Overhaul - Automatic Transmission: Assembly

NOTE: If the transaxle assembly is being reconditioned (clutch/seal replacement) or replaced, it is necessary to perform the Quick Learn Procedure using the DRBIII® Scan Tool (Refer to SHIFT QUALITY QUICK-LEARN PROCEDURE (2002) or TRANSAXLE SHIFT QUALITY QUICK LEARN PROCEDURE (2003)).

Install the output bearing cups, use Special Tool # 5050A. See Fig 1.

Fig 1: Identifying Bearing Cup Installation Special Tool 5050A
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Install low/reverse piston retainer gasket. See Fig 2.

Fig 2: Installing Piston Retainer Gasket
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Install low/reverse piston retainer. See Fig 3.

Fig 3: Installing Piston Retainer
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Install low/reverse piston retainer-to-case screws and torque to 5 N.m (45 in. lbs.). See Fig 4.

Fig 4: Installing Retainer Attaching Screws
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Install low/reverse clutch piston. See Fig 5.

Fig 5: Installing Low/Reverse Clutch Piston
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Assemble guide bracket assembly as shown in Fig 6 and Fig 7 .

Fig 6: Exploded View Of Guide Bracket
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Fig 7: Installing Guide Bracket
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Install guide bracket pivot shaft. See Fig 8.

Fig 8: Installing Guide Bracket Pivot Shaft
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CAUTION: When installing, be sure guide bracket and split sleeve touch the rear of the transaxle case.
Install park sprag pivot retaining screw and torque to 5 N.m (45 in. lbs.). See Fig 9.

Fig 9: Installing Parking Sprag Pivot Retaining Screw
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Install low/reverse piston belleville spring into position. See Fig 10.

Fig 10: Installing Low/Reverse Piston Return Spring
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Install and load low/reverse spring compressor tool as shown in Fig 11 andFig 12 to facilitate snap ring installation.

Fig 11: Identifying Low/Reverse Spring Compressor Tool
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Fig 12: Installing Compressor Tool
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Install snap ring and remove compressor tool. See Fig 13.

Fig 13: Installing Snap Ring
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Install rear carrier front bearing cone. See Fig 14.

Fig 14: Installing Rear Carrier Front Bearing Cone
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Check output bearing preload. Output bearing preload must be checked and/or adjusted if any of the following items have been replaced:
- Output shaft (rear carrier assembly)
- Output shaft bearings
- Transaxle case
  1. PRELOAD CHECK/SHIM SELECTION: Install rear output shaft bearing cone and special tool 6618A. See Fig 15.
    
    Fig 15: Installing Bearing
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  2. Install special tool 6618A. See Fig 16. Lightly tighten retaining screws. Screws should be below the plate surface, but do not snug screws.
    
    Fig 16: Installing Special Tool
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  3. Turn case over on arbor press so that the plate is resting on the press base. CAUTION: The output shaft will extend through the hole of tool 6618A. Ensure your press table has clearance for the output shaft.
  4. Install shim on output shaft. See Fig 17. Apply small amount of petrolatum onto the shim to hold it in place. Use the original shim as a starting point. If original shim is not available, use the thickest shim available. Refer to Output Shaft Rear Shim Chart for available sizes.
    
    Fig 17: Installing Shim
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  5. Install output shaft/rear carrier into rear bearing. The shaft must be pressed into position. Use special tool MD-998911 (Disc) and C- 4171 and C4171-2 (Handle) to press shaft into rear bearing. See Fig 18.
    
    Fig 18: Pressing Shaft Into Case
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  6. Do not reuse old transfer shaft nut or output shaft nut because the removed stake weakens the nut flange. Using special tools 6497 and 6498, install new output shaft nut. Do not reuse old output shaft nut. Tighten new output shaft nut to 271 N.m (200 ft. lbs.).
  7. Check the turning torque of the output shaft. See Fig 19. The shaft should have 1 to 8 in. lbs. of turning torque. If the turning torque is higher than 8 in. lbs., install a thicker shim. If turning torque is less than 1 in. lb., install a thinner shim. Make sure there is no end play.
    
    Fig 19: Checking Turning Torque
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  8. The new nut must be staked after the correct turning torque is obtained. See Fig 20 and Fig 21 . Use special tool 6639 to stake output shaft nut and special tool 6589 to stake transfer shaft. CAUTION: Failure to stake shaft nuts could allow the nuts to back-off during use.
    
    Fig 20: Staking Output Shaft Nut
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    Fig 21: Identifying Properly Staked Nut
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Apply Mopar® ATF RTV (MS-GF41) as shown in Fig 22. Install main sump baffle to transaxle case and torque screw to 5 N.m (45 in. lbs.). See Fig 23.

Fig 22: Applying Sealant Properly
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Fig 23: Locating Main Sump Vent Baffle
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CAUTION: When reinstalling drive chains, the blue link must face outward.
Install output sprocket spacer. See Fig 24.

Fig 24: Installing Output Sprocket Spacer
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CAUTION: The chain sprockets have a slip fit onto the shafts. Apply only a slight amount of pressure to the chain spreader to release the chain pressure. If chain sprockets are not spread slightly, installation will be difficult.
Install transfer chain and sprockets to transfer shaft and output shaft. See Fig 25.

Fig 25: Installing Chains & Both Sprockets As An Assembly
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Remove chain spreader. See Fig 26.

Fig 26: Remove Chain Spreader
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Install transfer shaft sprocket snap rings and wave washers. See Fig 27 and Fig 28 .

Fig 27: Installing Transfer Shaft Sprocket Snap Ring & Wave Washer
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Fig 28: Installing Output Shaft Sprocket Snap Ring & Wave Washer
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CAUTION: Be sure to reinstall the chain snubber and chain oiler when reassembling.
Install transfer chain snubber and torque screws to 5 N.m (45 in. lbs.). See Fig 29.

Fig 29: Installing Chain Snubber
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Install chain oiler and torque screw to 5 N.m (45 in. lbs.). See Fig 30.

Fig 30: Installing Chain Oiler
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Stand trans upright on bellhousing
Install chain cover. See Fig 31.Chain cover must be free of old sealant, dirt and oil before applying new sealant. Apply a 1/8 inch bead of Mopar® ATF RTV (MS-GF41) to flange of cover.

Fig 31: Installing Chain Cover
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Install low/reverse clutch pack. See Fig 32. Leave uppermost disc out to facilitate snap ring installation.

Fig 32: Installing Low/Reverse Clutch Pack
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Install low/reverse reaction plate snap ring. See Fig 33.

Fig 33: Installing Low/Reverse Reaction Plate Snap Ring
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Install one low/reverse clutch disc. See Fig 34.

Fig 34: Installing One Disc
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Install low/reverse reaction plate with flat side up. See Fig 35.

Fig 35: Installing Low/Reverse Reaction Plate
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Install tapered snap ring (tapered side out) as shown in Fig 36 and Fig 37 .

Fig 36: Identifying Tapered Snap Ring Instructions
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Fig 37: Installing Snap Ring
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Measure low/reverse clutch pack. Set up dial indicator as shown in Fig 38. Press down clutch pack with finger and zero dial indicator. Record measurement in four (4) places and take average reading. Low/Reverse clutch pack clearance is 0.86 to 1.52 (0.034 to 0.060 inch).

Fig 38: Checking Low/Reverse Clutch Clearance
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Select the proper low/reverse reaction plate to achieve specifications:

Fig 39: Low/Reverse Reaction Plate Chart
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Install 2/4 clutch pack. See Fig 40. Stagger 2/4 clutch disc pads as shown in Fig 41.

Fig 40: Installing 2/4 Clutch Pack
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Fig 41: Staggering 2/4 Clutch Plate Pads
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NOTE: When installing the 2-4 clutch plates and discs, the orientation should be alternated so the pilot pads of adjacent plates do not align, refer to Fig 41.
Install 2/4 clutch belleville spring. See Fig 42 and Fig 43 .

Fig 42: Installing 2/4 Clutch Return Spring
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Fig 43: Identifying Proper Orientation of 2/4 Clutch
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Install 2/4 clutch retainer. See Fig 44.

Fig 44: Installing 2/4 Clutch Retainer
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Set up Tool 5058 as shown in Fig 45. Compress 2/4 clutch just enough to facilitate snap ring installation.

Fig 45: Installing 2/4 Clutch Retainer Snap Ring
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Measure 2/4 clutch clearance: Set up dial indicator as shown in Fig 46. Press down clutch pack with finger and zero dial indicator. Record measurement in four (4) places and take average reading. The 2/4 clutch pack clearance is 0.76 to 2.64 mm (0.030 to 0.104 inch). If not within specifications, the clutch is not assembled properly. There is no adjustment for the 2/4 clutch clearance.

Fig 46: Checking 2/4 Clutch Clearance
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Install the #7 needle bearing to the rear sun gear. See Fig 47.The number 7 needle bearing has three anti-reversal tabs and is common with the number 5 and number 2 position. The orientation should allow the bearing to seat flat against the rear sun gear. A small amount of petrolatum can be used to hold the bearing to the rear sun gear.

Fig 47: Installing Number 7 Bearing
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Install rear sun gear and #7 needle bearing. See Fig 48.

Fig 48: Installing Install Rear Sun Gear
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Install front carrier/rear annulus assembly and #6 needle bearing. See Fig 49.

Fig 49: Installing Front Carrier/Rear Annulus Assembly
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Install front sun gear assembly and #4 thrust washer. See Fig 50.

Fig 50: Installing Front Sun Gear Assembly
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Determine proper #4 thrust plate thickness.
1. Select the thinnest #4 thrust plate thickness.
  
  Fig 51: Thrust Plate Chart
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2. Install #4 thrust plate using petrolatum to hold into position. See Fig 52.
  
  Fig 52: Installing Thrust Plate
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3. Install input clutch assembly. Ensure the input clutch assembly is completely seated by viewing position through input speed sensor hole. See Fig 53.If view through input speed sensor hole is not as shown in Fig 53 , the input clutches assembly is not seated properly.
  
  Fig 53: View Through Turbine Speed Sensor Hole
  Courtesy of DAIMLERCHRYSLER CORP.
4. Remove the oil pump o-ring and install oil pump and gasket to transaxle. See Fig 54. Use screw-in dowels or phillips-head screwdrivers to align pump to case. Be sure to reinstall O-ring on oil pump after selecting the proper No. 4 thrust plate.
  
  Fig 54: Removing Oil Pump O-Ring
  Courtesy of DAIMLERCHRYSLER CORP.
5. Measure the input shaft end play with the transaxle in the vertical position. This will ensure that the measurement will be accurate.
6. Set up and measure end play using End Play Set 8266 and Dial Indicator Set C3339 as shown in Fig 55.
  
  Fig 55: Measuring Input Shaft End Play Using Tool 8266 (Typical)
  Courtesy of DAIMLERCHRYSLER CORP.
7. Measure input shaft end play. Input shaft end play must be .005 to .025 inch. For example, if end play reading is 0.055 inch, select No. 4 Thrust Plate which is 0.071 to 0.074 thick. This should provide an input shaft end play reading of 0.020 inch, which is within specifications.
8. See chart to select the proper No. 4 thrust plate.
9. Remove oil pump, gasket, and input clutch assembly to gain access to and install proper #4 thrust plate.
  CAUTION: If view through input speed sensor hole is not as shown in Fig 53, the input clutches assembly is not seated properly.
Install input clutch assembly with proper thrust plate. See Fig 56.

Fig 56: Installing Input Clutch Assembly
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Install #1 caged needle bearing. See Fig 57.

Fig 57: Installing Caged Needle Bearing
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Replace cooler bypass valve if transmission failure has occurred. See Fig 58.
CAUTION: Bypass valve must be replaced if transmission failure occurs.

Fig 58: Installing Bypass Valve
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NOTE: To align oil pump, gasket, and case during installation, use threaded dowels or phillips screwdrivers.
Install oil pump gasket. See Fig 59.

Fig 59: Installing Oil Pump Gasket
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Install oil pump and torque oil pump-to-case bolts to 28 N.m (250 in. lbs.). See Fig 60.

Fig 60: Installing Oil Pump Attaching Bolts
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Install long stub shaft and bearing to housing. See Fig 61.

Fig 61: Installing Long Stub Shaft To Bellhousing
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NOTE: Install new halfshaft retainer clips.
Install long stub shaft bearing retaining snap ring. See Fig 62. Replace halfshaft retainer clips.

Fig 62: Installing Long Stub Shaft Snap Ring
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Install low/reverse accumulator as shown in Fig 63.

Fig 63: Installing Low/Reverse Accumulator
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Install low/reverse accumulator plug. See Fig 64.

Fig 64: Installing Low/Reverse Accumulator Plug (Cover)
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Install low/reverse accumulator snap ring. See Fig 65.

Fig 65: Installing Low/Reverse Accumulator Snap Ring
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Install underdrive and overdrive accumulators as shown in Fig 66, Fig 67 and Fig 68 .

Fig 66: Locating Accumulators
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Fig 67: Installing Underdrive Accumulator & Springs
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Fig 68: Installing Overdrive Accumulator & Springs
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CAUTION: Do not handle the valve body by the manual shaft. Damage could result.
Install valve body into place as shown in Fig 69.

Fig 69: Installing Valve Body To Transaxle
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Install seven (7) valve body-to-case bolts and torque to 12 N.m (105 in. lbs.). SeeFig 70.

Fig 70: Installing Valve Body Bolts (7)
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Install transaxle oil filter. See Fig 71.

Fig 71: Installing Transaxle Oil Filter
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Install transaxle oil pan with a bead of Mopar® ATF RTV (MS-GF41). See Fig 72. Torque oil pan-to-case bolts to 23 N.m (17 ft. lbs.). Install both speed sensors from transaxle case. See Fig 73. Torque speed sensors to 27 N.m (20 ft. lbs.).

Fig 72: Installing Transaxle Oil Pan
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Fig 73: Installing Input & Output Speed Sensors
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As a final check of the transaxle, measure the input shaft end play. This will indicate when a #4 thrust plate change is required. The number 4 thrust plate is located behind the overdrive clutch hub. Attach a dial indicator to transaxle bell housing with its plunger seated against end of input shaft. See Figure. Move input shaft in and out to obtain end play reading. End play specifications are 0.13 to 0.64 mm (0.005 to 0.025 inch). If not within specifications, make the necessary thrust plate adjustment.