Chrysler Le Baron, Dodge Dynasty, Plymouth Acclaim. Manual — part 99
TRANSAXLE
CONTENTS
page
page
41TE FOUR SPEED AUTOMATIC TRANSAXLE . 85
41TE FOUR SPEED TRANSAXLE HYDRAULIC
SCHEMATICS
. . . . . . . . . . . . . . . . . . . . . . . . 170
41TE ON-BOARD DIAGNOSTICS
. . . . . . . . . . 145
A-523, A-543, and A-568 MANUAL
TRANSAXLE
. . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SPECIFICATIONS
. . . . . . . . . . . . . . . . . . . . . . 183
THREE SPEED TORQUEFLITE AUTOMATIC
TRANSAXLE
. . . . . . . . . . . . . . . . . . . . . . . . . . 35
THREE SPEED TRANSAXLE HYDRAULIC
SCHEMATICS
. . . . . . . . . . . . . . . . . . . . . . . . 162
A-523, A-543, and A-568 MANUAL TRANSAXLE
INDEX
page
page
Bearing Adjustment Procedure
. . . . . . . . . . . . . . 31
Differential Bearing Preload Adjustment
. . . . . . . . 33
Gearshift Linkage Adjustment (Cable Operated)
. . 2
General Information
. . . . . . . . . . . . . . . . . . . . . . . . 1
In-Car Transaxle Disassemble/Assemble
. . . . . . . . 4
Out of Car Transaxle—Disassemble and Assemble . 6
Subassembly-Recondition
. . . . . . . . . . . . . . . . . . 15
Transaxle Removal and Installation
. . . . . . . . . . . . 5
GENERAL INFORMATION
Safety goggles should be worn at all times
when working on these transaxles. All manual
transaxles use SAE 5W-30 engine oil, meeting SG
and/or SG-CC qualifications, as the lubricant in order
to reduce wear.
This 5-speed manual transaxles combine gear reduc-
tion, ratio selection, and differential functions in one
unit. It is housed in a die-cast aluminum case (Fig. 1).
All shift forks are cast iron. Do not interchange 1-2
or 5th shift fork pads with the 3-4 shift fork pads.
All synchronizers use a winged strut design that
prevents the struts from popping out of position.
If any synchronizer is to be disassembled, mark
all parts so that they will be reassembled in the
same position.
CAUTION: 1-2 synchronizer assembly components
must NOT be interchanged with any other synchro-
nizer assembly. Do not interchange with previous
model years transaxles; they will NOT function cor-
rectly.
A-523 AND A-543 MANUAL TRANSAXLE
The A-523 manual transaxle is used in all 4-cylinder
applications, except high output turbocharged engines.
The A-543 manual transaxle is used only with V-6
engines.
To reduce wear, the manual transaxle uses SAE
5W-30 engine oil as the lubricant.
Gear ratios for the A-523 and A-543 are as follows:
1st—3.31, 2cd—2.06, 3rd—1.36, 4th—0.97, 5th—0.71,
Reverse—3.14. The final drive ratio is 3.77.
CAUTION: All gears and shafts must not be inter-
changed with previous model years; they will not
function correctly.
Fig. 1 External Transaxle Components
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TRANSAXLE
21 - 1
A-568 HEAVY—DUTY MANUAL TRANSAXLE
The greater torque of the high output turbo engines
require a stronger transmission. It includes a die-cast
aluminum case and a stronger, coarse-pitch gear set. It
has five forward speed ratios and reverse. Gear ratios
are
as
follows:
1st—3.31,
2nd—1.89,
3rd—1.28,
4th—0.94, 5th—0.71, Reverse—3.14. Final drive ratio
of 3.85 was selected for maximum performance. All
forward gears are synchronized.
To reduce wear, this transaxle, in common with other
manual transaxles, uses SAE 5W-30 engine oil as the
lubricant.
IDENTIFICATION
A-523, A-543, and A-568: the transaxle model, assem-
bly number, build date, and final-drive ratio are
stamped on a tag that is attached to the top of the
transaxle (Fig. 2).
Certain
transaxle
assemblies
utilize
high-
strength Steel in various gears to provide adequate
life in heavy-duty applications. Therefore, it is im-
perative that the correct transaxle assembly
number is utilized when ordering service parts.
Also, be sure to reinstall this tag whenever it is
removed, so the information is available for future
service.
The last eight digits of the Vehicle Identification
Number (V.I.N.) are stamped on a raised boss on top
of the clutch housing area.
GEARSHIFT LINKAGE ADJUSTMENT (CABLE
OPERATED)
Before replacing the gearshift selector cable or
crossover cable for a hard-shifting complaint, dis-
connect both cables at the transaxle (Fig. 3). Then,
from the driver’s seat, manually operate the gear-
Fig. 2 A-523, A-543, and A-568 Transaxle
Identification
Fig. 3 Gearshift Mechanism
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TRANSAXLE
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shift lever through all gear ranges. If the gearshift
lever moves smoothly, the cable(s) should NOT be re-
placed. If the gear lever binds replace the cable that
is causing the binding condition.
(1) Working over the left front fender, remove the
lock pin from the transaxle gearshift (selector shaft)
housing (Fig. 4).
(2) Reverse the lock pin (so long end is down) and
insert lock pin into same threaded hole. A hole in the
selector shaft will align with the lock pin, allowing
the lock pin to be screwed into the housing. This op-
eration locks the selector shaft in the 3-4 neutral po-
sition.
(3) Remove or install gearshift knob (Fig. 5 or 6).
(4) Remove or install boot (Fig. 7) or console.
(5) Remove or install selector and crossover cables
(Fig. 8 or 9).
Cable attachment clips must be installed from
the side. Install cable fittings to shifter pins by
pushing with thumb.
Fig. 4 Manual Transaxle Pinned in the Neutral
Position to Adjust Gearshift
Fig. 5 Remove Gearshift Knob
Fig. 6 Install Gearshift Knob
Fig. 7 Remove or Install Boot
Fig. 8 Remove Cables
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TRANSAXLE
21 - 3
CAUTION: Be sure crossover bellcrank does NOT
move when tightening adjusting screw (Fig. 10).
CAUTION: Proper torque to the crossover cable ad-
justing screw is very important (Fig. 10).
(6) Remove lock pin from gearshift housing and re-
install lock pin (so long end is up) in gear shift hous-
ing. Tighten lock pin to 8 N
Im (70 in. lbs.).
(7) Check for shift into first and reverse.
(8) Gearshift mechanism and cables are now func-
tioning properly.
IN-CAR TRANSAXLE DISASSEMBLE/ASSEMBLE
The following items can be serviced without remov-
ing the transaxle from the vehicle:
• Gear shift housing
• Synchronizers
• Intermediate shaft speed gears
• Input shaft
• Reverse idler gear and shaft
• Shift forks and pads
• Shift rails
• Roller detents
• Speedometer pinion
• All external covers
Observe following procedure:
(1) Disconnect negative cable from battery.
(2) Remove both shift cables from shift cover levers.
(3) Remove left front wheel and tire assembly and
left splash shield.
(4) Place drain pan under transaxle and remove
transaxle rear end cover.
(5) Push out the fifth fork roll pin and slide the fifth
fork and synchronizer sleeve off the rail/hub.
(6) Remove the fifth hub snap ring, hub assembly
and speed gear.
(7) Remove fifth gear nut and fifth input gear.
(8) Remove the bearing retainer plate, interlock
plate and shuttles.
CAUTION: Before removing the gearshift housing
assembly, reverse the lock pin (so the long end is
down) and insert lock pin into the same threaded
hole. This procedure will save time when the gear
shift housing assembly is reinstalled.
(9) Remove selector shaft housing bolts (note the two
pilot bolts) and remove housing.
(10) Remove roller detents and springs, noting that
the rollers align with the shift rails.
(11) Push out the 1-2 and 3-4 lug roll pins, remove
the reverse pivot lever and fifth rail C-Clip. If a roll
pin or C-Clip falls, be sure to remove it from the
bottom of the case.
(12) Pull out the fifth shift rail and remove the fifth
shift lug and interlock pin.If the pin falls, be sure to
remove it from the bottom of the case.
(13) Remove the intermediate shaft ball bearing
snap ring and the bearing support plate.
(14) Remove reverse shift rail and lug assembly.
(15) Remove the reverse idler shaft and gear assem-
bly.
(16) Rotate the 1-2 shift lug and rail, and 3-4 shift
lug towards the front of the vehicle.
(17) Firmly grasp both the input and intermediate
shaft assemblies and pull them out of the transmission
with the 1-2 and 3-4 shift rails, lugs and forks.
The differential assembly can only be serviced
by removing the complete transaxle from the
vehicle because bearing preload must be reset.
The components listed in the first paragraph can now
be serviced. Refer to the appropriate subassembly
recondition section.
To reassemble the transaxle in the vehicle, reverse
the above procedure using the proper sealants. Fill the
transaxle with SAE 5W-30 engine oil to the bottom of
the fill hole in the end cover.
Fig. 9 Install Cables
Fig. 10 Adjusting Crossover Cable
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TRANSAXLE
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