Dodge Omni/Horizon/Rampage 1978-1989 Repair Guide

Transaxle Overhaul

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DISASSEMBLY & ASSEMBLY



A-412 Models

WARNING
Final mainshaft adjustment requires a measurement made with a special tool.

  1. Remove the clutch pushrod, being careful not to bend it.
  2.  



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Fig. Fig. 1 Remove the clutch pushrod, being careful not to bend it

  1. Remove the selector shaft plug from the case.
  2.  
  3. Using pliers, remove the snap-ring and cone washer.
  4.  



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Fig. Fig. 2 Using pliers, remove the snap-ring and cone washer

  1. With special tool L-4443 or an equivalent, remove the drive flange.
  2.  



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Fig. Fig. 3 Remove the drive flange

  1. Next with special tool L-4445 or equivalent remove the drive flange seal.
  2.  



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Fig. Fig. 4 With special tool L-4445 or equivalent remove the drive flange seal

  1. Disconnect the selector shaft cover from the transaxle.
  2.  



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Fig. Fig. 5 Disconnect the selector shaft cover from the transaxle

  1. Remove the detent spring assembly and rubber boot, then tap out the selector shaft and pry out the oil seal.
  2.  
  3. Push out the selector shaft, then remove it and the seal.
  4.  



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Fig. Fig. 6 Push out the selector shaft ...



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Fig. Fig. 7 ... then remove the shaft ...



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Fig. Fig. 8 ... and the seal

  1. Using a small prybar, carefully pry out the two mainshaft bearing retaining nut rubber plugs.
  2.  
  3. Remove the four bolts and the clutch release bearing end cover. Hold the clutch release lever upwards while removing the cover to avoid loading or damage to the case threads. Take out the release bearing and plastic sleeve.
  4.  



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Fig. Fig. 9 Take out the release bearing and plastic sleeve

  1. Using two small prybars, push the circlip off the clutch torque shaft. Pull the torque shaft out of the case, then remove the pedal return spring and release lever. Pry out the torque shaft oil seal.
  2.  



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Fig. Fig. 10 Pull the torque shaft out of the case, then remove the pedal return spring and release lever



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Fig. Fig. 11 Pry out the torque shaft oil seal

  1. Remove the three mainshaft bearing retainer nuts; two were under the rubber covers removed earlier and the 3rd is inside the clutch release housing. The three studs and clips will drop into the case.
  2.  



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Fig. Fig. 12 Remove the three mainshaft bearing retainer nuts; two were under the rubber covers removed earlier and the 3rd is inside the clutch release housing. The three studs and clips will drop into the case

  1. Remove the ten case bolts and the four stud nuts, then the transaxle case.
  2.  



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Fig. Fig. 13 Remove the ten case bolts and the four stud nuts, then remove the transaxle case


WARNING
The factory uses a special tool to do this; it pushes against the end of the mainshaft. Make sure to tag the shims for reuse.

  1. Remove the transaxle case.
  2.  
  3. Remove the reverse idler set screw (bolt) and the backup light switch.
  4.  
  5. Remove the two bolts, the reverse shift fork and the supports.
  6.  



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Fig. Fig. 14 Remove the two bolts, then remove the reverse shift fork supports



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Fig. Fig. 15 Remove the reverse shift fork

  1. Remove the snapring from the end of the pinion shaft.
  2.  
  3. Pull off the bearing and the 4th gear from the end of the mainshaft. Remove the 4th gear needle bearing.
  4.  



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Fig. Fig. 16 Remove the mainshaft assembly and the pinion shaft 4th gear



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Fig. Fig. 17 Pull off the bearing and the 4th gear from the end of the mainshaft. Remove the 4th gear needle bearing

  1. Remove the 3rd-4th synchronizer and 3rd gear along with the needle bearing.
  2.  



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Fig. Fig. 18 Remove the 3rd-4th synchronizer and 3rd gear along with the needle bearing

  1. Using a small prybar, carefully pry off the shift rail E-clips, then remove the shift fork assembly.
  2.  



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Fig. Fig. 19 Carefully remove the shift rail E-clips



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Fig. Fig. 20 Remove the shift fork assembly

  1. Remove the mainshaft assembly; it can be disassembled by removing the snaprings and the components. The clutch pushrod seal and bushing assembly can be driven out of the shaft with a 3 / 8 in. (10mm) diameter brass rod. Replace it by driving it with a plastic hammer.
  2.  



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Fig. Fig. 21 Remove the mainshaft assembly; it can be disassembled by removing the snaprings and the components



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Fig. Fig. 22 The clutch pushrod seal and bushing assembly can be driven out of the shaft with a 3 / 8 in. (10mm) diameter brass rod

  1. Remove the pinion shaft snapring and the 3rd gear, then the 2nd gear and its needle bearing.
  2.  



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Fig. Fig. 23 Remove the pinion shaft snapring ...



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Fig. Fig. 24 ... 3rd gear ...



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Fig. Fig. 25 ... then the 2nd gear and needle bearings

  1. Pry or pull out the reverse idler gear shaft.
  2.  



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Fig. Fig. 26 Pry or pull out the reverse idler gear shaft


WARNING
Remove the plastic thrust button and install a tool at the end of the pinion shaft before using the puller. The pinion shaft bearing retainer is notched in two locations for the puller jaws. The inner sleeve for 2nd gear and 1st gear are removed together.

  1. Using L-4534 or an equivalent puller, remove the 1st gear and the 1st-2nd synchronizer assembly from the pinion shaft.
  2.  



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Fig. Fig. 27 Using a puller, tool L-4534 or equivalent, remove the 1st gear and the 1st-2nd synchronizer assembly from the pinion shaft

  1. Remove the 1st gear needle bearing and scribe a mark across the 1st-2nd synchronizer for reassembly.
  2.  



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Fig. Fig. 28 Lift off 1st and 2nd gear synchronizers



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Fig. Fig. 29 Remove the 1st gear needle bearing and scribe a mark across the 1st-2nd synchronizer for reassembly

  1. Remove the pinion shaft bolts, the retainer, the thrust washer (the flat side goes up) and the pinion shaft.
  2.  



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Fig. Fig. 30 Remove the pinion shaft bolts ...



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Fig. Fig. 31 ... the retainer ...



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Fig. Fig. 32 ... the thrust washer (the flat side goes up) ...



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Fig. Fig. 33 ... and the pinion shaft

To assemble:

  1. Place a 0.02 in. (0.65mm) shim in the bearing housing and press the small bearing cup into the clutch housing, then move the pinion up and down, measuring the end-play with a dial indicator.
  2.  


WARNING
Do not rotate the shaft while moving it up and down.

  1. The correct preload is determined by adding 0.008 in. (0.20mm) to the reading obtained from the dial indicator in Step 1, along with the shim thickness, 0.02 in. (0.65mm). For example: if the measurement is 0.02 in. (0.30mm), the correct shim to use is 0.05 in. (1.15mm) (0.65 + 0.03 + 0.20 = 1.15). Remove the pinion shaft ball bearing retainer and the pinion shaft. Remove the small bearing cup and the 0.02 in. (0.65mm) shim and install the correct shim.
  2.  
  3. If new bearings are installed on the pinion shaft, lubricate them with transaxle oil, install the shaft and check the shaft rotational pre-load with a torque wrench; it should be 4-13 inch lbs. (0.4-1.5 Nm), if not, reset the preload.
  4.  
  5. Install the pinion shaft and place the 1st gear thrust washer over the shaft, with the flat side up facing the gear. Install the pinion shaft retainer and tighten the bolts to 29 ft. lbs. (39 Nm).
  6.  
  7. Install the needle bearing, the 1st gear and the 1st gear synchronizer stop ring over the shaft.
  8.  


WARNING
The wear limit for spacing between the synchronizer teeth on the 1st gear and those on the stop ring is 0.02 in. (0.5mm). There is one tooth missing from the 1st gear stop ring on early models. The 1st gear will grind, if this ring isn't used. Later models have three teeth missing in three places, 120° apart.

  1. Align the marks on the 1st-2nd synchronizer hub and the sleeve, made on disassembly. Install the synchronizer, driving it into place.
  2.  
  3. Drive the 2nd gear needle bearing inner race into place over the shaft.
  4.  
  5. Drive the reverse idler gear shaft into place.
  6.  


WARNING
Make sure that the threaded hole in the top of the shaft is centered, pointing out between the two nearest case edge bolt holes.

  1. Place the 2nd gear needle bearing over the pinion shaft, then the 2nd gear stop ring, the 2nd gear and the 3rd gear onto the shaft; make sure that the 3rd gear has the thrust face down.
  2.  
  3. Install the 3rd gear snap-ring. Measure the end-play between 3rd gear and the snapring with a feeler gauge; it should be 0-0.004 in. (0-0.1mm). The snaprings are available in thicknesses from 0.1-0.12 in. (2.5-3.0mm) for adjustment. Replace the snapring with the one selected.
  4.  
  5. Seat the mainshaft assembly.
  6.  
  7. Install the shift fork assemblies and the E-clips.
  8.  
  9. Install the 4th gear needle bearing over the mainshaft and place the 4th gear synchronizer stop ring in place. Install the 4th gear and the snapring.
  10.  
  11. Install the reverse shift fork and the support brackets, then tighten the bolts to 105 inch lbs. (12 Nm).
  12.  
  13. Using a feeler gauge, measure the clearance between the top of the pinion shaft 2nd gear and the bottom of the mainshaft 3rd gear.
  14.  


WARNING
The ideal clearance is adjusted by forcing the mainshaft up or down in relation to the clutch case. The factory has a special tool to do this from the clutch end.

  1. The next step is to determine the thickness of the shim or shims to be placed between the mainshaft roller bearing and the transaxle case. The factory does this by inserting a special tool of the same thickness as the bearing in the case, installing the case, then measuring the up and down movement of the special tool with a dial indicator. Shims are available in 0.3-0.6mm sizes.
  2.  
  3. After the selected shim is installed behind the bearing, tighten the bearing retainer clamp bolts to 13 ft. lbs. (18 Nm). Install the transaxle case-to-clutch housing bolts, using the guide pin for alignment, and tighten the nuts and bolts to 20 ft. lbs. (27 Nm).
  4.  

A-460 Models

The Chrysler designed and built A-460 (4-speed) fully synchronized manual transaxle combines gear reduction, ratio selection and differential functions in one unit housed in a die cast aluminum case.

  1. With the transaxle removed from the vehicle, remove the differential cover bolts and the stud nuts, then remove the cover.
  2.  
  3. Remove the differential bearing retainer bolts.
  4.  
  5. Using tool No. L-4435, rotate the differential bearing retainer to remove it.
  6.  
  7. Remove the extension housing bolts, then the differential assembly and extension housing.
  8.  
  9. Take out the selector shaft housing bolts, then the selector shaft housing.
  10.  
  11. Remove the stud nuts and the bolts from the rear end cover, then using a small prybar, carefully pry off the rear end cover.
  12.  
  13. Using snapring pliers, remove the large snapring from the intermediate shaft rear ball bearing.
  14.  
  15. Take off the bearing retainer plate by tapping it with a plastic hammer.
  16.  
  17. Remove the 3rd-4th shift fork rail.
  18.  
  19. Remove the reverse idler gear shaft and gear.
  20.  
  21. Extract the input shaft gear assembly and the intermediate shaft gear assembly.
  22.  
  23. To remove the clutch release bearing, remove the E-clips from the clutch release shaft, then disassemble the clutch shaft components.
  24.  
  25. Take off the three input shaft seal retainer bolts, the seal, the retainer assembly and the select shim.
  26.  
  27. Using tools No. C-4171, C-4656 and an arbor press, press the input shaft front bearing cup from the transaxle case.
  28.  
  29. Using tool No. C-4660, remove the two bearing retainer strap bolts, then the intermediate shaft front bearing.
  30.  

To assemble:

The assembly of the transaxle is the reverse of disassembly; however, please note the following:

  1. Using tools No. C-4657, C-4171 and an arbor press, press the front bearing onto the intermediate shaft; the input shaft front bearing cup is installed with the same tools used for removal.
  2.  
  3. Determine the shim thickness for the correct bearing end-play only if any of the following parts are replaced:
  4.  
    1. The transaxle case.
    2.  
    3. The input shaft seal retainer.
    4.  
    5. The bearing retainer plate.
    6.  
    7. The rear end cover.
    8.  
    9. The input shaft or bearings.
    10.  

  5. To determine proper shim thickness, refer to the Input Shaft Bearing End Play Adjustment.
  6.  
  7. Using tool No. C-4674 and a plastic hammer, install the input shaft oil seal.
  8.  
  9. Using a 0.1 in. (3mm) bead of RTV sealant, place it around the edge of the input shaft seal retainer and making sure the drain hole of the retainer is facing downward.
  10.  
  11. The differential bearing retainer is installed with the same special tool used for removal.
  12.  


WARNING
The rear end cover, the selector shaft housing and the differential cover are sealed with RTV sealant.

INTERMEDIATE SHAFT

WARNING
The 1st-2nd, the 3rd-4th shift forks and the synchronizer stop rings are interchangeable. However, if parts are to be reused, reassemble them in their original position.

  1. Remove the intermediate shaft rear bearing snapring.
  2.  
  3. Using the puller tool No. C-4693, remove the intermediate shaft rear bearing.
  4.  
  5. Using snapring pliers, remove the 3rd-4th synchronizer hub snapring.
  6.  
  7. Using the puller tool No. L-4534, remove the 3rd-4th synchronizer hub and the 3rd gear.
  8.  
  9. Remove the retaining ring, the split thrust washer, the 2nd gear and the synchronizer stop ring.
  10.  
  11. Using snapring pliers, remove the 1st-2nd synchronizer hub snapring.
  12.  
  13. Take off the 1st gear, the stop ring and the 1st-2nd synchronizer assembly.
  14.  
  15. Remove the 1st gear thrust washer and the anti-spin pin.
  16.  

To assemble:

The assembly of the intermediate shaft is the reverse of the disassembly; however, please note the following: When assembling the intermediate shaft, make sure the speed gears turn freely and have a minimum of 0.003 in. (0.08mm) end-play. When installing the 1st gear thrust washer make sure the chamfered edge is facing the pinion gear. When installing the 1st-2nd synchronizer make sure the relief faces the 2nd gear. Use an arbor press to install the intermediate shaft rear bearing, the 3rd-4th synchronizer hub and the 3rd gear.

INPUT SHAFT BEARING ADJUSTMENT
  1. Using special tool No. L-4656 with handle C-4171, press the input shaft front bearing cup slightly forward in the case. Then, using tool No. L-4655 with handle C-4171, press the bearing cup back into the case, from the front, to the properly position the bearing cup before checking the input shaft end-play.
  2.  


WARNING
This step is not necessary if the special tool No. L-4655 was previously used to install the input shaft front bearing cup in the case and no input shaft select shim has been installed since pressing the cup into the case.

  1. Select a gauging shim which will give 0.005-0.01 in. (0.025-0.50mm) end-play.
  2.  


WARNING
Measure the original shim from the input shaft seal retainer and select a shim 0.005 in. (0.25mm) thinner than the original for the gauging shim.

  1. Install the gauging shim on the bearing cup and the input shaft seal retainer.
  2.  
  3. Alternately tighten the input shaft seal retainer bolts until the retainer is bottomed against the case, then tighten the bolts to 21 ft. lbs. (28 Nm).
  4.  


WARNING
The input shaft seal retainer is used to draw the input shaft front bearing cup the proper distance into the case bore.

A-465, A-525 Models

The Chrysler designed and built A-465 (1983-84) and the A-525 (1985-88) fully synchronized 5-speed manual transaxles combine gear reduction, ratio selection and differential functions in one unit housed in a die cast aluminum case. The A-525 has a close ratio gearset with different 2nd, 3rd and 4th gear ratios than the A-465, to provide better performance through the gears, while the 1st and the 5th gear ratios are the same as the A-465 to maintain the same launch and top gear characteristics.

1984-85 MODELS
  1. With the transaxle removed from the vehicle, remove the differential cover bolts and the stud nuts, then remove the cover.
  2.  
  3. Remove the differential bearing retainer bolts.
  4.  
  5. Using tool No. L-4435, rotate the differential bearing retainer to remove it.
  6.  
  7. Remove the extension housing bolts, then the differential assembly and extension housing.
  8.  
  9. Extract the selector shaft housing bolts, then the selector shaft housing.
  10.  
  11. Remove the stud nuts and the bolts from the rear end cover, then using a small prybar, carefully pry off the rear end cover.
  12.  
  13. On 5-speeds, remove the 5th speed synchronizer strut retainer snapring, strut retainer plate, 5th gear synchronizer, shift fork with rail, intermediate shaft 5th gear, input shaft 5th gear snapring and 5th gear. Then, use a puller such as C-4693 with legs C-4621-1 to remove the 5th gear synchronizer hub. On 4-speeds, remove the large snapring from the intermediate shaft rear ball bearing.
  14.  
  15. Remove the bearing retainer plate by tapping it with a plastic hammer.
  16.  
  17. Take off the 3rd-4th shift fork rail.
  18.  
  19. Remove the reverse idler gear shaft and gear.
  20.  
  21. Remove the input shaft gear assembly and the intermediate shaft gear assembly.
  22.  
  23. To remove the clutch release bearing, remove the E-clips from the clutch release shaft, then disassemble the clutch shaft components.
  24.  
  25. Remove the three input shaft seal retainer bolts, the seal, the retainer assembly and the select shim.
  26.  
  27. Using tools No. C-4171, C-4656 and an arbor press, press the input shaft front bearing cup from the transaxle case.
  28.  
  29. Using tool No. C-4660, remove the two bearing retainer strap bolts, then the intermediate shaft front bearing.
  30.  
  31. Remove the 5th gear shifter pin, the 5th gear detent ball and the spring.
  32.  
  33. Remove the 5th gear synchronizer strut retainer plate snapring and the 5th gear synchronizer strut retainer plate.
  34.  
  35. Remove the 5th gear synchronizer assembly and shift fork with shift rail.
  36.  
  37. Remove the intermediate shaft 5th gear, the input shaft 5th gear snapring and the 5th gear.
  38.  
  39. Remove the bearing support plate bolts and pry off the bearing support plate.
  40.  

To assemble:

The assembly of the transaxle is the reverse of disassembly; however, please note the following:

  1. Using tools No. C-4657, C-4171 and an arbor press, press the front bearing onto the intermediate shaft; the input shaft front bearing cup is installed with the same tools used for removal.
  2.  
  3. Determine the shim thickness for the correct bearing end-play only if any of the following parts are replaced:
  4.  
    1. The transaxle case.
    2.  
    3. The input shaft seal retainer.
    4.  
    5. The bearing retainer plate.
    6.  
    7. The rear end cover.
    8.  
    9. The input shaft or bearings.
    10.  

  5. To determine proper shim thickness, refer to the Input Shaft Bearing End Play Adjustment at the end of this section.
  6.  
  7. Using tool No. C-4674 and a plastic hammer, install the input shaft oil seal.
  8.  
  9. Using a 0.1 in. (3mm) bead of RTV sealant, place it around the edge of the input shaft seal retainer and making sure the drain hole of the retainer is facing downward.
  10.  
  11. The differential bearing retainer is installed with the same special tool used for removal.
  12.  


WARNING
The rear end cover, the selector shaft housing and the differential cover are sealed with RTV sealant.

1986-89 MODELS
  1. With the transaxle removed from the vehicle, remove the eight differential cover bolts and the two stud nuts and remove the cover.
  2.  
  3. Remove the eight differential bearing retainer bolts.
  4.  
  5. Using the L-4435 or equivalent spanner wrench, rotate the differential bearing retainer to remove it.
  6.  
  7. Remove the four extension housing bolts, then remove the differential assembly and extension housing.
  8.  
  9. Remove the six selector shaft housing assembly bolts and remove the selector shaft housing assembly.
  10.  
  11. Remove the ten rear end cover bolts and remove the rear end cover. Clean the bead of RTV sealer off the rear end cover.
  12.  
  13. Using snapring pliers, remove the snapring from the 5th gear synchronizer strut retainer plate.
  14.  
  15. Using an Allen wrench, unscrew and then remove the 5th gear shift fork set screw. Then, lift the 5th gear synchronizer sleeve and shift fork off the synchronizer hub. Retrieve the (3) winged struts and top synchronizer spring.
  16.  
  17. Use a puller such as C-4693 with legs C-4621-1 to remove the 5th gear synchronizer hub. Retrieve the remaining synchronizer spring.
  18.  
  19. Slide the 5th gear off the intermediate shaft. With snapring pliers, remove the copper colored snapring retaining the 5th gear to the input shaft. Then, using a pulley puller such as C-4333, pull the 5th gear off the input shaft.
  20.  
  21. Remove the two remaining bearing support plate bolts. Then, use a screwdriver to gently pry off the bearing support plate.
  22.  
  23. With snapring pliers, remove the large snapring from the intermediate shaft rear ball bearing. Then, gently tap the lower surface of the bearing retainer plate with a plastic hammer to free it and lift it off the transaxle case. Clean the RTV sealer from both surfaces.
  24.  
  25. With a socket wrench, unscrew the 5th gear shifter guide pin. Then, remove it. Do the same with the 1st-2nd shift fork setscrew. Then, slide out the 1-2, 3-4 shift fork rail.
  26.  
  27. Slide out the reverse idler gear shaft, gear, and plastic stop.
  28.  
  29. Rotate the 3-4 shift fork to the left, and the 5th gear shifter to the right. Pull out the 5th gear shift rail. Then, pull out the input shaft assembly. Finally, pull out the intermediate shaft assembly.
  30.  
  31. Now, remove the 1-2, 3-4, and 5th gear shift forks.
  32.  
  33. To remove the clutch release bearing, take off the E-clips from the clutch release shaft, then disassemble the clutch shaft components.
  34.  
  35. Remove the three input shaft seal retainer bolts, the seal, the retainer assembly and the select shim.
  36.  
  37. Using tools No. C-4171, C-4656 and an arbor press, press the input shaft front bearing cup from the transaxle case.
  38.  
  39. Using tool No. C-4660, remove the two bearing retainer strap bolts, then the intermediate shaft front bearing.
  40.  
  41. Remove the 5th gear shifter pin, the 5th gear detent ball and the spring.
  42.  
  43. Remove the 5th gear synchronizer strut retainer plate snapring and the 5th gear synchronizer strut retainer plate.
  44.  
  45. Take off the 5th gear synchronizer assembly and shift fork with shift rail.
  46.  
  47. Remove the intermediate shaft 5th gear, the input shaft 5th gear snapring and the 5th gear.
  48.  
  49. Take off the bearing support plate bolts and pry off the bearing support plate.
  50.  

To assemble:

The assembly of the transaxle is the reverse of disassembly; however, please note the following:

  1. Using tools No. C-4657, C-4171 and an arbor press, press the front bearing onto the intermediate shaft; the input shaft front bearing cup is installed with the same tools used for removal.
  2.  
  3. Determine the shim thickness for the correct bearing end-play only if any of the following parts are replaced:
  4.  
    1. The transaxle case.
    2.  
    3. The input shaft seal retainer.
    4.  
    5. The bearing retainer plate.
    6.  
    7. The rear end cover.
    8.  
    9. The input shaft or bearings.
    10.  

  5. To determine proper shim thickness, refer to the Input Shaft Bearing End Play Adjustment at the end of this section.
  6.  
  7. Using tool No. C-4674 and a plastic hammer, install the input shaft oil seal.
  8.  
  9. Using a 0.12 in. (3mm) bead of RTV sealant, place it around the edge of the input shaft seal retainer and making sure the drain hole of the retainer is facing downward.
  10.  
  11. The differential bearing retainer is installed with the same special tool used for removal.
  12.  


WARNING
The rear end cover, the selector shaft housing and the differential cover are sealed with RTV sealant.

INTERMEDIATE SHAFT

WARNING
The 1st-2nd, the 3rd-4th shift forks and the synchronizer stop rings are interchangeable. However, if parts are to be reused reassemble in the original position.

  1. Remove the intermediate shaft rear bearing snapring.
  2.  
  3. Using the puller tool No. C-4693, remove the intermediate shaft rear bearing.
  4.  
  5. Using snapring pliers, remove the 3rd-4th synchronizer hub snapring.
  6.  
  7. Using the puller tool No. L-4534, remove the 3rd-4th synchronizer hub and the 3rd gear.
  8.  
  9. Extract the retaining ring, the split thrust washer, the 2nd gear and the synchronizer stop ring.
  10.  
  11. Using snapring pliers, remove the 1st-2nd synchronizer hub snapring.
  12.  
  13. Remove the 1st gear, the stop ring and the 1st-2nd synchronizer assembly.
  14.  
  15. Remove the 1st gear thrust washer and the anti-spin pin.
  16.  

To assemble:

The assembly of the intermediate shaft is the Reverse of the disassembly, however please note the following:



When assembling the intermediate shaft, make sure the speed gears turn freely and have a minimum of 0.003 in. (0.08mm) end-play.
 
When installing the 1st gear thrust washer make sure the chamfered edge is facing the pinion gear.
 
When installing the 1st-2nd synchronizer make sure the relief faces the 2nd gear.
 
Use an arbor press to install the intermediate shaft rear bearing, the 3rd-4th synchronizer hub and the 3rd gear.
 

INPUT SHAFT BEARING END PLAY ADJUSTMENT
  1. Using special tool No. L-4656 with handle C-4171, press the input shaft front bearing cup slightly forward in the case. Then, using tool No. L-4655 with handle C-4171, press the bearing cup back into the case, from the front, to the properly position the bearing cup before checking the input shaft end-play.
  2.  


WARNING
This step is not necessary if the special tool No. L-4655 was previously used to install the input shaft front bearing cup in the case and no input shaft select shim has been installed since pressing the cup into the case.

  1. Select a gauging shim which will give 0.001-0.196 in. (0.025-0.50mm) end-play.
  2.  


WARNING
Measure the original shim from the input shaft seal retainer and select a shim 0.25mm thinner than the original for the gauging shim.

  1. Install the gauging shim on the bearing cup and the input shaft seal retainer.
  2.  
  3. Alternately tighten the input shaft seal retainer bolts until the retainer is bottomed against the case, then tighten the bolts to 21 ft. lbs. (28 Nm).
  4.  


WARNING
The input shaft seal retainer is used to draw the input shaft front bearing cup the proper distance into the case bore.

 
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