Chrysler Stratus Convertible. Manual — part 108

(4) Replace bearings as a pair: If one differential

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).

(3) Press in new bearing cup into gear case side.
(4) Oil differential bearings with Mopar

t 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.).

Fig. 76 Reverse Idler Shaft Bolt

1 – CASE
2 – REVERSE IDLER SHAFT
3 – REVERSE IDLER SHAFT BOLT

Fig. 77 Reverse Fork Bracket

1 – REVERSE FORK BRACKET
2 – REVERSE CAM BLOCKOUT
3 – SHIFT BLOCKER ASSEMBLY

Fig. 78 Reverse Fork Screws

1 – SCREWS (2)
2 – REVERSE FORK BRACKET

Fig. 79 Differential Assembly

1 – INPUT SHAFT
2 – OUTPUT SHAFT
3 – DIFFERENTIAL
4 – CASE

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TRANSAXLE

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DISASSEMBLY AND ASSEMBLY (Continued)

(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. 80). 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
Step 7. Then press the bearing cup into clutch bell-
housing.

(9) Install clutch bellhousing. Install and torque

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. 81). 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.

(11) Recheck turning torque. Repeat Step 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
Mopar

t 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).

• 4th—1.41-1.97 mm (0.056-0.078 in).

• 5th—1.37-1.93 mm (0.054-0.076 in).
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 input shaft incorporates the 3rd, 4th, and 5th

speed gears and synchronizers on the assembly (Fig.
82).

(1) Install bearing splitter behind 5th speed gear.

Remove snap ring at 5th synchronizer hub on input
shaft (Fig. 83).

Fig. 80 Checking Differential Bearing End Play To

Determine Shim Thickness

1 – T-HANDLE
2 – DIAL INDICATOR SET
3 – SPECIAL TOOL C-4995

Fig. 81 Checking Differential Bearing Turning

Torque

1 – INCH-POUND TORQUE WRENCH
2 – SPECIAL TOOL C-4995

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TRANSAXLE

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DISASSEMBLY AND ASSEMBLY (Continued)

(2) Remove synchronizer and gear using shop

press (Fig. 84).

(3) Remove caged needle bearing (Fig. 85).
(4) Remove 4-5 gears split thrust washer ring (Fig.

86).

(5) Remove split thrust washer (Fig. 87).
(6) Remove split thrust washer separation pin

(Fig. 88).

(7) Remove 4th gear (Fig. 89).

Fig. 82 Input Shaft

1 – INPUT SHAFT
2 – STOP RING
3 – SLEEVE
4 – 5TH SPEED GEAR
5 – STOP RING
6 – SLEEVE
7 – 4TH SPEED GEAR
8 – STOP RING
9 – 3RD SPEED GEAR

Fig. 83 5th Synchro and Hub Snap Ring Removal

1 – SNAP RING PLIERS
2 – INPUT SHAFT
3 – BEARING SPLITTER
4 – SNAP RING

Fig. 84 Remove Synchronizer Using Shop Press

1 – PRESS RAM
2 – INPUT SHAFT
3 – BEARING SPLITTER
4 – SYNCHRONIZER ASSEMBLY

Fig. 85 Caged Needle Bearing Removal

1 – INPUT SHAFT
2 – CAGED NEEDLE BEARING

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DISASSEMBLY AND ASSEMBLY (Continued)

(8) Remove 4th gear caged needle bearing (Fig.

90). Check the caged needle bearing for a broken
retention spring.

(9) Remove blocking ring. Remove 3-4 synchronizer

hub retaining snap ring (Fig. 91).

(10) Install input shaft in shop press. Using bear-

ing splitter, remove 3-4 synchronizer and 3rd gear
(Fig. 92).

(11) Inspect the input shaft for worn or damaged

bearing races or chipped gear teeth. Replace as nec-
essary.

Fig. 86 Split Thrust Washer Ring Removal

1 – SPLIT THRUST WASHER RING
2 – INPUT SHAFT

Fig. 87 Split Thrust Washer Removal

1 – INPUT SHAFT
2 – SPLIT THRUST WASHER

Fig. 88 Split Thrust Washer Separation Pin

1 – SEPARATION PIN
2 – INPUT SHAFT
3 – PLIERS

Fig. 89 4th Gear Removal

1 – INPUT SHAFT
2 – 4TH GEAR

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DISASSEMBLY AND ASSEMBLY (Continued)