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G288 Manual Transaxle: Assembly

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Fig 1: Input Shaft Oil Trough
GC0022044Courtesy of DAIMLERCHRYSLER CORP.
1 - OIL TROUGH
  1. Install input shaft oil trough (1) to transaxle housing. See Fig 1.
    Fig 2: Output Shaft Oil Trough
    GC0022045Courtesy of DAIMLERCHRYSLER CORP.
    1 - OIL TROUGH
  2. Install output shaft oil trough (1) to transaxle housing. See Fig 2.
    Fig 3: Output Shaft Bearing Removal/Installation
    GC0022065Courtesy of DAIMLERCHRYSLER CORP.
    1 - INPUT SHAFT BEARING
    2 - OUTPUT SHAFT BEARING
  3. Install output shaft roller bearing to clutch bellhousing (1, 2). See Fig 3.
    Fig 4: Differential Assembly
    GC0022050Courtesy of DAIMLERCHRYSLER CORP.
    1 - DIFFERENTIAL ASSEMBLY
  4. Install differential assembly (1). See Fig 4.
    Fig 5: Heating Reverse Shaft Bearing Bore
    GC0022051Courtesy of DAIMLERCHRYSLER CORP.
    1 - HEAT GUN
    2 - BEARING BORE
  5. Using heat gun (1), heat reverse shaft bearing bore (2) in transaxle case to expand for reverse shaft/bearing installation. See Fig 5.
    Fig 6: Reverse Shaft and Fork Assembly
    GC0022052Courtesy of DAIMLERCHRYSLER CORP.
    1 - FORK/ROD ASSY.
    2 - REVERSE SHAFT ASSY.
  6. Install reverse shaft (2) and fork/rod (1). See Fig 6.
    Fig 7: Install Geartrain to Clutch Bellhousing
    GC0022053Courtesy of DAIMLERCHRYSLER CORP.
    1 - GEARTRAIN
    2 - REVERSE SHAFT ASSY.
  7. Install geartrain (1) (with forks/rods) into case. See Fig 7.
    Fig 8: Properly Installed Geartrain
    GC0022054Courtesy of DAIMLERCHRYSLER CORP.
    1 - INTERMEDIATE SHAFT
    2 - INPUT SHAFT
  8. Verify proper installation of input (2) and output shaft (1) assemblies, as well as proper orientation of shift rod/fork assemblies. See Fig 8.
    Fig 9: Install Geartrain Housing
    GC0022055Courtesy of DAIMLERCHRYSLER CORP.
    1 - TRANSAXLE HOUSING
    2 - CLUTCH BELLHOUSING
    3 - SEALER BEAD
  9. Install chip collector magnet to case and retain with grease.
  10. Apply a bead (3) of Mopar® Gasket Maker or Omnifit FD-40 to clutch bellhousing flange (2). Install geartrain housing (1). See Fig 9.
    Fig 10: Geartrain Housing-to-Clutch Bellhousing Bolts (Short)
    GC0022040Courtesy of DAIMLERCHRYSLER CORP.
    1 - BOLTS (18-SHORT)
  11. Install transaxle housing-to-clutch bellhousing short bolts (1) by hand. See Fig 10.
    Fig 11: Geartrain Housing-to-Clutch Bellhousing Bolts (Long)
    GC0022041Courtesy of DAIMLERCHRYSLER CORP.
    1 - BOLTS (2-LONG)
  12. Install transaxle housing-to-clutch bellhousing long bolts (1) by hand. See Fig 11.
    Fig 12: Torquing Transaxle Housing to Clutch Bellhousing Bolts
    GC0022056Courtesy of DAIMLERCHRYSLER CORP.
    1 - TORQUE WRENCH
  13. Torque (1) twenty (18 short, 2 long) geartrain housing-to-clutch bellhousing bolts to 28 N.m (21 ft. lbs.) torque. See Fig 12.
    Fig 13: Install Input Shaft Roller Bearing
    GC0022057Courtesy of DAIMLERCHRYSLER CORP.
    1 - HANDLE C-4171
    2 - INSTALLER 8871
    3 - SNAP RING
    4 - BEARING
  14. Using an arbor press and Handle C-4171 (1) and Installer 8871(2), install input shaft roller bearing (4). See Fig 13.
    Fig 14: Install Output Shaft Bearing
    GC0022058Courtesy of DAIMLERCHRYSLER CORP.
    1 - HANDLE C-4171
    2 - INSTALLER 8871
    3 - BEARING
  15. Using an arbor press and Handle C-4171 (1) and Installer 8871(2), install output shaft roller bearing (3). See Fig 14.
    Fig 15: Engage Fifth Gear
    GC0022037Courtesy of DAIMLERCHRYSLER CORP.
    1 - FIFTH GEAR FORK
    2 - SCREWDRIVER
  16. Engage fifth gear (1). See Fig 15.
    Fig 16: Engage Reverse Gear
    GC0022038Courtesy of DAIMLERCHRYSLER CORP.
    1 - REVERSE GEAR FORK
    2 - SCREWDRIVER
  17. Engage reverse gear (1). See Fig 16.
    Fig 17: Bearing Retaining Screws
    GC0022039Courtesy of DAIMLERCHRYSLER CORP.
    1 - RETAINING SCREWS (2)
  18. Install new  bearing retaining screws (1) and torque to 90-100 N.m (66-74 ft. lbs.). See Fig 17.
    Fig 18: Input Shaft Oil Diverter
    GC0022035Courtesy of DAIMLERCHRYSLER CORP.
    1 - DIVERTER
    2 - LOCATING PROVISIONS
  19. Install input shaft oil diverter (1). See Fig 18.
    Fig 19: Output Shaft Oil Diverter
    GC0022036Courtesy of DAIMLERCHRYSLER CORP.
    1 - DIVERTER
    2 - LOCATOR PROVISIONS
  20. Install output shaft oil diverter (1). See Fig 19.
    Fig 20: Proper Sealer Application
    GC0022059Courtesy of DAIMLERCHRYSLER CORP.
    1 - OIL DIVERTERS
    2 - SEALER BEAD
  21. Install a bead (2) of Mopar® Gear Sealant RTV to geartrain housing. See Fig 20.
    Fig 21: Apply Sealer to Cover
    GC0022060Courtesy of DAIMLERCHRYSLER CORP.
    1 - SEALER BEAD
    2 - END COVER
  22. Install a bead (1) of Mopar® Gear Sealant RTV to end cover. See Fig 21.
    Fig 22: End Cover-to-Case Bolts
    GC0022033Courtesy of DAIMLERCHRYSLER CORP.
    1 - END COVER
    2 - BOLT (9)
  23. Immediately install end cover (1) to geartrain housing. Install and torque nine (9) bolts (2) to 20-25 N.m (15-18 ft. lbs.). See Fig 22.
    Fig 23: Apply Sealer to Shift Shaft Mounting Location
    GC0022061Courtesy of DAIMLERCHRYSLER CORP.
    1 - SEALER BEAD
  24. Install bead (1) of Mopar® Gasket Maker or Omnifit FD-1664 to shift shaft assembly mounting pad. See Fig 23.
    Fig 24: Shift Shaft-to-Case Bolts
    GC0022031Courtesy of DAIMLERCHRYSLER CORP.
    1 - BOLT (4)
    NOTE: When installing shift shaft assembly, do not handle assembly by counterweight.
  25. Install shift shaft assembly. Use caution when installing. It is necessary to guide slot in shaft assembly over locating pin which is pressed into case.
  26. Install crossover lever assembly and four bolts (1). See Fig 24. Torque Shift Mechanism-to-Case bolts to 20-25 N.m (15-18 ft. lbs.).
    Fig 25: Identifying Plug, Spring And Pin
    GC0022029Courtesy of DAIMLERCHRYSLER CORP.
    1 - PLUG
    2 - SPRING
    3 - PIN
  27. Install shift shaft crossover detent pin (1), spring (2), and plug (3). See Fig 25. Torque plug to 20 N.m (15 ft. lbs.).
    Fig 26: Shift Shaft Detent Assembly
    GC0022030Courtesy of DAIMLERCHRYSLER CORP.
    1 - DETENT ASSEMBLY
  28. Install shift shaft selector detent assembly (1) with Mopar® Lock 'n Seal™. See Fig 26. Torque detent assembly 20-25 N.m (15-18 ft. lbs.).
    Fig 27: Backup Lamp Switch
    GC0022047Courtesy of DAIMLERCHRYSLER CORP.
    1 - BACKUP LAMP SWITCH
  29. Install back-up lamp switch (1). See Fig 27. Torque switch to 24 N.m (18 ft. lbs.).
    Fig 28: Seat with Soft-Tipped Hammer
    GC0022062Courtesy of DAIMLERCHRYSLER CORP.
    1 - DETENT PLUGS
    2 - SOFT-TIPPED HAMMER
  30. Install four shift rod detent plugs (1). Install new plugs as necessary.  Tap into place using a soft-tipped hammer (2). See Fig 28.
    Fig 29: Input Shaft Seal Installation
    GC0022064Courtesy of DAIMLERCHRYSLER CORP.
    1 - INSTALLER 8864
    2 - SEAL, INPUT SHAFT
  31. Install input shaft seal (2) using Installer 8864 (1). See Fig 29.
    Fig 30: Axle Seal Installation
    GC0022063Courtesy of DAIMLERCHRYSLER CORP.
    1 - INSTALLER 8916
  32. Install output (axle) shaft seals using Installer 8916 (1). See Fig 30.
    Fig 31: Concentric Slave Cylinder (CSC) Removal/Installation
    GC0022048Courtesy of DAIMLERCHRYSLER CORP.
    1 - CONCENTRIC SLAVE CYLINDER (CSC)
  33. Install concentric slave cylinder (1). See Fig 31. Torque bolts in three passes to specified torque. (Refer to TRANSMISSION/TRANSAXLE/MANUAL - SPECIFICATIONS) 
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