Chrysler Full-Size Vans 1989-1998 Repair Guide

Manual Transmission Assembly

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REMOVAL & INSTALLATION



See Figure 1



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Fig. Fig. 1: Clutch bell housing removal and installation

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the engine cover.
  4.  
  5. Disconnect the gear shift lever. On AX-15 transmissions, this step should be performed after the vehicle has been raised.
  6.  
  7. Raise and safely support the vehicle securely on jackstands.
  8.  
  9. Drain the transmission fluid.
  10.  
  11. Matchmark the rear driveshaft yoke to differential for installation reference.
  12.  
  13. Disconnect the rear universal joint and remove the driveshaft.
  14.  
  15. Disconnect the speedometer cable and back-up lamp switch electrical harnesses.
  16.  
  17. Support the rear of the engine.
  18.  
  19. Remove the rear mount to crossmember bolts/nuts.
  20.  
  21. Raise the rear of the engine slightly.
  22.  

Take care when raising the engine so nothing in the front of the engine is strained or damaged.

  1. Remove the rear transmission support crossmember.
  2.  
  3. Position a transmission jack under the transmission.
  4.  
  5. Remove transmission-to-clutch bell housing retaining bolts and pull the transmission rearward until the drive pinion clears the clutch.
  6.  
  7. Remove the transmission from the vehicle.
  8.  

To install:
  1. Installation is the reverse of the removal procedure. However, please pay attention to these special steps.
  2.  
  3. Place a small amount of multi-purpose grease into the clutch pilot bushing and on the clutch release bearing sleeve.
  4.  

Do not get any grease on flywheel face. Do not lubricate the end of the transmission input shaft, clutch disc splines, or clutch release levers.

  1. Align the clutch disc and backing plate with a spare drive pinion shaft or clutch aligning tool.
  2.  
  3. With the transmission in gear, turn the splines until they are aligned, then push the transmission input shaft into the clutch until it mates to the bell housing.
  4.  
  5. Tighten the transmission-to-clutch bell housing retaining bolts to 50 ft. lbs. (68 Nm).
  6.  
  7. Tighten the crossmember mounting bolts to 30 ft. lbs. (40 Nm).
  8.  
  9. Tighten the transmission mount-to-crossmember bolts to 50 ft. lbs. (68 Nm).
  10.  
  11. Tigthen the universal joint straps to 110 inch lbs. (19 Nm).
  12.  

 
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