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HOMESERVICE MANUALSDODGE AND RAM2000INTREPID R/TREPAIR AND DIAGNOSISTRANSMISSIONAUTOMATIC TRANSOVERHAUL - 42LE AUTOMATIC TRANSMISSIONTRANSAXLE REASSEMBLYTRANSFER DRIVE CHAIN & SPROCKETS
2000 Dodge and Ram Intrepid R/T

Transfer Drive Chain & Sprockets

2000 Dodge and Ram Intrepid R/TSECTION Transfer Drive Chain & Sprockets
  1. Sprocket height must be checked to ensure output shaft sprocket and transfer shaft sprockets are at same height. Sprocket height must be within .015" (.38 mm) of each other.
  2. Original output sprocket shim should be used as a starting point for checking output shaft sprocket height. If original output sprocket shim is not available, use output sprocket shim with thickness of .162-.170" (4.11-4.32 mm). This is thickest shim available.
  3. Install output sprocket shim on output shaft. Install output shaft sprocket on output shaft. On Prowler and all other models with 2.7L engine, output shaft sprocket contains 31 teeth and transfer shaft sprocket contains 34 teeth. On all other models with 3.2L and 3.5L engine, output shaft sprocket contains 32 teeth and transfer shaft sprocket contains 33 teeth.
  4. On all models, install transfer shaft sprocket on transfer shaft. Place straightedge on top of highest sprocket so straightedge is positioned above other sprocket. See Fig 1 . Using feeler gauge, measure height difference between sprockets.
    Fig 1: Checking Sprocket Height
    G94E36701Courtesy of CHRYSLER CORP.
  5. If output shaft sprocket is lower than transfer shaft sprocket, add this amount to thickness of output sprocket shim. If output shaft sprocket is higher than transfer shaft sprocket, subtract this amount from thickness of output sprocket shim. Output sprocket shims are available in 8 thicknesses from .104-.112" (2.64-2.84 mm) to .162-.170" (4.11-4.31 mm) in approximate .008" (.20 mm) increments.
  6. Remove straightedge, output shaft sprocket and output sprocket shim. Install replacement output sprocket shim. Recheck sprocket height. Once correct sprocket height is obtained, remove output shaft and transfer shaft sprockets.
  7. Install transfer drive chain on output shaft and transfer shaft sprockets with Blue link facing outward. See Figure .
  8. Install Chain Spreader (6550) between output shaft and transfer shaft sprockets. See Figure . Rotate nuts on chain spreader to apply pressure against sprockets and drive chain.
  9. Install transfer drive chain along with output shaft and transfer shaft sprockets on output shaft and transfer shaft. Ensure enough pressure is present on transfer drive chain, as not to damage splines on shafts when installing sprockets.
  10. Remove chain spreader. Install wave washers and snap rings to retain sprockets on shafts. Install original chain snubber. Tighten retaining bolts to specification. See TORQUE SPECIFICATIONS  .
    CAUTION: Chain snubber clearance between chain snubber and transfer drive chain must be checked.
  11. To check chain snubber clearance, insert screwdriver in hole below transfer drive chain. Pry transfer drive chain upward to release slack in transfer drive chain. See Fig 2 .
    12. NOTE: The following step was written using ATRA TSB No. 399, dated 06/2000.
  12. Using feeler gauge, measure clearance between chain snubber and top of transfer drive chain. Clearance should be 0-.030" (0-.76 mm). If clearance is not within specification, different chain snubber must be installed. Manufacturer has designed a replacement Snubber (4778989) with slightly offset holes to reduce chain-to-snubber clearance.
  13. Install proper chain snubber to obtain correct clearance. Tighten bolts to specification. See TORQUE SPECIFICATIONS  . Install chain oiler, if removed. See Figure . Apply sealant to chain cover. Install chain cover. Install and tighten chain cover bolts to specification.
Fig 2: Checking Chain Snubber Clearance
G94F36702Courtesy of CHRYSLER CORP.
RENDER: 1.0x

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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.