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Section 36 (C510 Manual Transmission (Service Information) 500 - 1.4L Turbo): Disassembly: Disassembly

WARNING: This page is about a different variant/trim than selected.
  1. Place the transaxle on a bench.
    Fig 1: Concentric Slave Cylinder (CSC) Boot
    GC0153663Courtesy of CHRYSLER GROUP, LLC
  2. Remove the Concentric Slave Cylinder (CSC) boot from the bell housing.
    Fig 2: CSC Retention Tabs
    GC0153664Courtesy of CHRYSLER GROUP, LLC
  3. Release the retention tabs from the CSC (1).
    Fig 3: CSC Bolts
    GC0153665Courtesy of CHRYSLER GROUP, LLC
  4. Remove the CSC bolts (1).
    Fig 4: Remove/Install CSC
    GC0153666Courtesy of CHRYSLER GROUP, LLC
  5. Remove the CSC from the case.
    Fig 5: Input Shaft Seal
    G00554087Courtesy of CHRYSLER GROUP, LLC
  6. Using a suitable tool, remove the input shaft seal (1).
    Fig 6: Shift Linkage Jam Nut
    GC0153667Courtesy of CHRYSLER GROUP, LLC
  7. Remove the shift linkage jam nut and discard  , remove the shaft.
    Fig 7: Shift Cable Retention Bracket Bolts
    GC0153668Courtesy of CHRYSLER GROUP, LLC
  8. Remove the shift cable retention bracket bolts and remove the bracket.
    Fig 8: Rear Cover Bolts
    GC0153669Courtesy of CHRYSLER GROUP, LLC
  9. Remove the six rear cover bolts (1).
    Fig 9: Remove/Install Rear Cover Case
    GC0153670Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Use a heat gun or the equivalent to soften the gasket material prior to removal.

  10. Carefully remove the rear cover.
    Fig 10: Gear Shaft Locking Nuts
    GC0153671Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Engage two gears, locking the transmission, prior to removing the shaft nuts.

  11. Remove the staking on both gear shaft locking nuts (1).
  12. Remove the nuts and discard.
    Fig 11: Fifth Gear Fork Retaining Bolt
    GC0153672Courtesy of CHRYSLER GROUP, LLC
  13. Remove the fifth gear fork retaining bolt (1).
    Fig 12: Fifth Gear Shift Fork And Synchronizer Hub Assembly & Fifth Gear
    GC0153673Courtesy of CHRYSLER GROUP, LLC
  14. Remove the fifth gear shift fork and synchronizer hub assembly (1).
  15. Remove the fifth gear (2).
    Fig 13: Separating Fifth Gear Shift Fork From Synchronizer Sleeve
    GC0153734Courtesy of CHRYSLER GROUP, LLC
  16. Separate the fifth gear shift fork (2) from the synchronizer sleeve (1).
    Fig 14: Rear Bearing Retainer Plate Bolt
    G00554085Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Late build rear bearing retainer plate.

  17. Remove the six rear bearing retainer plate bolts (1).
    Fig 15: Rear Bearing Retainer Plate Bolt
    GC0153674Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Early build rear bearing retainer plate.

  18. Remove the one rear bearing retainer plate bolt (1).
    Fig 16: Remove/Install Rear Bearing Retainer Plate
    GC0153675Courtesy of CHRYSLER GROUP, LLC
  19. Remove the rear bearing retainer plate.
    Fig 17: Identifying Shaft Bearing Retainer Clips
    GC0157716Courtesy of CHRYSLER GROUP, LLC
  20. Remove the both shaft bearing retainer clips (1).
    Fig 18: Reverse Idler Gear Bolt, Reverse Light Switch & Shift Shaft Detents
    GC0153676Courtesy of CHRYSLER GROUP, LLC
  21. Remove the reverse idler gear bolt (1).
  22. Remove the reverse light switch (2).
  23. If equipped, remove the shift shaft detents (3).
    Fig 19: Shift Linkage Bolts & Bracket
    GC0153677Courtesy of CHRYSLER GROUP, LLC
  24. Remove the shift linkage bolts (1) and bracket (2).
    Fig 20: Differential Seal Plate Bolts
    GC0153678Courtesy of CHRYSLER GROUP, LLC
  25. Remove the differential seal plate bolts (1), remove the plate.
    Fig 21: Remove/Install Shim
    GC0153679Courtesy of CHRYSLER GROUP, LLC
  26. Remove and retain the shim as it will be re-used during the assembly process.
    Fig 22: Case Bolts
    GC0153680Courtesy of CHRYSLER GROUP, LLC
  27. Remove 13 case bolts (1).
    Fig 23: Case Bolts Size Variance
    GC0153681Courtesy of CHRYSLER GROUP, LLC
  28. Note that the bolt sizes differ in these locations.
    Fig 24: Bell Housing Area Bolts
    GC0153682Courtesy of CHRYSLER GROUP, LLC
  29. Remove the final 4 bolts from the bell housing area and split the case halves.
    Fig 25: Gear Control Selector Lever Pinch Bolt
    GC0153726Courtesy of CHRYSLER GROUP, LLC
  30. Remove the gear control selector lever pinch bolt (1).
    Fig 26: Lever & Roll Pin
    GC0153727Courtesy of CHRYSLER GROUP, LLC
  31. Remove the roll pin (2) using a suitable punch.
  32. Remove the lever (1) using a screwdriver or the equivalent to disengage the splines.
    Fig 27: Gear Control Shaft Flange Bolts
    GC0153728Courtesy of CHRYSLER GROUP, LLC
  33. Remove the gear control shaft flange bolts and remove the shaft assembly.
    Fig 28: Second Spring And Protector Assembly
    GC0153729Courtesy of CHRYSLER GROUP, LLC
  34. Remove the second spring and protector as an assembly.
    Fig 29: Reverse Fork Assembly & Bolts
    GC0153683Courtesy of CHRYSLER GROUP, LLC
  35. Remove the reverse fork assembly bolts and remove the assembly.
    Fig 30: Shifter Fork Bolts
    GC0153684Courtesy of CHRYSLER GROUP, LLC
  36. Remove the shifter fork bolts (1 and 2).
    Fig 31: Engagement Pawls
    GC0153725Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Note their positions and do not lose them or attempt to reassemble the transaxle without them.

  37. The shifter fork rods are held in position with a series of engagement pawls (1, 2 and 3).
    Fig 32: 1st - 2nd Speed Rod And Fork, 3rd - 4th Speed Rod & 5th Speed Rod
    GC0153685Courtesy of CHRYSLER GROUP, LLC
  38. When removing the 1st - 2nd speed rod and fork (1). Vertical adjustment to the position of the 3rd - 4th speed rod (2) as well as the 5th speed rod (3) may be necessary.
    Fig 33: Remove/Install 1st - 2nd Speed Rod & Fork
    GC0153686Courtesy of CHRYSLER GROUP, LLC
  39. When removing the 1st - 2nd speed rod (1) and fork (2) simultaneously.
    Fig 34: 3rd - 4th Speed Rod & Fork
    GC0153687Courtesy of CHRYSLER GROUP, LLC
  40. Remove the 3rd - 4th speed rod (1), the fork (2) will stay in place.
    Fig 35: 5th Speed Rod & 3rd - 4th Speed Shift Fork
    GC0153688Courtesy of CHRYSLER GROUP, LLC
  41. Remove the 5th speed rod along with the 3rd - 4th speed shift fork.
  42. Remove the engagement pawls from the transmission case.
    Fig 36: Input & Output Shafts
    GC0153689Courtesy of CHRYSLER GROUP, LLC
  43. Remove the input and output shafts together.
    Fig 37: Reverse Idler Gear Assembly
    GC0153690Courtesy of CHRYSLER GROUP, LLC
  44. Remove the reverse idler gear assembly (1).
    Fig 38: Remove/Install Differential
    GC0153691Courtesy of CHRYSLER GROUP, LLC
  45. Remove the differential.
    Fig 39: Magnet
    GC0153692Courtesy of CHRYSLER GROUP, LLC
  46. Remove the magnet.
    Fig 40: Bell Housing Side Output Shaft Roller Bearing
    GC0153693Courtesy of CHRYSLER GROUP, LLC
  47. Remove the bell housing side output shaft roller bearing.
    Fig 41: Removing Differential Bearing Race
    GC0153694Courtesy of CHRYSLER GROUP, LLC
  48. Remove the differential bearing race using (special tool #C-637, Slide Hammer, Universal) and (special tool #9664, Remover, Bearing Cup).
  49. Remove the axle seals. Refer to SEAL, AXLE DRIVE SHAFT, REMOVAL  .
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