Страница 1: ...MANUAL TRANSMISSION Service anual L 1 1 Dodg_ St_lth A T Turbo aCk1saa M ublehl IIIIrTl00 TlNIn Turbo _1 1__ Mlt ubi hl 30QOElT VA4...
Страница 2: ...rial The authors of this manual will not be held responsible for any personal injury or damage to property incurred while performing the procedures described within All tasks in this manual are undert...
Страница 3: ...ion and for application of sealants and adhesives is provided by using symbols in the diagram of component parts or on the page following the component parts page 4IiN Grease multipurpose unless there...
Страница 4: ...re 1 Pushrod 2 Boot lAO_A 3 Piston cup lAO_A 4 Piston 5 Conical spring 6 Cap 7 Bleeder screw 8 Release cylinder Disassembly service points JAc Removal of piston cup piston TFM0494 1 Remove the corrosi...
Страница 5: ...21 CLUTCH Maintenance Standards 21 2 Torque Specifications 21 2 Lubrication 21 2 Special Tools 21 3 Clutch Assembly 21 4 Clutch Release Cylinder 21 8 Clutch Damper 21 10...
Страница 6: ...oil line bracket attachment bolt 14 tUbs 19 N m 3 way type connector mounting bolt 14 tUbs 19 N m Clutch release cylinder mounting bolt 14 tUbs 19 N m Union bolt 17 ft lbs 23 Nm Clutch cover installat...
Страница 7: ...Clutch Special Tool Tool Part Number MD998126 Name Clutch disk centering guide 21 3 Use Positioning the clutch disk...
Страница 8: ...9 Bracket 10 Insulator 11 Banjo bolt 12 Crush washer 23 19 c 4iM Clutch Clutch Assembly 14 ft lbs 19 Nm 4 5 1 fI o6 3 2 11 ft lbs y 15 Nm 7 14 fUbs 19 Nm 13 16 rf 10 15 1 1 11 ft lbs 115 Nm 1D12 1 1 7...
Страница 9: ...neven contact deterioration due to seizure adhesion of oil or grease and replace the clutch disc if defective 2 Measure the rivet sink and replace the clutch disc if it is out of specification Limit 0...
Страница 10: ...lation service points A Installation of clutch release bearing 1 Fill the lip section with grease as illustrated Specified grease Molykote TA 2 B Lubrication of release fork 1 Apply grease to release...
Страница 11: ...nd squeeze it in place with a brush Specified grease Molykote TA 1 or 2 2 Use the clutch disc guide to position clutch disc on flywheel 3 When installing the clutch cover tighten the bolts in a diagon...
Страница 12: ...Cap 7 Bleeder screw 8 Release cylinder TFM0494 Disassembly service points OAt Removal of piston cup piston 1 Remove the corrosion from the piston removal port of the release cylinder 2 Remove the pis...
Страница 13: ...bottom middle and top If the diameter of the cylinder exceeds the outside diameter of the piston by more than the limit value replace the release cylinder assembly Limit value 0 15 mm Assembly servic...
Страница 14: ...Clutch Clutch Damper f k26 5 ft lbs 9Nm Inspection Clutch damper 5 6 5 ft lbs 9Nm TFM0392 1 Check that there are no scratches on the parts indicated in the illustration 2 Clean completely the inside o...
Страница 15: ...Assembly service point A Installation of O ring 1 Apply the specified brake fluid onto the O ring and securely install it onto the position of the clutch damper indicated in the illustration Specified...
Страница 16: ...22 7 Torque Specifications 22 8 Special Tools 22 9 Transn 1ission 22 13 Input Shaft 22 34 Intern 1ediate Shaft 22 40 3rd 4th Gear Synchronizers 5th 6th Gear Synchronizers W6MG1 22 50 W6MG1 22 51 Cente...
Страница 17: ...22 2 Cross section W5MG1 Manual Transmission Summary...
Страница 18: ...Manual Transmission Summary Cross section WSMG1 22 3...
Страница 19: ...Drive gear ratio 27 36 3 972 Speedometer Final Drive gear ratio 28 36 4 155 1994 Model Vear North American Market Transaxle model Ratio Speedometer Final Drive set gear ratio W6MG1 0 FNBR B 28 36 3 8...
Страница 20: ...Type Input shaft lock bolt Rear cover to center case installation bolt Stopper plate installation bolt Center case to clutch housing installation bolt Shift shaft to clutch housing installation bolt...
Страница 21: ...s Item Type Spline section of center output shaft and mating sleeve Molykote TA 1 or 2 of transfer case lip section of all oil seals Synchronizer friction surfaces and mating surfaces API Classificati...
Страница 22: ...adjustment spacers 0 40 0 50 0 20 Intermediate shaft preload 0 25 adjustment spacers 0 30 0 50 0 20 Center differential preload 0 25 adjustment spacers 0 30 0 50 0 10 0 15 Front output shaft preload 0...
Страница 23: ...to rear cover bolt 18 fUbs 25 Nm Shift shaft bolt 7 fUbs 10 Nm Shift shaft guide bolt 17 ft lbs 23 Nm W5MG1 Detent 22 ft lbs 30 Nm W6MG1 Guide bolt 15 ft lbs 20 Nm W6MG1 Oil tank bolt 5 fUbs 7 Nm W6M...
Страница 24: ...aller Rear cover puller ass y 5 MIT Rear cover puller adapter 6 MIT Working base ass y 5 MIT 22 9 Usage Installation of outer bearing race Installation of outer bearing race Installation of outer bear...
Страница 25: ...oil seal installer MD998812 Installer cap MD998813 Installer 100 Usage Removal of input shaft lock bolt W5MG1 W6MG1 Installation of rear cover W5MG1 W6MG1 Installation of transfer case tail housing o...
Страница 26: ...earing race MD998823 Installer Installation of reverse synchronizer adapter 48 hub and inner bearing race MD998824 Installer Installation of 3 4 synchronizer hub adapter 50 bearing sleeve 5th gear and...
Страница 27: ...22 12 Tool Manual Transmission Special Tools Number MD998917 MD999566 Name Bearing remover Claw Usage Removal of taper bearings Removal of outer bearing races...
Страница 28: ...Procedure AU 1 Transfer case 2 Speedometer gear 3 Transmission mount 4 Gearshift cable bracket 5 Reverse light switch 6 Gasket a 7 Venttube A G 52 fUbs 70Nm 7 3 3 ft lbs I 4 Nm i r 2 I W Coat all int...
Страница 29: ...ng JCC R 16 Input shaft bearing a 17 Oil seal P 18 Oil seal 19 Oil tank 20 Front differential 21 Front output shaft 19 14 1 20 Coat all internal parts in gear oil before reassembly JDc O 22 Outer bear...
Страница 30: ...ace G 34 Oil seal 35 Center differential F 36 Outer bearing race E 37 Spacer 37 7 5 fUbs 10 Nm 39 t T 43 1 1 41m 38 42 35 70 ft lbs 95Nm 18 ft lbs 25 Nm Coat all internal parts in gear oil before reas...
Страница 31: ...AA 1 Transfer case 2 Speedometer gear 3 Transmission mount 4 Gearshift cable bracket 5 Reverse light switch 6 Gasket Z 7 Venttube A 9 4iI 14 ft lbs 19 Nm J 8 4 1 _52 ft lbs 70Nm 14 ft lbs 19 Nm 3 ft l...
Страница 32: ...ut shaft bearing 0 19 Oil seal P 20 Oil seal 21 Oil tank 22 Front differential 21 15 b 25 18 fUbs 25Nm 4iiiI Coat all internal parts in gear oil before reassembly 23 Front output shaft lO o O 24 Outer...
Страница 33: ...race G 39 Oil seal 40 Center differential F 41 Outer bearing race 7 5 fUbs 10Nm 34 45 32 42 t 15 43m 33 44 41 E 42 Spacer 40 18 fUbs 25Nm Coat all internal parts in gear oil before reassembly CFO C 4...
Страница 34: ...ints JAO Removal of shift shaft 1 Place the shift shaft in the neutral position and pull to remove JB0 Removal of dO Nel pin 1 The dowel pin is driven out in the direction illustrated J C0 Removal of...
Страница 35: ...illustrated oF0 Removal of input shaft rear seal cap 1 Drive a nail or similar pointed object into seal cap and pull to remove oGo Removal of input shaft lock bolt 1 Set the rear cover and shaft assem...
Страница 36: ...MG I MB991578 3 Lock bolt is removed oH0 Removal of rear cover Adjustment before assembly Selection of spacers for adjustment 1 Place solder length approximately 10 mm and diameter approximately 1 6mm...
Страница 37: ...t and center case are installed at the same time 6 The rear cover is installed and the bolts are tightened to the specifed torque 7 Remove each outer race and remove the solder Measure the thickness o...
Страница 38: ...s and rails into the special tool 2 Using an electric heater or similar device heat the special tool Heating temperature 110 120 C 230 248 F 3 The heated special tool is placed against the inner race...
Страница 39: ...input shaft and intermediate shaft are set into the special tool 2 Shift both forks in the direction shown in the illustration This will lock the shafts so that the input shaft lock bolt can be instal...
Страница 40: ...is applied to the illustrated position on the poppet cover Note Brand Mitsubishi Genuine Sealant part number MD997740 or equivalent 2 Install the bolts in the poppet cover 3 Apply thread locking compo...
Страница 41: ...th specified grease Specified grease Molykote TA 1 or 2 H Installation of outer bearing race I Installation of outer bearing race J Installation of transmission case 1 Apply sealant to the illustrated...
Страница 42: ...compound to the threads of the bolt and tighten to the specified torque Note Brand Loc tite 242 3M Threadlocker 4170 or equivalent K Installation of stopper plate 1 Install the bolts into the stopper...
Страница 43: ...race N Installation of oil guide 1 The notch in the oil guide is installed in the illustrated position Note If the oil guide is broken or damaged replace it with a new one 0 Installation of outer bea...
Страница 44: ...nput shaft front bearing 1 Install the bearing with the hole facing downward S Installation of clutch housing 1 Apply sealant to the illustrated position on the rear cover Sealant Brand Loc tite 17430...
Страница 45: ...ead locking compound to the threads of the bolt and tighten to the specified torque Note Brand Loc tite 242 3M Threadlocker 4170 or equivalent T Installation of shift shaft 1 Apply sealant to the illu...
Страница 46: ...TFMOSI4 TFM0433 2 Apply a coating of grease to the shift shaft to prevent the return spring from falling off during installation 3 The shift shaft must be kept in the position shown during installatio...
Страница 47: ...compound to the threads of the bolt and tighten to the specified torque Note Brand Loc tite 242 3M Threadlocker 4170 or equivalent V Installation of guide bolt 1 Apply thread locking compound to the...
Страница 48: ...lation of gear select lever 1 Apply thread locking compound to the threads of the bolt and tighten to the specified torque Note Brand Loc tite 242 3M Threadlocker 4170 or equivalent Z Installation of...
Страница 49: ...ronizer ring OBQ H 6 Synchronizer sleeve H 7 Synchronizer ball H 8 Synchronizer spring Manual Transmission Input Shaft 6 5 12 Coat all internal parts in gear oil before reassembly DQ D 9 Bearing sleev...
Страница 50: ...h gear 5 Needle bearing JCr J 6 Bearing sleeve 9 I 7 5 6 Synchronizer hub 8 5th gear 9 Needle bearing JEr G 10 Bearing sleeve 8 7 4 5 Coat all internal parts in gear oil before reassembly IH 11 Spacer...
Страница 51: ...put Shaft Disassembly service points JAo Removal of 5th gear JB0 Removal of synchronizer sleeve 1 Because there is a tendency for the synchronizer springs to pop out cover the assembly with your hand...
Страница 52: ...Heating temperature 110 120 C 230 248 F Note Try not to heat the part too much Material will weaken under high temperature B Installation of 3 4 synchronizer hub Note Adjust the synchronizer ring and...
Страница 53: ...lnstaliation of bearing sleeve 1 Using an electric heater or similar device heat the bearing sleeve Heating temperature 110 120 C 230 248 F Note Try not to heat the part too much Material will weaken...
Страница 54: ...ric heater or similar device heat the bearing sleeve Heating temperature 110 120 C 230 248 F Note Try not to heat the part too much Material will weaken under high temperature K Installation of 5th ge...
Страница 55: ...ball J 10 Synchronizer spring J 11 Synchronizer key JCO I 12 Bearing sleeve H 13 Synchronizer hub 14 Outer synchronizer ring G 15 Synchronizer friction ring 9 0 10 1 11 14 21 24 16 Inner synchronizer...
Страница 56: ...eeve J 8 Synchronizer ball J 9 Synchronizer spring J 10 Synchronizer key lCO I 11 Bearing sleeve H 12 Synchronizer hub 13 Outer synchronizer ring G 14 Synchronizer friction ring 15 Inner synchronizer...
Страница 57: ...al of inner bearing race W6MG I Inner race MD998917 L__ t L_ TFM0532 W5MG I Bearing sleeve TFM0 447 W6MG I TFM0533 JB0 Removal of synchronizer sleeve 1 Because there is a tendency for the synchronizer...
Страница 58: ...rmediate Shaft 22 43 W5MGI W6MGI W5MGI W6MGI 5th gear side 000 Removal of inner bearing race TFM0534 Bearing sleeve oE0 Removal of bearing sleeve TFM0535 Assembly service points A Installation of 5 R...
Страница 59: ...nizer hub TFM0537 TFM0452 Bearing sleeve TFM0538 Note Adjust the synchronizer ring and hub to the illustrated position B Installation of reverse synchronizer hub C lnstaliation of bearing sleeve 1 Usi...
Страница 60: ...zer sleeve with the grooves in the synchronizer hub 4 Shift the synchronizer sleeve to the 5th gear side 5 Install the synchronizer balls 3 positions 6 Install the synchronizer ring 7 While holding do...
Страница 61: ...Inner race TFM0457 Inner race TFM0543 2 Verify direction of synchronizer sleeve during installation 3 Install the synchronizer balls 3 positions F Installation of inner bearing race G Installation of...
Страница 62: ...H lnstaliation of 1 2 synchronizer hub Note Orientation of hub is the same for W6MG1 Note Adjust the synchronizer ring and hub to the illustrated position 1 Installation of bearing sleeve 1 Using an e...
Страница 63: ...ith chamfer facing outside 2 Verify direction of synchronizer sleeve during installation 3 Shift the synchronizer sleeve to the 2nd gear side 4 Install the synchronizer balls 3 positions 5 The synchro...
Страница 64: ...Manual Transmission Intermediate Shaft 22 49 W5MGI MD998812 MD998825 W6MGI MD9988 12 1 1 MD998825 Inner race K Installation of inner bearing race TFM0465 Inner race TFM0548...
Страница 65: ...U 3 Synchronizer sleeve U 4 Synchronizer ball U 5 Synchronizer spring 6 Synchronizer hub TFM0549 Disassembly service points OAG Removal of synchronizer sleeve 1 Because there is a tendency for the sy...
Страница 66: ...sleeve U 4 Synchronizer ball U 5 Synchronizer spring 6 Synchronizer hub TFM0549 Disassembly service points OAG Removal of synchronizer sleeve 1 Because there is a tendency for the synchronizer spring...
Страница 67: ...ly Procedure E 1 Dowel dAO D 2 End cover dBO C 3 Inner bearing race dCO B 4 Needle bearing 5 Planetary gear set 6 Viscous coupling 7 Sun gear 8 Center output shaft lDG A 9 Inner bearing race 10 Center...
Страница 68: ...Differential 22 53 Disassembly service points oAe Removal of planetary gear cover 1 Drive the spring pin down into the illustrated position oBe Removal of inner bearing race oce Removal of needle bea...
Страница 69: ...4 B Installation of needle bearing 1 Press the needle bearing into the illustrated position C Installation of inner bearing race D Installation of inner bearing race 1 Align the spring pin holes of th...
Страница 70: ...ng race lAc A 2 Inner bearing race 3 Output shaft MD998801 MD998812 MD998813 MD998825 Inner race TFM0475 Inner race TFM0476 Coat all internal parts in gear oil before reassembly Disassembly service po...
Страница 71: ...22 56 MD9988 12 MD998825 Manual Transmission Front Output Shaft B Installation of inner bearing race Inner race TFM0477...
Страница 72: ...y Disassembly Procedure 9 12 10 G 1 Reverse shaft carrier bolt 2 Washer 3 Reverse shaft carrier 4 Reverse gear 5 Needle bearings F 6 Reverse gear shaft E 7 Input shaft bearing retainer 11 13 8 Input s...
Страница 73: ...oil before reassembly Disassembly Procedure 8 5 11 9 G 1 Reverse shaft carrier bolt 2 Washer 3 Reverse shaft carrier 4 Reverse gear 5 Needle bearings E 6 Input shaft bearing retainer 10 18 ft lbs 25N...
Страница 74: ...Removal of outer bearing race Assembly service points A Installation of oil guide 1 When installing the oil guide align the channels of the guide with the notches in the rear cover Note If the oil gu...
Страница 75: ...3 Remove the bearing and the solder Measure the thickness of the crushed solder with a micrometer and select and install a spacer of thickness that gives standard preload End Play 0 02 mm 0 05 mm 4 I...
Страница 76: ...he bolt holes as shown in order to install the idler shaft bolt G Installation of reverse gear shaft bolt W5MG1 Reverse gear carrier bolt W6MG1 1 Apply thread locking compound to the threads of the bo...
Страница 77: ...e OAOitA 2 Inner bearing race 3 Differential MD998812 MD998823 Bearing Inner race TFM 0040 3 4 Ring gear bolt 1 52 ft lbs 70Nm 4 oCiiiiI Coat all internal parts in gear oil before reassembly Disassemb...
Страница 78: ...Manual Transmission Front Differential 22 63 MD998812 MD998825 Inner race TFM0491 B Installation of inner bearing race...
Страница 79: ...Oil seal 5 Sleeve Oil seal TFM0370 Slit Spring pin TFM0369 5 1 3 t 1m Assembly service points A Installation of oil seal 1 Press the oil seal into position as illustrated B Installation of speedometer...
Страница 80: ...7 5 Nm Disassembly Procedure ItA 1 Oil seal ItA 2 Oil seal 3 Washer 4 Oil fill bolt 5 Transfer case 5 Assembly service points A Installation of oil seal 1 After installation of oil seal fill the lip s...
Страница 81: ...in It r 0 11 ui anoIher 2 hours How oddibQnol m y be Ill depend 011 1 Of oeh dul d on proccoood o Simply oo ct Y d It nl ht y k fVice awomtD nl As be IW bold Ih po U f your veiokk or to order II m bef...
Страница 82: ...00 Qf the obQv vehicle may tht trarufer e to fail Thi u1d au he wbeelllQ lock up end sul in 1 accident without wamins NII I The lrOn fer case_ i ted If he nnsfer C6S 1 lO1 leakinS lhe Innsf case oil m...
Страница 83: ...ervice about r lhMc vehicles B Transfer Case Due 10 the small number ofinvolved vehicle peeled tn requir on fer U t replacrooenl no pam will b di buted nitially Tnn re uses should be ordered only afte...
Страница 84: ...the InInSf o ase Fipe I d Oem Ihc drlUn plug and thm inst ll it into the u nsfa case Tithtcn the drain plug o 300 in_lbf OS N m Pagel Flgu 1 c Fill the tI1Insfer case with Mopar 7SW 9OIGL S Gear Lube...
Страница 85: ...transfer case filler plug 5 Remove the transf r cas dram plug and dram the IlUld from the transfer ea e figure 1 G Remove the WO nuts that secun Ihe exhaust pipe to the rear M bocharger mQumed catalyt...
Страница 86: ...e downward then discOIUlect the transfer case from the drive shaft and sel it on a c1eaJl work surface IMPORTANT nil KOT allow the drive shaft to hang as hi could damage the universal joint or bend th...
Страница 87: ...ousing 10 tn adapta OOu mg figuK 5 NOTE Tb re are fl 5 bola OD S pHil Njulpptd thIeJ and se to 7 bolts nn 6 spHil Njuipped ehid 16 Position the tmn fa cast vertioally on a of pM 3nd sepru3t the geru h...
Страница 88: ...l guide pipe when lIeparating the housings on 6 speed equipped ebicles Figure 7 Ii While holding lhe gear housing rotate the inpul gear and nute It condirion Figure 8 GEAR HOUSING 6 5PEED Page 7 DO NO...
Страница 89: ...place Transfer Case 20 Remove the gear housing to adapter housing O ring Figure 10 Use care to not d lO wge the O ring seat I OTE The O ring Is loc tted on the adapter housing for 5 speed equipped veh...
Страница 90: ...ear housing tap one of the COVer boll bosses unril the cover hail tumed sufficiently 26 Set the Ilear housing 011 the work surface with the cOvc r 011 the side WhiJe holding the gear housing i th your...
Страница 91: ...the inpul shaft seal from Ille gear housin 32 S the adapter hou ing ntmsion housing assembly 00 the work surface lth the output shaft facing upward 33 Carefully remove the OIItput shaft oeal To remove...
Страница 92: ...e housing with an arbor press until the scal conta ls the seal Figure 15 36 FOR S SPEF D TRANSFER CASES ONLY remove the sc al installation 1001 and place the supplied 2 5 IlUIl spacer on lOp of Ihe ut...
Страница 93: ...e installed if the cover has an O ring groove If the cowr does NOT bave 3n O ring gToo e DO NOT install a cover O ring 39 In ilall the mput geu mto the gear housing by placmg the input gear assembly o...
Страница 94: ...aft opening 10 hold Ihe gear In position and then mm the gear housing over Figure 19 4 L Put a bead orsealanL Mopar xle RTV PiN 0501 3477A or c qUIvalcnI on the gear hOlLMe cover tlange FIgure 20 Figu...
Страница 95: ...the cOver boiL I s all the co U boilS and tighlen 10 220 in ib 25 N Page 14 Flgu e 21 45 LubriC31e be supplied gear hou ing lo a iaptor housing O ring ith Mopar 75W 90 GL 5 Goar Lube lnstilllht O ring...
Страница 96: ...t the gear housing by lightly lapping it willi a plastic halluuer Page 15 PUT A BEAD OF SEA1 ANTON GEAR HOUSING TO ADAPTER HOUSING FLANGE sPEED ONLY Figure 22 4X Apply 1opar Lock Seal Mopar PiN 431803...
Страница 97: ...the breather hole and then install the breather 55 In stall a new aluminum gasket onto the tiller plug Install the filler plug into the transfer case and tighten the plug to 300 m lbs 35 N m 56 Fill...
Страница 98: ...case onto the transaxle FIgure 3 60 Imaall the tranSfer e se mounting boilS and tighten the mountmg boilS to 65 ft Ibs 87 N m figur 3 R the te po y dri veohaft support 61 Remove th tempoRJy el haust...
Страница 99: ...msfer case filler plug Remov tk transfer drain plug Figure 25 and dnull the fluid ftnm the trnn fer C Remo e the two nulS that secure tht exhaust pipe 11 the rear twbocharger mowued catalytic cOIlvene...
Страница 100: ...he trdIlSfercase aside tor return to th Varranty Material Rclum CCnlcr REMOVE FIVE TRANSFER CASE TO TRANSAXLE BOLTS Figure 27 Page 19 DISCONNECT TRANSFER CASE FROM DRIVESHAFT IMPORTANT Do i iOT allow...
Страница 101: ...E WITH CORRECT AMOUNT OF T 90GEAR LUBE THROUGH OUTPUT SHAFT OPENING 15 Coat the transa xle output shaft and the driveshaft splines with Mopar White Lithium Grease or equivalent In Insert lhe driv shaf...
Страница 102: ...ppIiable deale lIowance CO you cl n PIrIIIIIi 1 Removed 1nrISf asci mtW of returned I tho Warnnly MatcrW Return eml Removaltnns f SCI of dnlined and fully bled NOTE Sec Iho Warnnty Admini tnt tion Man...
Страница 103: ...e Kn 1 eqllu knl by first cia lIIIil They art tcquested to lehe appo ntmmt for this erv c wI h 1M de ers A copy fthe owner k1l j anoched Enclosed lIh each owner leuer i an Owner Notir rion Form Thc in...