Intermediate Shaft: Disassembly

CAUTION: Do not re-use snap rings when servicing the intermediate shaft assembly. Discard upon disassembly and install new ones provided with available snap ring service kit.

NOTE: Depending on date of transaxle manufacture, some intermediate shafts will utilize a needle bearing under the 2nd and 5th Speed Gears.

Install intermediate shaft assembly to arbor press table with bearing splitter P-334 under the reverse gear.
Install 8486 - 4 button to intermediate shaft. Using arbor press ram, press reverse gear and intermediate roller bearing off of shaft, while holding remaining assembly with hand (Fig 1 ).

Fig 1: Removing Bearing And Reverse Gear
Courtesy of DAIMLERCHRYSLER CORP.
Remove reverse gear blocker ring.
Remove reverse gear needle bearing (Fig 2 ).

Fig 2: Removing Reverse Gear Needle Bearing
Courtesy of DAIMLERCHRYSLER CORP.
Remove 5/R synchro snap ring (Fig 3 ).

Fig 3: Removing 5/R Synchro Snap Ring
Courtesy of DAIMLERCHRYSLER CORP.
Remove 5/R synchro (Fig 4 ).

Fig 4: Removing 5/R Synchronizer
Courtesy of DAIMLERCHRYSLER CORP.
Remove 5th gear blocker ring (Fig 5 ).

Fig 5: Removing 5th Gear Blocker Ring
Courtesy of DAIMLERCHRYSLER CORP.
Remove 5th gear and needle bearing (if equipped) (Fig 6 ).

Fig 6: Removing 5th Gear
Courtesy of DAIMLERCHRYSLER CORP.
Remove 3/4 cluster gear snap ring (Fig 7 ).

Fig 7: Removing 3/4 Cluster Gear Snap Ring
Courtesy of DAIMLERCHRYSLER CORP.
Install shaft assembly into fixture 8483, with split collar 8483 - 3 oriented chamfer side up. (Fig 8 ). Place 8483 - 2 into position with chamfer side up (Fig 9 ).

Fig 8: Identifying Fixture 8483
Courtesy of DAIMLERCHRYSLER CORP.

Fig 9: Loading Intermediate Shaft
Courtesy of DAIMLERCHRYSLER CORP.
Using an arbor press, press intermediate shaft out of 3/4 cluster gear (Fig 10 ).
Remove intermediate shaft from fixture and remove 3/4 cluster gear from shaft (Fig 11 ).

Fig 10: Pressing Intermediate Shaft Out Of 3/4 Cluster Gear
Courtesy of DAIMLERCHRYSLER CORP.

Fig 11: Identifying 3/4 Cluster Gear
Courtesy of DAIMLERCHRYSLER CORP.
Remove 2nd gear and needle bearing (if equipped) (Fig 12 ).

Fig 12: Removing 2nd Gear
Courtesy of DAIMLERCHRYSLER CORP.
Remove 2nd gear reactor ring (Fig 13 ).

Fig 13: Removing 2nd Gear Reactor Ring
Courtesy of DAIMLERCHRYSLER CORP.
Remove 2nd gear friction cone (Fig 14 ).

Fig 14: Removing 2nd Gear Friction Cone
Courtesy of DAIMLERCHRYSLER CORP.
Remove 2nd Gear outer blocker ring (Fig 15 ).

Fig 15: Removing 2nd Gear Outer Blocker Ring
Courtesy of DAIMLERCHRYSLER CORP.
Remove 1/2 synchro snap ring (Fig 16 ).

Fig 16: Removing 1/2 Synchro Snap Ring
Courtesy of DAIMLERCHRYSLER CORP.
Remove 1/2 synchro from shaft (Fig 17 ).

Fig 17: Removing 1/2 Synchronizer
Courtesy of DAIMLERCHRYSLER CORP.
Remove 1st gear blocker ring (Fig 18 ).

Fig 18: Removing 1st Gear Blocker Ring
Courtesy of DAIMLERCHRYSLER CORP.
Remove 1st gear friction cone (Fig 19 ).

Fig 19: Removing 1st Gear Friction Cone
Courtesy of DAIMLERCHRYSLER CORP.
Remove 1st gear reactor ring (Fig 20 )

Fig 20: Removing 1st Gear Reactor Ring
Courtesy of DAIMLERCHRYSLER CORP.
Remove 1st gear from shaft (Fig 21 ).

Fig 21: Removing 1st Gear
Courtesy of DAIMLERCHRYSLER CORP.
Remove 1st gear needle bearing (Fig 22 ).

Fig 22: Removing 1st Gear Needle Bearing
Courtesy of DAIMLERCHRYSLER CORP.
Remove intermediate shaft roller bearing snap ring (Fig 23 ).

Fig 23: Removing Intermediate Shaft Roller Bearing Snap Ring
Courtesy of DAIMLERCHRYSLER CORP.
Press intermediate shaft out of roller bearing supported by bearing splitter P-334 (Fig 24 ). Roller bearing is not re-usable once removed. It is necessary to install a new roller bearing upon re-assembly.

Fig 24: Removing Intermediate Shaft Roller Bearing
Courtesy of DAIMLERCHRYSLER CORP.