Output Shaft - Chrysler neon 1997 Service Manual

1ST GEAR STOP RING SLEEVE REVERSE GEAR
PL
DISASSEMBLY AND ASSEMBLY (Continued)

OUTPUT SHAFT

CAUTION: The output shaft is serviced as an
assembly. Do not try to repair any component on
the output shaft. If the 1-2 synchronizer or gear
fails, it is necessary to replace the output shaft
assembly.
It is necessary to check the synchronizer stop ring
gap. Use a feeler gauge to measure the gaps between
the stop rings and the speed gears. The correct gaps
are listed below:
• 1st—1.04-1.72 mm (0.041-0.069 in).
• 2nd—0.94-1.72 mm (0.038-0.069 in).
• 3rd—1.37-1.93 mm (0.054-0.076 in).
• 4th—1.41-1.97 mm (0.056-0.078 in).
• 5th—1.37-1.93 mm (0.054-0.076 in).
If a stop ring gap does not fall within the specifi-
cations it must be inspected for wear and replaced. If
the 1st or 2nd synchronizer stop ring is worn beyond
specifications, the complete output shaft assembly
must be replaced.
The output shaft incorporates the 1st and 2nd
gears and synchronizers on the assembly (Fig. 97).
Fig. 97 Output Shaft
DIFFERENTIAL
Shim thickness need be determined only if any of
the following parts are replaced:
• Transaxle gear case
• Clutch bellhousing case
• Differential case
• Differential bearings
Refer to Bearing Adjustment Procedure in the
Adjustments section at the end of this section to
determine proper shim thickness. This will provide
correct bearing preload and proper bearing turning
torque.
STOP RING 2ND SPEED GEAR OUTPUT SHAFT
SPEED SENSOR DRIVE TOOL C-293-45 SPECIAL TOOL C-293-PA SPECIAL TOOLC-4171 SPECIAL GEAR
DIFFERENTIAL BEARINGS
Fig. 98 Remove Differential Bearing Cone
Fig. 99 Install Differential Bearing Cone
DIFFERENTIAL TOOL L-4410 SPECIAL BEARING CONE ASSEMBLY TOOLC-4996 SPECIAL
TRANSAXLE 21 - 25