Index Chrysler Chrysler Crossfire - service repair manual 2005 year

Content .. 799 800 801 802 ..

Chrysler Crossfire. Manual - part 801

REMOVAL

1. Remove the front center console. (Refer to 23 -

BODY/INTERIOR/CENTER

CONSOLE

-

REMOVAL).

2. Remove the gear shift lever handle.

3. Disconnect the wire harness connectors (2) at the

rear of the shift mechanism.

4. Remove the retaining bolts (3).

5. Lift the shift mechanim up and disconnect the shift

rod. Remove the shift mechanism from the vehicle.

INSTALLATION

1. Connect the shift rod to the shift mechanism and

install the retainer clip.

2. Position the shift mechanism (1) in the vehicle.

3. Install the retaining bolts (3). Tighten the bolts to 7

N·m (65 in. lbs.).

4. Connect the wire harness (2) connectors at the

rear of the shift mechanism.

5. Install the front center console. (Refer to 23 - BODY/INTERIOR/CENTER CONSOLE - INSTALLATION).

6. Install the gear shift lever handle.

GEAR SHIFT ROD

REMOVAL

1. Raise and support the vehicle.

2. Remove the retaining clip at the shifter (1).

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3. Remove the retaining clip at the transmission shift

arm and remove the shift rod from the vehicle.

INSTALLATION

1. Position the shift rod on the transmission shift arm an install the clip.

2. Position the shift rod on the shifter and install the clip.

3. Lower the vehicle and check the operation of the shift mechanism.

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AUTOMATIC - NAG1 SERVICE INFORMATION

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MANUAL - SERVICE INFORMATION

TABLE OF CONTENTS

page

page

MANUAL - SERVICE INFORMATION

. . . . . . . . . . . . . . . . . . . . . . . . 355

. . . . . . . . . . . . . . . . . . . . . . . . . . 356

DIAGNOSIS AND TESTING

. . . . . . . . . . . . . . . 356

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 357

. . . . . . . . . . . . . . . . . . . . . . . . . . . 360

. . . . . . . . . . . . . . . . . . . . . . . . 360

SPECIFICATIONS - GEAR RATIOS

. . . . . . . 363

. . . . . . . . . . . . . . . . . . . . 364

SPECIFICATIONS - FLUID CAPACITY

. . . . . . . . . . . . . . . . . . . . . . . 365

FLUID

. . . . . . . . . . . . . . . . . . . . . . . . 367

STANDARD PROCEDURE

STANDARD PROCEDURE - FLUID DRAIN

AND FILL . . . . . . . . . . . . . . . . . . . . . . . . . . . 367

STANDARD PROCEDURE - CHECKING

FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . . 367

BACKUP LAMP SWITCH

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 368

. . . . . . . . . . . . . . . . . . . . . . . . 369

OUTPUT FLANGE SEAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 369

. . . . . . . . . . . . . . . . . . . . . . . . 371

DETENT PLUG

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 373

. . . . . . . . . . . . . . . . . . . . . . . . 373

INPUT SHAFT SEAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 374

. . . . . . . . . . . . . . . . . . . . . . . . 374

TRANSMISSION FRONT SECTION

. . . . . . . . . . . . . . . . . . . . . . . . 375

. . . . . . . . . . . . . . . . . . . . . . . . . . . 375

REAR SECTION HOUSING

. . . . . . . . . . . . . . . . . . . . . . . . 376

. . . . . . . . . . . . . . . . . . . . . . . . . . . 376

REVERSE SHAFT

. . . . . . . . . . . . . . . . . . . . . . . . 377

GEARTRAIN HOUSING

. . . . . . . . . . . . . . . . . . . . . . . . 377

. . . . . . . . . . . . . . . . . . . . . . . . . . . 379

MAINSHAFT W/INPUT SHAFT

. . . . . . . . . . . . . . . . . . . . . . . . 383

. . . . . . . . . . . . . . . . . . . . . . . . 383

. . . . . . . . . . . . . . . . . . . . . . . . . . . 390

COUNTERSHAFT

. . . . . . . . . . . . . . . . . . . . . . . . 397

. . . . . . . . . . . . . . . . . . . . . . . . . . . 401

SYNCHRONIZER

. . . . . . . . . . . . . . . . . . . . . . . . 404

. . . . . . . . . . . . . . . . . . . . . . . . . . . 405

GEAR SHIFT LEVER HANDLE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 405

. . . . . . . . . . . . . . . . . . . . . . . . 406

REVERSE LOCKOUT CABLE

. . . . . . . . . . . . . . . . . . . . . . . . 406

STANDARD PROCEDURE - REVERSE

LOCKOUT CABLE ADJUSTMENT

. . . . . . . . . 406

SHIFT MECHANISM

. . . . . . . . . . . . . . . . . . . . . . . . 412

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 412

. . . . . . . . . . . . . . . . . . . . . . . . 414

MANUAL - SERVICE INFORMATION

DESCRIPTION

The manual transmission is a fully synchronized two-shaft transmission with six forward gears and one reverse gear.
The 6th gear is used to save fuel and reduce engine speed. The manual transmission is equipped with a conven-
tional dry clutch with automatic wear adjuster which is operated by a central clutch operator. The transmission is
maintenance-free and has a permanent oil fill. A precise and light shift with short shifting travels is achieved by the
following measures:

•

Transmission of the shift lever movement to the transmission by the shift rod and control cable

•

Central shift shaft supported on needle bearings

•

Multiple-cone synchronization in 1st, 2nd, 3rd and 4th gear

•

Fully-synchronized reverse gear

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OPERATION

The gear assemblies and shafts are located between two bearing planes. The divided transmission housing is made
up of a light metal alloy, the housing parts of which are sealed with liquid sealing agent. The input shaft is supported
by a pilot bearing in the flywheel and by a deep-groove ball bearing in the transmission housing. The main shaft and
input shaft are inserted into each other on a common shaft plane in the transmission housing and are supported by
deep-groove ball bearings. The countershaft is designed as a hollow shaft to reduce weight and is supported by a
deep-groove ball bearing and a roller sleeve. The shaft play does not have to be adjusted due to the very tight
production tolerances of the gear wheels and housing halves, as well as the use of roller sleeves.

DIAGNOSIS AND TESTING

LOW LUBRICANT LEVEL

A low transmission lubricant level is generally the result of a leak, inadequate lubricant fill, or an incorrect lubricant
level check.

Leaks can occur at the mating surfaces of the gear case and adaptor or from the front/rear seals. A suspected leak
could also be the result of an overfill condition.

Leaks at the rear of the extension or adapter housing will be from the housing oil seals. Leaks at component mating
surfaces will probably be the result of inadequate sealer, gaps in the sealer, incorrect bolt tightening, or use of a
non–recommended sealer.

A leak at the front of the transmission will be from either the front bearing retainer or retainer seal. Lubricant may
be seen dripping from the clutch housing after extended operation. If the leak is severe, it may also contaminate the
clutch disc causing the disc to slip, grab, and/or chatter.

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MANUAL - SERVICE INFORMATION

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