Shift Rails Overhaul; Transaxle; Transaxle Case Overhaul - Chrysler Stratus RHD 1999 Electronic Service Manual

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DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 128 Synchronizer Sleeve
Fig. 129 Keys in Hub

SHIFT RAILS OVERHAUL

(1) Remove shift rails from the geartrain.
(2) To service the 5-R shift rail, remove the C-clip
retaining the reverse shift lever arm. Remove the 5th
shift fork roll pin and remove the 5th shift fork.
Remove the shift lug roll pin and remove the shift
lug. Replace parts as necessary.
(3) To service the 3-4 shift rail, remove the roll pin
retaining the 3-4 shift fork. Remove the shift fork.
Remove the shift lug roll pin and remove the shift
lug. Replace parts as necessary.
(4) To service the 1-2 shift rail, remove the roll pin
retaining the 1-2 shift fork. Remove the shift fork
and replace parts as necessary.

TRANSAXLE CASE OVERHAUL

The sealant used to seal the transaxle case halves
is Mopar Gasket Maker, Loctite 518, or equivalent.
The sealant used for the bearing end–plate cover is
Mopar RTV.
The components that are left in the gear cases
when the gear train is pulled out are the:
• Axle shaft seals
• Output bearing race and retainer
• Input bearing and sleeve
• Differential bearing cones
• Shift rail bushings
• Shift shafts
• Shift shaft seals
• Shift shaft bushings
• Rear bearing oil feed trough
AXLE SHAFT SEALS
REMOVAL
(1) Insert a flat–blade pry tool at outer edge of
axle shaft seal (Fig. 130).
(2) Tap on the pry tool with a small hammer and
remove axle shaft seal.
Fig. 130 Axle Shaft Seal Removal
INSTALLATION
(1) Clean axle shaft seal bore of any excess sealant.
(2) Align axle shaft seal with axle shaft seal bore.
(3) Install axle seal on tool #6709 with C-4171 and
insert into axle shaft seal bore.
(4) Tap seal into position (Fig. 131).
OUTPUT BEARING
REMOVAL
NOTE: The position of the output shaft bearing is
critical. The bearing is not identical end–to–end.
Install bearing with larger diameter cage ring facing
out.
(1) Remove caged roller bearing from output bear-
ing race (Fig. 132).
(2) Remove screws at output bearing retainer
strap (Fig. 133).

TRANSAXLE

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