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HOMESERVICE MANUALSDODGE AND RAM2000INTREPID R/TREPAIR AND DIAGNOSISTRANSMISSIONAUTOMATIC TRANSOVERHAUL - 42LE AUTOMATIC TRANSMISSIONTRANSAXLE DISASSEMBLYDIFFERENTIAL ASSEMBLY, TRANSFER SHAFT & COMPONENTSREMOVAL
2000 Dodge and Ram Intrepid R/T

Differential Assembly, Transfer Shaft & Components: Removal

2000 Dodge and Ram Intrepid R/TSECTION Removal
  1. Before removing transfer drive chain, perform preliminary inspection. See PRELIMINARY INSPECTION  .
  2. Remove chain cover from rear of transaxle if not previously removed. See Figure . Remove bolts, chain oiler and chain snubber. Remove snap ring and wave washer from end of output and transfer shafts.
    CAUTION: Output shaft and transfer shaft sprockets are a slip fit on shaft. Sprockets must be spread a small amount to release tension from transfer drive chain for removal and installation of sprockets to prevent component damage. Do not apply excessive force on sprockets when using chain spreader.
  3. Install Chain Spreader (6550) between output shaft and transfer shaft sprockets. See Fig 1 . Rotate nuts on chain spreader to apply pressure against sprockets and release tension on sprockets from transfer drive chain.
  4. Remove transfer drive chain with output shaft and transfer shaft sprockets as an assembly. Remove output sprocket shim from output shaft. See Figure .
    Fig 1: Removing Transfer Drive Chain & Sprockets
    G94B36666Courtesy of CHRYSLER CORP.
  5. If long stub shaft is not removed, remove snap ring retaining long stub shaft in transaxle case. Long stub shaft is left stub shaft when viewed from rear of transaxle. Install Adapter (6669) on end of long stub shaft. Attach slide hammer on adapter. Using slide hammer, pull long stub shaft from transaxle case.
    6. CAUTION: Reference marks must be placed on inner and outer bearing adjusters to ensure proper location during reassembly to maintain proper differential bearing torque. These marks will be used when no components are changed and original differential bearings and races are used.
  6. Place reference marks on transaxle case and inner bearing adjuster located near input shaft for reassembly reference. See Figure . Place reference marks on differential cover and outer bearing adjuster located near short stub shaft on right side of transaxle for reassembly reference.
    7. CAUTION: Note number of turns inner and outer bearing adjusters are threaded into transaxle case during removal. Bearing adjusters must be set in exact position when reinstalled if original components are used.
  7. Remove bolt and bearing adjuster lock bracket from inner bearing adjuster. Using Socket (6502-B), unscrew inner bearing adjuster from transaxle case, noting number of turns for reassembly reference.
  8. Remove bolt and lock bracket from outer bearing adjuster. See Figure . Using Socket (6503), loosen outer bearing adjuster, noting number of turns for reassembly reference.
  9. Remove bolts and differential cover. See Figure . Remove differential assembly. Remove differential vent baffle plate located on inside of transaxle case, near bearing race opening for differential assembly. See Figure .
  10. Remove bolt and vent baffle plate. Vent baffle plate is located on rear of transaxle case, between output shaft and transfer shaft openings. See Figure .
    11. CAUTION: Failure to release staked areas on transfer shaft nut before removing will result in thread damage on transfer shaft.
  11. Using die grinder, grind 2 staked areas on shoulder of transfer shaft nut so staked area is thinner. Using a hammer and chisel, release 2 staked areas away from transfer shaft. Use care not to damage transfer shaft.
  12. Install Holder (6497) on transfer shaft nut. Using breaker bar and Adapter (6498), remove transfer shaft nut by rotating breaker bar and transfer shaft clockwise. See Figure .
  13. Using press, press transfer shaft downward until rear bearing can be removed. Release press. Transfer shaft cannot be removed from transaxle case until bearing race for rear bearing is removed from transaxle housing.
  14. Using Bearing Race Remover (6577), pull bearing race for rear bearing from transaxle case. See Fig 2 . Remove baffle plate (if equipped) from transfer shaft. See Fig 3 . Remove transfer shaft shim from transfer shaft.
  15. Remove transfer shaft from transaxle case. Note direction of front and rear oil seal installation in transaxle case. Remove front and rear oil seals from transaxle case by tapping oil seals toward rear of transaxle case.
  16. Remove front bearing race for transfer shaft from transaxle case, if necessary. Press bearing from transfer shaft, if necessary. Remove depth shim from transfer shaft. See Fig 3 .
Fig 2: Removing Rear Bearing Race
G94C36667Courtesy of CHRYSLER CORP.
RENDER: 1.0x

NO RELATED

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.