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Section 61 (C510 Manual Transmission (Service Information) - 500): Disassembly

WARNING: This page is about a different variant/trim than selected.
  1. Place the transaxle on a bench.
    GC0153663Courtesy of CHRYSLER GROUP, LLC
  2. Remove the Concentric Slave Cylinder (CSC) boot from the bell housing.
    GC0153664Courtesy of CHRYSLER GROUP, LLC
  3. Release the retention tabs from the CSC (1).
    GC0153665Courtesy of CHRYSLER GROUP, LLC
  4. Remove the CSC bolts (1).
    GC0153666Courtesy of CHRYSLER GROUP, LLC
  5. Remove the CSC from the case.
    GC0177160Courtesy of CHRYSLER GROUP, LLC
  6. Using a suitable tool, remove the input shaft seal (1).
    GC0153667Courtesy of CHRYSLER GROUP, LLC
  7. Remove the shift linkage jam nut and discard  , remove the shaft.
    GC0153668Courtesy of CHRYSLER GROUP, LLC
  8. Remove the shift cable retention bracket bolts and remove the bracket.
    GC0153669Courtesy of CHRYSLER GROUP, LLC
  9. Remove the six rear cover bolts (1).
    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.
    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.
    GC0153672Courtesy of CHRYSLER GROUP, LLC
  13. Remove the fifth gear fork retaining bolt (1).
    GC0153673Courtesy of CHRYSLER GROUP, LLC
  14. Remove the fifth gear shift fork and synchronizer hub assembly (1).
  15. Remove the fifth gear (2).
    GC0153734Courtesy of CHRYSLER GROUP, LLC
  16. Separate the fifth gear shift fork (2) from the synchronizer sleeve (1).
    GC0177166Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Late build rear bearing retainer plate.

  17. Remove the six rear bearing retainer plate bolts (1).
    GC0153674Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Early build rear bearing retainer plate.

  18. Remove the one rear bearing retainer plate bolt (1).
    GC0153675Courtesy of CHRYSLER GROUP, LLC
  19. Remove the rear bearing retainer plate.
    GC0157716Courtesy of CHRYSLER GROUP, LLC
  20. Remove the both shaft bearing retainer clips (1).
    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).
    GC0153677Courtesy of CHRYSLER GROUP, LLC
  24. Remove the shift linkage bolts (1) and bracket (2).
    GC0153678Courtesy of CHRYSLER GROUP, LLC
  25. Remove the differential seal plate bolts (1), remove the plate.
    GC0153679Courtesy of CHRYSLER GROUP, LLC
  26. Remove and retain the shim as it will be re-used during the assembly process.
    GC0153680Courtesy of CHRYSLER GROUP, LLC
  27. Remove 13 case bolts (1).
    GC0153681Courtesy of CHRYSLER GROUP, LLC
  28. Note that the bolt sizes differ in these locations.
    GC0153682Courtesy of CHRYSLER GROUP, LLC
  29. Remove the final 4 bolts from the bell housing area and split the case halves.
    GC0153726Courtesy of CHRYSLER GROUP, LLC
  30. Remove the gear control selector lever pinch bolt (1).
    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.
    GC0153728Courtesy of CHRYSLER GROUP, LLC
  33. Remove the gear control shaft flange bolts and remove the shaft assembly.
    GC0153729Courtesy of CHRYSLER GROUP, LLC
  34. Remove the second spring and protector as an assembly.
    GC0153683Courtesy of CHRYSLER GROUP, LLC
  35. Remove the reverse fork assembly bolts and remove the assembly.
    GC0153684Courtesy of CHRYSLER GROUP, LLC
  36. Remove the shifter fork bolts (1 and 2).
    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).
    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.
    GC0153686Courtesy of CHRYSLER GROUP, LLC
  39. When removing the 1st - 2nd speed rod (1) and fork (2) simultaneously.
    GC0153687Courtesy of CHRYSLER GROUP, LLC
  40. Remove the 3rd - 4th speed rod (1), the fork (2) will stay in place.
    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.
    GC0153689Courtesy of CHRYSLER GROUP, LLC
  43. Remove the input and output shafts together.
    GC0153690Courtesy of CHRYSLER GROUP, LLC
  44. Remove the reverse idler gear assembly (1).
    GC0153691Courtesy of CHRYSLER GROUP, LLC
  45. Remove the differential.
    GC0153692Courtesy of CHRYSLER GROUP, LLC
  46. Remove the magnet.
    GC0153693Courtesy of CHRYSLER GROUP, LLC
  47. Remove the bell housing side output shaft roller bearing.
    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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