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MANUAL TRANS OVERHAUL - MITSUBISHI W5M & W6M SERIES

MANUAL TRANSMISSIONS Mitsubishi W5M31, W5M33 & W5MG1

APPLICATIONS

CHRYSLER MOTORS

TRANSMISSION APPLICATIONS (CHRYSLER MOTORS)

MITSUBISHI

TRANSMISSION APPLICATIONS (MITSUBISHI)

Vehicle Application Transmission ModelColt Wagon

1989 (4WD) KM2211990-94 (4WD) W5M311992-94 (4WD) W5M33

Laser (1993-94, AWD Turbo) W5M33Stealth (1991-94, AWD Turbo) W5MG1Talon (1990-94, AWD Turbo) W5M33Vista/Summit Wagon

1989 (AWD) KM2211990-94

(1.8L, AWD) W5M31(2.4L, AWD) W5M33

Vehicle Application Transmission ModelEclipse

1990-92 (AWD Turbo) W5M311993-94 (AWD Turbo) W5M33

Expo (1992-94)Expo LRV (1.8L, AWD) W5M31Expo (2.4L, AWD) W5M33

Galant1990-92 (AWD Non-Turbo) W5M311991-92

(AWD Non-Turbo) W5M31(AWD Turbo) W5M33

3000 GT (1992-94)Five Speed (AWD Turbo) W5MG1Six Speed (AWD Turbo) (1) W6MG1

(1) Service information not available.

1994 Mitsubishi Eclipse GS

MANUAL TRANS OVERHAUL - MITSUBISHI W5M & W6M SERIES MANUAL TRANSMISSIONS Mitsubishi W5M31, W5M33 & W5MG1



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Viernes, 09 de Marzo de 2007 09:45:22 a.m. © 2005 Mitchell Repair Information Company, LLC.

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Viernes, 09 de Marzo de 2007 09:45:30 a.m. Page 1 © 2005 Mitchell Repair Information Company, LLC.

IDENTIFICATION

Transaxle model can be identified by vehicle information code plate located on bulkhead in engine compartment.

DESCRIPTION

Mitsubishi Manual Transaxles KM221, W5M31 and W5M33 are equipped with 3 shift rails, 3 synchronizer assemblies and 3 shafts. Transmission features limited slip AWD using 2 differential assemblies and a viscous coupling. Rear wheel drive consists of transfer assembly directing power to a separate differential at rear axle. Transfer assembly attaches externally to clutch housing, allowing transfer assembly to be serviced as a separate unit. See Fig. 1 .

LUBRICATION & ADJUSTMENTS

See appropriate TRANSMISSION SERVICING - M/T article in MANUAL TRANS SERVICE section.

For 1989 Colt Wagon, see TRANSMISSION SERVICING - M/T For 1990-92 Colt Wagon, see TRANSMISSION SERVICING - M/T For 1993 Colt Wagon, see TRANSMISSION SERVICING - M/T For 1994 Colt Wagon, see TRANSMISSION SERVICING - M/T For 1993 Laser, see TRANSMISSION SERVICING - M/T For 1994 Laser, see TRANSMISSION SERVICING - M/T For 1991-92 Stealth, see TRANSMISSION SERVICING - M/T For 1993 Stealth, see TRANSMISSION SERVICING - M/T For 1994 Stealth, see TRANSMISSION SERVICING - M/T For 1990 Talon, see TRANSMISSION SERVICING - M/T For 1991 Talon, see TRANSMISSION SERVICING - M/T For 1992 Talon, see TRANSMISSION SERVICING - M/T For 1993 Talon, see TRANSMISSION SERVICING - M/T For 1994 Talon, see TRANSMISSION SERVICING - M/T For 1989 Vista/Summit Wagon, see TRANSMISSION SERVICING - M/T For 1990-92 Vista/Summit Wagon, see TRANSMISSION SERVICING - M/T For 1993 Vista/Summit Wagon, see TRANSMISSION SERVICING - M/T For 1994 Vista/Summit Wagon, see TRANSMISSION SERVICING - M/T For 1990-91 Eclipse, see TRANSMISSION SERVICING - M/T

NOTE: Mitsubishi transaxle W5MG1 cannot be disassembled. There are 6 external seals, 2 air breather caps, oil filler plug and drain plug that are serviceable. See Fig. 2 . If any other parts are defective, transaxle must be replaced as an assembly.



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For 1992 Eclipse, see TRANSMISSION SERVICING - M/T For 1993 Eclipse, see TRANSMISSION SERVICING - M/T For 1994 Eclipse, see TRANSMISSION SERVICING - M/T For 1992 Expo LRV, see TRANSMISSION SERVICING - M/T For 1993 Expo LRV, see TRANSMISSION SERVICING - M/T For 1994 Expo LRV, see TRANSMISSION SERVICING - M/T For 1992 Expo, see TRANSMISSION SERVICING - M/T For 1993 Expo, see TRANSMISSION SERVICING - M/T For 1994 Expo, see TRANSMISSION SERVICING - M/T For 1990-91 Galant, see TRANSMISSION SERVICING - M/T For 1992 Galant, see TRANSMISSION SERVICING - M/T For 1992 3000 GT, see TRANSMISSION SERVICING - M/T For 1993 3000 GT, see TRANSMISSION SERVICING - M/T For 1994 3000 GT, see TRANSMISSION SERVICING - M/T

ON-VEHICLE SERVICE

AXLE SHAFT OIL SEAL REPLACEMENT

Removal & Installation

1. Disconnect axle shaft from transaxle. See appropriate AXLE SHAFTS - FRONT article in DRIVE AXLES section. See menu below.

2. Disconnect front exhaust pipe connection and remove transfer assembly. Remove oil seal(s) from transaxle case.

3. There are 2 different types of axle shaft oil seals for right and left sides. See Fig. 1 through Fig. 3 . Install NEW oil seals in transaxle case. Ensure oil seals are installed in proper locations.

4. Lubricate oil seal with gear oil and install in transaxle case. Reinstall transfer assembly and reconnect axle shaft(s). Fill transaxle with API GL-4 or GL-5, SAE 75W-85W or 75W-90 hypoid gear oil.



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Fig. 1: Transaxle Assembly (W5M33 Shown; W5M31 Similar)Courtesy of CHRYSLER CORP.



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Fig. 2: Sectional View Of W5MG1 TransaxleCourtesy of CHRYSLER CORP.



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Fig. 3: Sectional View Of W6MG1 Transaxle Courtesy of CHRYSLER CORP.



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TRANSFER OIL SEAL REPLACEMENT

Removal & Installation

1. Remove drive shaft from transfer unit output shaft, then remove oil seal. See appropriate AXLE SHAFTS - FRONT article in DRIVE AXLES section. See menu below.

2. Lubricate oil seal with gear oil and reinstall in transaxle case. Install drive shaft and fill transaxle with API GL-4 or GL-5, SAE 75W-85W or 75W-90 hypoid gear oil.

For 1989 Colt Wagon, see AXLE SHAFTS - FRONT For 1990 Colt Wagon, see AXLE SHAFTS - FRONT For 1991-92 Colt Wagon, see AXLE SHAFTS - FRONT For 1993 Colt Wagon, see AXLE SHAFTS - FRONT For 1994 Colt Wagon, see AXLE SHAFTS - FRONT For 1993 Laser, see AXLE SHAFTS - FRONT For 1994 Laser, see AXLE SHAFTS - FRONT For 1991-92 Stealth, see AXLE SHAFTS - FRONT For 1993 Stealth, see AXLE SHAFTS - FRONT For 1994 Stealth, see AXLE SHAFTS - FRONT For 1990 Talon, see AXLE SHAFTS - FRONT For 1991-92 Talon, see AXLE SHAFTS - FRONT For 1993 Talon, see AXLE SHAFTS - FRONT For 1994 Talon, see AXLE SHAFTS - FRONT For 1989 Vista/Summit Wagon, see AXLE SHAFTS - FRONT For 1990 Vista/Summit Wagon, see AXLE SHAFTS - FRONT For 1991-92 Vista/Summit Wagon, see AXLE SHAFTS - FRONT For 1993 Vista/Summit Wagon, see AXLE SHAFTS - FRONT For 1994 Vista/Summit Wagon, see AXLE SHAFTS - FRONT For 1990-92 Eclipse, see AXLE SHAFTS - FRONT For 1993 Eclipse, see AXLE SHAFTS - FRONT For 1994 Eclipse, see AXLE SHAFTS - FRONT For 1992 Expo LRV, see AXLE SHAFTS - FRONT For 1993 Expo LRV, see AXLE SHAFTS - FRONT For 1994 Expo LRV, see AXLE SHAFTS - FRONT For 1992 Expo, see AXLE SHAFTS - FRONT For 1993 Expo, see AXLE SHAFTS - FRONT For 1994 Expo, see AXLE SHAFTS - FRONT For 1990-92 Galant, see AXLE SHAFTS - FRONT For 1992 3000 GT, see AXLE SHAFTS - FRONT For 1993 3000 GT, see AXLE SHAFTS - FRONT



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For 1994 3000 GT, see AXLE SHAFTS - FRONT

TROUBLESHOOTING

See TROUBLE SHOOTING - BASIC PROCEDURES article in the GENERAL TROUBLE SHOOTING section.

REMOVAL & INSTALLATION

See appropriate TRANSMISSION REMOVAL & INSTALLATION - M/T article in the MANUAL TRANS SERVICE section.

For Colt Wagon, see TRANSMISSION REMOVAL & INSTALLATION - M/T For Stealth, see TRANSMISSION REMOVAL & INSTALLATION - M/T For Vista/Summit Wagon, see TRANSMISSION REMOVAL & INSTALLATION - M/T For Eclipse, see TRANSMISSION REMOVAL & INSTALLATION - M/T For Expo LRV, see TRANSMISSION REMOVAL & INSTALLATION - M/T For Expo, see TRANSMISSION REMOVAL & INSTALLATION - M/T For 3000 GT, see TRANSMISSION REMOVAL & INSTALLATION - M/T

TRANSAXLE DISASSEMBLY

1. Remove rear cover. Remove reverse brake cone and wave spring. See Fig. 1 . Remove back-up light switch and gasket from transaxle case adapter.

2. Remove restrict ball assembly and gasket. Remove poppet (detent) balls, springs, and plugs. Remove speedometer driven gear assembly and air breather.

3. Remove 5th speed gear shift fork spring pin. Unstake input shaft and intermediate gear lock nuts. Using control lever and select lever, shift transaxle into reverse. Install splined socket and breaker bar on input shaft. Install 10 mm bolt in clutch housing and position breaker against bolt to prevent input shaft from rotating. Remove lock nuts. Remove 5th gear synchronizer assembly with 5th gear shift fork.

4. Remove 5th speed gear needle bearing and 5th speed intermediate gear. Remove viscous coupling snap ring. Remove viscous coupling from shaft and steel ball from splines of shaft. See Fig. 1 .

5. Remove center shaft from clutch housing end of transaxle. Stand transaxle assembly on clutch housing and remove transaxle case adapter. On W5M33 transaxle, remove 3 bearing outer race and spacer pairs. On W5M31 transaxle, remove 2 outer bearing race and spacer pairs.

6. Remove center differential assembly. Remove reverse idler gear shaft bolt and gasket from transaxle case. 7. Remove bolts attaching transaxle case to clutch housing. Separate cases. Remove both oil guides. 8. Lift outer bearing race and shims off of front differential. Remove bolt and stopper bracket from transaxle

case. 9. Remove bolt and reverse shift lever assembly with reverse shift lever shoe from clutch housing. Lift

reverse idler gear and shaft. 10. Lift front output shaft assembly with needle bearing out of clutch housing. Lift front differential assembly

out of clutch housing.



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11. Shift 1st-2nd speed shift fork into 2nd speed. Shift 3rd-4th speed shift fork into 4th speed. Rotate shift controls in direction of arrows in numerical order to remove.

12. Remove shift lugs from control finger and interlock plate. Raise each shift rail upward and out of clutch housing. Remove all shift rails and forks.

13. Lift input shaft assembly and remove intermediate gear assembly. Remove outer bearing race from clutch housing. See Fig. 1 .

COMPONENT DISASSEMBLY & REASSEMBLY

5TH SPEED SYNCHRONIZER

Disassembly & Inspection

1. Slide synchronizer sleeve off synchronizer hub and remove springs and keys. Reassemble synchronizer hub and sleeve to ensure smooth operation with no binding.

2. Remove sleeve and inspect inside diameter for wear or damage. Synchronizer hub and sleeve should be replaced as a set only.

3. Inspect center protrusion of synchronizer keys for wear. Inspect both springs for deformation or damage.

Reassembly

Reassemble hub and sleeve with oil groove of hub toward 5th gear side. Install keys and springs and ensure spring protrusions in front and rear springs are not in same key.

CENTER DIFFERENTIAL

Disassembly

1. Remove taper roller bearings from each side of differential assembly. Remove bolts and output gear from differential case.

2. Remove side gear, spacer and then pinion shaft from differential case. Removal washers, pinions, spacers, and side gear from case.

Inspection & Reassembly

1. DO NOT reuse taper roller bearings and races if bearing has been removed from shaft. 2. Install spacer, side gear, pinion gear, washer, and pinion shaft into differential case after inspection.

Select and install thickest spacer that ensures smooth rotation of pinion gear when holding pinion shaft.



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Fig. 4: Exploded View Of Center Differential (W5M31) Courtesy of CHRYSLER CORP.



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Fig. 5: Exploded View Of Center Differential (W5M33) Courtesy of CHRYSLER CORP.

3. Install side gear, spacer, and output gear. Apply 3M STUD Locking (4170) to output gear bolts and torque to 52-59 ft. lbs. (70-80 N.m). See Fig. 4 and Fig. 5 .

4. Ensure side gears turn smoothly. Measure pinion backlash. Center differential pinion backlash should



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be .0001-.0060" (.025-.150 mm). Press taper roller bearings in place at ends of differential assembly.

FRONT OUTPUT SHAFT

Disassembly, Inspection & Reassembly

1. Remove taper roller bearings from front output shaft. Inspect bearings for wear or damage. See Fig. 1 . 2. Inspect gear teeth and splines of shaft for wear or damage. Press taper roller bearings in place on front

output shaft. See TRANSAXLE SPECIFICATIONS for end play specifications.

FRONT DIFFERENTIAL

Disassembly

1. Remove bolts and differential drive gear from differential case. Remove ball bearings from ends of differential assembly. DO NOT re-use bearings removed from shaft.

2. Drive pinion shaft lock pin from case. See Fig. 6 . Remove pinion shaft, pinions, and washers, side gears, and spacers from case.

Reassembly

1. Install spacers on back of side gears and install into differential case. Install washers on back of pinions and install into case while turning side gears. Install pinion shaft. Measure backlash between pinion and side gears.

2. Adjustments to pinion backlash should provide same backlash for both side gears. Front differential pinion backlash should be .001-.006" (.025-.150 mm).

3. Install NEW pinion shaft lock pin and ensure lock pin head is lower than case flange surface. Press ball bearings in place at ends of differential.

4. Apply 3M STUD LOCK (4170) to bolts and install differential drive gear. Torque drive gear bolts to 96-103 ft. lbs. (130-140 N.m) in crisscross pattern. See Fig. 6 .



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Fig. 6: Exploded View Of Front DifferentialCourtesy of CHRYSLER CORP.

INTERMEDIATE GEAR

Disassembly

1. Remove snap ring, taper roller bearing, bearing sleeve and 1st gear. Remove needle bearing with synchronizer ring and spring. Remove 1st-2nd gear synchronizer sleeve, key, hub and ring.

2. Remove 2nd gear, needle bearing, taper roller bearing and intermediate gear. DO NOT reuse ball bearings removed from shaft. See Fig. 7 .

Inspection

1. Inspect needle bearing surface of intermediate gear for wear or damage. Inspect splines for damage. Inspect bearings for wear.

2. Inspect synchronizer ring gear teeth and inside surface for wear or damage. Measure synchronizer ring-to-gear clearance. Synchronizer ring clearance limit is .020" (.50 mm). Ensure synchronizer sleeve and hub slide together smoothly. Inspect sleeve inside front and rear ends for damage. Inspect hub end surface for wear at gear contact points. If necessary, replace synchronizer hub and sleeve as a set.

3. Inspect synchronizer key center protrusions for wear. Check springs for deformation. Inspect speed gear clutch teeth, cone, and gear bore for wear or damage.

Reassembly

1. Press taper roller bearing in place on threaded end of intermediate gear. Assemble 1st-2nd synchronizer and install synchronizer assembly with 2nd gear and needle bearing on intermediate gear.

2. Install 1st gear with needle bearing and sleeve on intermediate gear. Press taper roller bearing in place, install snap ring, and measure end play between snap ring and bearing. Intermediate gear end play should be .0004-.0043" (.010-.110 mm) on W5M31 and .0004-.0055" (.010-.140 mm) on W5M33. End play is adjustable with various thickness snap rings.



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Fig. 7: Exploded View Of Intermediate Gear AssemblyCourtesy of CHRYSLER CORP.

INPUT SHAFT

Disassembly

1. Remove snap ring and ball bearing (taper bearing on W5M33) from splined end of input shaft. Press bearing sleeve off threaded end of input shaft.

2. Remove snap ring and rear ball bearing from input shaft. Remove spacer and 4th gear, with needle bearing and sleeve, from input shaft. See Fig. 8 . Remove 3rd-4th synchronizer assembly and 3rd gear from input shaft.

Inspection

1. Inspect needle bearings and needle bearing surfaces of input shaft for wear or damage. Ensure needle bearings rotate smoothly on shaft without abnormal noise or play. Check splines for signs of wear or damage.

2. Inspect synchronizer rings for wear or damage and measure synchronizer ring-to-gear clearances. Synchronizer ring to gear clearance should be no less than .020" (.50 mm).

3. Inspect synchronizer hub and sleeve condition and operation. Inspect synchronizer keys and springs for wear or damage. Inspect gear teeth, cone, and bore of speed gears for wear or damage.

Reassembly

1. Install 3rd gear with needle bearing and 3rd-4th synchronizer assembly on input shaft. Press bearing sleeve on input shaft from threaded end.

2. Install needle bearing and 4th gear on input shaft. Press ball bearing on input shaft after installing spacer. Spacers with identification mark "1" are installed with identification mark toward 4th gear side. Spacers without identification marks may be installed in either direction.

3. After NEW ball bearing is pressed in place, install NEW snap ring. Press bearing sleeve on input shaft. Install front ball bearing and NEW snap ring. Install thickest snap ring that fits into snap ring groove. Snap rings are available in 3 sizes.



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Fig. 8: Input Shaft Assembly (W5M31 Shown; W5M33 Is Similar) Courtesy of CHRYSLER CORP.



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CLUTCH HOUSING

Disassembly & Inspection

1. Remove bolt and select lever assembly with select lever shoe. Remove interlock plate bolt and gasket. 2. Drive lock pin out of control finger. Drive spring pin out of stopper body. Before driving out pins, ensure

pins are aligned to prevent contact with clutch housing when removing. 3. Disassemble and remove neutral return spring assembly. See Fig. 9 . Remove control shaft, boot, and oil

seal from clutch housing. 4. Remove control shaft needle bearings from clutch housing using a 13 mm socket and extension. Inspect

all clutch housing components for signs of wear or damage and replace as necessary. See Fig. 9 .

Reassembly

1. Install stopper plate, return spring, pin, and spring pin in clutch housing. See Fig. 9 . Using a 14 mm socket and extension, drive control shaft needle bearings into clutch housing and ensure the side of the bearing with stamped type number faces surface "A". See Fig. 9 .

2. Using a 14 mm socket, install control shaft oil seal in clutch housing. Position control shaft boot and install control shaft in clutch housing.

3. Assemble and install neutral return spring assembly in clutch housing. See Fig. 9 . DO NOT reuse lock pin or spring pin. Install spring pin so slit is at right angle to control shaft centerline.

4. Install interlock plate bolt and gasket and torque to 15-20 ft. lbs. (20-27 N.m). Attach select lever shoe to select lever assembly and install on clutch housing. Torque select lever bolts to 11-16 ft. lbs. (15-22 N.m).



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Fig. 9: Exploded View Of Clutch HousingCourtesy of CHRYSLER CORP.

TRANSFER CASE

Disassembly

1. Remove cover and gasket from transfer case subassembly. Remove extension housing from transfer case adapter. See Fig. 10 .

2. Separate transfer case from transfer case adapter. Remove spacer and "O" ring from between transfer case and adapter sub-assemblies.

Reassembly

1. To ensure proper bevel gear tooth contact pattern, brush on a thin even coat of machine Blue or Red lead to both surfaces of driven bevel gear. Using old spacer, assemble transfer case and adapter subassemblies and torque bolts to 26-31 ft. lbs. (35-42 N.m). Install transfer case and transfer adapter with gear mating marks aligned.

2. Attach preload socket and side gear holder to drive bevel gear shaft and rotate one turn in direction of normal rotation and one turn in reverse rotation. Ensure mating marks of driven bevel gear and transfer case are aligned when viewed through cover opening. Separate transfer case and adapter subassemblies and inspect tooth contact pattern. See Fig. 11 . To adjust drive bevel gear tooth contact, replace driven bevel gear mount adjusting spacer. See BEVEL GEAR BACKLASH ADJUSTMENT.

3. If tooth contact pattern is normal, complete transfer case and transfer adapter assembly. Ensure drive bevel gear and driven bevel gear backlash is .0031-.0051" (.080-.130 mm). See Fig. 11 . See BEVEL GEAR BACKLASH ADJUSTMENT if backlash is not as specified.

4. Use a NEW "O" ring between transfer case and transfer case adapter for final assembly. Apply Mitsubishi Sealant (MD997740) to extension housing in a uniform and continuous bead. Install extension housing and tighten bolts to 11-16 ft. lbs. (15-22 N.m). Apply 3M ATD Sealant (8660) to both sides of transfer case cover gasket. Install transfer case cover and tighten bolts to 80 INCH lbs. (9 N.m).

Cleaning & Inspection

Inspect all splines for wear or damage. Check bearing surfaces for scoring, scratches or excessive wear. Spacers should be replaced with NEW spacers of same thickness. Replace all "O" rings. Clean all surfaces with solvent and dry with compressed air.

Transfer Case Sub-assembly

1. Remove transfer case cover, bolts, spacer and "O" ring from side of transfer case. Slide drive bevel gear assembly with outer races and spacers out of transfer case and inspect for wear or damage.

2. If necessary, use a press to remove and install drive bevel gear bearings or drive bevel gear. When installing drive bevel gear, ensure mating marks on drive bevel gear shaft and gear are aligned.

3. To complete transfer case assembly, replace seal. Install bearing races and drive bevel gear assembly with mating marks on transfer case and drive bevel gear shaft aligned. Tighten transfer case cover bolts to 26-31 ft. lbs. (35-42 N.m).



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4. Ensure bevel gear rotating drive torque is 15-22 INCH lbs (1.7-2.5 N.m). Replace adjusting spacers if rotating torque is not as specified. When replacing adjusting spacers, use spacers of similar thickness.

Transfer Case Adapter Sub-assembly

1. Unstake lock nut and remove from driven bevel gear assembly. Remove driven bevel gear assembly, bearing, spacer, collar and bearing races. Inspect all components for wear or damage. Replace as necessary.

2. Assemble driven bevel gear, taper roller bearing, collar, existing spacer, and outer bearing race in transfer case adapter and align mating marks. Install outer bearing race, taper roller bearing, and lock nut in transfer case adapter. Tighten lock nut to 103-118 ft. lbs (140-160 N.m). Ensure turning torque is 9-15 INCH lbs. (1.0-1.7 N.m). Driven bevel gear turning torque can be adjusted by replacing driven bevel gear spacer. Stake lock nut in 2 positions.



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Fig. 10: Exploded View Of Transfer AssemblyCourtesy of CHRYSLER CORP.

BEVEL GEAR BACKLASH ADJUSTMENT

1. On a standard tooth contact pattern, wear is distributed evenly between small end side "A" and large end side "C". Drive side tooth face "B" is side on which force acts when running forward. Coast side tooth face "D" is side on which force acts when reversing. See Fig. 11 .

2. If contact pattern is at "C" end of "B" and "A" end of "D", driven bevel is too close to drive bevel gear. Use a thicker bevel gear mount adjusting spacer to separate driven bevel gear from drive bevel gear. See Fig. 11 .

3. If contact pattern is at "C" end of "D" and "A" end of "B", driven bevel gear is too separated from drive bevel gear. Use a thinner driven bevel gear mount adjusting spacer to bring driven bevel gear closer to drive bevel gear. See Fig. 11 .

4. If correct tooth contact pattern cannot be obtained by changing driven bevel gear mount adjusting spacer, change drive bevel gear preload adjusting spacer and drive bevel gear mount adjusting spacer. See Fig. 11 .

5. Driven bevel gear mount spacers are available in various sizes .0051-.0205" (.13-.52 mm). Drive bevel gear mount spacers are available in various sizes .0528-.0657" (1.34-1.67 mm). Drive bevel gear preload spacers are available in various sizes .0504-.0728" (1.28-1.85 mm).

6. If driven bevel gear height is too small, replace drive bevel gear mount adjusting spacer with spacer one size thicker and replace drive bevel preload adjusting spacer with spacer one size thinner. If driven bevel gear height is too large, replace drive bevel gear mount adjusting spacer with spacer one size thinner and replace drive bevel gear preload adjusting spacer with spacer one size thicker. See Fig. 11 .

7. Repeat step 6 until tooth contact pattern is equal to or close to standard pattern. If tooth contact pattern cannot be adjusted close to standard pattern, replace drive bevel gear and driven bevel gear as a set and readjust tooth contact.



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Fig. 11: Measuring Bevel Gear Backlash Courtesy of CHRYSLER CORP.

TRANSAXLE REASSEMBLY

1. Install magnet and magnet holder in clutch housing and ensure proper installation direction. Install rear output shaft oil seal.

2. Install drive shaft oil seals. See AXLE SHAFT OIL SEAL REPLACEMENT under ON-VEHICLE SERVICE . Ensure notch in left side drive shaft oil seal is facing up. Install input shaft front oil seal.

3. Install front differential outer race, oil guide, and intermediate gear outer race in clutch housing. Install input shaft assembly with intermediate gear assembly in clutch housing.

4. Install input shaft front bearing retainer and torque hex bolts and countersunk bolt to 11-16 ft. lbs. (15-22 N.m). Apply 3M STUD Locking Sealant (4170) to first 5 mm of threads.

5. To install shift rail assembly, shift 1st-2nd synchronizer sleeve to 2nd speed. Shift 3rd-4th synchronizer sleeve to 4th speed.

6. Fit shift forks to synchronizer sleeves and install shift rails through forks and reverse lug into clutch housing. Turn shift rails and engage shift lugs to control finger and interlock plate. Install new spring pins. See Fig. 12 .

7. Install front differential assembly in clutch housing and front differential spacer in transaxle case. Install front output shaft assembly and needle bearing in clutch housing. Install front output shaft spacer and outer race in transaxle case.

8. Install reverse idler gear and shaft in clutch housing. Install reverse shift lever and shoe and torque bolts to 11-16 ft. lbs. (15-22 N.m).

9. Install stopper bracket and torque bolt to 11-16 ft. lbs. (15-22 N.m). Measure front output shaft preload and front differential case end play by placing 2 pieces of solder measuring approximately .4" (10 mm) long, .12" (3 mm) diameter at spacer locations.

10. Place 2 more pieces of solder (same size) on front differential bearing outer race. Install transaxle case and torque bolts to 26-31 ft. lbs. (35-42 N.m). Remove transaxle case from clutch housing.

11. Measure thickness of crushed solder to determine spacer thickness needed to obtain front differential end play of .0020-.0067" (.050-.170 mm) and front output shaft preload of .0031-.0051" (.080-.130 mm).

12. Install oil guide in transaxle case and apply sealant to clutch housing sealing surface for assembly. Center reverse idler gear shaft and install bolt. Torque bolt to 32-41 ft. lbs. (43-55 N.m).

13. Install center differential assembly with outer race in transaxle case. Place 6 pieces of solder (use procedure in steps 9) and 10)) at spacer positions. Install outer bearing race.

14. Install transaxle case adapter and rear cover and torque bolts to 26-31 ft. lbs. (35-42 N.m). Remove transaxle case adapter and rear cover.

15. Measure thickness of crushed solder to determine spacer thickness needed to obtain input shaft end play 0-.0020" (0-.050 mm), intermediate gear preload of .0031-.0051" (.080-.130 mm), and center differential case preload of .0031-.0051" (.080-.130 mm). Apply sealant and install transaxle case adapter.

16. Install steel ball and move center shaft to seat steel ball. Install viscous coupling and select snap ring to provide viscous coupling end play of .0039-.0102" (.100-.260 mm).

17. Install 5th speed intermediate gear on intermediate shaft and 5th speed gear with needle bearing on input shaft. Mate 5th speed shift fork with 5th gear synchronizer assembly and install simultaneously.



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18. Shift transaxle into reverse with control and select levers. Attach Input Shaft Holder (MD998802) to input shaft. Install NEW lock nuts on intermediate and input shafts and torque to 103-118 ft. lbs. (140-160 N.m).

19. Stake input shaft lock nut in 2 positions and intermediate shaft lock nut in one place. Install NEW spring pin in 5th speed shift fork.

20. Apply 3M Super Weatherstrip Adhesive (8001) to clutch housing contact area of air breather and install in clutch housing.

21. Install speedometer driven gear assembly in case with NEW "O" ring and seal (if necessary). Install poppet (detent) balls (3), springs (3), and plugs. Torque poppet plugs to 22-31 ft. lbs. (30-42 N.m).

22. Install restrict ball assembly and back-up light switch and torque both to 22-26 ft. lbs. (30-35 N.m). Apply 3M STUD Locking Compound (4170) to countersunk bolt threads. Install reverse brake cone. Torque bolts to 35-49 INCH lbs. (4.0-5.5 N.m).

23. Position NEW wave spring on 5th gear synchronizer. Apply Mitsubishi Sealant (MD997740) in a uniform and continuous bead .04-.08" (1-2 mm) to rear cover and install. Torque rear cover bolts to 26-31 ft. lbs. (35-42 N.m). See Fig. 1 .



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Fig. 12: Installing Shift Rail Assembly Courtesy of CHRYSLER CORP.

TRANSAXLE SPECIFICATIONS

TRANSAXLE SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Application In. (mm)Center Differential

Differential Case Preload .0031-.0051 (.08-.13)Viscous Coupling End Play .0039-.0102 (.10-.26)Differential Side Gear End Play .0020-.0100 (.05-.25)

Front DifferentialDifferential Case End Play .0020-.0067 (.050-.170)Differential Pinion Backlash .001-.006 (.025-.150)

TransaxleFront Output Shaft Preload .0031-.0051 (.080-.130)Input Shaft Rear Bearing End Play .0004-.0035 (.010-.090)Intermediate Gear Preload .0031-.0051 (.080-.130)W5M31

Input Shaft Front Bearing End Play .0004-.0047 (.010-.120)Intermediate Gear Bearing End Play .0004-.0043 (.010-.110)

W5M33Input Shaft End Play .0000-.0020 (.000-.050)Intermediate Gear Bearing End Play .0004-.0055 (.010-.140)Synchronizer Ring Clearance Limit .020 (.50)

Transfer Bevel Gear Set Backlash .0031-.0051 (.080-.130)Turning Torque INCH Lbs. (N.m)Transfer Case

Drive Bevel Gear 15-22 (1.7-2.5)Driven Bevel Gear 9-15 (1.0-1.7)

Application Ft. Lbs. (N.m)Back-Up Light Switch 22-26 (30-35)Bearing Retainer Bolt 11-16 (15-22)Center Differential Drive Gear Bolts 52-59 (70-80)Driven Bevel Gear Lock Nut 103-118 (140-160)Front Differential Drive Gear Bolts 52-59 (70-80)Input Shaft Lock Nut 103-118 (140-160)Interlock Plate Bolt 11-16 (15-22)



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Intermediate Shaft Lock Nut 103-118 (140-160)Oil Drain Plug 22-26 (30-35)Oil Filler Plug 22-26 (30-35)Poppet Plug 22-31 (30-42)Rear Cover Bolts 26-31 (35-42)Restrict Ball 22-26 (30-35)Reverse Idler Shaft Bolt 32-41 (43-55)Reverse Shift Lever Bolt 11-16 (15-22)Select Lever Assembly Bolt 11-16 (15-22)Stopper Bracket Bolt 11-16 (15-22)Transaxle Case Bolts 26-31 (35-42)Transfer Assembly Mounting Bolts 41-44 (55-60)Transfer Case Adapter Bolts 26-31 (35-42)Transfer Cover Bolts 26-31 (35-42)Transfer Driven Bevel Gear Lock Nut 103-118 (140-160)Transfer Extension Housing Bolts 11-16 (15-22)

INCH Lbs. (N.m)Transaxle Reverse Brake Cone Screws 35-49 (4.0-5.5)Transaxle Speedometer Mounting Bolt 27-44 (3-5)Transfer Case Cover 71-89 (8-10)



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transmission applications (chrysler motors) … · zfor vista/summit wagon, see transmission...

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