tow CHEVROLET DYNASTY 1993 Service Manual

(12) Remove nut and bolt attaching the generator/
power steering pump bracket, support strut (Fig. 16). (13) Lower vehicle.
(14) Remove the 2 bolts holding the power steering
fluid reservoir to the generator bracket. Remove the
bolt attaching the tube/hose assemblies to the power
steering pump bracket (Fig. 17). Then remove the
fluid reservoir and tube/hose as an assembly from ve-
hicle. (15) Remove the engine wiring harness routing
clip from the generator bracket. (16) Loosen but DO NOT REMOVE the bolt (Fig.
18) holding the engine bracket assembly to the en-
gine support assembly. (17) Remove upper generator to generator bracket
mounting bolt (Fig. 19). Rotate the generator assem-
bly back toward the dash panel. (18) Remove the 4 bolts holding the generator
bracket to the engine and intake manifold (Fig. 19).
Remove generator bracket from engine. (17) Remove the generator assembly, to lower gen-
erator bracket bolt (Fig. 19). Without removing wir-
ing harness from generator. Remove generator from
bracket and lay generator on top of intake manifold. (18) Remove the power steering pump out through
the top, in the area between engine and dash panel
where the generator was mounted. (19) Transfer the required parts from the removed
power steering pump, to the replacement power
steering pump.
Fig. 14 Power Steering Pump Mounting 3.3 & 3.8 ltr.
Fig. 15 Serpentine Belt Tensioner
Fig. 16 Bracket Support Strut
Fig. 17 Power Steering Fluid Reservoir Mounting
Ä STEERING 19 - 17

(4) Slide and tap in reservoir retainer clips until
tab locks to housing (Fig. 4). (5) Install pump. Refill reservoir with Mopar
Power Steering Fluid or equivalent.
FLOW CONTROL VALVE FITTING O-RING SEAL
REMOVAL
(1) Remove pressure hose from pump fitting. Re-
move pump and pulley if necessary. (2) Remove fitting from pump housing (Fig. 5).
Pre-
vent flow control valve and spring from sliding
out of housing bore. (3) Remove and discard O-ring seal (Fig. 5).
INSTALLATION
(1) If necessary, clean and install flow control valve
and spring in pump housing bore (Fig. 5). Be sure the
hex nut end of the valve is facing the in toward
the pump. (2) Install O-ring seal onto fitting (Fig. 5).
(3) Install fitting in pump housing and tighten to 75
N Im (55 ft. lbs.)
(4) Install pump and pulley if necessary. Install
pressure hose to fitting.
Fig. 1 Pump and Reservoir
Fig. 2 Flow Control Valve/Spring Installation
Fig. 3 Remove Reservoir Clips (Typical)
Ä STEERING 19 - 23

CAUTION: Be sure crossover bellcrank does NOT
move when tightening adjusting screw (Fig. 10).
CAUTION: Proper torque to the crossover cable ad-
justing screw is very important (Fig. 10).
(6) Remove lock pin from gearshift housing and re-
install lock pin (so long end is up) in gear shift hous-
ing. Tighten lock pin to 8 N Im (70 in. lbs.).
(7) Check for shift into first and reverse.
(8) Gearshift mechanism and cables are now func-
tioning properly.
IN-CAR TRANSAXLE DISASSEMBLE/ASSEMBLE
The following items can be serviced without remov-
ing the transaxle from the vehicle:
² Gear shift housing
² Synchronizers
² Intermediate shaft speed gears
² Input shaft
² Reverse idler gear and shaft
² Shift forks and pads
² Shift rails ²
Roller detents
² Speedometer pinion
² All external covers
Observe following procedure:
(1) Disconnect negative cable from battery.
(2) Remove both shift cables from shift cover levers.
(3) Remove left front wheel and tire assembly and
left splash shield. (4) Place drain pan under transaxle and remove
transaxle rear end cover. (5) Push out the fifth fork roll pin and slide the fifth
fork and synchronizer sleeve off the rail/hub. (6) Remove the fifth hub snap ring, hub assembly
and speed gear. (7) Remove fifth gear nut and fifth input gear.
(8) Remove the bearing retainer plate, interlock
plate and shuttles.
CAUTION: Before removing the gearshift housing
assembly, reverse the lock pin (so the long end is
down) and insert lock pin into the same threaded
hole. This procedure will save time when the gear
shift housing assembly is reinstalled. (9) Remove selector shaft housing bolts (note the two
pilot bolts) and remove housing. (10) Remove roller detents and springs, noting that
the rollers align with the shift rails. (11) Push out the 1-2 and 3-4 lug roll pins, remove
the reverse pivot lever and fifth rail C-Clip. If a roll
pin or C-Clip falls, be sure to remove it from the
bottom of the case. (12) Pull out the fifth shift rail and remove the fifth
shift lug and interlock pin. If the pin falls, be sure to
remove it from the bottom of the case. (13) Remove the intermediate shaft ball bearing
snap ring and the bearing support plate. (14) Remove reverse shift rail and lug assembly.
(15) Remove the reverse idler shaft and gear assem-
bly. (16) Rotate the 1-2 shift lug and rail, and 3-4 shift
lug towards the front of the vehicle. (17) Firmly grasp both the input and intermediate
shaft assemblies and pull them out of the transmission
with the 1-2 and 3-4 shift rails, lugs and forks. The differential assembly can only be serviced
by removing the complete transaxle from the
vehicle because bearing preload must be reset. The components listed in the first paragraph can now
be serviced. Refer to the appropriate subassembly
recondition section.
To reassemble the transaxle in the vehicle, reverse
the above procedure using the proper sealants. Fill the
transaxle with SAE 5W-30 engine oil to the bottom of
the fill hole in the end cover.
Fig. 9 Install Cables
Fig. 10 Adjusting Crossover Cable
21 - 4 TRANSAXLE Ä

ing seat will give a false end play reading while
gauging for proper shims. Improperly seated bearing
cups and cones are subject to low mileage failure.(2) Bearing cups and cones should be replaced if they
show signs of pitting or heat distress. If distress is seen
on either the cup or bearing rollers, both cup and cone
must be replaced. (3) Bearing preload and drag torque specifications
must be maintained to avoid premature bearing
failures. Used (original) bearing may lose up to 50% of
the original drag torque after break in. All bearing
adjustments must be made with no other compo-
nent interference or gear intermesh. (4) Replace bearings as a pair. For example, if one
differential bearing is defective, replace both differen-
tial bearings. If one input shaft bearing is defective,
replace both input shaft bearings. (5) Bearing cones must notbe reused if removed.
(6) Turning torque readings should be obtained
while smoothly rotating in either direction (break-
away reading is not indicative of the true turning
torque). (7) Replace oil baffle, if damaged.
INPUT SHAFT BEARING END PLAY ADJUST-MENT
(1) Using Tool C-4656 with Handle C-4171, press
input shaft front bearing cup slightly forward in case.
Then, using Tool C-4655 with Handle C-4171, press
bearing cup back into case from the front. Properly
position bearing cup, before checking input shaft end
play (see input shaft front bearing cup replace in
Subassembly Recondition section).This step is
not necessary if Tool C-4655 was previously used
to install input shaft front bearing cup in the
case. Also no input shaft shim has been installed
since pressing cup into case. (2) Select a gauging shim which will give 0.025 to
0.254mm (.001 to .010 inch) end play. SUGGESTION:
Measure original shim from input shaft seal retainer and select a shim 0.254mm (.010
inch) thinner than original for the gauging shim.
(3) Install gauging shim on bearing cup and install
input shaft seal retainer.
CAUTION: The input shaft seal retainer is used to
draw the input shaft front bearing cup the proper
distance into the case bore during this step. Alter-
nately tighten input shaft seal retainer bolts until
input shaft seal retainer is bottomed against case.
Tighten bolts to 28 N Im (21 ft. lbs.).
(4) Oil input shaft bearings with SAE 5W-30 engine
oil and install input shaft in case. Install bearing
retainer plate with input shaft rear bearing cup
pressed in and bearing support plate installed. Tighten
all bolts and nuts to 28 N Im (21 ft. lbs.).
(5) Position dial indicator to check input shaft end
play. Apply moderate load, by hand, to input shaft
splines (Fig. 1). Push toward rear while rotating input
shaft back and forth a number of times to settle out
bearings. Zero dial indicator. Pull input shaft toward
the front while rotating input shaft back and forth a
number of times to settle out bearings. Record end play.
(6) The shim required for proper bearing end play is
the total of the gauging shim thickness, plus end play,
minus (constant) end play of 0.051mm (.002 inch).
Combine shims, if necessary, to obtain a shim within
.04mm (.0016 inch) of the required shim (see Shim
Chart for proper shim). (7) Remove input shaft seal retainer and gauging
shim. Install shim(s) selected in step (6). Then reinstall
input shaft seal retainer with a 1/16 inch bead of
MOPAR tGasket Maker, Loctite, or equivalent for a
gasket. Record end play. Observe the CAUTIONin
step (3). Tighten input shaft seal retainer bolts to 28
N Im (21 ft. lbs.).
Fig. 14 Checking Side Gear End Play
Fig. 1 Checking Input Shaft Bearing End Play to De-
termine Shim Thickness
21 - 32 TRANSAXLE Ä

so that pump housing and case front may be covered
with soapy solution or water. Leaks are sometimes
caused by porosity in the case or pump housing.If a leak source is located, that part and all associ-
ated seals, O-rings, and gaskets should be replaced
with new parts.
GEARSHIFT LINKAGE ADJUSTMENT
Normal operation of the Park/Neutral Position
Switch provides a quick check to confirm proper
manual linkage adjustment. Move the selector level slowly upward until it
clicks into the ``P'' Park notch in the selector gate. If
the starter will operate the ``P'' position is correct. After checking ``P'' position, move selector slowly
toward ``N'' Neutral position until lever drops in the
``N'' stop. If the starter will also operate at this point
the gearshift linkage is properly adjusted. If the
starter fails to operate in either position, linkage ad-
justment is required.
CAUTION: When it is necessary to disassemble
linkage cable from levers, which use plastic grom-
mets as retainers, the grommets should be replaced
with new grommets. Use a prying tool to force rod
from grommet in lever, then cut away old grommet.
Use pliers to snap new grommet into lever and rod
into grommet.
(1) Set parking brake.
(2) Place gearshift lever in P(PARK) position.
(3) Loosen clamp bolt on gearshift cable bracket.
(4) Column shift: Insure that preload adjustment
spring engages fork on transaxle bracket. (5) Pull the shift lever by hand to the front detent
position (PARK) and tighten lock. Tighten screw to
11 N Im (100 in. lbs.). Gearshift linkage should now
be properly adjusted. (6) Check adjustment as follows:(a) Detent position for neutral and drive should
be within limits of hand lever gate stops. (b) Key start must occur only when shift lever is
in park or neutral positions.
THROTTLE PRESSURE LINKAGE ADJUSTMENT
The throttle pressure cable adjustment is very im-
portant to proper transaxle operation. This adjust-
ment positions a valve which controls shift speed,
shift quality, and part throttle downshift sensitivity.
If the setting is too long, early shifts and slippage be-
tween shifts may occur. If the setting is too short,
shifts may be delayed and part throttle downshifts
may be very sensitive.
CABLE ADJUSTMENT PROCEDURE (4-CYL.)
(1) Perform transaxle throttle pressure cable ad-
justment while engine is at normal operating tem-
perature. (2) Loosen cable mounting bracket lock screw.
(3) Bracket should be positioned with both bracket
alignment tabs touching the transaxle cast surface.
Tighten lock screw to 12 N Im (105 in. lbs.) see Fig-
ure 8.
(4) Release cross-lock on the cable assembly (pull
cross-lock upward) see Figure 7. (5) To insure proper adjustment, the cable must be
free to slide all the way toward the engine, against
its stop, after the cross-lock is released. (6) Move transaxle throttle control lever fully
clockwise, against its internal stop, and press cross-
lock downward into locked position (Fig. 7). (7) The adjustment is complete and transaxle
throttle cable backlash was automatically removed. (8) Test cable freedom of operation by moving the
transaxle throttle lever forward (counterclockwise).
Then slowly release it to confirm it will return fully
rearward (clockwise). (9) No lubrication is required for any component of
the throttle cable system.
ROD ADJUSTMENT PROCEDURE (6-CYL.)
(1) Perform transaxle throttle pressure cable ad-
justment while engine is at normal operating tem-
perature. (2) Loosen adjustment swivel lock screw.
(3) To insure proper adjustment, swivel must be
free to slide along flat end of throttle rod so that pre-
load spring action is not restricted. Disassemble and
clean or repair parts to assure free action, if neces-
sary. (4) Hold transaxle throttle lever firmly toward en-
gine, against its internal stop and tighten swivel lock
screw to 11 N Im (100 in. lbs.)
(5) The adjustment is finished and linkage back
lash was automatically removed by the preload
spring. (6) If lubrication is required see Lubrication,
Group 0.
Fig. 8 Throttle Pressure CableÐTypical
21 - 46 TRANSAXLE Ä

washed in a suitable solvent, then dried by com-
pressed air. Do not wipe parts with shop towels. All
mating surfaces in the transaxles are accurately ma-
chined; therefore, careful handling of all parts must
be exercised to avoid nicks or burrs. Remove all old sealant before applying new MO-
PAR tAdhesive Sealant.
Use only MOPAR tAdhesive Sealant when install-
ing oil pan. Put MOPAR tAdhesive Sealant on the oil pan
flange (Fig. 2) and on all oil pan bolts (underside of
bolt head).
Fig. 12 Raise or Lower Transaxle
Fig. 13 Pry Engine for Clearance
Fig. 1 Transaxle Oil Pan Bolts
Fig. 2 Transaxle Oil Pan
Fig. 3 Oil Filter Screws
Ä TRANSAXLE 21 - 51

CAUTION: Prevent manual shaft rotation during in-
stallation and removal. (2) With rotary motion, install converter hub seal
cup over input shaft. It must go through the con-
verter hub seal until the cup bottoms against the
pump gear lugs. Secure with cup retainer strap using
starter upper hole and opposite bracket hole. (3) Attach and clamp hose from nozzle of Tool
C-4080 to the upper cooler line fitting position in
case.
CAUTION: Do not, under any circumstances, pres-
surize a transaxle to more than 10 psi.
(4) Pressurize the transaxle using Tool C-4080 un-
til the pressure gauge reads 8 psi. Position transaxle
so that pump housing and case front may be covered
with soapy solution of water. Leaks are sometimes
caused by porosity in the case or pump housing. If a leak source is located, that part and all associ-
ated seals, O-rings, and gaskets should be replaced
with new parts.
GEARSHIFT LINKAGE ADJUSTMENT
Normal operation of the transmission range switch
(PRNDL) and park/neutral position switch provides a
quick check to confirm proper manual linkage adjust-
ment. Move the selector level slowly upward until it
clicks into the ``P'' Park notch in the selector gate. If
the starter will operate the ``P'' position is correct. After checking ``P'' position, move selector toward
``N'' Neutral position until lever drops in the ``N''
stop. If the starter will also operate at this point the
gearshift linkage is properly adjusted.
CAUTION:When it is necessary to disassemble link-
age cable from levers, which use plastic grommets
as retainers, the grommets should be replaced with
new grommets. Use a prying tool to force rod from
grommet in lever, then cut away old grommet. Use
pliers to snap new grommet into lever and rod into
grommet.
(1) Set parking brake.
(2) Place gearshift lever in P(PARK) position.
(3) Loosen clamp bolt on gearshift cable bracket.
(4) Column shift: Insure that preload adjustment
spring engages fork on transaxle bracket. (5) Pull the shift lever by hand to the front detent
position (PARK) and tighten lock screw to 11 N Im
(100 in. lbs.). Gearshift linkage should now be prop-
erly adjusted. (6) Check adjustment as follows:(a) Detent position for neutral and drive should
be within limits of hand lever gate stops. (b) Key start must occur only when shift lever is
in park or neutral positions.
ALUMINUM THREAD REPAIR
Damaged or worn threads in the aluminum tran-
saxle case and valve body can be repaired by the use
of Heli-Coils, or equivalent. This repair consists of
drilling out the worn-out damaged threads. Then tap
the hole with a special Heli-Coil tap, or equivalent,
and installing a Heli-Coil insert, or equivalent, into
the hole. This brings the hole back to its original
thread size. Heli-Coil, or equivalent, tools and inserts are
readily available from most automotive parts suppli-
ers.
COOLERS AND TUBES REVERSE FLUSHING
When a transaxle failure has contaminated the
fluid, the oil cooler(s) must be flushed and the cooler
bypass valve in the transaxle must be replaced. The
torque converter must also be replaced with an ex-
change unit. This will insure that metal particles or
sludged oil are not later transferred back into the re-
conditioned (or replaced) transaxle.
Fig. 5 Torque Converter Hub Seal Cup
Fig. 6 Hub Seal Cup Retaining Strap
21 - 98 TRANSAXLE Ä

Now that both shaft assemblies and thrust washers
are properly installed, reinstall overdrive clutch and
reverse clutch as shown in Figures 20 through 28.
Rechecking these clutch clearances is not neces-
sary, as they were set and approved previously.
VALVE BODY-RECONDITION
Prior to removing any transaxle subassemblies, plug
all openings and thoroughly clean exterior of the unit,
preferably by steam. Cleanliness through entire disas-
sembly and assembly cannot be overemphasized. When
disassembling, each part should be washed in a suit-
able 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. Tag all springs, as they are removed, for reas-
sembly identification.
Fig. 33 Install No. 3 Thrust Washer
Fig. 34 Install No. 3 Thrust Plate
Fig. 35 Install Overdrive Shaft Assembly
Fig. 36 Input Clutch Assembly
Fig. 1 Oil Pan Bolts
21 - 132 TRANSAXLE Ä

(2) Remove push-in fasteners holding hood latch
cover to radiator closure panel and separate cover
from vehicle. (3) Disconnect hood release cable casing and cable
end from hood latch assembly. Refer to Hood Latch
Removal procedure in this section. (4) Remove hood latch release cable handle attach-
ing bolts from under left lower edge of instrument
panel. (5) Disengage release cable rubber grommet from
engine compartment dash panel behind instrument
panel. (6) Rout cable assembly through engine compart-
ment around battery, under fender lip, under relay
bank, and under wiring harnesses, toward dash
panel. Push cable through access hole in dash panel
under the brake master cylinder, into passenger com-
partment.
HOOD LATCH RELEASE CABLE INSTALLATION
Reverse the preceding operation.
COWL COVER
REMOVAL (FIG. 6)
(1) Raise hood to full up position.
(2) Disconnect windshield washer hoses from wiper
arms. (3) Remove windshield wiper arm assemblies. Re-
fer to Group 8K, Windshield Wiper and Washer Sys-
tems. (4) Remove plastic expanding type fasteners hold-
ing cowl cover to cowl, below windshield. (5) Lift back of cowl cover and slide cover rearward
from under dash panel to hood seal and separate
cover from vehicle.
INSTALLATION
Reverse the preceding operation.
FRONT END SPLASH SHIELDS
FRONT WHEELHOUSE SPLASH SHIELD REMOVAL (FIG. 7)
(1) Hoist vehicle and support on suitable safety
stands. (2) Remove front wheel assembly.
(3) Remove push-in fasteners holding front wheel-
house splash shield to fender opening lip and inner
wheelhouse area. (4) Separate wheelhouse splash shield from vehi-
cle.
FRONT WHEELHOUSE SPLASH SHIELD INSTALLATION
Reverse the preceding operation.
TRANSAXLE SPLASH SHIELD REMOVAL (FIG.7)
(1) Remove one front wheelhouse splash shield
push-in fastener and separate wheelhouse splash
shield from transaxle splash shield. (2) Remove transaxle splash shield attaching bolts
and separate transaxle splash shield from vehicle.
TRANSAXLE SPLASH SHIELD INSTALLATION
Reverse the preceding operation.
ENGINE DRIVE BELT SPLASH SHIELD REMOVAL (FIG. 8)
(1) Hoist vehicle and support on suitable safety
stands. (2) Remove bolts holding engine drive belt splash
shield to right frame rail. (3) Separate drive belt splash shield from vehicle.
ENGINE DRIVE BELT SPLASH SHIELDINSTALLATION
Reverse the preceding operation.
Fig. 5 Hood Latch Release Cable Assembly
Fig. 6 Cowl Cover Assembly
Ä AA-BODY 23 - 13

FRONT DOOR SIDE VIEW MIRROR
REMOVAL (FIG. 16)
(1) Remove front door trim panel.
(2) Remove side view mirror remote adjusting
knob cover, if equipped. (3) Remove screws holding mirror bezel to door
frame and separate bezel from door. Loosen set-screw
holding bezel to mirror adjuster cable, if equipped. (4) Remove silencer seal from door frame behind
mirror bezel. (5) Disconnect power mirror wire connector, if
equipped. (6) Remove access hole cover.
(7) Remove nuts holding mirror to door frame and
separate mirror from door.
INSTALLATION
Reverse the preceding operation.
FRONT DOOR GLASS
REMOVAL (FIG. 17)
(1) Remove door trim panel, silencer pad, and wa-
ter shield. (2) Position door glass half way up in door glass
opening. (3) Insert door glass removal tool C-4867 between
the glass slide and channel retaining lip at approxi-
mately 50 mm (2 in.) down from top rearward corner
of glass. Push handle of tool toward glass to open
channel. Push downward at the front of the glass to
separate the slide from the channel. (4) Insert door glass removal tool C-4867 between
the glass slide and channel retaining lip at approxi-
mately 50 mm (2 in.) up from bottom rearward cor-
ner of glass through opening in inner door panel.
Push handle of tool toward glass to open channel.
Pull upward at front of glass to separate the slide
from the channel. Do not allow upper slide to snap
bank into channel. (5) Rotate front of glass downward and slide glass
forward to separate glass lift channel from regulator
lift arm roller. (6) Remove door glass through opening at top of
door.
INSTALLATION
(1) Lower door glass into opening at top of door.
(2) Tip rear of glass downward and insert window
regulator lift arm roller into glass lift channel. (3) Guide door glass into glass run weatherstrip at
front of door. (4) Push top of glass rearward to snap top slide
into glass run channel. (5) Push downward at front of glass to snap bottom
slide into glass run channel. (6) Install water shield, silencer pad and trim
panel.
FRONT DOOR BELT MOULDING AND
WEATHERSTRIP
BELT MOULDING AND WEATHERSTRIP REMOVAL (FIG. 18)
(1) Remove trim panel, silencer pad, and water
shield as necessary to gain access to belt moulding
attaching screws. (2) Remove door glass.
(3) Remove screws holding belt moulding and
weatherstrip to outer door panel and separate moul-
ding from door.
BELT MOULDING AND WEATHERSTRIP INSTALLATION
Reverse the preceding operation.
Fig. 16 Front Door Side View Mirror
Fig. 17 Front Door Glass
Ä AA-BODY 23 - 17