Transaxle Reassembly

NOTE: Replace all gaskets, seals and roll pins with new ones. Oil all rolling or sliding parts and grease seal lips before reassembly.

Place mainshaft assembly into transmission case. Using a bearing installer, drive middle mainshaft bearing onto mainshaft and into case while holding front of mainshaft by hand. Install needle bearing and synchronizer, then slide input shaft/pinion gear assembly into transmission case with needle bearing engaging end of mainshaft.

Position countergear into case. Install respective snap rings on front needle bearing and rear ball bearing. Drive needle bearing and ball bearing into case. Install front bearing retainer with a bearing spacer which will give a clearance of 0-.004" (0-.1 mm) at dimension "C" See Fig 1 . Apply a sealer to both sides of gasket.

Fig 1: Retainer-to-Bearing Clearance Measurement

Courtesy of CHRYSLER CORP.

FRONT BEARING RETAINER SPACER SIZES

Application (Color)	Thickness In. (mm)
Black	.033 (.84)
No Color	.037 (.94)
Red	.040 (1.0)
White	.044 (1.1)
Yellow	.047 (1.2)
Blue	.051 (1.3)
Green	.054 (1.4)

Install rear bearing retainer. Place reverse idler shaft into position and install bolts to act as guides. Using a large drift, drive reverse idler shaft into case.
Install needle bearing, reverse idler gear and thrust washer with ground side facing gear. Install and tighten castle nut.
Check to see that end play between washer and gear is .005-011" (.12-.28 mm). Then install cotter pin in castle nut. See Fig 2 .

Fig 2: Using a Feeler Gauge to check Reverse Idler Gear End Play
Courtesy of CHRYSLER CORP.
Assemble 5th gear synchronizer. See Fig 3 . Install spacer, stop plate, synchronizer ring and 5th gear on mainshaft.

Fig 3: 5th Gear Synchronizer Assembly
Courtesy of CHRYSLER CORP.
Install and tighten lock nut, staking it at a notch in mainshaft. End play measured between 5th gear and lock nut should be .004-.010" (.10-.25 mm).
Install spacer and 5th countergear ball bearing. Tighten lock nut and stake into notch at rear end of countergear. Engage 1st-2nd and 3rd-4th shift forks in their respective synchronizer sleeves.
Slide lower shift rail into position and install shift fork roll pin. Install lower interlock plunger. Next install middle shift rail and roll pin. Position 5th-Reverse shift fork in synchronizer sleeve. Install upper interlock plunger.
Slide upper shift rail into position and install shift fork roll pin. Install all 3 detent balls and springs with small end of spring facing ball. Screw detent plugs approximately .24" (6.1 mm) into case and apply sealer to head of plugs. See Fig 4 .

Fig 4: Installing Detent Balls, Springs and Plugs
Courtesy of CHRYSLER CORP.
Install snap ring in forward groove of mainshaft. Install bearing retaining snap ring. Install speedometer gear snap ring and speedometer gear. Finally install snap ring.
Apply sealer to both sides of extension housing gasket and position on housing. While holding shifter fully to the left, slide housing onto mainshaft. Make sure forward end of control finger is snugly fitted in slot of shift lug. Apply sealer to threads of attaching bolts and tighten bolts.
Install neutral return plungers "A" and "B", springs and plugs. Then install detent ball, spring and plug. Screw all plugs flush with housing and apply sealer to head of plugs. See Fig 5 .

Fig 5: Installing Neutral Return Plungers
Courtesy of CHRYSLER CORP.
Using sealer, install speedometer drive lock plate. Place steel ball in position and screw back-up light switch into housing. Install bottom pan and gasket.
Install stopper bracket assembly to extension housing cover, making sure reverse resistance plate is smoothly moved on bracket. Install extension housing cover on extension housing.