torque CHEVROLET DYNASTY 1993 Service Manual

TRANSAXLE
CONTENTS
page page
41TE FOUR SPEED AUTOMATIC TRANSAXLE . 85
41TE FOUR SPEED TRANSAXLE HYDRAULICSCHEMATICS ........................ 170
41TE ON-BOARD DIAGNOSTICS .......... 145
A-523, A-543, and A-568 MANUAL TRANSAXLE ........................... 1 SPECIFICATIONS
...................... 183
THREE SPEED TORQUEFLITE AUTOMATIC TRANSAXLE .......................... 35
THREE SPEED TRANSAXLE HYDRAULIC SCHEMATICS ........................ 162
A-523, A-543, and A-568 MANUAL TRANSAXLE INDEX
page page
Bearing Adjustment Procedure .............. 31
Differential Bearing Preload Adjustment ........ 33
Gearshift Linkage Adjustment (Cable Operated) . . 2
General Information ........................ 1 In-Car Transaxle Disassemble/Assemble
........ 4
Out of Car TransaxleÐDisassemble and Assemble . 6
Subassembly-Recondition .................. 15
Transaxle Removal and Installation ............ 5
GENERAL INFORMATION
Safety goggles should be worn at all times
when working on these transaxles. All manual
transaxles use SAE 5W-30 engine oil, meeting SG
and/or SG-CC qualifications, as the lubricant in order
to reduce wear. This 5-speed manual transaxles combine gear reduc-
tion, ratio selection, and differential functions in one
unit. It is housed in a die-cast aluminum case (Fig. 1). All shift forks are cast iron.
Do not interchange 1-2
or 5th shift fork pads with the 3-4 shift fork pads.
All synchronizers use a winged strutdesign that
prevents the struts from popping out of position. If any synchronizer is to be disassembled, mark
all parts so that they will be reassembled in the
same position.
CAUTION: 1-2 synchronizer assembly components
must NOT be interchanged with any other synchro-
nizer assembly. Do not interchange with previous
model years transaxles; they will NOT function cor-
rectly.
A-523 AND A-543 MANUAL TRANSAXLE
The A-523 manual transaxle is used in all 4-cylinder
applications, except high output turbocharged engines.
The A-543 manual transaxle is used only with V-6
engines. To reduce wear, the manual transaxle uses SAE
5W-30 engine oil as the lubricant. Gear ratios for the A-523 and A-543 are as follows:
1stÐ3.31, 2cdÐ2.06, 3rdÐ1.36, 4thÐ0.97, 5thÐ0.71,
ReverseÐ3.14. The final drive ratio is 3.77.
CAUTION: All gears and shafts must not be inter-
changed with previous model years; they will not
function correctly.
Fig. 1 External Transaxle Components
Ä TRANSAXLE 21 - 1

A-568 HEAVYÐDUTY MANUAL TRANSAXLE
The greater torque of the high output turbo engines
require a stronger transmission. It includes a die-cast
aluminum case and a stronger, coarse-pitch gear set. It
has five forward speed ratios and reverse. Gear ratios
are as follows: 1stÐ3.31, 2ndÐ1.89, 3rdÐ1.28,
4thÐ0.94, 5thÐ0.71, ReverseÐ3.14. Final drive ratio
of 3.85 was selected for maximum performance. All
forward gears are synchronized. To reduce wear, this transaxle, in common with other
manual transaxles, uses SAE 5W-30 engine oil as the
lubricant.
IDENTIFICATION
A-523, A-543, and A-568: the transaxle model, assem-
bly number, build date, and final-drive ratio are
stamped on a tag that is attached to the top of the
transaxle (Fig. 2). Certain transaxle assemblies utilize high-
strength Steel in various gears to provide adequate
life in heavy-duty applications. Therefore, it is im-
perative that the correct transaxle assembly
number is utilized when ordering service parts.
Also, be sure to reinstall this tag whenever it is
removed, so the information is available for future
service. The last eight digits of the Vehicle Identification
Number (V.I.N.) are stamped on a raised boss on top
of the clutch housing area.
GEARSHIFT LINKAGE ADJUSTMENT (CABLE
OPERATED)
Before replacing the gearshift selector cable or
crossover cable for a hard-shiftingcomplaint, dis-
connect both cables at the transaxle (Fig. 3). Then,
from the driver's seat, manually operate the gear-
Fig. 2 A-523, A-543, and A-568 Transaxle Identification
Fig. 3 Gearshift Mechanism
21 - 2 TRANSAXLE Ä

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

The C-Clip groves in the selector shaft will
damage the oil seal. Install oil seal after selector
shaft is installed. Always use a new oil seal when
selector shaft is removed. Proper torque to the 5-R blocker attaching
bolts is very important (Fig. 8).
Fig. 4 Remove Oil Seal
Fig. 5 Install Oil Seal
Fig. 6 Remove Vent Cap
Fig. 7 Crossover Shaft Roll Pin
Fig. 8 5-R Blocker Attaching Bolts
Fig. 9 5-R Blocker Assembly
21 - 22 TRANSAXLE Ä

INPUT SHAFT
Shim thickness need only be determined if any of
the following parts are replaced:
² Transaxle case
² Input shaft seal retainer
² Bearing retainer plate
² Rear end cover
² Input shaft
² Input shaft bearings
Refer to Bearing Adjustment Procedure in rear
of this section to determine proper shim thickness for
correct bearing end play and proper turning torque.
Fig. 1 Remove Input Shaft Rear Bearing Cone
Fig. 2 Install Input Shaft Rear Bearing Cone
Fig. 3 Remove Input Shaft Front Bearing Cone
Fig. 4 Install Input Shaft Front Bearing Cone
Fig. 5 Remove Input Shaft Rear Bearing Cup
21 - 26 TRANSAXLE Ä

CAUTION: Bolt on bearing support plate before in-
stalling input shaft rear bearing cup.
A-523, A-543 DIFFERENTIAL
Shim thickness need only be determined if any of
the following parts are replaced:
² Transaxle case
² Differential bearing retainer
² Extension housing
² Differential case
² Differential bearings
CAUTION: Differential covers are not interchange-
able from case to case.
Refer to Bearing Adjustment Procedure in rear
of this section to determine proper shim thickness for
correct bearing preload and proper bearing turning
torque.
Fig. 6 Install Input Shaft Rear Bearing Cup
Fig. 1 Remove Differential Bearing Cone
Fig. 2 Install Differential Bearing Cone
Fig. 3 Remove Differential Bearing Cone
Fig. 4 Install Differential Bearing Cone
Ä TRANSAXLE 21 - 27

CAUTION: Always install new ring gear bolts. Bolts
must be properly torqued (See Tightening Refer-
ence). After assembling the differential side gears, pinion
gears and pinion gears withthe pinion gear washers,
but without the side gear thrust washers. Rotate the
assembly two full revolutions both clockwise and
counterclockwise. Set up dial indicator as shown and record end play.
Rotate side gear 90 degrees and record another end
play. Again, rotate side gear 90 degrees and record a
final end play. Using the smallest end play recorded, shim that
side gear to within .001 to .013 inch. The other side
gear should be checked using the same procedure.
Fig. 5 Remove or Install Ring Gear Bolts and Ring Gear
Fig. 6 Remove Pinion Shaft Roll Pin
Fig. 7 Remove or Install Pinion Shaft
Fig. 8 Remove or Install Pinion Gears, Side Gears,and Thrust Washers by Rotating Side Gears to Opening in Case
Fig. 9 Differential Gears
21 - 28 TRANSAXLE Ä

CAUTION: Side gear end play must be within .001 to
.013 inch. Four select thrust washers are available:
.032, .037, .042, and .047 inch.
A-568 DIFFERENTIAL
Shim thickness need only be determined if any of the
following parts are replaced:
² Transaxle case
² Differential bearing retainer
² Extension housing
² Differential case
² Differential bearings
Refer to Bearing Adjustment Procedure in rear of
this section to determine proper shim thickness for
correct bearing preload and proper bearing turning
torque.
Fig. 1 Remove Differential Bearing Cone
Fig. 2 Install Differential Bearing Cone
Fig. 3 Remove Differential Bearing Cone
Fig. 10 Checking Side Gear End Play
Fig. 11 Checking Side Gear End Play
Ä TRANSAXLE 21 - 29

CAUTION: Always install new ring gear bolts. Bolts
must be properly torqued (See Tightening Refer-
ence).
Fig. 4 Install Differential Bearing Cone
Fig. 5 Remove or Install Ring Gear Bolts
Fig. 6 Remove Ring Gear
Fig. 7 Remove 3 Roll Pins
Fig. 8 Install 3 Roll Pins
Fig. 9 Ring Gear and Side Gear Removed
21 - 30 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