Transaxle: NV T350 (A-578) Manual Transaxle

PL TRANSAXLE 21 - 1
TRANSAXLE
CONTENTS
page page
31TH AUTOMATIC TRANSAXLE . . . . . . . . . . . . . 40 NV T350 (A-578) MANUAL TRANSAXLE . . . . . . . 1
NV T350 (A-578) MANUAL TRANSAXLE
INDEX
page page
GENERAL INFORMATION GEARSHIFT KNOB . . . . . . . . . . . . . . . . . . . . . . . 4

GEAR RATIOS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GEARSHIFT MECHANISM REPLACEMENT . . . . . 6
GEARSHIFT PATTERN . . . . . . . . . . . . . . . . . . . . . 2 SELECTOR LEVER . . . . . . . . . . . . . . . . . . . . . . . 8
NV T350 MANUAL TRANSAXLE . . . . . . . . . . . . . . 1 SHIFT SHAFT SEALS . . . . . . . . . . . . . . . . . . . . . . 8
SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SELECTION OF LUBRICANT . . . . . . . . . . . . . . . . 2 VEHICLE SPEED SENSOR DRIVE GEAR . . . . . . 7
SPECIAL ADDITIVES . . . . . . . . . . . . . . . . . . . . . . 2 DISASSEMBLY AND ASSEMBLY
TRANSAXLE IDENTIFICATION INFORMATION . . . 2 DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . 24
DESCRIPTION AND OPERATION INPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 20
AXLE SEALS . . . . . . . . . . . . . . . . . . . . . . . . . ... 3 OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . 24
SHIFT LEVERS . . . . . . . . . . . . . . . . . . . . . . . ... 3 SHIFT RAILS OVERHAUL . . . . . . . . . . . . . . . . . 29
DIAGNOSIS AND TESTING SYNCHRONIZER . . . . . . . . . . . . . . . . . . . . . . . . 29
CLUTCH PROBLEMS . . . . . . . . . . . . . . . . . . . . . . 3 TRANSAXLE CASE OVERHAUL . . . . . . . . . . . . . 30
COMMON PROBLEM CAUSES . . . . . . . . . . . . . . 3 TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
HARD SHIFTING . . . . . . . . . . . . . . . . . . . . . . . . . 3 CLEANING AND INSPECTION
LOW LUBRICANT LEVEL . . . . . . . . . . . . . . . . . . . 3 SYNCHRONIZER . . . . . . . . . . . . . . . . . . . . . . . . 35
NOISY OPERATION . . . . . . . . . . . . . . . . . . . . . . . 3 TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
SLIPS OUT OF GEAR . . . . . . . . . . . . . . . . . . . . . 3 ADJUSTMENTS
SERVICE PROCEDURES BEARING ADJUSTMENT PROCEDURE . . . . . . . 35
FLUID DRAIN AND FILL . . . . . . . . . . . . . . . . . ... 3 DIFFERENTIAL BEARING PRELOAD
REMOVAL AND INSTALLATION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . 36
AXLE SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 GEARSHIFT CROSSOVER CABLE . . . . . . . . . . . 35
BACK-UP LAMP SWITCH . . . . . . . . . . . . . . . . . . . 7 SPECIFICATIONS
CROSSOVER LEVER . . . . . . . . . . . . . . . . . . . . . . 7 NV T350 (A-578) SPECIFICATIONS . . . . . . . . . . 37
GEARSHIFT BOOT . . . . . . . . . . . . . . . . . . . . . . . 4 SPECIAL TOOLS
GEARSHIFT CABLES . . . . . . . . . . . . . . . . . . . . . . 4 NV T350 (A-578) MANUAL TRANSAXLE . . . . . . . 37
GENERAL INFORMATION ring for shifting ease. The reverse idler gear is sup-
ported on a sliding spindle idler shaft. The transaxle
NV T350 MANUAL TRANSAXLE case is aluminum with a steel end–plate bearing
cover. It is housed in a die-cast aluminum case fea-
NOTE: Safety goggles should be worn at all times turing a two–piece, middle split design.
when working on these transaxles. The NV T350 (A-578) transaxle internal compo-
nents can be serviced only by separating the gear
This five speed is a constant-mesh manual tran- case from the bellhousing case.
saxle. All gear ranges, except reverse, are synchro-
nized. The reverse gear utilizes a brake and blocking
21 - 2 TRANSAXLE PL
GENERAL INFORMATION (Continued)
CAUTION: The transaxle output shaft is serviced as aid in detecting fluid leaks. The use of transmission
a unit. No disassembly and reassembly is possible. sealers should be avoided, since they may adversely
Damage to the transaxle may result. affect seals.
SEALANTS
TRANSAXLE IDENTIFICATION INFORMATION The sealant used to seal the transaxle case halves
The transaxle model, assembly number, and build and input bearing is Mopart Gasket Maker, Loctitet
date are on a metal I.D. tag that is attached to the 518, or equivalent. The sealant used for the bearing
end cover of the transaxle (Fig. 1). This information end plate cover is Mopart RTV.
is also shown on a bar code label that is attached to
the front of the transaxle. GEAR RATIOS
CAUTION: All gears and shafts must not be inter-
changed with other transaxles; they will not func-
tion correctly.
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 lb. ft.
The gear ratios of each transaxle are shown in the
following chart. The chart also shows which transax-
les are available with the reverse–input shaft brake.
This brake allows easier shifting into reverse and
helps eliminate reverse gear clash.
Fig. 1 Metal I.D. Tag

ENGINE 2.0 SOHC 1.8 BUX or 1.8 RIGHT
NOTE: Transaxles use various final drive gear EUROPE 2.0L HAND
ratios in different vehicle applications. Therefore, it AND U.S. SALES DRIVE
is necessary that the correct transaxle assembly CODE ONLY
number is used when ordering service parts. ACR
The last eight digits of the Vehicle Identification GEAR
Number (V.I.N.) are stamped on the case, below the 1st 3.54 3.54 3.54
back–up lamp switch. 2nd 2.13 2.13 2.13
NOTE: There are four different versions of this 3rd 1.36 1.36 1.36
transaxle. There are no external differences 4th 1.03 1.03 1.03
between the models. Refer to the identification tag 5th 0.72 0.81 0.81
on the transaxle to determine which transaxle the
FINAL 3.55 3.94 3.94
vehicle is equipped with.
DRIVE
REVERSE NO YES YES
SELECTION OF LUBRICANT BRAKE
NV T350 (A-578) transaxles use Mopart Type M.S. CLUTCH CABLE CABLE HYDRAULIC
9417 Manual Transaxle Fluid. Hypoid gear lube, RELEASE
engine oil, and/or automatic transmission fluid SYSTEM
should not be used in this transaxle. Hard shift-
ing effort, bearing, gear, and/or synchronizer failure GEARSHIFT PATTERN
may occur if incorrect fluid is used.
The NV T350 (A-578) transaxle shift pattern is a
modified H–pattern (Fig. 2). Overdrive fifth and
SPECIAL ADDITIVES reverse gears are in–line and outboard of the first
The addition of any fluids to the transaxle, other
through fourth gear positions.
than the fluid listed above, is not recommended. An
exception to this policy is the use of special dyes to
PL TRANSAXLE 21 - 3
NOISY OPERATION
Transaxle noise is most often a result of worn or
damaged components. Chipped, broken gear or syn-
chronizer teeth, and brinnelled, spalled bearings all
cause noise.
Abnormal wear and damage to the internal compo-
nents is frequently the end result of insufficient
lubricant.
SLIPS OUT OF GEAR

Transaxle disengagement may be caused by mis-
aligned or damaged shift components, or worn teeth
on the drive gears or synchronizer components. Incor-
rect assembly also causes gear disengagement.
LOW LUBRICANT LEVEL

Fig. 2 NV T350 (A-578) Shift Pattern Insufficient transaxle lubricant is usually the
DESCRIPTION AND OPERATION result of leaks, or inaccurate fluid level check or refill
method. Leakage is evident by the presence of oil
SHIFT LEVERS around the leak point. If leakage is not evident, the
The shift levers are serviceable in the vehicle. The condition is probably the result of an underfill.
shift levers are different from each other and do not If air–powered lubrication equipment is used to fill
interchange. a transaxle, be sure the equipment is properly cali-
brated. Equipment out of calibration can lead to an
SELECTOR LEVER underfill condition.
The selector shaft uses a lever with a weight on
the end. The weight is used to improve shift feel and CLUTCH PROBLEMS
reduce noise. Worn, damaged, or misaligned clutch components
The selector lever is retained by two roll pins (one can cause difficult shifting, gear clash, and noise.
inside the other). A worn or damaged clutch disc, pressure plate, or
release bearing can cause hard shifting and gear
AXLE SEALS clash.
The axle shaft seals are identical for both sides of
the differential and will interchange.
SERVICE PROCEDURES
DIAGNOSIS AND TESTING FLUID DRAIN AND FILL

All NV T350 (A-578) transaxles are equipped with
COMMON PROBLEM CAUSES a fill plug. The fill plug is located on the left side of
The majority of transaxle malfunctions are a result the transaxle differential area (Fig. 3). The fluid level
of: should be within 3/16 inch from the bottom of the
• Insufficient lubrication transaxle fill hole (vehicle must be level when check-
• Incorrect lubricant ing).
• Misassembled or damaged internal components All NV T350 (A-578) transaxles are equipped with
• Improper operation a drain plug. The drain plug is located on the lower
right side of the transaxle differential housing (Fig.
HARD SHIFTING 4). Tighten drain plug to 28 N·m (250 in. lbs.)
Hard shifting may be caused by a misadjusted Dry fill lubricant capacity is approximately 1.9-2.2
crossover cable. If hard shifting is accompanied by liters (4.0-4.6 pints). Wipe the outside of the tran-
gear clash, synchronizer clutch and stop rings, or saxle if any lubricant spills.
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.
21 - 4 TRANSAXLE PL
SERVICE PROCEDURES (Continued)
Fig. 3 Fill Plug Location Fig. 5 Gearshift Knob

(3) Snip the plastic retaining clips at the base of
the boot (Fig. 6). Remove the boot from the gearshift
mechanism.
Fig. 4 Drain Plug Location

REMOVAL AND INSTALLATION
GEARSHIFT KNOB Fig. 6 Gearshift Boot
INSTALLATION
REMOVAL
(1) For installation, reverse removal procedure.
(1) Pull shifter boot down and away from shifter
Install new plastic retaining clips.
roll pin.
(2) Pry legs of shift knob away from shift lever roll GEARSHIFT CABLES
pin using a flat blade pry tool.
Use this procedure if either of the shift cables
(3) Remove knob from shifter handle (Fig. 5).
require replacement.
INSTALLATION
REMOVAL
(1) For installation, reverse removal procedure.
(1) Disconnect Power Distribution Center from
battery tray and set aside.
GEARSHIFT BOOT (2) Remove air cleaner inlet horn.
REMOVAL (3) Remove battery and battery tray.
(1) Remove shifter knob. Refer to gearshift knob (4) Disconnect gear shift cable ends from transaxle
removal. shift levers (Fig. 7) (Fig. 8).
(2) Remove the console assembly. Refer to Group
CAUTION: Pry up with equal force on both sides of
23, Body.
shifter cable isolator bushings to avoid damaging
cable isolator bushings.
PL TRANSAXLE 21 - 5
REMOVAL AND INSTALLATION (Continued)
Fig. 7 Selector Cable Removal Fig. 9 Grommet Retaining Nuts (Interior)
Fig. 8 Crossover Cable Removal Fig. 10 Cable Retaining Clips

(5) Remove cable to bracket retaining clips at tran- (11) Lift vehicle on hoist. Remove self-tapping
saxle. screw securing grommet plate to underbody heat
shield and floor pan (Fig. 11).
CAUTION: It is recommended that new cable retain-
ing clips be used for reinstallation.
(6) Pull cables up out of transaxle bracket.

(7) Remove console from vehicle. Refer to Group
23, Body.
(8) Remove floor pan grommet retaining nuts (Fig.
9).
(9) Remove cable retaining clips at shifter (Fig.
10).
CAUTION: It is recommended that new cable retain-

ing clips be used for reinstallation.
(10) Disconnect shift cables from shifter. Pry with

equal force on both sides of shifter cable isolator
bushings to avoid damaging bushings.
Fig. 11 Grommet Retaining Screw (Underbody)
21 - 6 TRANSAXLE PL
(12) Detach cables from cable support clip in tun-
nel above exhaust catalyst.
(13) Remove shift cable assembly from vehicle.
INSTALLATION
CAUTION: Gearshift cable bushings must not be

lubricated or the bushings will swell and split.
(1) To install, reverse removal procedure. After

cables have been replaced, cable adjustment should
be checked. Refer to cable adjustment procedure in
this section.
CAUTION: Only the crossover cable is adjustable.

The selector cable does not have any adjustment
capabilities.
Fig. 13 Crossover Lever Pin Procedure
GEARSHIFT CROSSOVER CABLE

GEARSHIFT MECHANISM REPLACEMENT
ADJUSTMENT REMOVAL
(1) Remove shift console from vehicle. (1) Remove shifter knob.
(2) Loosen adjusting screw on crossover cable at (2) Remove console assembly. Refer to Group 23,
shifter (Fig. 12). Body for procedure.
(3) Remove shifter boot.
(4) Disconnect gearshift cables at shifter end.
(5) Remove the parking brake mechanism. Refer to
Group 5, Brakes for procedure.
(6) Remove the airbag control module. Refer to
Group 8M, Passive Restraint System for procedure.
(7) Remove the two remaining nuts at the base of
the gearshift mechanism (Fig. 14). Remove shifter.
Fig. 12 Crossover Cable Adjustment Screw

(3) 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. 13). Be sure drill bit goes into transaxle
case at least one half inch.
(4) 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. lbs.). Care must be Fig. 14 Gearshift Mechanism
taken to avoid moving the shift mechanism off-center INSTALLATION
during screw tightening. (1) For installation, reverse removal procedure.
(5) Remove drill bit from transaxle case and per-
form functional check by shifting transaxle into all
gears.
(6) Reinstall center shift console. Blouse boot out
around console. Seat boot lip on top of console.
PL TRANSAXLE 21 - 7
VEHICLE SPEED SENSOR DRIVE GEAR
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove wiring connector from speed sensor.
CAUTION: Clean area around speed sensor before

removing. This prevents the possibility of dirt from
entering the transaxle during speed sensor
removal.
(3) Remove speed sensor retaining bolt (Fig. 15).
Fig. 16 Back-up Lamp Switch

INSTALLATION
(1) To install, reverse removal procedure. Teflon
tape or equivalent must be used on switch threads.
CAUTION: Do not overtighten switch.
(2) Confirm back-up lamps are functioning prop-

erly following installation.
CROSSOVER LEVER
REMOVAL
Fig. 15 Speed Sensor Retaining Bolt (1) Remove crossover cable. Refer to Gearshift
(4) Remove speed sensor from transaxle. Cable removal.
(2) Using a pin punch, remove the crossover roll
CAUTION: Carefully remove vehicle speed sensor pin from lever.
so that sensor drive gear does not fall into tran- (3) Pull up and remove the crossover lever from
saxle. Should sensor drive gear fall into the tran- the transaxle crossover shaft (Fig. 17).
saxle during sensor removal, drive gear must be
reattached to sensor.
(5) Remove speed sensor drive gear from speed

sensor.
INSTALLATION
(1) To install, reverse removal procedure.
(2) Confirm vehicle speedometer is functioning
properly following installation.
BACK-UP LAMP SWITCH

The back-up lamp switch is located on the top left
front side of the transaxle case (Fig. 16).
REMOVAL
(1) Lift vehicle on hoist. Fig. 17 Crossover Lever
(2) From bottom side of vehicle, remove wiring
connector from switch. INSTALLATION
(3) Unscrew switch from transaxle. (1) For installation, reverse removal procedure.
Replace the roll pin that was removed with a new
one.
21 - 8 TRANSAXLE PL
SELECTOR LEVER
The selector shaft uses a lever with a weight on
the end. The weight is used to improve shift–feel and
reduce noise.
The selector lever is retained by two roll pins (one
inside the other).
REMOVAL
(1) Remove the selector cable. Refer to Gearshift
Cable removal.
(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
INSTALLATION
(1) For installation, reverse removal procedure. Fig. 19 Axle Shaft Seal Removal
Replace the roll pins that were removed with new
ones. The correct orientation for the roll pins is SHIFT SHAFT SEALS
shown in (Fig. 18). 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.
TRANSAXLE
NOTE: The transaxle can be removed from the
vehicle without having to remove the engine.
All transaxle components are serviced with the

Fig. 18 Correct Orientation of Roll Pins transaxle out of the vehicle with the exception of:
• Selector shaft seal
AXLE SEALS • Crossover shaft seal
The axle shaft seals are identical for both sides of • End plate
the differential and will interchange. • Axle shaft seals
• Shift levers
REMOVAL • Back up lamp switch
(1) Remove axle shaft. Refer to Group 2, Suspen- • Vehicle speed sensor
sion and Driveshafts for service procedures.
(2) Insert a flat–blade pry tool at outer edge of REMOVAL
axle shaft seal (Fig. 19). (1) Disconnect the battery.
(3) Tap on the pry tool with a small hammer and (2) Pull Power Distribution Center up and out of
remove axle shaft seal. its holding bracket. Set Power Distribution Center
aside to gain clearance.
INSTALLATION (3) Remove battery heat shield and remove battery
(1) Clean axle shaft seal bore of any excess seal- from engine compartment. Remove battery tray from
ant. engine compartment. Disconnect cruise control (if
(2) Align axle shaft seal with axle shaft seal bore. equipped).
(3) Install axle seal on tool #6709 and C-4171 and (4) Remove vehicle speed sensor wire.
insert into axle shaft seal bore. (5) Disconnect back-up lamp switch wiring at tran-
(4) Tap seal into position. saxle.
PL TRANSAXLE 21 - 9
CAUTION: Pry up with equal force on both sides of
shifter cable isolator bushing to avoid damaging
cable isolator bushing.
(6) Disconnect both gear shift cables ends from

transaxle shift levers (Fig. 20).
Fig. 22 Remove Clutch Cable From Lever
Fig. 20 Shift Cables

(7) Remove clutch housing vent cap, exposing the
clutch cable end and clutch release lever. Then
remove clutch cable from transaxle bellhousing (Fig.
21) (Fig. 22).
Fig. 23 Linkage Bracket Bolts

CAUTION: When reinstalling driveshafts, new drive-
shaft retaining clips must be used. Do not reuse old
clips. Failure to use new clips may result in disen-
Fig. 21 Pull Clutch Cable Backward gagement of inner constant-velocity joint.
(8) Remove shift cable mounting bracket (Fig. 23).
(9) Remove Accelerator cable shield (if equipped). (16) Remove power hop damper and bracket.
(10) Remove intake manifold support bracket (if (17) Remove lower starter bolt (Fig. 24).
equipped) and upper starter bolt. (18) Remove transaxle to rear lateral bending
(11) Remove upper bellhousing bolts. strut from engine and transaxle (Fig. 25).
(12) Install engine bridge fixture and support (19) Support transaxle with a transmission jack.
engine. (20) Remove front motor mount through-bolt.
(13) Lift vehicle on hoist and remove front wheels. Remove front motor mount bolts from engine and
(14) Drain fluid from transaxle. transaxle.
(15) Remove both front driveshafts. Refer to Group (21) Remove lower dust–shield screw and dust
2, Suspension for procedure. shield.
21 - 10 TRANSAXLE PL
Fig. 26 Left Transaxle Mount Through-Bolt

(27) Remove transaxle from vehicle.
(28) Remove modular clutch assembly from tran-
saxle input shaft.
INSTALLATION
Fig. 24 Starter Bolts (1) To install transaxle, reverse removal procedure.
(2) After installing transaxle, fill transaxle to bot-
tom of fill plug hole (vehicle level on hoist). Fill tran-
saxle with Mopart type M.S. 9417 Manual Transaxle
Fluid before lowering vehicle to floor.
(3) Verify that vehicle’s back-up lights and speed-
ometer are functioning properly. Crossover cable
adjustment procedure is required after installing
transaxle in car to ensure proper shifter adjustment.
Road test vehicle for proper transaxle function.
DISASSEMBLY AND ASSEMBLY

TRANSAXLE
The NV T350 (A-578) transaxle internal compo-
nents can be serviced only by separating the gear
case from the bellhousing case.
Fig. 25 Bracket Removal
(22) Rotate engine crankshaft clockwise to expose CAUTION: The transaxle output shaft is serviced
driveplate–to–modular clutch bolts. as a unit. No disassembly and reassembly is possi-
ble. Damage to the transaxle may result.
NOTE: Before removal of bolts, mark the driveplate
and clutch pressure plate for ease of assembly
alignment. DISASSEMBLY
(1) Place transaxle on bench.
(23) Remove four driveplate–to–modular clutch (2) Remove shift levers. Remove transaxle case
bolts to separate driveplate from clutch assembly. half bolts (Fig. 27).
(24) Push modular clutch assembly into the tran- (3) Place two screwdrivers into the slots provided
saxle bellhousing for easier transaxle removal. in the case halves near the dowels (Fig. 28). Separate
(25) Remove frame rail to left transaxle mount the case halves (Fig. 29).
through-bolt (Fig. 26). (4) Remove bellhousing half from gear case half
(26) Remove left transaxle mount from transaxle. (Fig. 30).
Then push mount up to gain clearance for transaxle (5) Remove output shaft roller bearing from output
removal. shaft.
PL TRANSAXLE 21 - 11
DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 30 Bellhousing Case Half Removal

Fig. 27 Case Bolts
Fig. 31 Differential Assembly Removal

Fig. 28 Transaxle Case Halves
Fig. 32 Reverse Idler Shaft Bolt Removal

Fig. 29 Separate Case Halves
(6) Remove differential assembly (Fig. 31).
(7) Remove reverse idler shaft bolt (Fig. 32).
Remove reverse idler gear (Fig. 33).
(9) Using snap–ring pliers, remove selector shaft
spacer (Fig. 36).
(10) Pull the selector shaft shift pin out of the slot
in the blocker assembly. Turn selector shaft up and
out of the way (Fig. 37).
Fig. 33 Reverse Idler Gear Removal

(8) Remove two screws retaining reverse fork
bracket (Fig. 34). Remove reverse fork bracket and
reverse cam blockout assembly (Fig. 35).
Fig. 36 Remove Selector Shaft Spacer
Fig. 34 Screws Retaining Reverse Fork Bracket
Fig. 37 Selector Shaft
Fig. 35 Remove Reverse Fork Bracket

(11) Remove transaxle end cover (Fig. 38) (Fig. 39). (13) Using bench fixture and shims provided (Mill-
er tools # 6785, 6785-1, and 6785-2), turn transaxle
over. Install transaxle onto bench fixture (Fig. 41).
Verify shim spacers are in position on bench fixture.
Install transaxle into shop press.
Fig. 38 Transaxle Cover Removal

(12) Remove two snap rings retaining the output
Fig. 41 Bench Fixture

(14) Install bearing fixture Miller tool #6768 onto
transaxle end bearings (Fig. 42). Verify tool is prop-
erly aligned to input and output shafts.
Fig. 39 End Cover

shaft and the input shaft to the bearings (Fig. 40).
Fig. 42 Bearing Fixture

CAUTION: The oil dams in the input and output
shafts can be damaged while pressing on the
shafts if the bearing fixture is not used properly.
(15) Install transaxle gear case into shop press.

Press output and input shaft assemblies out of case
(Fig. 43).
(16) Remove transaxle from press.
(17) Carefully remove transaxle case from the
shaft assemblies and bench fixture (Fig. 44). Be sure
the oil–feed trough to the end bearings is not dam-
aged (Fig. 45).
Fig. 40 Snap Rings Retaining Bearings
(Fig. 49) (Fig. 50). TRANSAXLE W/O REVERSE
BRAKE: Remove plastic spacer from the input shaft
assembly.
Fig. 43 Pressing Gears Out of Case
Fig. 46 Reverse Brake Shim
Fig. 44 Transaxle Case Removal
Fig. 47 Reverse Brake Friction Cone
Fig. 45 Oil Feed Trough

(18) TRANSAXLE W/REVERSE BRAKE:
Remove the reverse brake blocking ring, shim, Fig. 48 Reverse Brake Blocking Ring
reverse brake friction cone, bearing and race from
the input shaft assembly (Fig. 46) (Fig. 47) (Fig. 48)
Fig. 49 Reverse Brake Needle Bearing Fig. 52 1–2 Shift Fork Removal
(21) Remove input and output shaft assemblies
from bench fixture (Fig. 53).
Fig. 50 Reverse Brake Race

(19) Remove the shift blocker assembly from the
bench fixture (Fig. 51). Fig. 53 Gear Train Removal
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.
ASSEMBLY
The sealant used to seal the transaxle case halves
is Mopart Gasket Maker, Loctitet 518, or equivalent.
The sealant used for the bearing end plate cover is
Mopart RTV.
(1) Verify bench fixture shims are removed from
bench fixture. Install output and input shafts into
bench fixture (Miller tool #6785) (Fig. 54).
(2) Install shift rails and forks into bench fixture
Fig. 51 Shift Blocker Removal (Fig. 55).
(3) Install shift blocker assembly into bench fix-
(20) Remove the 1-2 shift fork from the output ture (Fig. 56).
shaft (Fig. 52).
Fig. 54 Bench Fixture Fig. 57 Reverse Brake Race Installation
Fig. 55 Shift Rail Installation Fig. 58 Reverse Brake Needle Bearing
Fig. 56 Shift Blocker Installation Fig. 59 Reverse Brake Blocking Ring Installation
(4) Install reverse brake race onto input shaft (Fig.
57).
(5) Install reverse brake needle bearing (Fig. 58).
(6) Install reverse brake blocking ring (Fig. 59).
(7) Install reverse brake friction cone (Fig. 60).
Fig. 62 Gear Case Half

Fig. 60 Reverse Brake Friction Cone Installation
(8) Install reverse brake shim (Fig. 61). Apply
petroleum jelly to shim to hold in place.
Fig. 63 Friction Cone Lugs
Fig. 61 Reverse Brake Shim

(9) Install gear–case half over bench fixture (Fig.
62). Line up shift finger over 3-4 lug.
(10) Line up reverse brake friction cone lugs to the
slots in the gear case (Fig. 63). Verify reverse brake
shim is in position.
(11) Position input and output bearings on the
shafts. Using Miller tool C-4992-1, press on input
and output shaft bearings until they bottom into the
case and against the shafts (Fig. 64).
Fig. 64 Installing Input and Output Bearings

(12) Install shaft snap rings at input and output
bearings (Fig. 65).
Fig. 67 Selector Shaft
Fig. 65 Snap Rings Retaining Bearings

(13) Apply Mopart RTV sealant to end–cover outer
edge and around bolt holes. Install end–cover onto
gear case. Tighten end cover bolts to 29 N·m (21 ft.
lbs.) torque (Fig. 66).
Fig. 68 Reverse Idler Gear
Fig. 66 Transaxle End Cover

(14) Remove gear case from bench fixture.
(15) Install gear case in a holding fixture with end
cover facing down.
(16) Turn selector shaft into slot on blocker assem-
bly (Fig. 67).
(17) Push selector shaft spacer clip onto selector
shaft. Install shift levers.
(18) Install reverse idler gear and shaft. Install
bolt into shaft. Tighten bolt on shaft to 26 N·m (19 ft.
lbs.) torque (Fig. 68) (Fig. 69). Fig. 69 Reverse Idler Shaft Bolt
(19) Install reverse fork bracket and reverse lock- BEARING ADJUSTMENT PROCEDURE
out. Tighten screws to 11 N·m (96 in. lbs.) torque (1) Use extreme care when removing and install-
(Fig. 70) (Fig. 71). 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. 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
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
Fig. 70 Reverse Fork Bracket 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).
Fig. 71 Reverse Fork Screws (3) Press in new bearing cup into gear case side.
(4) Oil differential bearings with Mopart type M.S.
(20) Install differential into gear case (Fig. 72). 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. lbs.).
(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. 73). Record
end play.
(7) The shim required for proper bearing preload is
the total of end play, plus (constant) preload of
Fig. 72 Differential Assembly
Mopart Gasket Maker, Loctitet 518, or equivalent,
on the flat surface of the case mating flange. Install
clutch bellhousing onto gear case. Install and tighten
case bolts to 29 N·m (21 ft. lbs.).
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:
• 1st—1.04-1.72 mm (0.041-0.069 in).
• 2nd—0.94-1.72 mm (0.038-0.069 in).
• 3rd—1.37-1.93 mm (0.054-0.076 in).
Fig. 73 Checking Differential Bearing End Play To • 4th—1.41-1.97 mm (0.056-0.078 in).
Determine Shim Thickness • 5th—1.37-1.93 mm (0.054-0.076 in).
If a stop ring gap does not fall within the specifi-
0.18mm (0.007 in.). Never combine shims to obtain
cations, it must be inspected for wear and replaced.
the required preload.
If the 1st or 2nd synchronizer stop ring is worn
(8) Remove case bolts. Remove clutch bellhousing
beyond specifications, the complete output shaft
differential bearing cup. Install shim(s) selected in
assembly must be replaced.
Step 7. Then press the bearing cup into clutch bell-
The input shaft incorporates the 3rd, 4th, and 5th
housing.
speed gears and synchronizers on the assembly (Fig.
(9) Install clutch bellhousing. Install and torque
75).
case bolts to 26 N·m (19 ft. lbs.).
(10) Using Special Tool C-4995 and an inch-pound
torque wrench, check turning torque of the differen-
tial assembly (Fig. 74). The turning torque should
be 6 to 12 in. lbs. 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.
Fig. 75 Input Shaft
Fig. 74 Checking Differential Bearing Turning

Torque
(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
(1) Install bearing splitter behind 5th speed gear.
Remove snap ring at 5th synchronizer hub on input
shaft (Fig. 76).
Fig. 78 Caged Needle Bearing Removal
Fig. 76 5th Synchro and Hub Snap Ring Removal

(2) Remove synchronizer and gear using shop
press (Fig. 77).
Fig. 79 Split Thrust Washer Ring Removal
Fig. 77 Remove Synchronizer Using Shop Press

(3) Remove caged needle bearing (Fig. 78).
(4) Remove 4-5 gears split thrust washer ring (Fig.
79).
(5) Remove split thrust washer (Fig. 80).
Fig. 80 Split Thrust Washer Removal

(6) Remove split thrust washer separation pin
(Fig. 81).
Fig. 83 Caged Needle Bearing Removal
Fig. 81 Split Thrust Washer Separation Pin

(7) Remove 4th gear (Fig. 82).
Fig. 84 3-4 Synchronizer Hub Snap Ring
Fig. 82 4th Gear Removal

(8) Remove 4th gear caged needle bearing (Fig.
83). Check the caged needle bearing for a broken
retention spring.
(9) Remove blocking ring. Remove 3-4 synchronizer
hub retaining snap ring (Fig. 84).
(10) Install input shaft in shop press. Using bear-
ing splitter, remove 3-4 synchronizer and 3rd gear
(Fig. 85).
(11) Remove 3rd gear caged needle bearing (Fig.
86). 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 nec- Fig. 85 3rd Gear Removal
essary.
ASSEMBLY
The snap rings that are used on the input shaft
are available in select fit sizes. Use the thickest snap
ring that fits in each snap ring groove.
Fig. 86 3rd Gear Caged Needle Bearing Fig. 88 Split Thrust Washer Separation Pin
(1) Place input shaft into shop press. Installation
(2) Install 3rd gear caged needle bearing on input
shaft.
(3) Install 3rd gear and 3-4 synchronizer onto
input shaft. Install Tool #C-3717 over input shaft and
press on synchronizer hub and 3rd gear (Fig. 87).
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. 89 Split Thrust Washer Installation
Fig. 87 Press On 3rd Gear Synchronizer Hub

(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. 88).
(8) Install split thrust washer onto input shaft
(Fig. 89). Fig. 90 Retaining Ring Installation
(9) Install split thrust washer retaining ring (Fig. (10) Install 5th gear caged needle bearing (Fig.
90). 91).
Fig. 91 Caged Needle Bearing Installation Fig. 93 5th Gear Synchronizer Snap Ring
(11) Using special tool #C-3717, install 5th speed Installation
gear and synchronizer (Fig. 92). The 5th gear syn- • 3rd—1.37-1.93 mm (0.054-0.076 in).
chronizer hub has the letter S stamped on the top • 4th—1.41-1.97 mm (0.056-0.078 in).
face of the hub. This designates that the hub must be • 5th—1.37-1.93 mm (0.054-0.076 in).
installed with the S facing upward. 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. 94).
Fig. 92 5th Speed Gear Installation

(12) Install 5th gear synchronizer snap ring (Fig.
93).
OUTPUT SHAFT
CAUTION: The output shaft is serviced as an Fig. 94 Output Shaft
assembly. Do not try to repair any component on DIFFERENTIAL
the output shaft. If the 1-2 synchronizer or gear Shim thickness need be determined only if any of
fails, it is necessary to replace the output shaft the following parts are replaced:
assembly. • Transaxle gear case
• Clutch bellhousing case
It is necessary to check the synchronizer stop ring
• Differential case
gap. Use a feeler gauge to measure the gaps between
• Differential bearings
the stop rings and the speed gears. The correct gaps
Refer to Bearing Adjustment Procedure in the
are listed below:
Adjustments section at the end of this section to
• 1st—1.04-1.72 mm (0.041-0.069 in).
determine proper shim thickness. This will provide
• 2nd—0.94-1.72 mm (0.038-0.069 in).
correct bearing preload and proper bearing turning
torque.
DIFFERENTIAL BEARINGS
Fig. 97 Remove Differential Bearing Cone
Fig. 98 Install Differential Bearing Cone
Fig. 96 Install Differential Bearing Cone

RING GEAR Fig. 99 Remove or Install Ring Gear Bolts and Ring
Gear
CAUTION: Always install new ring gear bolts. (1) Position speedometer drive gear onto differen-
Tighten ring gear bolts to 81 N·m (60 ft. lbs.) torque. tial assembly (Fig. 102).
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.
100) (Fig. 101).
Fig. 102 Speedometer Drive Gear

(2) Using Miller Tool # L-4440 and steel stock,
press speedometer drive gear onto differential (Fig.
103) (Fig. 104). Do not use a hammer.
Fig. 100 Pry Off Speedometer Drive Gear
Fig. 103 Press Gear onto Diferential

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.
Fig. 101 Speedometer Drive Gear Removed

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.
Fig. 104 Drive Gear Pressed onto Differential Fig. 107 Pinion Shaft Removal
REMOVAL (3) Rotate side gears to opening in differential
(1) Remove pinion shaft retaining pin (Fig. 105) (Fig. 108).
(Fig. 106).
Fig. 108 Remove Pinion Gears, Side Gears, and

Fig. 105 Remove Pinion Shaft Retaining Pin Thrust Washers by Rotating Side Gears to Opening
in Case
(4) Remove differential gears (Fig. 109).
Fig. 106 Retaining Pin Removed

(2) Remove pinion shaft (Fig. 107).
Fig. 109 Differential Gears

INSTALLATION
(1) Assemble the differential side gears, pinion
gears and pinion gears with the pinion gear washers.
(2) Install pinion shaft retaining pin (Fig. 110).
Fig. 111 Staking Retaining Pin

other side gear should be checked using the same
procedure.
Fig. 110 Install Retaining Pin CAUTION: Side gear end play must be within 0.001
to 0.013 inch. Five select thrust washers are avail-
(3) Stake pinion shaft retaining pin with a suitable able: 0.027, 0.032, 0.037, 0.042, and 0.047 inch.
chisel (Fig. 111).
(4) Rotate the assembly two full revolutions both (7) After the end play is measured and adjusted,
clockwise and counterclockwise. replace speedometer drive gear with a new one.
(5) Set up dial indicator as shown and record end Install drive gear lip downward. For service informa-
play (Fig. 112) (Fig. 113). Rotate side gear 90 degrees tion, refer to Speedometer Drive Gear service in this
and record another end play. Again, rotate side gear section.
90 degrees and record a final end play.
(6) Using the smallest end play recorded, shim
that side gear to within 0.001 to 0.013 inch. The
Fig. 112 Checking Side Gear End Play (Typical) Fig. 114 Synchronizer Assembly
Fig. 115 Synchronizer Balls

Fig. 113 Checking Side Gear End Play (Typical)
SYNCHRONIZER
DISASSEMBLY
Place synchronizer in a clean shop 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. 114).
(3) Insert key into hub and spring.
(4) Apply petroleum jelly to the hole in the key.
Insert balls into each key (Fig. 115). Fig. 116 Synchronizer Sleeve
(5) Slide sleeve over the hub and depress balls as
you carefully slip the sleeve into position (Fig. 116). SHIFT RAILS OVERHAUL
(6) Line up stop ring tang over the keys in the hub (1) Remove shift rails from the geartrain.
(Fig. 117). Install stop rings. Center the keys and (2) To service the 5-R shift rail, remove the C-clip
balls by pushing on both stop rings. retaining the reverse shift lever arm. Remove the 5th
shift fork roll pin and remove the 5th shift fork.
Fig. 117 Keys in Hub Fig. 118 Axle Shaft Seal Removal
Remove the shift lug roll pin and remove the shift INSTALLATION
lug. Replace parts as necessary. (1) Clean axle shaft seal bore of any excess seal-
(3) To service the 3-4 shift rail, remove the roll pin ant.
retaining the 3-4 shift fork. Remove the shift fork. (2) Align axle shaft seal with axle shaft seal bore.
Remove the shift lug roll pin and remove the shift (3) Install axle seal on tool #6709 with C-4171 and
lug. Replace parts as necessary. insert into axle shaft seal bore.
(4) To service the 1-2 shift rail, remove the roll pin (4) Tap seal into position (Fig. 119).
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 Mopart Gasket Maker, Loctitet 518, or equivalent.
The sealant used for the bearing end–plate cover is
Mopart RTV.
The components that are left in the gear cases
when the gear train is pulled out are the:
• Axle shaft seals
• Output bearing race and retainer
• Input bearing and sleeve
• Differential bearing cones
• Shift rail bushings
• Shift shafts
• Shift shaft seals
Fig. 119 Axle Seal Installation
• Shift shaft bushings
• Rear bearing oil feed trough OUTPUT BEARING
AXLE SHAFT SEALS REMOVAL
REMOVAL NOTE: The position of the output shaft bearing is

(1) Insert a flat–blade pry tool at outer edge of critical. The bearing is not identical end–to–end.
axle shaft seal (Fig. 118). Install bearing with larger diameter cage ring facing
(2) Tap on the pry tool with a small hammer and out.
remove axle shaft seal.
(1) Remove caged roller bearing from output bear-
ing race (Fig. 120).
(2) Remove screws at output bearing retainer
strap (Fig. 121).
(3) Install tool #6787 and slide hammer (Fig. 122).
Tighten tool to output bearing race.
(4) Using slide hammer, remove output bearing
race.
Fig. 120 Output Roller Bearing
Fig. 122 Output Bearing Race Removal
Fig. 121 Output Bearing Strap

INSTALLATION
(1) Line up output bearing race to race bore.
(2) Insert tool #4628 with C-4171 into output bear-
ing race (Fig. 123). 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. lbs.).
INPUT BEARING AND SLEEVE

The input bearing is a one–piece bearing and
sleeve unit (Fig. 124). The sleeve is the slide point for
the clutch–release bearing and lever.
Fig. 123 Output Bearing Race Installation

Fig. 124 Input Bearing And Sleeve Fig. 126 Input Bearing Tool
REMOVAL
(1) Install tool #6342 over input bearing on the
gear case side of the transaxle clutch housing.
(2) Press the input bearing out of the housing (Fig.
125).
Fig. 127 Input Bearing Installed

(2) Install Miller tool #L-4518 into the differential
bearing cup (Fig. 128).
Fig. 125 Input Bearing Removal

INSTALLATION
(1) Apply coating of Loctitet sealant on bearing
outer diameter. Position sleeve and bearing assembly
at input bearing bore.
(2) Install tool #C-4680-1 over input bearing (Fig.
126).
(3) Using the spacer tool #4894 and shop press,
install input bearing into bore until it is fully seated
(Fig. 127).
DIFFERENTIAL BEARING CUPS
REMOVAL
(1) Remove differential assembly from gear case Fig. 128 Tool Installed in Bearing
using the procedure outlined in this group. (3) Install the tool cup over the tool (Fig. 129).
(2) Using tool #MD998343, 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) 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.
Fig. 129 Tool Cup Installed SHIFT SELECTOR SHAFT
(4) Tighten the tool until the race is removed from REMOVAL
the case. (1) Disassemble transaxle using the procedure out-
lined in this group.
INSTALLATION (2) With the transaxle disassembled, remove the
(1) Position the bearing cup into the case. selector shaft by pushing on the shaft from the out-
(2) Install the bearing cup onto Miller tool side. Pull shaft out from the inside.
#L-4520.
(3) Using Miller tool #L-4520 and C-4171 driver, INSTALLATION
install differential bearing cup into the transaxle (1) Reverse removal procedure to install selector
case. shaft.
SHIFT RAIL BUSHINGS SHIFT CROSSOVER SHAFT
REMOVAL REMOVAL
(1) Thread tool #6786 into shift rail bushing. (1) Disassemble transaxle using the procedure out-
(2) Install slide hammer #3752 onto tool. lined in this group.
(3) Remove bushing using slide hammer and tool (2) With the transaxle disassembled, remove the
assembly (Fig. 130). crossover shaft seal.
(3) Using snap–ring pliers, remove the snap ring
at the crossover shaft bore (Fig. 131).
Fig. 130 Shift Rail Bushing Removal

INSTALLATION
(1) Line up replacement bushing in bore. Fig. 131 Crossover Shaft Snap Ring
(4) Push the crossover shaft in the case and SHIFT CROSSOVER SHAFT BUSHING
remove the crossover assembly.
REMOVAL
INSTALLATION (1) Install slide hammer #3752 through the cross-
(1) Reverse removal procedure to install crossover over bushing.
shaft. (2) Thread nut and washer onto slide hammer.
(3) Using the slide hammer, remove the crossover
SHIFT SELECTOR SHAFT BUSHING shaft bushing (Fig. 134).
REMOVAL
(1) Remove selector shaft using procedure in this
group.
(2) Thread tool #6786 into bushing.
(3) Install slide hammer #3752 onto tool and
remove bushing using slide hammer (Fig. 132).
Fig. 134 Crossover Shaft Bushing Removal

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
Fig. 132 Selector Shaft Bushing Removal bore.
INSTALLATION REAR BEARING OIL FEED TROUGH
(1) Position replacement bushing over selector The bearing oil feed trough is retained in the case
shaft bore. by a pin that is molded into the case and clips that
(2) Using an appropriate size deep–well socket, are part of the trough (Fig. 135).
install bushing in selector shaft bore (Fig. 133).
Fig. 135 Oil Feed Trough

Fig. 133 Selector Shaft Bushing Installation
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.
CLEANING AND INSPECTION

TRANSAXLE
Clean the gears, bearings, shafts, synchronizers,
thrust washers, oil feeder, shift mechanism, gear
case, and bellhousing with solvent. Dry all parts Fig. 136 Crossover Cable Adjustment Screw
except the bearings with compressed air. Allow the
bearings to either air dry or wipe them dry with (3) Pin transaxle crossover lever in 3-4 neutral
clean shop towels. position using a 1/4 inch drill bit. Align hole in cross-
Inspect the gears, bearings, shafts and thrust over lever with the hole in the boss on the transaxle
washers. Replace the bearings and cups if the rollers case (Fig. 137). Be sure drill bit goes into transaxle
are worn, chipped, cracked, flat spotted, or brin- case at least one–half inch.
nelled, 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. Fig. 137 Crossover Lever Pin Procedure
INSPECT (4) The shifter is spring–loaded and self–centering.
Proper inspection of components involve: Allow shifter to rest in its neutral position. Torque
• Teeth, for wear, scuffed, nicked, burred, or bro- adjustment screw to 8 N·m (70 in. lbs.). Care must be
ken teeth taken to avoid moving the shift mechanism off-center
• Keys, for wear or distortion during screw tightening.
• Balls and springs, for distortion, cracks, or wear (5) Remove drill bit from transaxle case and per-
If any of these conditions exist in these compo- form functional check by shifting transaxle into all
nents, replace as necessary. gears.
(6) Reinstall center shift console. Blouse boot out
around console. Seat boot lip on top of console.
ADJUSTMENTS
BEARING ADJUSTMENT PROCEDURE
GEARSHIFT CROSSOVER CABLE
(1) Remove shift console from vehicle. GENERAL RULES ON SERVICING BEARINGS
(2) Loosen adjusting screw on crossover cable at (1) Use extreme care when removing and install-
shifter (Fig. 136). ing bearing cups and cones. Use only an arbor press
ADJUSTMENTS (Continued)
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 or gear intermesh.
(4) Replace bearings as a pair: If one differential
bearing is defective, replace both differential bear- Fig. 138 Checking Differential Bearing End Play to
ings, if one input shaft bearing is defective, replace Determine Shim Thickness
both input shaft bearings. Step 7. Then press the bearing cup into clutch bell-
(5) Bearing cones must not be reused if removed. housing.
(6) Turning torque readings should be obtained (9) Install clutch bellhousing. Install and torque
while smoothly rotating in either direction. case bolts to 26 N·m (19 ft. lbs.).
(10) Using Special Tool C-4995 and an inch-pound
DIFFERENTIAL BEARING PRELOAD ADJUSTMENT torque wrench, check turning torque of the differen-
tial assembly (Fig. 139). The turning torque
NOTE: True bearing turning torque readings can be
should be 6 to 12 in. lbs. If the turning torque is
obtained only with the geartrain removed from the
too high, install a 0.05mm (0.002 inch) thinner
case.
shim. If the turning torque is too low, install a
(1) Remove bearing cup and existing shim from 0.05mm (0.002 inch) thicker shim.
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 Mopart 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. lbs.).
(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 Fig. 139 Checking Differential Bearing Turning
indicator. To obtain end play readings, apply a Torque
medium load in an upward direction while rolling
(11) Recheck turning torque. Repeat Step 10 until
differential assembly back and forth (Fig. 138).
the proper turning torque is obtained.
Record end 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.
(8) Remove case bolts. Remove clutch bellhousing
differential bearing cup. Install shim(s) selected in
SPECIFICATIONS SPECIAL TOOLS

NV T350 (A-578) SPECIAL TOOLS–NV T350 (A-578) MANUAL
TRANSAXLE
DESCRIPTION TORQUE
Back-up Lamp Switch. . . . . . . . . .24 N·m (18 ft. lbs.)
Crossover Cable Adj. Screw . . . . . .8 N·m (70 in. lbs.)
Drain Plug . . . . . . . . . . . . . . . . .30 N·m (267 in. lbs.)
Differential Ring Gear Bolts . . . . .81 N·m (60 ft. lbs.)
Dust Shield to Transaxle . . . . . .12 N·m (105 in. lbs.)
End Plate Cover Bolts . . . . . . . . .29 N·m (21 ft. lbs.)
Front Engine Mount to Trans . . .108 N·m (80 ft. lbs.)
Front Mount Through Bolt . . . . . .61 N·m (45 ft. lbs.)
Front Mount to Engine Bolt . . . . .54 N·m (40 ft. lbs.)
Lateral Bending Adapter Blocks C-293–45
Strut to Engine. . . . . . . . . . . . .54 N·m (40 ft. lbs.)
Lateral Bending Strut to Trans. . .54 N·m (40 ft. lbs.)
Left Mount Through Bolt . . . . . .108 N·m (80 ft. lbs.)
Left Mount to Transaxle . . . . . . . .54 N·m (40 ft. lbs.)
Output Bearing Race Ret. Strap .11 N·m (96 in. lbs.)
Power Hop Damper Bkt. to
Trans. . . . . . . . . . . . . . . . . . . . .54 N·m (40 ft. lbs.)
Power Hop Damper to
Frame Bkt. . . . . . . . . . . . . . . . .54 N·m (40 ft. lbs.)
Power Hop Damper to
Trans. Bkt. . . . . . . . . . . . . . . . .54 N·m (40 ft. lbs.) Puller Press C-293–PA
Reverse Fork Bracket. . . . . . . . . .11 N·m (96 in. lbs.)
Reverse Idler Shaft Bolt . . . . . . . .26 N·m (19 ft. lbs.)
Shift Cable Bracket to
Transaxle . . . . . . . . . . . . . . . .28 N·m (250 in. lbs.)
Transaxle Case Bolts . . . . . . . . . .29 N·m (21 ft. lbs.)
Transaxle to Engine Bolt . . . . . . .95 N·m (70 ft. lbs.)
Trans. to Eng. Intake Bkt. Bolts . .95 N·m (70 ft. lbs.)
Vehicle Speed Sensor . . . . . . . . . . .7 N·m (60 in. lbs.)
Vertical Bending Strut to
Engine . . . . . . . . . . . . . . . . . .108 N·m (80 ft. lbs.)
Vertical Bending Strut to Trans. .108 N·m (80 ft. lbs.)
Dial Indicator C-3339
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
METRIC MEA-
TRANSAXLE U.S. MEASURE
SURE
NV T350 1.9-2.2 Liters 2.0-2.3 Quarts
Sleeve C-3717
SPECIAL TOOLS (Continued)
Seal Installer C-4992

Slide Hammer C-3752
Torque Tool C-4995
Universal Handle C-4171
Adapter C-4996
Bearing Installer C-4628
Installer L-4410
Seal Remover C-4680

Bearing Remover 6768

Special Jaw Set L-4518
Bench Fixture 6785

Bearing Splitter 1130
Remover 6786
Driver 6342
Remover 6787
Seal Installer 6709
31TH AUTOMATIC TRANSAXLE
INDEX
page page
GENERAL INFORMATION THROTTLE PRESSURE CABLE . . . . . . . . . . . . . 60

FLUID LEVEL AND CONDITION . . . . . . . . . . . . . 41 TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
GENERAL INFORMATION . . . . . . . . . . . . . . . . . 40 VEHICLE SPEED SENSOR PINION GEAR . . . . . 64
SELECTION OF LUBRICANT . . . . . . . . . . . . . . . 41 DISASSEMBLY AND ASSEMBLY
SPECIAL ADDITIVES . . . . . . . . . . . . . . . . . . . . . 41 ACCUMULATOR-RECONDITION . . . . . . . . . . . . 83
DESCRIPTION AND OPERATION DIFFERENTIAL REPAIR . . . . . . . . . . . . . . . . . . . 95
AUTOMATIC TRANSMISSION SHIFTER/ FRONT CLUTCH-RECONDITION . . . . . . . . . . . . 78
IGNITION INTERLOCK . . . . . . . . . . . . . . . . . . 42 FRONT PLANETARY AND ANNULUS GEAR-
CLUTCHES, BAND SERVOS, AND RECONDITION . . . . . . . . . . . . . . . . . . . . . . . . 81
ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . 42 KICKDOWN SERVO (CONTROLLED LOAD)-
FLOW CONTROL VALVES . . . . . . . . . . . . . . . . . 42 RECONDITION . . . . . . . . . . . . . . . . . . . . . . . . 83
GEARSHIFT AND PARKING LOCK CONTROLS . 42 LOW/REVERSE (REAR)
GOVERNOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 SERVO-RECONDITION . . . . . . . . . . . . . . . . . . 82
HYDRAULIC CONTROL SYSTEM . . . . . . . . . . . . 42 OIL PUMP-RECONDITION . . . . . . . . . . . . . . . . . 78
PRESSURE REGULATING VALVES . . . . . . . . . . 42 OUTPUT SHAFT REPAIR . . . . . . . . . . . . . . . . . . 89
PRESSURE SUPPLY SYSTEM . . . . . . . . . . . . . . 42 PARKING PAWL . . . . . . . . . . . . . . . . . . . . . . . . . 89
TORQUE CONVERTER CLUTCH SOLENOID REAR CLUTCH-RECONDITION . . . . . . . . . . . . . 79
WIRING CONNECTOR . . . . . . . . . . . . . . . . . . 43 TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
TORQUE CONVERTER CLUTCH . . . . . . . . . . . . 42 TRANSFER SHAFT REPAIR . . . . . . . . . . . . . . . . 83
DIAGNOSIS AND TESTING VALVE BODY RECONDITION . . . . . . . . . . . . . . . 74
CLUTCH AND SERVO AIR PRESSURE TESTS . 54 CLEANING AND INSPECTION
FLUID LEAKAGE-TRANSAXLE TORQUE VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
CONVERTER HOUSING AREA . . . . . . . . . . . . 55 ADJUSTMENTS
HYDRAULIC PRESSURE TESTS . . . . . . . . . . . . 52 BAND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 101
INTERLOCK SYSTEM OPERATION CHECK . . . . 55 BEARING ADJUSTMENT PROCEDURES . . . . . 101
ROAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 DIFFERENTIAL BEARING . . . . . . . . . . . . . . . . . 102
THREE SPEED TRANSAXLE DIAGNOSIS AND GEARSHIFT CABLE . . . . . . . . . . . . . . . . . . . . . . 99
TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 HYDRAULIC CONTROL PRESSURE
SERVICE PROCEDURES ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . 101
ALUMINUM THREAD REPAIR . . . . . . . . . . . . . . 58 OUTPUT SHAFT BEARING . . . . . . . . . . . . . . . . 102
FLUID AND FILTER CHANGE . . . . . . . . . . . . . . . 56 SHIFTER/IGNITION INTERLOCK SYSTEM . . . . 100
FLUID DRAIN AND REFILL . . . . . . . . . . . . . . . . . 57 THROTTLE PRESSURE CABLE ADJUSTMENT
FLUSHING COOLERS AND TUBES . . . . . . . . . . 58 PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 100
OIL PUMP VOLUME CHECK . . . . . . . . . . . . . . . 58 TRANSFER SHAFT BEARING . . . . . . . . . . . . . 103
REMOVAL AND INSTALLATION SCHEMATICS AND DIAGRAMS
GEARSHIFT CABLE . . . . . . . . . . . . . . . . . . . . . . 59 31TH TRANSAXLE HYDRAULIC SCHEMATIC . 105
GEARSHIFT MECHANISM . . . . . . . . . . . . . . . . . 60 SPECIFICATIONS
INTERLOCK MECHANISM . . . . . . . . . . . . . . . . . 63 31TH AUTOMATIC TRANSAXLE . . . . . . . . . . . . 113
PARK/NEUTRAL STARTING AND BACK-UP 31TH TRANSAXLE TORQUE
LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . 64 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 113
PUMP OIL SEAL . . . . . . . . . . . . . . . . . . . . . . . . . 67 SPECIAL TOOLS
SHIFTER IGNITION INTERLOCK CABLE . . . . . . 61 31TH AUTOMATIC TRANSAXLE . . . . . . . . . . . . 114
GENERAL INFORMATION This transaxle combines torque converter, three

speed transmission, final drive gearing, and differen-
GENERAL INFORMATION tial into a front wheel drive system. The identifica-
tion markings and usage of the transaxle are charted
NOTE: Safety goggles should be worn at all times in Diagnosis and Tests.
when working on these transaxles.
NOTE: Transaxle operation requirements are differ- cal gear on the transfer shaft drives the differential
ent for each vehicle and engine combination. Some ring gear. The final drive gearing is completed with
internal parts will be different to provide for this. one of two gear ratios; 2.98 or 3.19 depending on
Therefore, when replacing parts, refer to the seven model and application.
digit part number stamped on rear of the transaxle
oil pan flange. FLUID LEVEL AND CONDITION
Within this transaxle, there are three primary NOTE: The transmission and differential sump have
areas: a common oil sump with a communicating opening
(1) Main center line plus valve body. between the two.
(2) Transfer shaft center line (includes governor
and parking sprag). The torque converter fills in both the P (Park) and
(3) Differential center line. N (Neutral) positions. Place the selector lever in P
Center distances between the main rotating parts (Park) to be sure that the fluid level check is accu-
in these three areas are held precise to maintain a rate. The engine should be running at idle
low noise level. speed for at least one minute, with the vehicle
The torque converter, transaxle area, and differen- on level ground. This will ensure complete oil
tial are housed in an integral aluminum die casting. level stabilization between differential and
The differential oil sump is common with the transmission. The fluid should be at normal operat-
transaxle sump. Separate filling of the differen- ing temperature (approximately 82° C. or 180° F.).
tial is NOT necessary. The fluid level is correct if it is in the HOT region
The torque converter is attached to the crankshaft (cross-hatched area) on the dipstick.
through a flexible driving plate. Cooling of the con- Low fluid level can cause a variety of conditions,
verter is accomplished by circulating the transaxle because it allows the pump to take in air along with
fluid through a remote cooler. There are two types of the fluid. As in any hydraulic system, air bubbles
coolers used. An oil-to-water type cooler located in make the fluid spongy therefore, pressures will be
the radiator side tank and/or an oil-to-air heat low and will build up slowly.
exchanger. The torque converter assembly is a sealed Improper filling also can raise the fluid level too
unit that cannot be disassembled. high. When the transaxle has too much fluid, the
The transaxle fluid is filtered by an internal filter gears churn up foam and cause the same conditions
attached to the lower side of the valve body assembly. that occur with a low fluid level.
Engine torque is transmitted to the torque con- In either case, the air bubbles can cause overheat-
verter and then through the input shaft to multiple- ing, fluid oxidation, and varnishing. This can inter-
disc clutches in the transaxle. The power flow fere with normal valve, clutch, and servo operation.
depends on the application of the clutches and bands. Foaming also can result in fluid escaping from the
Refer to Elements in Use Chart in Diagnosis and transaxle dipstick, where it may be mistaken for a
Tests section. leak.
The transaxle consists of: Along with fluid level, it is important to check the
• Two multiple-disc clutches condition of the fluid. When the fluid smells burned,
• An overrunning clutch or is contaminated with metal or friction material
• Two servos particles, a complete transaxle overhaul is needed.
• A hydraulic accumulator Be sure to examine the fluid on the dipstick closely.
• Two bands If there is any doubt about its condition, drain out a
• Two planetary gear sets sample for a double check.
This provides three forward ratios and a reverse
ratio. The common sun gear of the planetary gear SELECTION OF LUBRICANT
sets is connected to the front clutch by a driving It is important that the proper lubricant be used in
shell. The driving shell is splined to the sun gear and these transmissions. Mopar ATF PLUS 3 (Automatic
front clutch retainer. The hydraulic system consists Transmission Fluid- type 7176) should be used to aid
of an oil pump and a single valve body which con- in ensuring optimum transmission performance. It is
tains all of the valves except the governor valves. important that the transmission fluid be maintained
The transaxle sump and differential sump are both at the prescribed level using the recommended fluids.
vented through the dipstick. Output torque from the
main center line is delivered through helical gears to SPECIAL ADDITIVES
the transfer shaft. This gear set is a factor in the Chrysler Corporation does not recommend the
transaxle final drive (axle) ratio. The shaft also car- addition of any fluids to the transmission, other than
ries the governor and parking sprag. An integral heli- that fluid listed above. An exception to this policy is
the use of special dyes to aid in detecting fluid leaks. The kickdown valve makes possible a forced down-
The use of transmission sealers should be avoided, shift from third to second, second to first, or third to
since they may adversely affect seals. first (depending on vehicle speed). This can be done
by depressing the accelerator pedal past the detent
feel near wide open throttle.
DESCRIPTION AND OPERATION The shuttle valve has two separate functions and
performs each independently of the other. The first is
TORQUE CONVERTER CLUTCH providing fast release of the kickdown band, and
A torque converter clutch is standard on all vehi- smooth front clutch engagement when a lift-foot
cles. The torque converter clutch is activated only in upshift from second to third is made. The second
direct drive and is controlled by the engine electron- function is to regulate the application of the kick-
ics. A solenoid on the valve body, is powered by the down servo and band when making third–to–second
powertrain control module to activate the torque con- kickdown.
verter clutch. The bypass valve provides for smooth application
of the kickdown band on 1-2 upshifts.
HYDRAULIC CONTROL SYSTEM The torque converter clutch solenoid allows for the
The hydraulic control system makes the transaxle electronic control of the torque converter clutch. It
fully automatic, and has four important functions to also disengages the torque converter at closed throt-
perform. The components of any automatic control tle. This is done during engine warm-up and part-
system may be grouped into the following basic throttle acceleration.
groups: The switch valve directs oil to apply the torque
• Pressure supply system converter clutch in one position. The switch valve
• Pressure regulating valves releases the torque converter clutch in the other posi-
• Flow control valves tion.
• Clutches
• Band servos CLUTCHES, BAND SERVOS, AND ACCUMULATOR
Taking each of these basic groups or systems in The front and rear clutch pistons, and both servo
turn, the control system may be described as follows: pistons, are moved hydraulically to engage the
clutches and apply the bands. The pistons are
PRESSURE SUPPLY SYSTEM released by spring tension when hydraulic pressure
The pressure supply system consists of an oil pump is released. On the 2-3 upshift, the kickdown servo
driven by the engine through the torque converter. piston is released by spring tension and hydraulic
The single pump furnishes pressure for all hydraulic pressure.
and lubrication requirements. Oil pump housing The accumulator controls the hydraulic pressure
assemblies are available with preselected pump on the apply–side of the kickdown servo during the
gears. 1-2 upshift; thereby cushioning the kickdown band
application at any throttle position.
PRESSURE REGULATING VALVES
The pressure regulating valve controls line pres- AUTOMATIC TRANSMISSION SHIFTER/IGNITION
sure dependent on throttle opening. The governor
INTERLOCK
valve transmits regulated pressure to the valve body
The Shifter/Ignition Interlock, is a mechanical
(in conjunction with vehicle speed) to control upshift
cable operated system (Fig. 1). It interconnects the
and downshift.
automatic transmission floor–mounted shifter to the
The throttle valve transmits regulated pressure to
steering column ignition switch. The interlock system
the transaxle (dependent on throttle position) to con-
locks the floor–mounted shift lever into the PARK
trol upshift and downshift.
position whenever the ignition switch is in the LOCK
or ACCESSORY position. When the key is in the
FLOW CONTROL VALVES
OFF or RUN position, the shifter is unlocked and
The manual valve provides the different transaxle
will move into any position. Also the interlock system
drive ranges selected by the vehicle operator.
prevents the ignition switch from being turned to
The 1-2 shift valve automatically shifts the tran-
LOCK or ACCESSORY position, unless shifter is in
saxle from first to second or from second to first,
the PARK position.
depending on the vehicle operation.
The 2-3 shift valve automatically shifts the tran-
GEARSHIFT AND PARKING LOCK CONTROLS
saxle from second to third or from third to second
The transaxle is controlled by a lever type gear-
depending on the vehicle operation.
shift incorporated within the console. The control has
DESCRIPTION AND OPERATION (Continued)
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

THREE SPEED TRANSAXLE DIAGNOSIS AND
TESTS
Automatic transaxle malfunctions may be caused
Fig. 1 Shifter Ignition Interlock System Components by four general conditions:
(1) Poor engine performance
six selector lever positions: P (Park), R (Reverse), N (2) Improper adjustments
(Neutral), and D (Drive), 2 (Second), and 1 (First). (3) Hydraulic malfunctions
The parking lock is applied by moving the selector (4) Mechanical malfunctions
lever past a gate to the (P) position. Do not apply Diagnosis of these problems should always begin
the parking lock until the vehicle has stopped; by checking the easily accessible variables; fluid level
otherwise, a severe banging noise will occur. and condition, gearshift cable adjustment, and throt-
tle pressure cable adjustment. Then perform a road
TORQUE CONVERTER CLUTCH SOLENOID WIRING test to determine if the problem has been corrected
or that more diagnosis is necessary. If the problem
CONNECTOR exists after the preliminary tests and corrections are
If the solenoid wiring connector is unplugged, the
completed, hydraulic pressure tests should be per-
torque converter will not engage (Fig. 2).
formed
31TH HYDRAULIC TROUBLE CODE CHARTS

The following charts should be used to help diag-
nose hydraulic or mechanical faults in the transaxle.
Fig. 2 Torque Converter Clutch Solenoid Wiring

Connector
DIAGNOSIS AND TESTING (Continued)
Diagnosis Guide
Diagnosis Guide
Diagnosis Guide
Diagnosis Guide
Diagnosis Guide
Diagnosis Guide
Diagnosis Guide
Diagnosis Guide
ROAD TEST The process of elimination can be used to detect
Prior to performing a road test, check the fluid any unit that slips and to confirm proper operation of
level and control cable adjustments. good units. Road testing can usually diagnose slip-
During the road test, the transaxle should be oper- ping units, although the actual cause of the problem
ated in each position to check for slipping and any may not be detected. Practically any condition can be
variation in shifting. caused by leaking hydraulic circuits or sticking
If vehicle operates at high speeds, but has poor valves.
acceleration, the converter’s overrunning clutch may Therefore, unless the condition is obvious, the tran-
be slipping. If acceleration is normal, but high throt- saxle should never be disassembled until hydraulic
tle opening is needed for high speeds, the stator pressure tests have been performed.
clutch may have seized.
Observe closely for slipping or engine speed flare- HYDRAULIC PRESSURE TESTS
up. Slipping or flare-up in any gear usually indicates Pressure testing is a very important step in the
clutch, band, or overrunning clutch problems. If the diagnostic procedure. These tests usually reveal the
condition is far advanced, an overhaul will probably cause of most transaxle problems.
be necessary to restore normal operation. Before performing pressure tests, check fluid level
In most cases, the clutch or band that is slipping and condition, as well as control cable adjustments.
can be determined by noting the transaxle operation Fluid must be at operating temperature (150 to 200
in all selector positions and then comparing which degrees F.).
internal units are applied in those positions. The Install an engine tachometer. Raise vehicle on a
Elements–in–Use Chart provides a basis for road test hoist that allows front wheels to turn, and position
analysis. tachometer so it can be read.
The rear clutch is applied in both the D first gear Disconnect throttle cable and shift cable from tran-
and 1 first gear positions. Also, the overrunning saxle levers so they can be controlled from outside
clutch is applied in D first gear and the low/reverse the vehicle.
band is applied in 1 first gear position. If the tran- Attach 150 psi gauges to ports required for test
saxle slips in D range first gear, but does not slip in being conducted. A 300 psi gauge (C-3293) is required
1 first gear, the overrunning clutch is slipping. Simi- for reverse pressure test at rear servo.
larly, if the transaxle slips in any two forward gears, Test port locations are shown in (Fig. 3).
the rear clutch is slipping.
Using the same procedure, the rear clutch and TEST ONE (SELECTOR IN 1)
front clutch are applied in D third gear. If the tran- (1) Attach gauges to line and low-reverse ports.
saxle slips in third gear, either the front clutch or the (2) Operate engine at 1000 rpm for test.
rear clutch is slipping. By selecting another gear that (3) Move selector lever on transaxle all the way
does not use one of those units, the unit that is slip- rearward (1 position).
ping can be determined. If the transaxle also slips in (4) Read pressures on both gauges as throttle lever
reverse, the front clutch is slipping. If the transaxle on transaxle is moved from full clockwise position to
does not slip in reverse, the rear clutch is slipping. full counterclockwise position.
ELEMENTS IN USE AT EACH POSITION OF THE SELECTOR LEVER

Fig. 3 Test Port Locations

TEST TWO (SELECTOR 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
Fig. 4 Governor Pressure Tap with lever clockwise and 10 to 35 psi with lever at
(5) Line pressure should read 52 to 58 psi with full counterclockwise.
throttle lever clockwise. Pressure should gradually (7) This tests pump output, pressure regulation,
increase to 80 to 88 psi.as lever is moved counter- and condition of rear clutch and lubrication hydraulic
clockwise. circuits.
(6) Low/reverse pressure should read the same as
TEST THREE (SELECTOR IN D)
line pressure, within 3 psi.
(1) Attach gauges to line and kickdown release
(7) This tests pump output, pressure regulation,
ports.
and condition of rear clutch and rear servo hydraulic
(2) Operate engine at 1600 rpm for test.
circuits.
(3) Move selector lever on transaxle two detents smoothly to changes in mph and should return to 0
forward from full rearward position. This is selector to 3 psi when vehicle is stopped. High pressure
D position. (above 3 psi) at standstill will prevent the transaxle
(4) Read pressures on both gauges as throttle lever from downshifting.
on transaxle is moved from full clockwise to the full
counterclockwise position. THROTTLE PRESSURE
(5) Line pressure should read 52 to 58 psi with No gauge port is provided for throttle pressure.
throttle lever clockwise. Pressure should gradually Incorrect throttle pressure should be suspected if
increase to 80 to 88 psi. as lever is moved counter- part throttle upshift speeds are either delayed or
clockwise. occur too early in relation to vehicle speed. Engine
(6) Kickdown release is pressurized only in direct runaway on shifts can also be an indicator of low
drive and should be same as line pressure within 3 throttle pressure setting, or misadjusted throttle
psi, up to kickdown point. cable.
(7) This tests pump output, pressure regulation, In no case should throttle pressure be adjusted
and condition of rear clutch, front clutch, and until the transaxle throttle cable adjustment has
hydraulic circuits. been verified to be correct.
TEST FOUR (SELECTOR IN REVERSE) CLUTCH AND SERVO AIR PRESSURE TESTS
(1) Attach 300 psi gauge to low-reverse port. A no–drive condition might exist even with correct
(2) Operate engine at 1600 rpm for test. fluid pressure, because of inoperative clutches or
(3) Move selector lever on transaxle four detents bands. The inoperative units, clutches, bands, and
forward from full rearward position. This is selector servos can be located through a series of tests. This
R position. is done by substituting air pressure for fluid pressure
(4) Low/reverse pressure should read 180 to 220 (Fig. 5).
psi with throttle lever clockwise. Pressure should The front and rear clutches, kickdown servo, and
gradually increase to 260 to 300 psi. as lever is low/reverse servo can be tested by applying air pres-
moved counterclockwise. sure to their respective passages. To make air pres-
(5) This tests pump output, pressure regulation, sure tests, proceed as follows:
and condition of front clutch and rear servo hydraulic
circuits. NOTE: Compressed air supply must be free of all
(6) Move selector lever on transaxle to D position dirt and moisture. Use a pressure of 30 psi.
to check that low/reverse pressure drops to zero.
(7) This tests for leakage into rear servo, due to Remove oil pan and valve body. Refer to Valve
case porosity, which can cause reverse band burn out. Body for removal procedure.
TEST RESULT INDICATIONS FRONT CLUTCH

(1) If proper line pressure, minimum to maximum, Apply air pressure to front clutch apply passage
is found in any one test, the pump and pressure reg- and listen for a dull thud, which indicates that front
ulator are working properly. clutch is operating. Hold air pressure on for a few
(2) Low pressure in D, 1, and 2 but correct pres- seconds and inspect system for excessive oil leaks.
sure in R, indicates rear clutch circuit leakage.
REAR CLUTCH
(3) Low pressure in D and R, but correct pressure
Apply air pressure to rear clutch apply passage
in 1 indicates front clutch circuit leakage.
and listen for a dull thud, which indicates that rear
(4) Low pressure in R and 1, but correct pressure
clutch is operating. Also, inspect for excessive oil
in 2 indicates rear servo circuit leakage.
leaks. If a dull thud cannot be heard in the clutches,
(5) Low line pressure in all positions indicates a
place finger tips on clutch housing and again apply
defective pump, a clogged filter, or a stuck pressure
air pressure. Movement of piston can be felt as the
regulator valve.
clutch is applied.
GOVERNOR PRESSURE
KICKDOWN SERVO (FRONT)
Test only if transaxle shifts at wrong vehicle
Direct air pressure into KICKDOWN SERVO ON
speeds when throttle cable is correctly adjusted.
passage. Operation of servo is indicated by a tighten-
(1) Connect a 0-150 psi pressure gauge to governor
ing of front band. Spring tension on servo piston
pressure take-off point. It is located at lower right
should release the band.
side of case, below differential cover.
(2) Operate transaxle in third gear to read pres-
sures. The governor pressure should respond
Fig. 5 Air Pressure Tests

LOW AND REVERSE SERVO (REAR) operation on the vehicle. This will determine if the
Direct air pressure into LOW/REVERSE SERVO torque converter or transaxle is leaking.
APPLY passage. Operation of servo is indicated by a
tightening of rear band. Spring tension on servo pis- TORQUE CONVERTER LEAKAGE
ton should release the band. Possible sources of torque converter leakage are:
If clutches and servos operate properly, no upshift • Torque converter weld leaks at the outside diam-
indicates that a malfunction exists in the valve body. eter (peripheral) weld
• Torque converter hub weld
FLUID LEAKAGE-TRANSAXLE TORQUE • Torque converter impeller shell cracked adjacent
CONVERTER HOUSING AREA to hub
(1) Check for source of leakage. • At drive lug welds
(2) Since fluid leakage near the torque converter
NOTE: Hub weld is inside and not visible. Do not
area may be from an engine oil leak, the area should
attempt to repair. Replace torque converter.
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 INTERLOCK SYSTEM OPERATION CHECK
following checks: (1) Place shifter in PARK, the ignition switch
(4) When leakage is determined to originate from should rotate freely from OFF to LOCK position.
the transaxle, check fluid level prior to removal of When the shifter is moved to the DRIVE position,
the transaxle and torque converter. the ignition switch should not rotate from OFF to
(5) High oil level can result in oil leakage out the LOCK.
vent in the dipstick. If the fluid level is high, adjust (2) Moving shifter out of PARK should be possible
to proper level. only when ignition switch is in the OFF or the RUN
(6) After performing this operation, inspect for position. Movement of the shifter from the PARK
leakage. If a leak persists, perform the following
position should not be possible when the ignition DIPSTICK TUBE FLUID SUCTION METHOD
switch is in the LOCK or the ACCESSORY position. (1) When performing the fluid suction method,
(3) If the interlock system, operates in any way make sure the transaxle is at full operating temper-
other than as described above, repair of the interlock ature.
system is required. See Adjustment and Repair pro- (2) To perform the dipstick tube fluid suction
cedures in this section for the required procedures. method, use a suitable fluid suction device (Vaculay
or equivalent).
(3) Insert the fluid suction line into the dipstick
SERVICE PROCEDURES
tube.
FLUID AND FILTER CHANGE NOTE: Verify that the suction line is inserted to the
When the factory fill fluid is changed, only fluids lowest point of the transaxle oil pan. This will
labeled MOPARt ATF PLUS 3 (Automatic Transmis- ensure complete evacuation of the fluid in the pan.
sion fluid) Type 7176 should be used. (4) Follow the manufacturers recommended proce-
If the transaxle is disassembled for any reason, the dure and evacuate the fluid from the transaxle.
fluid and filter should be changed. (5) Remove the suction line from the dipstick tube.
(6) Add 4 Quarts of Mopar ATF Plus 3 Type 7176
30,000 MILE TRANSAXLE OIL CHANGE
transaxle fluid.
When a vehicle attains 30,000 miles on its odome-
(7) Start the engine and allow it to idle for a min-
ter it is recommended that the transaxle oil be
imum of one minute. With the parking brake applied,
changed. To change the oil, use the procedure that
press your foot on the service brake and cycle the
follows:
transaxle from park to all gear positions ending in
It is recommended that a transaxle fluid exchanger
neutral or park.
(ATF 2000+ or equivalent) be used to replace the
(8) Check the transaxle fluid level and add an
used fluid in the transaxle. If a fluid exchanger is not
appropriate amount to bring the transaxle fluid level
available use a fluid suction pump (Vaculay or equiv-
to 3mm (1/8 in.) below the ADD mark on the dip-
alent) to draw the fluid out of the dipstick tube. If a
stick.
fluid suction pump is not available remove the oil
(9) Recheck the fluid level after the transaxle is at
pan and drain the fluid.
normal operating temperature. The level should be in
CAUTION: Chrysler Corporation does not recom- the HOT range.
mend using any fluid exchanger that introduces
TRANSAXLE OIL PAN DROP METHOD
additives into the transaxle.
This procedure involves removing the transaxle oil
pan to drain the transaxle fluid.
TRANSAXLE FLUID EXCHANGER METHOD (1) Bring the vehicle up to normal operating tem-
(1) To perform the transaxle fluid exchange, the perature. Drive the vehicle a minimum of 10 miles.
transaxle must be at operating temperature. Drive (2) Raise the vehicle on the hoist.
the vehicle till it reaches full operating temperature. (3) Loosen the transaxle oil pan and drain the
(2) Verify that the fill tank on the transaxle fluid fluid into a suitable container.
exchanger (ATF 2000+ or equivalent) is clean and (4) Remove the pan and clean all sealant from the
dry. pan and transaxle mating surfaces. Clean the mag-
(3) Fill the tank to the recommended fill capacity net and the inside of the pan.
with Mopar ATF Plus 3 Type 7176. (5) Apply a 1/8 inch bead of Mopar RTV Sealant to
(4) Hookup the vehicle to the machine following the mounting flange of the transaxle oil pan. Apply
the manufacturers instructions. Perform the RTV Sealant to the underside of the attaching bolts.
exchange procedure following the instructions pro- Attach the oil pan to the transaxle. Tighten the bolts
vided with the machine. to 19 N•m (165 in. lbs.).
(5) Once machine has completed the fluid (6) Lower the vehicle and add 4 Quarts of Mopar
exchange. Check the fluid level and condition and fill ATF Plus 3 Type 7176 transaxle fluid.
to proper level with Mopar ATF Plus 3 Type 7176. (7) Start the engine and allow it to idle for a min-
NOTE: Verify that the transaxle cooler lines are press your foot on the service brake and cycle the
tightened to proper specifications. Cooler line transaxle from park to all gear positions ending in
torque specification is 2 N•m (18 in. lbs.). neutral or park.
(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- (11) Recheck the fluid level after the transaxle is
stick. at normal operating temperature. The level should be
(9) Recheck the fluid level after the transaxle is at in the HOT range. Drive the vehicle a minimum of
normal operating temperature. The level should be in 10 miles.
the HOT range. Drive the vehicle a minimum of 10 (12) Raise the vehicle on the hoist.
miles. (13) Remove the pan and clean all sealant from
(10) Raise the vehicle on the hoist. the pan and transaxle mating surfaces. Clean the
(11) Check for leaks around the transaxle oil pan magnet and the inside of the pan.
sealing surfaces. (14) Separate the filter from the valve body to
(12) Recheck the fluid level. The level should be in allow additional fluid to drain from the transaxle.
the HOT range. Inspect the filter O-ring for any damage and replace
as necessary.
SEVERE USAGE SERVICE (15) After the transaxle has stopped draining,
If the vehicle exhibits any of the following symp- reinstall the filter and O-ring.
toms, it is recommended that the transaxle oil and (16) Apply a 1/8 inch bead of Mopar RTV Sealant
filter be replaced. to the mounting flange of the transaxle oil pan.
• Transaxle oil discolored Apply RTV Sealant to the underside of the attaching
• Transaxle oil has high mileage bolts. Attach the oil pan to the transaxle. Tighten the
• Oil feels grimy when rubbed between fingertips bolts to 19 N•m (165 in. lbs.).
• Poor shift quality (17) Lower the vehicle and add 4 Quarts of Mopar
• Delayed gear engagement ATF Plus 3 Type 7176 transaxle fluid.
• Vehicle shudder between shifts (18) Start the engine and allow it to idle for a min-
TRANSAXLE OIL AND FILTER REPLACEMENT press your foot on the service brake and cycle the
This procedure involves changing the transaxle transaxle from park to all gear positions ending in
fluid and filter, driving the vehicle for 10 miles and neutral or park.
changing the transaxle fluid a second time. (19) Check the transaxle fluid level and add an
(1) Bring the vehicle up to normal operating tem- appropriate amount to bring the transaxle fluid level
perature. Drive the vehicle a minimum of 10 miles. to 3mm (1/8 in.) below the ADD mark on the dip-
(2) Raise the vehicle on the hoist. stick.
(3) Loosen the transaxle oil pan and drain the (20) Recheck the fluid level after the transaxle is
fluid into a suitable container. at normal operating temperature. The level should be
(4) Remove the pan and clean all sealant from the in the HOT range.
pan and transaxle mating surfaces. Clean the mag-
net and the inside of the pan. FLUID DRAIN AND REFILL
(5) Separate the filter and O-ring from the valve (1) Raise vehicle on a hoist (See Group 0, Lubrica-
body. Inspect the O-ring for cuts or improper instal- tion). Place a drain container, with a large opening,
lation. This could lead to delayed garage shifts. under transaxle oil pan.
(6) Install a new filter. Replace the O-ring as nec- (2) Loosen pan bolts and tap the pan at one corner
essary. to break it loose allowing fluid to drain, then remove
(7) Apply a 1/8 inch bead of Mopar RTV Sealant to the oil pan.
the mounting flange of the transaxle oil pan. Apply (3) Install a new filter and gasket on bottom of the
RTV Sealant to the underside of the attaching bolts. valve body and tighten retaining screws to 5 N·m (40
Attach the oil pan to the transaxle. Tighten the bolts inch-pounds).
to 19 N•m (165 in. lbs.). (4) Clean the oil pan and magnet. Reinstall pan
(8) Lower the vehicle and add 4 Quarts of Mopar using new sealant. Tighten oil pan bolts to 19 N·m
ATF Plus 3 Type 7176 transaxle fluid. (165 in. lbs.).
(9) Start the engine and allow it to idle for a min- (5) Pour four quarts of Mopar ATF PLUS 3 (Auto-
imum of one minute. With the parking brake applied, matic Transmission Fluid) type 7176 into the tran-
press your foot on the service brake and cycle the saxle filler tube.
transaxle from park to all gear positions ending in (6) Start engine and allow to idle for at least one
neutral or park. minute. Then, with parking and service brakes
(10) Check the transaxle fluid level and add an applied, move selector lever momentarily to each
appropriate amount to bring the transaxle fluid level position, ending in the PARK or NEUTRAL position.
to 3mm (1/8 in.) below the ADD mark on the dip- (7) Add sufficient fluid to bring level to 1/8 inch
stick. below the ADD mark.
(8) Recheck fluid level after transaxle is at normal NOTE: When flushing transmission cooler and
operating temperature. The level should be in the lines, ALWAYS reverse flush.
HOT region.
(5) Connect the BLUE pressure line to the OUT-
ALUMINUM THREAD REPAIR LET (From) cooler line.
Damaged or worn threads in the aluminum tran- (6) Connect the CLEAR return line to the INLET
saxle case and valve body can be repaired by the use (To) cooler line
of Heli-Coils. This repair consists of drilling out the (7) Turn pump ON for two to three minutes to
worn-out or damaged threads. Then tap the hole with flush cooler(s) and lines. Monitor pressure readings
a Heli-Coil tap, and install a Heli-Coil insert into the and clear return lines. Pressure readings should sta-
hole. This brings the hole back to its original thread bilize below 20 psi. for vehicles equipped with a sin-
size. gle cooler and 30 psi. for vehicles equipped with dual
Heli-Coil tools and inserts are readily available coolers. If flow is intermittent or exceeds these pres-
from most automotive parts suppliers. sures, replace cooler.
(8) Turn pump OFF.
FLUSHING COOLERS AND TUBES (9) Disconnect CLEAR suction line from reservoir
When a transaxle failure has contaminated the at cover plate. Disconnect CLEAR return line at
fluid, the oil cooler(s) must be flushed. The cooler cover plate, and place it in a drain pan.
bypass valve in the transaxle must be replaced also. (10) Turn pump ON for 30 seconds to purge flush-
The torque converter must also be replaced with an ing solution from cooler and lines. Turn pump OFF.
exchange unit. This will ensure that metal particles (11) Place CLEAR suction line into a one quart
or sludged oil are not later transferred back into the container of Mopar ATF Plus 3 t type 7176 automatic
reconditioned (or replaced) transaxle. transmission fluid.
The recommended procedure for flushing the cool- (12) Turn pump ON until all transmission fluid is
ers and tubes is to use Tool 6906A Cooler Flusher. removed from the one quart container and lines. This
purges any residual cleaning solvent from the trans-
WARNING: WEAR PROTECTIVE EYEWEAR THAT mission cooler and lines. Turn pump OFF.
MEETS THE REQUIREMENTS OF OSHA AND ANSI (13) Disconnect alligator clips from battery. Recon-
Z87.1–1968. WEAR STANDARD INDUSTRIAL RUB- nect flusher lines to cover plate, and remove flushing
BER GLOVES. adapters from cooler lines.
KEEP LIGHTED CIGARETTES, SPARKS, FLAMES,
AND OTHER IGNITION SOURCES AWAY FROM THE OIL PUMP VOLUME CHECK
AREA TO PREVENT THE IGNITION OF COMBUSTI- After the new or repaired transmission has been
BLE LIQUIDS AND GASES. KEEP A CLASS (B) FIRE installed, fill to the proper level with Mopar ATF
EXTINGUISHER IN THE AREA WHERE THE PLUS 3 (Type 7176) automatic transmission fluid.
FLUSHER WILL BE USED. The volume should be checked using the following
KEEP THE AREA WELL VENTILATED. procedure:
DO NOT LET FLUSHING SOLVENT COME IN CON- (1) Disconnect the From cooler line at the trans-
TACT WITH YOUR EYES OR SKIN: IF EYE CONTAM- mission and place a collecting container under the
INATION OCCURS, FLUSH EYES WITH WATER FOR disconnected line.
15 TO 20 SECONDS. REMOVE CONTAMINATED
CLOTHING AND WASH AFFECTED SKIN WITH CAUTION: With the fluid set at the proper level,
SOAP AND WATER. SEEK MEDICAL ATTENTION. fluid collection should not exceed (1) quart or inter-
nal damage to the transmission may occur.
COOLER FLUSH USING TOOL 6906A (2) Run the engine at curb idle speed, with the
(1) Remove cover plate filler plug on Tool 6906A. shift selector in neutral.
Fill reservoir 1/2 to 3/4 full of fresh flushing solution. (3) If fluid flow is intermittent or it takes more
Flushing solvents are petroleum based solutions gen- than 20 seconds to collect one quart of ATF, discon-
erally used to clean automatic transmission compo- nect the To Cooler line at the transaxle.
nents. DO NOT use solvents containing acids, water, (4) Refill the transaxle to proper level and recheck
gasoline, or any other corrosive liquids. pump volume.
(2) Reinstall filler plug on Tool 6906A. (5) If flow is found to be within acceptable limits,
(3) Verify pump power switch is turned OFF. Con- replace the cooler. Then fill transmission to the
nect red alligator clip to positive (+) battery post. proper level, using Mopar ATF PLUS 3 (Type 7176)
Connect black (-) alligator clip to a good ground. automatic transmission fluid.
(4) Disconnect the cooler lines at the transmission.
(6) If fluid flow is still found to be inadequate,
check the line pressure using the Transaxle Hydrau-
lic Pressure Test procedure.
REMOVAL AND INSTALLATION

GEARSHIFT CABLE
REMOVAL
(1) Disconnect both battery cables.
(2) Pull up and remove the power distribution cen-
ter.
(3) Remove the battery thermoguard.
(4) Remove the battery and battery holddown from
the battery tray.
(5) Remove the battery tray and cruise control
Fig. 7 Gearshift Cable
servo (if equipped).
(6) Remove the screw from the cable bracket at the
transaxle (Fig. 6).
Fig. 8 Cable Mounting

(16) Remove the one screw at the shift cable grom-
Fig. 6 Gearshift Cable met plate (Fig. 9).
(17) Loosen screws on shift cable grommet plate.
(7) Squeeze the three metal tabs in and remove
Slide plate out and away from heat shield.
the cable from the bracket.
(8) Remove the floor console. Refer to Group 23,
Body.
(9) Remove the gearshift knob set screw and knob.
(10) Remove gearshift indicator lamp at shifter
bezel.
(11) Remove the screws retaining the shifter bezel.
(12) Using a flat–blade pry tool, remove the shifter
cable core end from the shift lever pin (Fig. 7).
(13) Using a small screwdriver, pry the cable con-
duit end tabs away from the shifter mechanism. Pull
up on the conduit end and slide the end out of the
gearshift mechanism.
(14) Remove the three nuts retaining the shift
cable grommet plate to the floor pan (Fig. 8).
(15) Hoist vehicle. Refer to Group 0, Lubrication
and Maintenance.
Fig. 9 Cable Mounting Underbody
(18) Carefully remove the cable from the under-
body by unfolding the cable retainer clip as you go
along.
INSTALLATION
(1) To install gearshift cable, reverse removal pro-
cedure.
(2) Adjust gearshift cable using the adjustment
procedure in this Group.
GEARSHIFT MECHANISM
REMOVAL
(1) Disconnect battery negative cable and isolate.
(2) Remove console assembly. Refer to Group 23,
Body.
(3) Remove the gearshift knob set screw and knob. Fig. 11 Shifter Ignition Interlock Cable
(4) Remove the screws retaining the gearshift indi-
cator bezel and remove bezel and indicator lamp.
(5) Using a flat–blade pry tool, remove the shifter
cable end from the gearshift pin (Fig. 10).
Fig. 12 Gearshift Mechanism

THROTTLE PRESSURE CABLE
Fig. 10 Gearshift Cable REMOVAL

(1) Unsnap the throttle pressure cable end at the
(6) Pry the two tabs on the cable conduit end away throttle control lever at transaxle (Fig. 13).
from the gearshift mechanism and pull up on the (2) Squeeze the retaining tabs inward at the
cable. Remove the gearshift cable from the gearshift mounting bracket (Fig. 14). Remove the cable from
mechanism. the bracket.
(7) Pry up the adjuster lock on the shifter/ignition (3) Unsnap the cable end from the throttle linkage
interlock cable. Unsnap the shifter/ignition interlock cam. Squeeze the tabs inward at the bracket (Fig.
cable end fitting from the groove in the gearshift 15). Remove the cable from the vehicle.
mechanism. Remove the cable core end from the
plastic cam of the shifter mechanism (Fig. 11). INSTALLATION
(8) Remove the nuts at the base of the gearshift (1) To install cable, reverse removal procedure.
mechanism (Fig. 12). Remove the shifter mechanism. Refer to cable adjustment procedure for proper cable
adjustment.
INSTALLATION
(1) For installation, reverse removal steps. Refer to THROTTLE PRESSURE CABLE ADJUSTMENT
Cable Adjustment for proper cable adjustment proce- PROCEDURE
dure. The throttle pressure cable adjustment is very
important to proper transaxle operation. This adjust-
ment positions a valve that controls shift speed, shift
may be delayed and part throttle downshifts may be
very sensitive.
(1) Perform transaxle throttle pressure cable
adjustment while engine is at normal operating tem-
perature.
(2) Release cross-lock on the cable assembly (pull
cross-lock upward) See (Fig. 14).
(3) To insure proper adjustment, the cable must be
free to slide all the way toward the engine, against
its stop, after the cross-lock is released.
(4) Move transaxle throttle control lever fully
clockwise, against its internal stop, and press cross-
lock downward into locked position.
The adjustment is complete and transaxle throttle
cable backlash was automatically removed.
Test cable freedom of operation by moving the
Fig. 13 Throttle Pressure Cable And Lever transaxle throttle lever forward (counterclockwise).
Then slowly release it to confirm it will return fully
rearward (clockwise).
No lubrication is required for any component of the
throttle cable system.
SHIFTER IGNITION INTERLOCK CABLE

REMOVAL
(1) Disconnect and isolate, the battery negative (-)
cable from the vehicle battery.
(2) Remove console assembly. Refer to Group 23,
Body.
(3) Remove the gearshift knob set screw and knob.
(5) Pry up the adjuster lock on the shifter/ignition
interlock cable. Unsnap the shifter/ignition interlock
Fig. 14 Throttle Pressure Cable Bracket
cable end fitting from the groove in the gearshift
mechanism (Fig. 16).
(6) Remove the cable core end from the plastic cam
of the shifter mechanism.
Fig. 15 Cable End At Throttle Linkage

quality, and part throttle downshift sensitivity. If the
setting is too long, early shifts and slippage between
shifts may occur. If the setting is too short, shifts Fig. 16 Shifter Ignition Interlock Cable
(7) Pull cable up and out of the gearshift mecha- (2) Install the ignition switch into housing. Turn
nism. the ignition switch to the RUN position.
(8) Remove the three screws along the bottom of (3) Install the interlock cable into the interlock
the lower steering column cover and screw on the left housing at the steering column (Fig. 18). Verify the
outward face of cover. cable snaps into the housing.
(9) Grasp the cover and pull rearward until the
clips disengage.
(10) Remove two screws at the upper area of the
column liner and lower left corner.
(11) Remove steering column cover and steering
column cover liner.
(12) Lift up the top cover and cluster bezel until
the clips disengage and separate to provide clear-
ance.
(13) Insert a screwdriver into access hole in the
lower shroud. Depress the cylinder button while
rotating the cylinder with the key inserted between
the ON and START positions. This will disengage the
cylinder from the column.
(14) Pull out the key cylinder.
(15) Remove the three lower–to–upper shroud
attaching screws through the bottom of the lower Fig. 18 Interlock Cable at Interlock Housing
shroud.
(16) Separate the upper and lower shrouds. (4) Install interlock cable into routing clip located
(17) Grasp the interlock cable clip and connector. within the wiring harness.
Remove the cable from the interlock housing (Fig. (5) Route interlock cable to the console.
17). (6) Install the 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.
(7) Adjust the Shifter/Ignition Interlock System.
See Interlock System Adjustment, in this section.
(8) Perform the Shifter/Ignition Interlock System
operation check, as described in the beginning of this
section.
(9) Install console assembly. Refer to Group 23,
Body.
(10) Install screws retaining the gearshift indica-
tor bezel and install bezel and indicator lamp.
(11) Install the gearshift knob set screw and knob.
(12) Install two screws at the upper area of the
column liner and lower left corner.
(13) Snap the clips in at the lower column cover.
Install the three screws along the bottom of the lower
Fig. 17 Interlock Cable and Connector steering column cover and screw on the left outward
(18) Unclip the cable from the retaining clip face of cover.
located within the wiring harness. (14) Install key cylinder.
(19) Remove interlock cable from under center con- (15) Position the shrouds in place. Install the three
sole mounting bracket and out front of dash panel. lower–to–upper shroud attaching screws through the
bottom of the lower shroud.
INSTALLATION (16) Reinstall the ignition lock cylinder into hous-
ing.
CAUTION: When installing interlock cable assem- (17) Reconnect the battery negative (-) cable to the
bly, care must be taken not to bend exposed cable vehicle battery.
wire and slug at shifter end of cable.
(1) Route interlock cable into lower dash panel.

INTERLOCK SYSTEM ADJUSTMENT INTERLOCK MECHANISM
If ignition switch cannot be turned to the LOCK
position, with shifter in PARK, an adjustment of the REMOVAL
Interlock System may be required. To adjust Shifter/ (1) Remove the lower column covers, ignition
Ignition Interlock System, follow procedure listed switch, and shrouds. Refer to Interlock Cable
below. Replacement.
(1) Disconnect and isolate, the battery negative (-) (2) Grasp the interlock cable and connector firmly.
cable from the vehicle battery. Remove the interlock cable (Fig. 20).
(2) Remove console assembly. Refer to Group 23, (3) Remove the two interlock mechanism–to–steer-
Body. ing column attaching screws (Fig. 21). Remove the
(3) Remove the gearshift knob set screw and knob. interlock housing.
(5) Reinstall the gearshift knob.
(6) Place shifter in PARK.
(7) Turn ignition switch to the LOCK or ACCES-
SORY position. If cable has lost its adjustment, man-
ually position cable to get key into LOCK or
ACCESSORY position. Grasp slug on interlock cable
with needle nose pliers and pull back on cable. This
will allow the ignition switch to be turned to the
LOCK or ACCESSORY position.
(8) Check that the interlock cable slug is com-
pletely seated into the shifter interlock lever.
(9) Check that the ignition switch is still in the
(10) Pry up the adjuster lock on the shifter/igni-
tion interlock cable (Fig. 19). Fig. 20 Interlock Cable
Fig. 19 Interlock Cable Adjuster Lock Fig. 21 Interlock Mechanism

(11) Place a 1mm (0.040) shim between the larger INSTALLATION
diameter portion of the shifter gate pin and the plas- (1) Position the interlock housing at steering col-
tic cam (Fig. 19). umn. Install the two interlock mechanism–to–steer-
(12) The spring on the interlock cable should auto- ing column attaching screws. Torque screws to 3 N·m
matically compensate for the slack in the adjuster. (21 in. lbs.).
(13) Snap down the interlock adjuster lock onto (2) Snap the interlock cable into the housing.
the cable and remove the shim. (3) Install the lower column covers, shrouds, and
(14) After adjusting the interlock system, perform ignition switch. Refer to Interlock Cable Replace-
the Interlock System Operation Check in the Adjust- ment.
ments section of this group.
VEHICLE SPEED SENSOR PINION GEAR (6) No continuity should exist from either pin to
When the sensor is removed for any reason, a the case.
NEW O-ring must be installed on its outside diame-
ter. TRANSAXLE
REMOVAL REMOVAL
(1) Remove harness connector from sensor. Be sure
weather seal stays on harness connector. NOTE: The transaxle can be removed from the
(2) Remove bolt securing the sensor in the exten- vehicle without having to remove the engine.
sion housing.
The transaxle and torque converter must be
(3) Carefully pull sensor and pinion gear assembly
removed as an assembly; otherwise, the torque con-
out of extension housing.
verter drive plate, pump bushing, or oil seal may be
(4) Remove pinion gear from sensor.
damaged. The drive plate will not support a load;
INSTALLATION therefore, none of the weight of the transaxle should
(1) To install, reverse the above procedure. Be sure be allowed to rest on the plate during removal.
extension housing and sensor flange are clean prior All transaxle components are serviced with the
to installation. Always use a NEW sensor O-ring. transaxle out of the vehicle. The components that are
(2) Tighten bolt to 7 N·m (60 in. lbs.). Tighten serviceable in the vehicle are:
speedometer cable to 4 N·m (35 in. lbs.). • Axle shaft seals
• Back–up lamp switch
PARK/NEUTRAL STARTING AND BACK-UP LAMP • End plate
• Extension housing
SWITCH
• Neutral safety switch
TEST • Shift lever
The park/neutral starting switch is the center ter- • Transaxle oil pan
minal of the three terminal switch. It provides • Valve Body
ground for the starter solenoid circuit through the • Vehicle speed sensor
selector lever in PARK and NEUTRAL positions only. (1) Disconnect the battery.
(1) To test switch, remove wiring connector from (2) Pull Power Distribution Center up and out of
switch and test for continuity between center pin of its holding bracket. Set Power Distribution Center
switch and transaxle case. Continuity should exist aside to gain clearance.
only when transaxle is in PARK or NEUTRAL. (3) Remove battery heat shield and remove battery
(2) Check gearshift cable adjustment before replac- from engine compartment. Remove battery tray from
ing a switch that tests bad. engine compartment. Disconnect cruise control (if
equipped).
REMOVAL (4) Remove vehicle speed sensor wiring.
(1) Unscrew switch from transaxle case allowing (5) Disconnect neutral safety switch and torque
fluid to drain into a container. Move selector lever to converter control wiring at transaxle.
PARK, then to NEUTRAL position, and inspect to see
the switch operating lever fingers are centered in CAUTION: Pry up with equal force on both sides of
switch opening. shifter cable isolator bushing to avoid damaging
cable isolator bushing.
INSTALLATION
(1) Screw the switch with a new seal into tran- (6) Disconnect gear shift cable end from transaxle
saxle case and tighten to 33 N·m (24 ft. lbs.). Retest shift lever (Fig. 22). Remove bracket bolt at transaxle
switch with the test lamp. (Fig. 23).
(2) Add fluid to transaxle to bring up to proper (7) Remove throttle pressure control cable from
level. lever. Then remove bracket bolts at the transaxle
(3) The back-up lamp switch circuit is through the (Fig. 24).
two outside terminals of the three terminal switch. (8) Remove dipstick tube.
(4) To test switch, remove wiring connector from (9) Remove transaxle cooler lines and plug lines
switch and test for continuity between the two out- (Fig. 25).
side pins. (10) Remove throttle pressure control cable sup-
(5) Continuity should exist only with transaxle in port bracket bolts. Remove upper bellhousing bolts
REVERSE position. and upper starter bolt (Fig. 26).
Fig. 22 Gearshift Cable Fig. 25 Cooler Lines
Fig. 23 Shifter Cable Bracket Fig. 26 Starter and Bellhousing Bolts
Fig. 24 Bracket Removal Fig. 27 Engine Bridge Fixture

(11) Install engine bridge fixture and support (13) Remove both front driveshafts. Refer to Group
engine (Fig. 27). 2, Suspension for procedure.
(12) Lift vehicle on hoist and remove front wheels.
CAUTION: When reinstalling driveshafts, new drive-
shaft retaining clips must be used. Do not reuse old
clips. Failure to use new clips may result in disen-
gagement of inner constant–velocity joint.
CAUTION: The exhaust flex joint must be discon-

nected from the exhaust manifold anytime the
engine is lowered. If the engine is lowered while the
flex pipe is attached, damage will occur.
(14) Remove bolts securing exhaust flex joint to

exhaust manifold. Disconnect exhaust pipe from
manifold.
(15) Remove transaxle to rear lateral bending
strut from engine and transaxle (Fig. 28).
Fig. 29 Front Engine Bracket
Fig. 28 Bracket Removal

(16) Remove front engine bracket through–bolt.
Remove front engine bracket bolts (Fig. 29).
(17) Remove lower starter bolt (Fig. 30).
(18) Remove lower dust shield screw.
(19) Rotate engine clockwise to gain access to con-
verter bolts (Fig. 31). Remove torque converter bolts
(Fig. 32). Mark converter to flex plate for reassembly
ease.
(20) Support transaxle with a transmission jack.
(21) Remove left mount through–bolt (Fig. 33).
Remove left mount bolts from transaxle (Fig. 34).
(22) Remove left transaxle mount from transaxle.
(23) Remove rear engine bolt at transaxle. Fig. 30 Starter Bolts
(24) Carefully work transaxle and torque converter
(2) If torque converter was removed from transaxle
assembly rearward off engine block dowels. Disen-
be sure to align pump inner gear pilot flats with
gage converter hub from end of crankshaft. Attach a
torque converter impeller hub flats.
small C-clamp to edge of bellhousing. This will
(3) Adjust gearshift and throttle cables.
hold torque converter in place during transaxle
(4) Refill transaxle with MOPARt ATF PLUS 3
removal. Lower transaxle and remove assembly
(Automatic Transmission Fluid) type 7176.
from under the vehicle.
(5) Verify that vehicle’s back-up lights and speed-
INSTALLATION ometer are functioning properly.
(1) To install transaxle, reverse removal procedure.
Fig. 31 Rotate Engine Fig. 34 Left Mount Bolts

REMOVAL
(1) Screw seal remover Tool C-3981-B into seal
(Fig. 35), then tighten screw portion of tool to with-
draw the seal.
Fig. 32 Torque Converter Bolts
Fig. 35 Remove Pump Oil Seal

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. 36).
DISASSEMBLY AND ASSEMBLY

TRANSAXLE
Prior to removing any transaxle parts, plug all
openings and clean the unit, preferably with steam.
Fig. 33 Left Transaxle Mount Through–Bolt When disassembling, each part should be washed in
a suitable solvent, then dried with compressed air.
PUMP OIL SEAL Do not wipe parts with shop towels. All mating sur-
The pump oil seal can be replaced without remov- faces in the transaxles are accurately machined;
ing the pump and reaction shaft support assembly therefore, careful handling of all parts must be exer-
from the transaxle case. cised to avoid nicks or burrs.
Fig. 36 Install Pump Oil Seal Fig. 38 Transaxle Oil Pan

DISASSEMBLY
Fig. 39 Oil Filter Screws

Fig. 37 Transaxle Oil Pan Bolts
Remove all old sealant before applying new seal-
ant.
Use only Mopart Silicone Rubber Sealant or equiv-
alent when installing oil pan.
Put sealant on the oil pan flange (Fig. 38) and on
all oil pan bolts (underside of bolt head).
Remove neutral starting and back-up lamp switch.
Measuring input shaft end play before disassembly
will usually indicate if a thrust washer change is
required. The thrust washer is located between input
and output shafts.
Attach a dial indicator to transaxle bell housing
with its plunger seated against end of input shaft
(Fig. 45).
Move input shaft in and out to obtain end play
reading. End play specifications are 0.19 to 1.50 mm Fig. 40 Oil Filter
(0.008 to 0.060 inch).
Fig. 41 Remove Parking Rod E-Clip Fig. 44 Valve Body and Governor Tubes
Fig. 42 Parking Rod Fig. 45 Measure Input Shaft End Play
Fig. 43 Valve Body Attaching Bolts Fig. 46 Loosen Lock Nut and Tighten Kickdown
Band Adjusting Screw
Record indicator reading for reference when reas-
sembling the transaxle.
Fig. 47 Pump Attaching Bolts Fig. 50 Oil Pump Gasket
Fig. 48 Install Tool C-3752 with Adapters L-4437 Fig. 51 Loosen Kickdown Band Adjusting Screw
Fig. 49 Oil Pump with No. 1 Thrust Washer Fig. 52 Kickdown Band and Strut
Fig. 53 Front Clutch Assembly Fig. 56 Front Planetary Gear Snap Ring
Fig. 54 No. 2 Thrust Washer and Rear Clutch Fig. 57 Front Planetary Gear Assembly
Fig. 55 No. 3 Thrust Washer

Remove Number 6 thrust washer from sun

gear driving shell.
Fig. 61 Rear Planetary Gear Assembly
Fig. 58 Sun Gear Driving Shell

Fig. 59 Sun Gear Driving Shell Components
Fig. 63 Overrunning Clutch Cam Assembly


Fig. 64 Overrunning Clutch Rollers and Spring
Fig. 68 Install Overrunning Clutch Rollers and

Fig. 65 Loosen or Adjust Low/Reverse Band
Springs
Fig. 66 Low/Reverse Band and Strut

ASSEMBLY
When rebuilding, reverse the above procedure.
VALVE BODY RECONDITION

NOTE: Tighten all valve body screws to 5 N·m (40
in. lbs.)
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.
Fig. 71 Remove or Install Valve Body Screws
Fig. 69 Detent Spring Attaching Screw and Spring

Fig. 72 Transfer Plate and Separator Plate
Fig. 70 Using Tool L-4553 on Valve Body Screw

Fig. 73 Steel Ball Locations
Fig. 74 Remove or Install Throttle Shaft E-Clip Fig. 77 Throttle Valve Lever Assembly
Fig. 75 Throttle Shaft E-Clip, Washer, and Seal Fig. 78 Manual Valve
Fig. 76 Manual Valve Lever Assembly

Fig. 79 Pressure Regulator and Adjusting Screw
Bracket
Fig. 80 Pressure Regulators and Manual Controls
Fig. 81 Governor Plugs

Fig. 82 Pressure Regulator Valve Plugs
Fig. 83 Shift Valves and Shuttle Valve

OIL PUMP-RECONDITION
Fig. 87 Measuring Pump Clearance (Gear to Pocket)

Fig. 84 Reaction Shaft Support Bolts tions).
FRONT CLUTCH-RECONDITION
DISASSEMBLY
Fig. 85 Reaction Shaft Support
Fig. 88 Front Clutch Waved Snap Ring
Fig. 86 Inner and Outer Pump Gears

NOTE: Also, check gear side clearance with a
straight edge and a feeler gauge (See Specifica-
Fig. 89 Thick Steel Plate and Waved Snap Ring Fig. 92 Front Clutch Return Spring and Piston
MEASURING PLATE CLEARANCE
Fig. 90 Front Clutch (4-Disc Shown)

Fig. 93 Measuring Front Clutch Plate Clearance
REAR CLUTCH-RECONDITION
INSPECTION
Inspect facing material on all driving discs.
Replace discs that are charred, glazed, or heavily pit-
ted. Discs should also be replaced if they show evi-
dence of material flaking off, or if facing material can
be scraped off easily. Inspect driving disc splines for
wear or other damage. Inspect steel plate and pres-
sure plate surface for burning, scoring, or damaged
driving lugs. Replace if necessary. Inspect plates and
discs for flatness; they must not be warped or cone-
shaped.
Inspect steel plate lug grooves in clutch retainer
for smooth surfaces; plates must travel freely in the
Fig. 91 Front Clutch Return Spring Snap Ring grooves. Note ball check in piston; be sure ball moves
ASSEMBLY freely. Inspect seal rings surfaces in clutch retainer
To reassemble, reverse the above procedure. for nicks or deep scratches; light scratches will not
interfere with sealing of the seals. Inspect Neoprene
seal rings for deterioration, wear, and hardness.
Inspect piston spring and waved snap ring for distor-
tion or breakage.
Inspect Teflon and/or cast iron seal rings on input
shaft for wear. Do not remove rings unless conditions
warrant. Inspect rear clutch to front clutch No. 2
thrust washer for wear. Washer thickness should be
0.061 to 0.063 inch. Replace if necessary.
DISASSEMBLY
Fig. 96 Piston Spring Waved Snap Ring
Fig. 94 Rear Clutch Outer Snap Ring
Fig. 97 Rear Clutch Piston and Piston Spring
Fig. 95 Rear Clutch (4-Disc Shown)
Fig. 98 Remove or Install Input Shaft Snap Ring

Fig. 99 Input Shaft Snap Ring Fig. 101 Front Planetary Gear Snap Ring and No. 4
Press out input shaft, if required. Thrust Washer (Always Install a New Snap Ring)
ASSEMBLY
To reassemble, reverse the above procedure.
MEASURING PLATE CLEARANCE
Fig. 102 Front Planetary Gear
Fig. 100 Measuring Rear Clutch Plate Clearance

FRONT PLANETARY AND ANNULUS GEAR-
RECONDITION
Fig. 103 Annulus Gear Support Front Snap Ring

Fig. 104 Front Annulus Gear Support and Snap Ring Fig. 107 Low/Reverse Servo Snap Ring
Fig. 105 Front Annulus Gear Support Snap Ring Fig. 108 Remove Retainer, Spring and Servo
LOW/REVERSE (REAR) SERVO-RECONDITION ASSEMBLY
DISASSEMBLY
Fig. 109 Low/Reverse Servo Assembly

To assemble, reverse the above procedure.
Fig. 106 Low/Reverse Lever
ACCUMULATOR-RECONDITION KICKDOWN SERVO (CONTROLLED LOAD)-
RECONDITION
DISASSEMBLY
DISASSEMBLY
Fig. 110 Accumulator Snap Ring

Fig. 113 Kickdown Servo Snap Ring
Fig. 111 Accumulator Plate and Snap Ring

Fig. 114 Kickdown Servo Rod Guide and Snap Ring
ASSEMBLY
TRANSFER SHAFT REPAIR

DISASSEMBLY
NOTE: Remove old sealant before applying new

sealant. Use MoparT RTV sealant, or equivalent,
when installing cover.
Fig. 112 Accumulator Spring and Piston

ASSEMBLY
Fig. 115 Kickdown Piston Return Spring and Piston Fig. 118 Remove or Install Rear Cover
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-
rup.
(3) Remove strap from transfer gear and stirrup.
(4) Remove stirrup from transfer gear.
Fig. 116 Controlled Load Kickdown Servo
Fig. 119 Remove Transfer Shaft Gear Retaining Nut
Fig. 117 Rear Cover Bolts

STIRRUP AND STRAP REMOVAL
NOTE: A stirrup and retaining strap is attached to

the transfer gear. The stirrup prevents the transfer
Fig. 120 Transfer Shaft Gear Nut and Washer Fig. 123 Using Tool L-4406-1 with Adapter L-4406-3,
Remove Transfer Shaft Gear Bearing Cone
Fig. 121 Remove Transfer Shaft Gear

Fig. 124 Install Transfer Shaft Gear Bearing Cone
Fig. 122 Transfer Shaft Gear and (Select) Shim

Fig. 125 Governor Support Retainer
Fig. 126 Remove Governor Support Retainer Fig. 129 Governor Assembly
Bearing Cup NOTE: Remove or install both governor valves and
governor body.
Fig. 127 Install Governor Support Retainer Bearing

Cup Fig. 130 Transfer Shaft Bearing Snap Ring
Fig. 128 Low/Reverse Band Anchor Pin Fig. 131 Remove Transfer Shaft and Bearing
Retainer Assembly
Fig. 132 Remove or Install Transfer Shaft and

Bearing Retainer Assembly Using Tool L-4512
Fig. 135 Install Transfer Shaft Bearing Cone
Fig. 133 Transfer Shaft and Bearing Retainer
Fig. 136 Remove Transfer Shaft Bearing Cup
Fig. 134 Remove Transfer Shaft Bearing Cone

Fig. 139 Checking Transfer Shaft End Play

STIRRUP AND STRAP INSTALLATION
Fig. 137 Install Transfer Shaft Bearing Cup Once bearing shim selection has been adjusted,
install stirrup and strap assembly onto transfer gear.
DETERMINING SHIM THICKNESS
Shim thickness need be determined only if any of NOTE: Once the stirrup assembly is positioned
the following parts are replaced: onto the transfer gear, it is necessary to “clock” the
• Transaxle case stirrup against the flats of the transfer gear retain-
• Transfer shaft ing nut.
• Transfer shaft gear
• Transfer shaft bearings (1) Position the stirrup on the transfer gear.
• Governor support retainer (2) Position strap.
• Transfer shaft bearing retainer (3) Install retaining bolts into transfer gear. Fin-
• Retainer snap ring ger–tighten bolts.
• Governor support (4) Turn stirrup clockwise against the flats of the
Refer to Bearing Adjustment Procedure in rear of transfer gear retaining nut.
this section to determine proper shim thickness. (5) Tighten retaining bolts to 23 N·m (200 in. lbs.).
(6) Bend tabs of strap up against “flats”of retain-
ing bolts.
ASSEMBLY
To install transfer shaft, reverse the above proce-
dure.
Fig. 138 Tighten Transfer Shaft Gear Retaining Nut

to 271 N·m (200 ft. lbs.)
PARKING PAWL ASSEMBLY
To install, reverse the above procedure.
DISASSEMBLY
OUTPUT SHAFT REPAIR
NOTE: Transfer shaft should be removed for repair of
output shaft. Planetary gear sets must be removed to
accurately check output shaft bearing turning torque.
STIRRUP AND RETAINING STRAP
NOTE: A stirrup and retaining strap (Fig. 143) 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
Fig. 140 Parking Sprag Rod Support
Fig. 143 Stirrup and Retaining Strap Assembly

Fig. 141 Support and Bolts
(1) Using a punch, bend tabs on strap flat against
output gear (Fig. 144).
Fig. 142 Parking Pawl, Return Spring, and Pivot Shaft

Fig. 144 Bend Strap Tabs Flat
(2) Remove bolts holding retaining strap to stirrup
(Fig. 145).
Fig. 147 Remove Stirrup From Gear
Fig. 145 Remove Strap Bolts

(3) Remove strap from output gear and stirrup
(Fig. 146).
Fig. 148 Stirrup and Strap Removed From Output

Gear
Fig. 146 Remove Strap From Stirrup and Gear

(4) Remove stirrup from output gear (Fig. 147)
(Fig. 148).
OUTPUT GEAR AND SHAFT
DISASSEMBLY
Fig. 149 Remove Output Shaft Retaining Nut and

Washer
Fig. 152 Remove Output Shaft Gear Bearing Cone
Fig. 150 Remove Output Shaft Gear

Fig. 153 Remove Output Shaft and Rear Annulus
Gear Assembly
Fig. 151 Output Shaft Gear and (Select) Shim

Fig. 154 Remove Output Shaft
Fig. 155 Remove Rear Planetary Annulus Gear Fig. 158 Install Output Shaft Gear Bearing Cone
Bearing Cone
Fig. 159 Install Rear Planetary Annulus Gear

Bearing Cone
Fig. 156 Remove Output Shaft Gear Bearing Cup
Fig. 160 Install Output Shaft into Rear Planetary

Fig. 157 Remove Rear Planetary Annulus Gear Annulus Gear
Bearing Cup
ASSEMBLY
Fig. 163 Install Output Shaft Assembly

Fig. 161 Install Output Shaft Gear Bearing Cup
Fig. 164 Output Shaft and (Select) Shims in Position
Fig. 162 Install Rear Planetary Annulus Gear

Bearing Cup
DETERMINING SHIM THICKNESS
Shim thickness need be determined only if any of
the following parts are replaced:
• Transaxle case
• Output shaft
• Rear planetary annulus gear
• Output shaft gear
• Rear annulus and output shaft gear bearing
cones
• Overrunning clutch race cups
Refer to Bearing Adjustment Procedure at the rear Fig. 165 Start Output Shaft Gear onto Output Shaft
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-pounds, the proper shim
has been installed.
Fig. 166 Holding Output Shaft Gear Fig. 169 Checking Bearing Turning Torque
STIRRUP AND 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 clockwise against the flats of the
Fig. 167 Tighten Output Shaft Retaining Nut to 271 output gear retaining nut (Fig. 170).
N·m (200 ft. lbs.)
Fig. 170 Turn Stirrup Clockwise Against Flats Of

Fig. 168 Checking Output Shaft End Play Retaining Nut
(5) Tighten retaining bolts to 23 N·m (200 in. lbs.)
(Fig. 171).
(6) Bend tabs of strap up against “flats”of retain-
ing bolts.
Fig. 171 Tighten Strap Retaining Nuts Fig. 174 Differential Cover Bolts
DIFFERENTIAL REPAIR
NOTE: The transfer shaft should be removed for dif-
ferential repair and bearing turning torque checking.
Fig. 175 Remove or Install Differential Cover

NOTE: Use MoparT RTV sealant, or equivalent,
when installing differential cover.
Fig. 172 Remove Extension Seal
Fig. 176 Remove Bearing Retainer Axle Seal
Fig. 173 Install New Seal into Extension

Fig. 177 Install Bearing Retainer Axle Seal Fig. 180 Differential Bearing Retainer (Typical)
NOTE: Use MoparT RTV sealant, or equivalent,
when installing differential bearing retainer.
Fig. 178 Differential Bearing Retainer Bolts
Fig. 181 Extension Bolts
Fig. 179 Remove or Install Bearing Retainer
Fig. 182 Remove or Install Extension Housing

Fig. 183 Differential and Extension Fig. 186 Install Differential Bearing Cone
WARNING: HOLD ONTO DIFFERENTIAL ASSEMBLY
TO PREVENT IT FROM ROLLING OUT OF HOUSING.
Use Mopart Silicone Rubber Adhesive Sealant, or
equivalent, when installing extension housing.
Fig. 187 Position Button and Collets Onto

Differential and Bearing (Ring Gear Side)

(Extension Housing Side)
Fig. 188 Position Tool 5048 Over Button and Collets

at Differential Bearing
Fig. 185 Position Bearing Cone Onto Differential

Fig. 189 Remove Differential Bearing Cone Fig. 191 Checking Side Gear End Play (Typical)
To install the differential bearing cup and cone on
the ring gear side, use Special Tool 5052, and Special
Tool C-4171.
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.
Fig. 192 Differential Bearing Retainer
Fig. 190 Checking Side Gear End Play

CAUTION: Side gear end play must be BETWEEN
0.001 to 0.013 inch.
Fig. 193 Position Bearing Cup Remover Tool in

Retainer
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,
Fig. 194 Remove Bearing Cup using a surface plate. Be sure all metering holes in
To remove the differential bearing cup from the steel plate are open. Using a penlight, inspect bores
extension housing/adapter side, use Special Tool in valve body for scores, scratches, pits, and irregu-
6062A, Remover. To install the differential bearing larities.
cup on the extension housing/adapter side, use Spe- Inspect all valve springs for distortion and col-
cial Tool 6536, Driver and Special Tool C-4171, Han- lapsed coils. Inspect all valves and plugs for burrs,
dle. nicks, and scores. Small nicks and scores may be
removed with crocus cloth, providing extreme care is
DETERMINING SHIM THICKNESS taken not to round off sharp edges. The sharpness of
Shim thickness need be determined only if any of these edges is vitally important. It prevents foreign
the following parts are replaced: matter from lodging between valve and valve body.
• Transaxle case This reduces the possibility of sticking. Inspect all
• Differential carrier valves and plugs for freedom of operation in valve
• Differential bearing retainer body bores.
• Extension housing When bores, valves, and plugs are clean and dry,
• Differential bearing cups and cones the valves and plugs should fall freely in the bores.
Refer to Bearing Adjustment Procedure in rear of The valve body bores do not change their dimensions
this section to determine proper shim thickness. 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.
ADJUSTMENTS
GEARSHIFT CABLE
Normal operation of the Park/Neutral Position
Switch provides a quick check to confirm proper link-
age adjustment.
Move the selector level slowly forward until it
clicks into the PARK (P) position. The starter should
operate.
After checking the (P) position, move selector
slowly toward the NEUTRAL (N) position until lever
Fig. 195 Install Bearing Cup drops in the (N) position. If the starter will operate
also at this point, the gearshift linkage is properly
adjusted. If the starter fails to operate in either posi-
tion, linkage adjustment is required.
ADJUSTMENT (1) Perform transaxle throttle pressure cable
(1) Set parking brake. adjustment while engine is at normal operating tem-
(2) Remove floor console. Refer to Group 23, Body. perature.
(3) Place gearshift lever in the (PARK) (P) posi- (2) Release cross-lock on the cable assembly (pull
tion. cross-lock upward) see (Fig. 197).
(4) Push down on the tab and unsnap the collar at
the shifter cable to allow the cable to be adjusted
(Fig. 196).
Fig. 197 Throttle Pressure Cable Adjuster Lock

(3) To ensure proper adjustment, the cable must be
free to slide all the way toward the engine, against
Fig. 196 Gearshift Cable Adjustment its stop, after the cross-lock is released.
(5) Move the gearshift lever on the transaxle to (4) Move transaxle throttle control lever fully
the PARKposition. clockwise, against its internal stop, and press cross-
(6) Verify the shift lever and transaxle are in the lock downward into locked position.
PARK position. Rotate collar on the shift cable The adjustment is complete and transaxle throttle
adjuster end up until it seats against the plastic cable backlash was automatically removed.
housing. NOTE: If the collar will not rotate to the Test cable freedom of operation by moving the
fully detented lock position, rotate the collar back to transaxle throttle lever forward (counterclockwise).
its initial unlocked position. Position the ATX in the Then slowly release it to confirm it will return fully
gated PARK position. Apply a slight load to the shift rearward (clockwise).
lever, fore or aft in vehicle, while simultaneously No lubrication is required for any component of the
rotating the collar upward to the LOCK position. The throttle cable system.
collar must seat against the plastic housing to
achieve the required detented lock position. The gear- SHIFTER/IGNITION INTERLOCK SYSTEM
shift linkage should now be properly adjusted. If ignition switch cannot be turned to the LOCK
Check adjustment as follows: position, with shifter in PARK, an adjustment of the
(7) Detent position for NEUTRAL and DRIVE Interlock System may be required. To adjust Shifter/
should be within limits of hand lever gate stops. Ignition Interlock System, follow procedure listed
(8) Key start must occur only when the shift lever below.
is in PARK or NEUTRAL positions. (1) Disconnect and isolate, the battery negative (-)
cable from the vehicle battery.
THROTTLE PRESSURE CABLE ADJUSTMENT (2) Remove console assembly. Refer to Group 23,
PROCEDURE Body.
The throttle pressure cable adjustment is very (3) Remove the gearshift knob set screw and knob.
important to proper transaxle operation. This adjust- (4) Remove the screws retaining the gearshift indi-
ment positions a valve which controls shift speed, cator bezel and remove bezel and indicator lamp.
shift quality, and part throttle downshift sensitivity. (5) Reinstall the gearshift knob.
If the setting is too long, early shifts and slippage (6) Place shifter in PARK.
between shifts may occur. If the setting is too short, (7) Turn ignition switch to the LOCK or ACCES-
shifts may be delayed and part throttle downshifts SORY position. If cable has lost its adjustment, man-
may be very sensitive. ually position cable to get key into LOCK or
ACCESSORY position. Grasp slug on interlock cable
with needle–nose pliers and pull back on cable. This (3) Back–off adjusting screw the number of turns
will allow the ignition switch to be turned to the listed under Specifications. A chart is located at the
LOCK or ACCESSORY position. rear of this section.
(8) Check that the interlock cable slug is com- (4) Tighten locknut to 14 N·m (10 ft. lbs.).
pletely seated into the shifter interlock lever.
(9) Check that the ignition switch is still in the HYDRAULIC CONTROL PRESSURE ADJUSTMENTS
(10) Pry up the adjuster lock on the shifter/igni- LINE PRESSURE
tion interlock cable (Fig. 198). An incorrect throttle pressure setting will cause
incorrect line pressure readings even though line
pressure adjustment is correct. Always inspect and
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 pressure.
THROTTLE PRESSURE
Throttle pressures cannot be tested accurately;
Fig. 198 Interlock Cable Adjuster Lock therefore, the adjustment should be measured if a
(11) The spring on the interlock cable should auto- malfunction is evident.
matically compensate for the slack in the adjuster. (1) Insert gauge pin of Tool C-3763 between the
(12) Then snap down the interlock adjuster lock throttle lever cam and kickdown valve.
onto cable. (2) By pushing in on tool, compress kickdown
(13) After adjusting the interlock system, perform valve against its spring so throttle valve is com-
the interlock system operation check. See Interlock pletely bottomed inside the valve body.
System Operation Check in this section. (3) While compressing spring, turn throttle lever
stop screw with adapter C-4553. Turn until head of
BAND ADJUSTMENT screw touches throttle lever tang, with throttle lever
cam touching tool and throttle valve bottomed. Be
KICKDOWN BAND (FRONT) sure adjustment is made with spring fully com-
The kickdown band adjusting screw is located on pressed and valve bottomed in the valve body.
left side (top front) of the transaxle case.
(1) Loosen locknut and back–off nut approximately BEARING ADJUSTMENT PROCEDURES
five turns. Test adjusting screw for free turning in (1) Take extreme care when removing and install-
the transaxle case. ing bearing cups and cones. Use only an arbor
(2) Using wrench, tighten adjusting screw to 8 press for installation, as a hammer may not
N·m (72 in. lbs.). properly align the bearing cup or cone. Burrs or
(3) Back–off adjusting screw the number of turns nicks on the bearing seat will give a false end play
listed in Specifications. Hold adjusting screw in this reading, while gauging for proper shims. Improperly
position and tighten locknut to 47 N·m (35ft. lbs.) seated bearing cup and cones are subject to low-mile-
age failure.
LOW/REVERSE BAND (REAR) (2) Bearing cups and cones should be replaced if
To adjust low/reverse band, proceed as follows: they show signs of pitting or heat distress.
(1) Loosen and back off locknut approximately five (3) If distress is seen on either the cup or bearing
turns. rollers, both cup and cone must be replaced.
(2) Using an inch-pound torque wrench, tighten
adjusting screw to 5 N·m (41 in. lbs.) true torque. 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 after 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.
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. lbs.).
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
OUTPUT SHAFT BEARING SHIM CHART
inch) or 13.65 mm (0.537 inch) shims are always
installed first. These shims have lubrication slots DIFFERENTIAL BEARING
that are necessary for proper bearing lubrica- (1) Position the transaxle assembly vertically on
tion. the support stand, differential bearing retainer side
(7) Shims thinner than 12.65 mm listed in the up.
chart are common to both the transfer shaft and out- (2) Install Tool L-4436A into the differential and
put shaft bearings. onto the pinion mate shaft.
(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. lbs.).
(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
Fig. 199 Tool L-4436 and Torque Wrench
to 8 inch pounds.
(3) Rotate the differential at least one full revolu- DIFFERENTIAL BEARING SHIM CHART
tion to ensure the tapered roller bearings are fully
seated. SHIM THICKNESS
(4) Using Tool L-4436A and an inch-pound torque MM INCH
wrench, check the turning torque of the differential.
.980 0.0386
The turning torque should be between 5 and 18
inch-pounds. 1.02 0.0402
1.06 0.0418
1.10 0.0434
1.14 0.0449
1.18 0.0465
1.22 0.0481
1.26 0.0497
1.30 0.0512
1.34 0.0528
1.38 0.0544
1.42 0.0560
1.46 0.0575
1.50 0.0591
1.54 0.0607
Fig. 200 Checking Differential Bearings Turning
1.58 0.0623
Torque
1.62 0.0638
(5) If the turning torque is within specifications,
remove tools. Setup is complete. 1.66 0.0654
(6) If turning torque is not within specifications 1.70 0.0670
proceed with the following steps. 2.02 0.0796
(a) Remove differential bearing retainer from
2.06 0.0812
the transaxle case.
(b) Remove the bearing cup from the differential tial. The turning torque should be between 5
bearing retainer using Tool 6062A. and 18 inch-pounds.
(c) Remove the existing shim from under the
cup. TRANSFER SHAFT BEARING
(d) Measure the existing shim. (1) Use tool L-4434 to remove the retaining nut
and washer. Remove the transfer shaft gear using
NOTE: If the turning torque was too high when
tool L-4407.
measured, install a .05 mm (.002 inch) thinner shim.
(2) Install a 2.29 mm (0.090 inch) and a 1.39 mm
If the turning torque is was too low, install a .05 mm
(0.055 inch) gauging shims on the transfer shaft
(.002 inch) thicker shim. Repeat until 5 to 18 inch-
behind the governor support.
pounds turning torque is obtained.
(3) Install transfer shaft gear and bearing assem-
Oil Baffle is not required when making shim
bly and torque the nut to 271 N·m (200 ft. lbs.).
selection.
To measure bearing end play:
(e) Install the proper shim under the bearing a. Attach tool L-4432 to the transfer gear.
cup. Make sure the oil baffle is installed properly b. Mount a steel ball with grease into the end of
in the bearing retainer, below the bearing shim the transfer shaft.
and cup. c. Push and pull the gear while rotating back and
(f) Install the differential bearing retainer using forth to insure seating of the bearing rollers.
Tool 5052 and C-4171. Seal the retainer to the d. Using a dial indicator, measure transfer shaft
housing with MOPARt Adhesive Sealant and end play.
torque bolts to 28 N·m (250 in. lbs.). e. Refer to the Transfer Bearing Shim Chart for
(7) Using Tool L-4436A and an inch-pound torque the required shim combination to obtain the proper
wrench, recheck the turning torque of the differen- bearing setting.
f. Use tool L-4434 to remove the retaining nut and
washer. Remove the transfer shaft gear using tool
L-4407.
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. lbs.). 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 .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.
TRANSFER BEARING SHIM CHART

SCHEMATICS AND DIAGRAMS

31TH TRANSAXLE HYDRAULIC SCHEMATIC

SCHEMATICS AND DIAGRAMS (Continued)







SPECIFICATIONS Flex Plate To Crankshaft Bolts. . .95 N·m (70 ft. lbs.)
Flex Plate To Torque
31TH AUTOMATIC TRANSAXLE Conv. Bolts . . . . . . . . . . . . . . . .68 N·m (50 ft. lbs.)
Fluid Filter Screw . . . . . . . . . . . . .5 N·m (45 in. lbs.)
Type . . . . . . . . . . .Automatic three speed with torque Front Motor Mount Bolt . . . . . . . .54 N·m (40 ft. lbs.)
converter and integral differential Governor Counterweight
Torque Converter Screw . . . . . . . . . . . . . . . . . . .28 N·m (250 in. lbs.)
Diameter. . . . . . . . . . . . . . .241 millimeters (9.48 in.) Governor To Support Bolt . . . . . . .7 N·m (60 in. lbs.)
Oil Capacity . . . . . . . . . . . . . .8.6 Liters (18.25 pints) Kickdown Band Adj. Lock Nut . . .47 N·m (35 ft. lbs.)
Oil Type . . . . . . . . . .Mopart ATF PLUS 3 Type 7176 Left Motor Mount Bolts . . . . . . . .54 N·m (40 ft. lbs.)
Cooling Method. . . . . . . .Water Heat Exchanger and/ Lower Bell Housing
or air to oil heat exchanger Cover Screw . . . . . . . . . . . . . . .41 N·m (30 ft. lbs.)
Lubrication . . . . . .Pump (internal-external gear-type Manual Cable To Trans.
Case Bolt . . . . . . . . . . . . . . . .28 N·m (250 in. lbs.)
Gear Ratios
Manual Control Lever Screw . . .12 N·m (105 in. lbs.)
Transmission Portion Oil Pan To Trans. Case Screw . .19 N·m (165 in. lbs.)
First Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.69 Output Gear Strap Bolts. . . . . . . .23 N·m (17 ft. lbs.)
Second Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.55 Output Shaft Nut . . . . . . . . . . .271 N·m (200 ft. lbs.)
Third Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.00 Park/Neutral Switch . . . . . . . . . . .34 N·m (25 ft. lbs.)
Reverse Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10 Pressure Check Plug . . . . . . . . . . .5 N·m (45 in. lbs.)
Pump To Case Bolts . . . . . . . . . .31 N·m (275 in. lbs.)
Pump Clearances Reaction Shaft Assembly Bolt . .28 N·m (250 in. lbs.)
Outer Gear To Pocket . . . . . . . . . . . . .0.045-0.141mm Rear Cover To Case Screw . . . . .19 N·m (165 in. lbs.)
(0.0018-0.0056 in.) Reverse Band Adj. Lock Nut . . .14 N·m (125 in. lbs.)
Outer Gear Side Clearance. . . . . . . . .0.020-0.046mm Reverse Band Shaft Plug . . . . . . . .7 N·m (60 in. lbs.)
(0.0008-0.0018 in.) Ring Gear Screw. . . . . . . . . . . . . .95 N·m (70 ft. lbs.)
Inner Gear Side Clearance . . . . . . . . .0.020-0.046mm Speedo. To Ext. Hous. Screw . . . . .7 N·m (60 in. lbs.)
(0.0008-0.0018 in.) Sprag Ret. To Transfer
Case Bolt . . . . . . . . . . . . . . . .28 N·m (250 in. lbs.)
Tapered Roller Bearing Settings Starter To Trans. Bell Bolts . . . . .54 N·m (40 ft. lbs.)
Differential Assembly . . .6 to 12 in. lbs. Drag Torque Stirrup Strap Ret. Bolts . . . . . . .23 N·m (200 in. lbs.)
Output Hub. . . . . . . . . . . .0 to 3 in. lbs. Drag Torque Throttle Cable To Trans.
Transfer Shaft . . . . . . . . .0.002 to 0.010 in. End Play Case Bolt . . . . . . . . . . . . . . . .12 N·m (105 in. lbs.)
Overall Drag At Output Hub . . .3 to 16 in. lbs. Drag Throttle Lever To Trans.
Torque Shaft Bolts . . . . . . . . . . . . . . .12 N·m (105 in. lbs.)
Trans. To Cyl. Block Bolt . . . . . . .95 N·m (70 ft. lbs.)
Clutch Pack Clearances Transfer Shaft Nut . . . . . . . . . .271 N·m (200 ft. lbs.)
Front Clutch (Not Adjustable) . . . . . . . .1.27-2.79mm Transfer Gear Strap Bolts . . . . . .23 N·m (17 ft. lbs.)
(0.050-0.110 in.) Valve Body Assy. To
Rear Clutch . . . . . . . . .0.71-1.10mm (0.028-0.043 in.) Case Bolts . . . . . . . . . . . . . . .12 N·m (105 in. lbs.)
Band Adjustment Valve Body Screw. . . . . . . . . . . . . .5 N·m (45 in. lbs.)
Kickdown, Backed Off From
8 N•m (72 in. lbs.) . . . . . . . . . . . . . . . 2 1/4 Turns
Low-Reverse, Backed Off From
5 N•m (41 in. lbs.) . . . . . . . . . . . . . . . .3 1/2 Turns
31TH TRANSAXLE TORQUE SPECIFICATIONS
DESCRIPTION TORQUE
Bell Housing Cover Bolts . . . . . .12 N·m (105 in. lbs.)
Cooler Hose To Rad. Conn. . . . . .12 N·m (105 in. lbs.)
Cooler Line Conn. . . . . . . . . . . .28 N·m (250 in. lbs.)
Diff. Bear. Ret. To Case Bolt . . .34 N·m (300 in. lbs.)
Diff. Cover To Case Bolt . . . . . . .19 N·m (165 in. lbs.)
Exten. Hous. To Case Bolt . . . . .28 N·m (250 in. lbs.)
SPECIAL TOOLS
31TH AUTOMATIC TRANSAXLE
Slide Hammer C-637
Puller Press Extension C-293-3
Pressure Gauge (Low) C-3292
Adapter Blocks C-293–36
Pressure Gauge (High) C-3293SP
Adapter Blocks C-293–52
Dial Indicator C-3339
Puller Press C-293–PA

Spring Compressor C-3575–A
Universal Handle C-4171
Band Adjusting Adapter
Seal Installer C-4193A
Oil Pump Puller C-3752
Bearing Installer C-4637
Seal Puller C-3981B
Adapter C-4658
Bearing Remover Jaws L-4406–2

Torque Tool C-4995
Adapter L-4406–3
Adapter C-4996
Gear Puller L-4407A

Remover Kit L-4406
Puller L-4407–6
Bearing Remover Cup L-4406–1
Gear Checking Plate L-4432

Bearing Installer L-4408
Gear Removing Plate L-4434

Bearing Puller L-4435

Differential Tool L-4436A

Installer Adapter L-4429-3
Special Jaw Set L-4518

Housing Remover Adapter L-4437
Installer L-4520
Starter Nut L-4439
Bearing Splitter P-334

Transfer Shaft Remover-Installer L-4512
Bearing Cone Remover 5048

Bearing Cup Remover L-4517
Bearing Installer 6536-A

Bearing Installer 5052
Cooling System Tester 7700

Bearing Cup Remover 6062-A
Seal Remover 7794-a

Transaxle: NV T350 (A-578) Manual Transaxle

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PL TRANSAXLE 21 - 1

31TH AUTOMATIC TRANSAXLE . . . . . . . . . . . . . 40 NV T350 (A-578) MANUAL TRANSAXLE . . . . . . . 1

NV T350 (A-578) MANUAL TRANSAXLE

GENERAL INFORMATION GEARSHIFT KNOB . . . . . . . . . . . . . . . . . . . . . . . 4

The differential is a conventional arrangement of

Fig. 1 Metal I.D. Tag

SLIPS OUT OF GEAR

LOW LUBRICANT LEVEL

DIAGNOSIS AND TESTING FLUID DRAIN AND FILL

Fig. 3 Fill Plug Location Fig. 5 Gearshift Knob

Fig. 4 Drain Plug Location

Fig. 7 Selector Cable Removal Fig. 9 Grommet Retaining Nuts (Interior)

Fig. 8 Crossover Cable Removal Fig. 10 Cable Retaining Clips

(6) Pull cables up out of transaxle bracket.

CAUTION: It is recommended that new cable retain-

(10) Disconnect shift cables from shifter. Pry with

CAUTION: Gearshift cable bushings must not be

(1) To install, reverse removal procedure. After

CAUTION: Only the crossover cable is adjustable.

GEARSHIFT CROSSOVER CABLE

Fig. 12 Crossover Cable Adjustment Screw

CAUTION: Clean area around speed sensor before

(3) Remove speed sensor retaining bolt (Fig. 15).

Fig. 16 Back-up Lamp Switch

CAUTION: Do not overtighten switch.

(2) Confirm back-up lamps are functioning prop-

(5) Remove speed sensor drive gear from speed

BACK-UP LAMP SWITCH

All transaxle components are serviced with the

(6) Disconnect both gear shift cables ends from

Fig. 22 Remove Clutch Cable From Lever

Fig. 20 Shift Cables

Fig. 23 Linkage Bracket Bolts

Fig. 26 Left Transaxle Mount Through-Bolt

DISASSEMBLY AND ASSEMBLY

Fig. 30 Bellhousing Case Half Removal

Fig. 31 Differential Assembly Removal

Fig. 32 Reverse Idler Shaft Bolt Removal

Fig. 33 Reverse Idler Gear Removal

Fig. 36 Remove Selector Shaft Spacer

Fig. 34 Screws Retaining Reverse Fork Bracket

Fig. 37 Selector Shaft

Fig. 35 Remove Reverse Fork Bracket

Fig. 38 Transaxle Cover Removal

Fig. 41 Bench Fixture

Fig. 39 End Cover

Fig. 42 Bearing Fixture

(15) Install transaxle gear case into shop press.

Fig. 43 Pressing Gears Out of Case

Fig. 46 Reverse Brake Shim

Fig. 44 Transaxle Case Removal

Fig. 47 Reverse Brake Friction Cone

Fig. 45 Oil Feed Trough

Fig. 50 Reverse Brake Race

Fig. 54 Bench Fixture Fig. 57 Reverse Brake Race Installation

Fig. 55 Shift Rail Installation Fig. 58 Reverse Brake Needle Bearing

Fig. 62 Gear Case Half

Fig. 63 Friction Cone Lugs

Fig. 61 Reverse Brake Shim