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Section 69 (C510 Manual Transmission (Service Information) 500 - 1.4L Turbo): Assembly: Assembly

WARNING: This page is about a different car, the 2015 Fiat 500. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Installing Differential Bearing Races With Special Tools
GC0153717Courtesy of CHRYSLER GROUP, LLC
  1. Install the left and right differential bearing races using (special tool #D-145, Installer, Bearing Cup) and (special tool #C-4171, Driver Handle, Universal).
    Fig 2: Bell Housing Side Output Shaft Roller Bearing
    GC0153693Courtesy of CHRYSLER GROUP, LLC
  2. Install the bell housing side output shaft roller bearing.
    Fig 3: Magnet
    GC0153692Courtesy of CHRYSLER GROUP, LLC
  3. Install the magnet.
    Fig 4: Remove/Install Differential
    GC0153691Courtesy of CHRYSLER GROUP, LLC
  4. Install the differential.
    NOTE:

    The pins and slots must be correctly oriented.

    Fig 5: Reverse Idler Shaft Locating Pin & Slots
    GC0153718Courtesy of CHRYSLER GROUP, LLC
  5. The reverse idler shaft locating pin (1) rests in the slot (2). The locating slot (3) aligns with a raised feature in the transmission case
    Fig 6: Reverse Idler Gear Assembly
    GC0153690Courtesy of CHRYSLER GROUP, LLC
  6. Install the reverse idler gear assembly (1).
    Fig 7: Input & Output Shafts
    GC0153689Courtesy of CHRYSLER GROUP, LLC
  7. Install the input and output shafts together.
    Fig 8: 5th Speed Rod & 3rd - 4th Speed Shift Fork
    GC0153688Courtesy of CHRYSLER GROUP, LLC
  8. Install the 5th speed rod along with the 3rd - 4th speed shift fork.
  9. Install the engagement pawls to the transmission case.
    Fig 9: 3rd - 4th Speed Rod & Fork
    GC0153687Courtesy of CHRYSLER GROUP, LLC
  10. Install the 3rd - 4th speed rod (1), the fork (2) will stay in place.
    Fig 10: Remove/Install 1st - 2nd Speed Rod & Fork
    GC0153686Courtesy of CHRYSLER GROUP, LLC
  11. When removing the 1st - 2nd speed rod (1) and fork (2) simultaneously.
    NOTE:

    The shifter fork rods are held in position with a series of engagement pawls. Note their positions and do not lose them or attempt to reassemble the transaxle without them.

    Fig 11: 1st - 2nd Speed Rod And Fork, 3rd - 4th Speed Rod & 5th Speed Rod
    GC0153685Courtesy of CHRYSLER GROUP, LLC
  12. When installing 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 12: Shifter Fork Bolts
    GC0153684Courtesy of CHRYSLER GROUP, LLC
  13. Install the shifter fork bolts (1 and 2), tighten to 17 N.m (13 lb ft.).
    Fig 13: Reverse Fork Assembly & Bolts
    GC0153683Courtesy of CHRYSLER GROUP, LLC
  14. Position the reverse fork assembly (2) and install the bolts (1). Tighten to 10 N.m (89 lb in.).
    Fig 14: Second Spring And Protector Assembly
    GC0153729Courtesy of CHRYSLER GROUP, LLC
  15. Install the second spring and protector as an assembly.
    Fig 15: Lever & Roll Pin
    GC0153727Courtesy of CHRYSLER GROUP, LLC
  16. Install the lever (1) using a screwdriver or the equivalent to engage the splines.
  17. Install the new  roll pin (2) using a suitable punch.
    Fig 16: Gear Control Selector Lever Pinch Bolt
    GC0153726Courtesy of CHRYSLER GROUP, LLC
  18. Install the gear control selector lever pinch bolt (1). Tighten to 16 N.m (12 lb ft.).
    Fig 17: Gear Control Shaft Flange Bolts
    GC0153728Courtesy of CHRYSLER GROUP, LLC
  19. Install the gear control shaft assembly and the shaft flange bolts.
    Fig 18: Bell Housing Area Bolts
    GC0153682Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The case halves must be assembled within 15 minutes after the application of the anaerobic sealant. Do not allow transmission oil or any other lubricants to come in contact with the sealant for at least one hour after the case halves have been assembled.

  20. Apply a uniform bead of Mopar / Fiat Case Sealer or the equivalent to the sealing surface of the case
  21. Assemble the case halves.
  22. Install the 4 bolts to the bell housing area and hand tighten.
    Fig 19: Case Bolts Size Variance
    GC0153681Courtesy of CHRYSLER GROUP, LLC
  23. Note that the bolt sizes differ in these locations.
    Fig 20: Case Bolts
    GC0153680Courtesy of CHRYSLER GROUP, LLC
  24. Install the 13 case bolts (1) and tighten all the bolts to 25 N.m (18 lb ft.).
    Fig 21: Shift Linkage Bolts & Bracket
    GC0153677Courtesy of CHRYSLER GROUP, LLC
  25. Install the shift linkage bolts (1) and bracket (2) tighten all the bolts to 25 N.m (18 lb ft.).
    Fig 22: Remove/Install Shim
    GC0153679Courtesy of CHRYSLER GROUP, LLC
  26. Install and retain the shim as it will be re-used during the assembly process.
    Fig 23: Differential Seal Plate Bolts
    GC0153678Courtesy of CHRYSLER GROUP, LLC
  27. Install the differential seal plate bolts (1) and plate (2) shim.
    Fig 24: Reverse Idler Gear Bolt, Reverse Light Switch & Shift Shaft Detents
    GC0153676Courtesy of CHRYSLER GROUP, LLC
  28. Install the reverse idler gear bolt (1).
  29. Install the reverse light switch (2).
  30. If equipped, install the detents (3).
    Fig 25: Identifying Shaft Bearing Retainer Clips
    GC0157716Courtesy of CHRYSLER GROUP, LLC
  31. Install both shaft bearing retaining clips (1).
    Fig 26: Remove/Install Rear Bearing Retainer Plate
    GC0153675Courtesy of CHRYSLER GROUP, LLC
  32. Install the rear bearing retainer plate.
    Fig 27: Rear Bearing Retainer Plate Bolt
    GC0153674Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Early build rear bearing retainer plate.

  33. Install the one rear bearing retainer plate bolt (1) and tighten to the proper Specification. Refer to SPECIFICATIONS .
    Fig 28: Bearing Retainer Bolts
    G00554085Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Late build rear bearing retainer plate.

  34. Install the six rear bearing retainer bolts (1) and tighten to the proper specification. Refer to SPECIFICATIONS .
    Fig 29: Installing Sleeve To Fork
    GC0153735Courtesy of CHRYSLER GROUP, LLC
  35. Place the sleeve in a bench vice featuring protective plates.
  36. Position the fork (2) so that the tapered part is in the same direction as that of the sleeve (1).
    NOTE:

    Hand pressure only. Do not use any impact type tools to aid in the installation of the sleeve to the fork.

    Fig 30: Manually Seating Fork Onto Sleeve
    GC0153736Courtesy of CHRYSLER GROUP, LLC
  37. Manually apply pressure on the fork until it is fully seated with the sleeve.
    Fig 31: Fifth Gear Shift Fork And Synchronizer Hub Assembly & Fifth Gear
    GC0153673Courtesy of CHRYSLER GROUP, LLC
  38. Install the fifth gear shift fork and synchronizer hub assembly (1).
  39. Install the fifth gear (2).
    Fig 32: Fifth Gear Fork Retaining Bolt
    GC0153672Courtesy of CHRYSLER GROUP, LLC
  40. Install the fifth gear fork retaining bolt (1).
    Fig 33: Gear Shaft Locking Nuts
    GC0153671Courtesy of CHRYSLER GROUP, LLC
    NOTE:

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

  41. Install the staking on both gear shaft locking nuts (1).
  42. Install the nuts to the transmission assembly and discard.
    Fig 34: Remove/Install Rear Cover Case
    GC0153670Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The case halves must be assembled within 15 minutes after the application of the anaerobic sealant. Do not allow transmission oil or any other lubricants to come in contact with the sealant for at least one hour after the case halves have been assembled.

  43. Apply a uniform bead of Mopar / Fiat Case Sealer or the equivalent to the sealing surface of the case
  44. Carefully Install the rear cover.
    Fig 35: Rear Cover Bolts
    GC0153669Courtesy of CHRYSLER GROUP, LLC
  45. Install the six rear cover bolts (1) and tighten to 25 N.m (18 lb ft.).
    Fig 36: Shift Cable Retention Bracket Bolts
    GC0153668Courtesy of CHRYSLER GROUP, LLC
  46. Install the shift cable retention bracket bolts and Install the bracket.
    Fig 37: Shift Linkage Jam Nut
    GC0153667Courtesy of CHRYSLER GROUP, LLC
  47. Install the new  shift linkage jam nut and tighten to specification.
    Fig 38: Input Shaft Seal
    G00554086Courtesy of CHRYSLER GROUP, LLC
  48. Apply a 1/4 inch wide bead of the specified sealant on the NEW input shaft seal (1) and install it on the transmission.
    49. Fig 39: Remove/Install CSC
    GC0153666Courtesy of CHRYSLER GROUP, LLC
  49. Install the Concentric Slave Cylinder (CSC) to the case.
    Fig 40: CSC Bolts
    GC0153665Courtesy of CHRYSLER GROUP, LLC
  50. Install the CSC bolts (1) and tighten to the proper specification. Refer to SPECIFICATIONS .
    Fig 41: CSC Retention Tabs
    GC0153664Courtesy of CHRYSLER GROUP, LLC
  51. Release the retention tabs to the CSC (1).
    Fig 42: Concentric Slave Cylinder (CSC) Boot
    GC0153663Courtesy of CHRYSLER GROUP, LLC
  52. Install the (CSC) boot to the bell housing.
  53. Install the axle seals. Refer to SEAL, AXLE DRIVE SHAFT, INSTALLATION  .
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