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Transaxle Reassembly

NOTE: For References to Transaxle Tightening Specifications, refer to TRANSAXLE SPECIFICATIONS 
NOTE: On KM 162 transaxle, 5th gear shift rail and fork are part of 3rd-4th rail and fork assemblies.
  1. Place differential assembly into clutch housing. Place 2 pieces of Plastigage .080" (2 mm) long on bearing outer race. See Fig 1 . Install transaxle case with gasket and tighten bolts to specifications.
    Fig 1: Measuring Differential End Play
    G95H55662Courtesy of CHRYSLER CORP.
  2. Remove transaxle case and measure Plastigage. Select proper spacer to give an end play of 0-.006" (0-.15 mm). Spacers range from .0516 (1.31 mm) to .0693 (1.76 mm) in .004" (.09 mm) increments.
  3. Turn sub-gear in direction of arrow stamped on gear to align .31" (8 mm) holes of sub-gear and intermediate gear. When holes are aligned, insert bolt of same diameter (long enough to maintain alignment).
  4. Mesh input and intermediate shaft together and place into transaxle case. On KM 165 transaxle, install selector shift rail and shift fork assembly together. On KM 162 transaxle, install 5th gear shift lug ensuring it is properly installed. See Fig 2 .
    Fig 2: Installing 5th Gear Shift Lug On KM 162 Transaxle
    G95F55660Courtesy of CHRYSLER CORP.
  5. On all transaxles, install poppet ball, spring and plug. Tighten plug until flush with housing surface. Apply sealant to cover plug. Install input bearing retainer. Pull out the sub-gear aligning bolt and install output shaft.
  6. With input shaft, intermediate gear and output shaft assembly installed, select spacers to adjust proper end play and preload of intermediate gear and output shaft, using following procedure.
  7. Place 2 pieces of Plastigage, .4" (10.16 mm) long, in-line on shoulders of intermediate gear and output shaft outer race holes of transmission case. See Fig 3 . Insert outer races in case and press firmly to hold Plastigage in position.
    Fig 3: Determining Intermediate Gear End Play & Output Shaft
    G95G55661Courtesy of CHRYSLER CORP., INC.
  8. Place new gasket (without sealant) on clutch housing. Install case-to-clutch housing bolts and tighten to specifications. Remove bolts, transmission case and outer races from case.
  9. Measure Plastigage and determine proper spacer to obtain proper intermediate gear end play and output shaft preload. End play should be 0-.002" (0-.05 mm). Preload should be .006-.008" (.15-.20 mm). Spacer's range in thickness from .0724" (1.84 mm) to .1055" (2.68 mm) in .0012" (.03 mm) increments.
  10. Install correct spacer and taper roller bearing races in transmission case. Insert 2 interlock plungers into housing and also insert interlock plungers into 3rd-4th shift rail.
  11. Install 1st-2nd and 3rd-4th shift rails and forks into case. Install spring pins making certain pin extends equally from each side. On KM 162 transaxle, install spacer to adjust clearance between 3rd-4th shift lug and 5th shift lug to .016" (.4 mm).
  12. On all transaxles, install reverse shift rail. Install detent balls, springs and plugs. Ensure smaller end of spring is toward ball and spring with white marking (shorter length) is for reverse shift rail. Install reverse shift lever assembly.
  13. Install reverse idler gear (chamfered side upward) and shaft and coat with oil. Measure distance "A" to determine reverse idler gear height. See Fig 4 . Specified distance should be 1.44-1.54" (36.7-39.0 mm). Replace reverse shift lever if not within specifications.
    Fig 4: Measuring Reverse Idler Gear Height
    G93B24399Courtesy of CHRYSLER CORP.
  14. Using sealant, install clutch housing gasket in place on transaxle. Place spacer for differential end play on differential gear. Install transaxle case and tighten bolts to specifications.
  15. Check oil seal hole for chamfer. If hole is not chamfered, lightly grease knurls on seal installer and carefully chamfer seal bore. Remove chips and insert seal.
TRANSAXLE SPECIFICATIONS

Application In. (mm)
Differential Case End Play 0-.006 (0-.15)
Intermediate Gear End Play 0-.002 (0-.05)
Output Shaft Preload .006-.008 (.15-.20)
Pinion Gear-to-Side Gear Backlash 0-.003 (0-.08)
Reverse Idler Gear Hiegt 1.44-1.54 (36.7-39.0)
Synchronizer Ring-to-Gear .032 (.8)
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