Dodge Intrepid Service Manual page 579

21 - 32 TRANSAXLE
42LE AUTOMATIC TRANSAXLE (Continued)
(12) Install rear carrier front bearing cone (Fig.
91).
Fig. 91 Install Rear Carrier Front Bearing Cone
1 - ARBOR PRESS
2 - SPECIAL TOOL C-4171
3 - SPECIAL TOOL 6052
4 - REAR CARRIER
(13) Check output bearing preload. Output bear-
ing preload must be checked and/or adjusted if
any of the following items have been replaced:
• Output shaft (rear carrier assembly)
• Output shaft bearings
• Transaxle case
(a) PRELOAD CHECK/SHIM SELECTION:
Install rear output shaft bearing cone and special
tool 6618A (Fig. 92).
(b) Install special tool 6618A (Fig. 93). Lightly
tighten retaining screws. Screws should be below
the plate surface, but do not snug screws.
(c) Turn case over on arbor press so that the
plate is resting on the press base. CAUTION: The
output shaft will extend through the hole of
tool 6618A. Ensure your press table has clear-
ance for the output shaft.
(d) Install shim on output shaft (Fig. 94). Apply
small amount of petrolatum onto the shim to hold
it in place. Use the original shim as a starting
point. If original shim is not available, use the
thickest shim available. Refer to Output Shaft
Rear Shim Chart for available sizes.
(e) Install output shaft/rear carrier into rear
bearing. The shaft must be pressed into position.
Use special tool MD-998911 (Disc) and C- 4171 and
C4171-2 (Handle) to press shaft into rear bearing
(Fig. 95).
(f) Do not re-use old transfer shaft nut or
output shaft nut because the removed stake
weakens the nut flange. Using special tools 6497
and 6498, install new output shaft nut. Do not
reuse old output shaft nut. Tighten new output
shaft nut to 271 N·m (200 ft. lbs.).
(g) Check the turning torque of the output shaft
(Fig. 96). The shaft should have 1 to 8 in. lbs. of
turning torque. If the turning torque is higher
than 8 in. lbs., install a thicker shim. If turning
torque is less than 1 in. lb., install a thinner shim.
Make sure there is no end play.
(h) The new nut must be staked after the correct
turning torque is obtained (Fig. 97) (Fig. 98). Use
special tool 6639 to stake output shaft nut and spe-
cial tool 6589 to stake transfer shaft. CAUTION:
Failure to stake shaft nuts could allow the
nuts to back-off during use.
Fig. 92 Bearing Installation
1 - SPECIAL TOOL 6618–A
2 - REAR OUTPUT SHAFT BEARING
LH