Chrysler Stratus Convertible. Manual — part 107
The sealant used for the bearing end plate cover is
Mopar
t RTV.
(1) Verify bench fixture shims are removed from
bench fixture. Install output and input shafts into
bench fixture (Miller tool #6785) (Fig. 60).
(2) Install shift rails and forks into bench fixture
(Fig. 61).
(3) Install shift blocker assembly into bench fix-
ture (Fig. 62).
(4) Install reverse brake race onto input shaft (Fig.
63).
Fig. 58 1–2 Shift Fork Removal
1 – 6785 BENCH FIXTURE
2 – 1–2 SHIFT FORK
Fig. 59 Gear Train Removal
1 – 6785 BENCH FIXTURE
2 – INPUT AND OUTPUT SHAFTS
Fig. 60 Bench Fixture
1 – BENCH FIXTURE
2 – GEARTRAIN
Fig. 61 Shift Rail Installation
1 – 6785 BENCH FIXTURE
2 – 1–2 SHIFT FORK
Fig. 62 Shift Blocker Installation
1 – 6785 BENCH FIXTURE
2 – SHIFT BLOCKER ASSEMBLY
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DISASSEMBLY AND ASSEMBLY (Continued)
(5) Install reverse brake needle bearing (Fig. 64).
(6) Install reverse brake blocking ring (Fig. 65).
(7) Install reverse brake friction cone (Fig. 66).
(8) Install reverse brake shim (Fig. 67). Apply
petroleum jelly to shim to hold in place.
(9) Install gear–case half over bench fixture (Fig.
68). Line up shift finger over 3-4 lug.
Fig. 63 Reverse Brake Race Installation
1 – REVERSE BRAKE RACE
Fig. 64 Reverse Brake Needle Bearing
1 – REVERSE BRAKE NEEDLE BEARING
Fig. 65 Reverse Brake Blocking Ring Installation
1 – REVERSE BRAKE BLOCKING RING
Fig. 66 Reverse Brake Friction Cone Installation
1 – REVERSE BRAKE FRICTION CONE
Fig. 67 Reverse Brake Shim
1 – REVERSE BRAKE SHIM
2 – REVERSE BRAKE FRICTION CONE
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TRANSAXLE
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DISASSEMBLY AND ASSEMBLY (Continued)
(10) Line up reverse brake friction cone lugs to the
slots in the gear case (Fig. 69). Verify reverse brake
shim is in position.
(11) Position input and output bearings on the
shafts. Using Miller tool C-4992-1, press on input
and output shaft bearings until they bottom into the
case and against the shafts (Fig. 70).
(12) Install shaft snap rings at input and output
bearings (Fig. 71).
(13) Apply Mopar
t RTV sealant to end–cover outer
edge and around bolt holes. Install end–cover onto
gear case. Tighten end cover bolts to 29 N·m (21 ft.
lbs.) torque (Fig. 72).
(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 blocker assem-
bly (Fig. 73).
(17) Push selector shaft spacer clip onto selector
shaft. Install shift levers.
(18) Install reverse idler gear and spacer (Fig. 74).
(19) Install reverse idler shaft (Fig. 75).
Fig. 68 Gear Case Half
1 – TRANSAXLE CASE
2 – BENCH FIXTURE
3 – GEARTRAIN
Fig. 69 Friction Cone Lugs
1 – CASE
2 – FRICTION CONE LUGS
3 – INPUT SHAFT
Fig. 70 Installing Input and Output Bearings
1 – INPUT AND OUTPUT BEARINGS
2 – SPECIAL TOOL C-4992-1
Fig. 71 Snap Rings Retaining Bearings
1 – SNAP RING PLIERS
2 – SNAP RINGS
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DISASSEMBLY AND ASSEMBLY (Continued)
(20) Install bolt into shaft. Tighten bolt on shaft to
26 N·m (19 ft. lbs.) torque (Fig. 76).
(21) Install reverse fork bracket and reverse lock-
out. Tighten screws to 11 N·m (96 in. lbs.) torque
(Fig. 77) (Fig. 78).
(22) Install differential into gear case (Fig. 79).
BEARING ADJUSTMENT PROCEDURE
(1) Use extreme care when removing and install-
ing bearing cups and cones. Use only an arbor press
for installation, as a hammer may not properly align
the bearing cup or cone. Burrs or nicks on the bear-
ing seat gives a false end–play reading while gauging
for proper shims. Improperly seated bearing cups and
cones are subject to low–mileage failure.
(2) Bearing cups and cones should be replaced if
they show signs of pitting or heat distress. If distress
is seen on either the cup or bearing rollers, both cup
and cone must be replaced.
(3) Bearing preload and drag torque specifications
must be maintained to avoid premature bearing fail-
ures. Used (original) bearings may lose up to 50% of
the original drag torque after break–in. All bearing
adjustments must be made with no other component
interference or gear intermesh.
Fig. 72 Transaxle End Cover
1 – TRANSAXLE CASE
2 – END COVER
Fig. 73 Selector Shaft
1 – SHIFT ASSEMBLY
2 – SELECTOR SHAFT
Fig. 74 Reverse Idler Gear and Spacer
1 – INPUT SHAFT
2 – CASE
3 – REVERSE IDLER GEAR SHAFT
4 – REVERSE IDLER GEAR
Fig. 75 Reverse Idler Shaft
1 – REVERSE IDLER SHAFT
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TRANSAXLE
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DISASSEMBLY AND ASSEMBLY (Continued)
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