures smooth and light rotation of the pinion gear when turned while holding the pinion shaft.
3. Install the side gear, spacer, and output gear, and tighten bolts to specification.
4. Select and install the thickest spacer, that allows smooth rotation of side gear.
5. Make sure that the two side gears turn smoothly.
Standard value: Center differential pinion backlash 0.025-0.150 mm (0.00098-0.00591 in.)
A - TAPER ROLLER BEARINGS INSTALLATION
Using the special tool, press-fit the taper roller bearing into position.
CAUTION: Apply the special tool to the inner race only when installing the bearing.
B - SEALANT TO BOLTS APPLICATION
Apply MOPAR Part No.4318031 or No.4318032 or equivalent sealant to the entire thread section of the bolts and quickly tighten bolts to specification in the order shown.
NOTE: If the bolts are to be reused, completely remove the old sealant from the threads.
C - TAPER ROLLER BEARINGS INSTALLATION
Using the special tool, press-fit the taper roller bearing into position.
CAUTION: Apply the special tool to the inner race only when installing the bearing.
FRONT OUTPUT SHAFT DISASSEMBLY AND ASSEMBLY
DISASSEMBLY SERVICE POINT
A - TAPER ROLLER BEARINGS REMOVAL
Using the special tool, remove the taper roller bearing.
CAUTION:
- Do not reuse the bearing if it has been removed from the shaft.
- Replace the inner and outer races of the taper roller bearing as a set.
REASSEMBLY SERVICE POINTS
A - TAPER ROLLER BEARING INSTALLATION
Using the special tool, press fit the taper roller bearing into position.
CAUTION: Apply the special tool to the inner race only when installing the bearing.
B - TAPER ROLLER BEARING INSTALLATION
Using the special tool, press fit the taper roller bearing into position.
CAUTION: Apply the special tool to the inner race only when installing the bearing.
CLUTCH HOUSING DISASSEMBLY AND REASSEMBLY
DISASSEMBLY SERVICE POINTS
A - LOCK PIN REMOVAL
Drive out the lock pin from the control finger.
CAUTION: When removing the lock pin, turn the control lever to a position so that the lock pin will not contact the clutch housing.
B - SPRING PIN REMOVAL
Drive out the spring pin from the stopper body.
CAUTION: When removing the spring pin, pull the control shaft in the direction shown so that the spring pin will not contact the clutch housing.
C - NEEDLE BEARING REMOVAL
Drive out the needle bearing using a socket wrench.