Chrysler Stratus Convertible. Manual — part 111

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. 120).

(3) Insert key into hub and spring.
(4) Apply petroleum jelly to the hole in the key.

Insert balls into each key (Fig. 121).

(5) Slide sleeve over the hub and depress balls as

you carefully slip the sleeve into position (Fig. 122).

(6) Line up stop ring tang over the keys in the hub

(Fig. 123). Install stop rings. Center the keys and
balls by pushing on both stop rings.

SHIFT RAILS OVERHAUL

(1) Remove shift rails from the geartrain.
(2) To service the 5-R shift rail, remove the C-clip

retaining the reverse shift lever arm. Remove the 5th
shift fork roll pin and remove the 5th shift fork.
Remove the shift lug roll pin and remove the shift
lug. Replace parts as necessary.

(3) To service the 3-4 shift rail, remove the roll pin

retaining the 3-4 shift fork. Remove the shift fork.
Remove the shift lug roll pin and remove the shift
lug. Replace parts as necessary.

(4) To service the 1-2 shift rail, remove the roll pin

retaining the 1-2 shift fork. Remove the shift fork
and replace parts as necessary.

Fig. 120 Synchronizer Assembly

1 – SLEEVE
2 – BALL
3 – KEY
4 – SPRING
5 – HUB

Fig. 121 Synchronizer Balls

1 – INPUT SHAFT
2 – HUB
3 – KEY
4 – BALL

Fig. 122 Synchronizer Sleeve

1 – SLEEVE
2 – INPUT SHAFT
3 – KEY

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TRANSAXLE

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DISASSEMBLY AND ASSEMBLY (Continued)

TRANSAXLE CASE OVERHAUL

The sealant used to seal the transaxle case halves

is Mopar

t Gasket Maker, Loctitet 518, or equivalent.

The sealant used for the bearing end–plate cover is
Mopar

t 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

• Shift shaft bushings

• Rear bearing oil feed trough

AXLE SHAFT SEALS

REMOVAL

(1) Insert a flat–blade pry tool at outer edge of

axle shaft seal (Fig. 124).

(2) Tap on the pry tool with a small hammer and

remove axle shaft seal.

INSTALLATION

(1) Clean axle shaft seal bore of any excess seal-

ant.

(2) Align axle shaft seal with axle shaft seal bore.
(3) Install axle seal on tool #6709 with C-4171 and

insert into axle shaft seal bore.

(4) Tap seal into position (Fig. 125).

OUTPUT BEARING

REMOVAL

CAUTION: THE POSITION OF THE OUTPUT SHAFT
BEARING IS CRITICAL. THE BEARING IS NOT
IDENTICAL END-TO-END. INSTALL BEARING WITH
LARGER DIAMETER CAGE RING FACING OUT.

(1) Remove caged roller bearing from output bear-

ing race (Fig. 126).

(2) Remove screws at output bearing retainer

strap (Fig. 127).

(3) Install tool #6787 and slide hammer (Fig. 128).

Tighten tool to output bearing race.

Fig. 123 Keys in Hub

1 – SNAP RING
2 – CLUTCH
3 – KEY
4 – BALL
5 – SPRING

Fig. 124 Axle Shaft Seal Removal

1 – AXLE SEAL
2 – PRY TOOL

Fig. 125 Axle Seal Installation

1 – TOOL C-4171
2 – TOOL 6709
3 – AXLE SEAL

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TRANSAXLE

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DISASSEMBLY AND ASSEMBLY (Continued)

(4) Using slide hammer, remove output bearing

race.

INSTALLATION

(1) Line up output bearing race to race bore.
(2) Insert tool #4628 with C-4171 into output bear-

ing race (Fig. 129). 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.).

Fig. 126 Output Roller Bearing

1 – INPUT BEARING
2 – OUTPUT BEARING
3 – LARGER DIAMETER CAGE RING

Fig. 127 Output Bearing Strap

1 – BEARING RETAINER
2 – OUTPUT BEARING RACE

Fig. 128 Output Bearing Race Removal

1 – C-3752
2 – SPECIAL TOOL 6787
3 – OUTPUT SHAFT BEARING RACE

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TRANSAXLE

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DISASSEMBLY AND ASSEMBLY (Continued)

INPUT BEARING AND SLEEVE

The input bearing is a one–piece bearing and

sleeve unit (Fig. 130). The sleeve is the slide point for
the clutch–release bearing and lever.

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.

131).

INSTALLATION

(1) Apply coating of Loctite

t sealant on bearing

outer diameter. Position sleeve and bearing assembly
at input bearing bore.

(2) Install tool #C-4680-1 over input bearing (Fig.

132).

(3) Using the spacer tool #4894 and shop press,

install input bearing into bore until it is fully seated
(Fig. 133).

Fig. 129 Output Bearing Race Installation

1 – TOOL C-4171
2 – TOOL C-4628
3 – OUTPUT BEARING RACE

Fig. 130 Input Bearing And Sleeve

1 – DIFFERENTIAL BEARING
2 – OUTPUT BEARING
3 – INPUT BEARING
4 – BEARING RETAINER

Fig. 131 Input Bearing Removal

1 – SPECIAL TOOL 6342
2 – BELLHOUSING HALF
3 – INPUT BEARING AND SLEEVE

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TRANSAXLE

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DISASSEMBLY AND ASSEMBLY (Continued)