Dodge Neon / Neon SRT-4. Manual — part 335

(2) Install intermediate shaft roller bearing snap

ring (Fig. 185).

(3) Install 1st gear thrust bearing (Fig. 186). Blue

markings on bearing should face down towards out-
put gear.

(4) Install 1st gear needle bearing to intermediate

shaft (Fig. 187).

(5) Install 1st gear to intermediate shaft (Fig.

188).

(6) Install 1/2 synchro to fixture 8483. Insert 1st

gear blocker ring, friction cone, and reactor ring as
shown in (Fig. 189).

(7) Install intermediate shaft to synchro assembly

on fixture (Fig. 190). When installing 1/2 synchro-
nizer, make sure to align oil slots on synchro-
nizer hub face with oil hole in the shaft splined
hub journal. Line up friction cone and reactor ring
tabs to gear slots. Remove shaft assembly from fix-
ture.

Fig. 185 Intermediate Shaft Roller Bearing Snap

Ring

1 - SNAP RING

Fig. 186 1st Gear Thrust Bearing Removal/

Installation

1 - THRUST BEARING

Fig. 187 1st Gear Needle Bearing

1 - 1ST GEAR NEEDLE BEARING

Fig. 188 1st Gear Installation

1 - 1ST GEAR

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INTERMEDIATE SHAFT (Continued)

(8) Install NEW 1/2 synchro snap ring (Fig. 191).

(9) Install 2nd gear blocker ring (Fig. 192).

(10) Install 2nd gear friction cone (Fig. 193).

Fig. 189 1/2 Synchro on Fixture 8483

1 - FIXTURE 8483
2 - 1ST GEAR BLOCKER RING
3 - 1ST GEAR FRICTION CONE
4 - 1ST GEAR REACTOR RING
5 - 1/2 SYNCHRONIZER

Fig. 190 Install 1/2 Synchro to Intermediate Shaft

1 - INTERMEDIATE SHAFT
2 - 1ST GEAR
3 - 1/2 SYNCHRO ASSEMBLY
4 - FIXTURE 8483

Fig. 191 1/2 Synchro Snap Ring

1 - SNAP RING
2 - 1/2 SYNCHRO HUB

Fig. 192 2nd Gear Blocker Ring

1 - 2ND GEAR BLOCKER RING

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INTERMEDIATE SHAFT (Continued)

(11) Install 2nd gear reactor ring (Fig. 194).

(12) Install 2nd gear and needle bearing to inter-

mediate shaft (Fig. 195) (Fig. 196).

(13) Press 3/4 cluster gear onto intermediate shaft

using cup 8481 (Fig. 197).

Fig. 193 2nd Gear Friction Cone

1 - 2ND GEAR FRICTION CONE

Fig. 194 2nd Gear Reactor Ring

1 - 2ND GEAR REACTOR RING

Fig. 195 2nd Gear Removal/Installation

1 - 2ND GEAR
2 - NEEDLE BEARING

Fig. 196 2nd Gear Needle Bearing Removal/

Installation

1 - NEEDLE BEARING

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INTERMEDIATE SHAFT (Continued)

(14) Install NEW 3/4 cluster gear snap ring (Fig.

198).

(15) Install 5th gear and needle bearing to inter-

mediate shaft (Fig. 199) (Fig. 200).

(16) Install 5th gear blocker ring to synchronizer

(Fig. 201).

Fig. 197 Install 3/4 Cluster Gear using Tool 8481

1 - ARBOR PRESS
2 - INSTALLER 8481
3 - 3/4 CLUSTER GEAR

Fig. 198 3/4 Cluster Gear Snap Ring

1 - SNAP RING

Fig. 199 5th Gear Removal/Installation

1 - 5TH GEAR
2 - NEEDLE BEARING

Fig. 200 5th Gear Needle Bearing Removal/

Installation

1 - 5TH GEAR NEEDLE BEARING

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T850 MANUAL TRANSAXLE

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INTERMEDIATE SHAFT (Continued)