Chrysler Stratus Convertible. Manual — part 96

NOTE: Side gear end play must be BETWEEN 0.001
to 0.013 inch.

ASSEMBLY

NOTE: Use Mopar

T

Silicone Rubber Adhesive Seal-

ant, or equivalent, on retainer and extension hous-
ing/adapter plate to seal to case.

(1) Using Miller Special Tool L-4410, and C-4171,

install differential bearing to differential (extension
housing side) (Fig. 382).

(2) Using Miller Special Tool 5052 and C-4171,

install differential bearing to differential (bearing
retainer side).

(3) Using Miller Special Tool 6061 and C-4171,

install differential bearing race to bearing retainer
(Fig. 383).

(4) Using Miller Special Tool L–4520 and C-4171,

install differential bearing to extension housing.

DIFFERENTIAL BEARING PRELOAD ADJUSTMENT

NOTE: Perform all differential bearing preload mea-
surements

with

the

transfer

shaft

and

gear

removed.

Fig. 380 Checking Side Gear End Play (Extension

Housing Side)

1 – SPECIAL TOOL C-4996 (NOTE POSITION)
2 – DIAL INDICATOR SET
3 – DIFFERENTIAL ASSEMBLY
4 – SIDE GEAR

Fig. 381 Checking Side Gear End Play (Bearing

Retainer Side)

1 – SPECIAL TOOL C-4996 (NOTE POSITION)
2 – DIAL INDICATOR SET
3 – DIFFERENTIAL ASSEMBLY

Fig. 382 Position Bearing Cone Onto Differential

1 – DIFFERENTIAL ASSEMBLY
2 – DIFFERENTIAL BEARING

Fig. 383 Differential Bearing Retainer

1 – DIFFERENTIAL BEARING CUP
2 – DIFFERENTIAL BEARING RETAINER

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TRANSAXLE

21 - 123

DISASSEMBLY AND ASSEMBLY (Continued)

DIFFERENTIAL BEARING PRELOAD ADJUSTMENT USING
EXISTING SHIM

(1) Position the transaxle assembly vertically on

the support stand, differential bearing retainer side
up.

(2) Install Tool L-4436A into the differential and

onto the pinion mate shaft (Fig. 384).

(3) Rotate the differential at least one full revolu-

tion to ensure the tapered roller bearings are fully
seated.

(4) Using Tool L-4436A and an inch-pound torque

wrench, check the turning torque of the differential
(Fig.

385).

The

turning

torque

should

be

between 5 and 18 inch-pounds.

(5) If the turning torque is within specifications,

remove tools. Setup is complete.

(6) If turning torque is not within specifications

proceed with the following steps.

(a) Remove differential bearing retainer from

the transaxle case.

(b) Remove the bearing cup from the differential

bearing retainer using Tool 6062A.

(c) Remove the existing shim from under the

cup.

(d) Measure the existing shim.

(e) If the turning torque was too high when mea-

sured, install a.05 mm (.002 inch) thinner shim. If
the turning torque is was too low, install a.05 mm
(.002 inch) thicker shim. Repeat until 5 to 18 inch-
pounds turning torque is obtained. Oil Baffle is not
required to be installed when making shim selec-
tion.

(f) Install the proper shim under the bearing

cup. Make sure the oil baffle is installed properly
in the bearing retainer, below the bearing shim
and cup.

(g) Install the differential bearing retainer using

Tool 5052 and C-4171. Seal the retainer to the
housing with MOPAR

t Adhesive Sealant and

torque bolts to 28 N·m (250 in. lbs.).
(7) Using Tool L-4436A and an inch-pound torque

wrench, recheck the turning torque of the differential
(Fig.

385).

The

turning

torque

should

be

between 5 and 18 inch-pounds.

Shim thickness need be determined only if any of

the following parts are replaced:

• Transaxle case

• Differential carrier

• Differential bearing retainer

• Extension housing

• Differential bearing cups and cones

Fig. 384 Tool L-4436 and Torque Wrench

1 – SPECIAL TOOL L-4436–A
2 – TORQUE WRENCH
3 – DIFFERENTIAL BEARING RETAINER

Fig. 385 Checking Differential Bearings Turning

Torque

1 – SPECIAL TOOL L-4436–A
2 – TORQUE WRENCH

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TRANSAXLE

JX

DISASSEMBLY AND ASSEMBLY (Continued)

DIFFERENTIAL BEARING SHIM CHART

PART NUMBER

SHIM THICKNESS

MM

INCH

4659257

.980

0.0386

4659258

1.02

0.0402

4659259

1.06

0.0418

4659260

1.10

0.0434

4659261

1.14

0.0449

4659262

1.18

0.0465

4659263

1.22

0.0481

4659264

1.26

0.0497

4659265

1.30

0.0512

4659266

1.34

0.0528

4659267

1.38

0.0544

4659268

1.42

0.0560

4659269

1.46

0.0575

4659270

1.50

0.0591

4659271

1.54

0.0607

4659272

1.58

0.0623

4659273

1.62

0.0638

4659274

1.66

0.0654

4659275

1.70

0.0670

4659283

2.02

0.0796

4659284

2.06

0.0812

PRELOAD ADJUSTMENT W/O SHIM

(1) Remove the bearing cup from the differential

bearing retainer using Miller special Tool 6062A.

(2) Remove existing shim from under bearing cup.
(3) Reinstall the bearing cup into the retainer

using Miller Special Tool 6061, and C-4171.

NOTE: Oil baffle is not required when making the
shim calculation.

(4) Install the bearing retainer into the case.

Torque bolts to 28 N

•m (250 in. lbs.).

(5) Position the transaxle assembly vertically on

the support stand and install Miller Special Tool
L-4436-A into the bearing retainer.

(6) Rotate the differential at least one full revolu-

tion to ensure the tapered roller bearings are fully
seated.

(7) Attach a dial indicator to the case and zero the

dial. Place the tip on the end of Special Tool
L-4436-A.

(8) Place a large screwdriver to each side of the

ring gear and lift. Check the dial indicator for the
amount of end play.

CAUTION: Do

not

damage

the

transaxle

case

and/or differential retainer sealing surface.

(9) Using the end play measurement that was

determined, add .18mm (.007 inch). This should give
you between 5 and 18 inch pounds of bearing pre-
load. Refer to the Differential Bearing Shim Chart to
determine which shim to use.

(10) Remove

the

differential

bearing

retainer.

Remove the bearing cup.

(11) Install the oil baffle. Install the proper shim

combination under the bearing cup.

(12) Install the differential bearing retainer. Seal

the retainer to the housing with Mopar

t Silicone

Rubber Adhesive Sealant. Torque bolts to 28 N

•m

(250 in. lbs.).

(13) Using Miller Special Tool L-4436-A and an

inch-pound torque wrench, check the turning torque
of the differential (Fig. 385). The turning torque
should be between 5-18 inch-pounds.

JX

TRANSAXLE

21 - 125

DISASSEMBLY AND ASSEMBLY (Continued)

NOTE: If turning torque is too high install a.05mm
(.002 inch) thicker shim. If the turning torque is too
low, install a.05mm (.002 inch) thinner shim. Repeat
until

5-18

inch-pounds

of

turning

torque

is

obtained.

CLEANING AND INSPECTION

CLEANING VALVE BODY

Prior to removing any transaxle parts, plug all

openings and clean unit, preferably by steam. Clean-
liness through entire disassembly and assembly can-
not be overemphasized. When disassembling, each
part should be washed in a suitable solvent, then
dried by compressed air. Do not wipe parts with
shop towels. All mating surfaces in the transaxles
are accurately machined; therefore, careful handling
of all parts must be exercised to avoid nicks or burrs.

NOTE: Tag all springs, as they are removed, for
reassembly identification.

ADJUSTMENTS

GEARSHIFT LINKAGE ADJUSTMENT

Normal operation of the Park/Neutral Position

Switch provides a quick check to confirm proper link-
age adjustment.

Move the selector level slowly forward until it

clicks into the (P) Park position. The starter should
operate.

After checking the (P) position, move selector

slowly toward the (N) Neutral position until lever is
in the (N) position. If the starter will also operate at
this point the gearshift linkage is properly adjusted.
If the starter fails to operate in either position, link-
age adjustment is required.

ADJUSTMENT

(1) Set parking brake.
(2) Remove the gearshift knob set screw and knob.
(3) Remove gearshift selector bezel and lamp wir-

ing.

(4) Install the gearshift knob set screw and knob.
(5) Place gearshift lever in the (P) (PARK) posi-

tion.

(6) Loosen the gearshift cable adjuster nut at the

shifter assembly (Fig. 386).

(7) Move the gearshift lever on the transaxle to

the park position.

(8) Verify the shift lever and transaxle are in park

position. Tighten the gearshift cable adjuster nut at
the shifter assembly. The gearshift linkage should
now be properly adjusted.

(9) Check adjustment as follows:
• Detent position for neutral and drive should be

within limits of hand lever gate stops.

• Key start must occur only when shift lever is in

park or neutral positions.

Fig. 386 Shift Cable Adjust Lever Nut

1 – CONSOLE
2 – ACCESS HOLE
3 – SHIFTER HANDLE

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TRANSAXLE

JX

DISASSEMBLY AND ASSEMBLY (Continued)