CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual

GEARSHIFT HOUSING
Roll pin must be flush with top of lever.
Fig. 1 Gearshift Housing Disassembled
Fig. 2 Remove or Install Roll Pin and LeverFig. 3 Dust Boot
Ä TRANSAXLE 21 - 21

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

For Disassembly: Drive roll pin out far enough
to clear the selector shaft, but not through. The
pin must remain in the selector so not to break
the housing.
Fig. 10 Crossover Shaft
Fig. 11 Selector Shaft C-Clip
Fig. 12 Selector Shaft C-Clip
Fig. 13 Selector Assembly Roll Pin
Fig. 14 Remove or Install Selector Shaft
Fig. 15 Disassembled View
Ä TRANSAXLE 21 - 23

DIFFERENTIAL BEARING RETAINER
Fig. 1 Remove Differential Bearing Retainer Seal
Fig. 2 Install Differential Bearing Retainer Seal
Fig. 3 Remove Differential Bearing Retainer Cup
Fig. 4 Differential Bearing Retainer
Fig. 5 Install Oil Baffle
Fig. 6 Insert (Select) Shim and Differential Bearing Retainer Cup
21 - 24 TRANSAXLE Ä

EXTENSION HOUSING
Fig. 1 Remove Extension Seal
Fig. 2 Install New Seal into Extension
Fig. 3 Remove Extension Bearing Cup
Fig. 4 Extension
Fig. 5 Install Extension Oil Baffle
Fig. 6 Install Extension Bearing Cup
Ä TRANSAXLE 21 - 25

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