Dodge Caliber. Manual — part 1186
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INSTALLATION
1. Install the inner seal into the PTU cover using
Installer 9852 and Handle C-4171.
2. Install the outer seal into the PTU cover using
Installer 9853 and Handle C-4171.
PM
POWER TRANSFER UNIT
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3. Install the side cover
4. Torque side cover bolts (1) to 23 N·m (17 ft. lbs.).
5. Install the right halfshaft (Refer to 3 - DIFFEREN-
TIAL
&
DRIVELINE/HALF
SHAFT
-
INSTALLATION)
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POWER TRANSFER UNIT
PM
T355 MANUAL TRANSAXLE
TABLE OF CONTENTS
page
page
T355 MANUAL TRANSAXLE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
DIAGNOSIS AND TESTING
COMMON PROBLEM CAUSES . . . . . . . . . . . . . . . 47
SEALS-AXLE SHAFT
SWITCH-BACK-UP LAMP
DIFFERENTIAL
ADJUSTMENT / SHIM SELECTION . . . . . . . . . . 72
CUPS-DIFFERENTIAL BEARING
FLUID
STANDARD PROCEDURE - FLUID DRAIN AND
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
BOOT-GEAR SHIFT
CABLE-GEAR SHIFT
KNOB-GEAR SHIFT
MECHANISM-GEAR SHIFT
BEARING AND SLEEVE-INPUT
SHAFT-INPUT
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
SHAFT-OUTPUT
BEARING AND RACE-OUTPUT
TROUGH-REAR BEARING OIL FEED
LEVER-SHIFT CROSSOVER
SHAFT-SHIFT CROSSOVER
BUSHING-SHIFT CROSSOVER SHAFT
RAIL AND FORK-SHIFT
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
BUSHINGS-SHIFT RAIL
SHAFT-SHIFT SELECTOR
BUSHING-SHIFT SELECTOR SHAFT
SEALS-SHIFT SHAFT
SYNCHRONIZER
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
CLEANING
CLEAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
INSPECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
SENSOR-VEHICLE SPEED
VEHICLE SPEED SENSOR . . . . . . . . . . . . . . . . . 105
PM
T355 MANUAL TRANSAXLE
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T355 MANUAL TRANSAXLE
DESCRIPTION
This five speed is a constant-mesh manual transaxle.
All gear ranges, except reverse, are synchronized.
The reverse gear utilizes a reverse brake for shifting
ease. The reverse idler gear is supported on a sliding
spindle idler shaft. The transaxle case is aluminum
with a steel end-plate bearing cover. It is housed in a
die-cast aluminum case featuring a two-piece, middle
split design.
The T355 transaxle internal components can be ser-
viced only by separating the gear case from the bell-
housing case.
CAUTION: The transaxle output shaft is serviced
as a unit. No disassembly and reassembly is pos-
sible. Damage to the transaxle may result.
TRANSAXLE IDENTIFICATION
The transaxle model, assembly number, and build
date are on a metal I.D. tag (1) that is attached to the
end cover of the transaxle.
This information is also shown on a bar code label (1)
that is attached to the front of the transaxle.
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T355 MANUAL TRANSAXLE
PM
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