Output Shaft - Chrysler Stratus RHD 1999 Electronic Service Manual

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DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 103 Caged Needle Bearing Installation
(11) Using special tool #C-3717, install 5th speed
gear and synchronizer (Fig. 104). The 5th gear syn-
chronizer hub has the letter S stamped on the top
face of the hub. This designates that the hub must be
installed with the S facing upward.
Fig. 104 5th Speed Gear Installation
(12) Install 5th gear synchronizer snap ring (Fig.
105).

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).
Fig. 105 5th Gear Synchronizer Snap Ring
Installation
• 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. 106).
Fig. 106 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.
TRANSAXLE 21 - 25