Assembly

NOTE: The sealant used to seal the transaxle case halves is MOPAR 54 Gasket Marker, Loctite 518 or equivalent. The sealant used for the bearing end plate cover is MOPAR 54 RTV.





1. Verify bench fixture shims are removed from bench fixture. Install output and input gear into pallet fixture (Miller tool #6785-3, or equivalent).





2. Install shift rails and forks into bench fixture.





3. Install shift blocker assembly into bench fixture.





4. Install reverse brake race onto input gear.





5. Install reverse brake needle bearing.





6. Install reverse brake blocking ring.





7. Install reverse brake friction cone.





8. Install reverse brake shim. Apply petroleum jelly to shim to hold in place.





9. Install gear case half over pallet fixture. Line up shift finger over 3/4 lug.





10. Line up reverse brake friction cone lug to the slots in the gear case. Verify reverse brake shim is in position.





11. Position input and output bearings on the shafts. Using Miller tool #C-4992-1, or equivalent press input and output shaft bearings until they bottom into the case and against the shafts.





12. Install shaft snap rings at input and output bearings.





13. Apply MOPAR RTV sealant to end cover outer edge and around bolt holes. Install end cover onto gear case. Tighten end cover bolts to 29 Nm (21 ft. lbs.) torque.
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 shift blocker assembly.
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 Nm (19 ft. lbs.) torque.








19. Install reverse fork bracket and reverse cam lockout assembly. Tighten screws to 11 Nm (115.2 inch lbs.) torque.





20. Install differential into gear case.