Service Information: Assembly

NOTE: If the transmission assembly is being reconditioned (clutch/seal replacement) or replaced, it is necessary to perform the Quick Learn Procedure using the scan tool (Refer to ELECTRICAL/ELECTRONIC CONTROL MODULES/TRANSMISSION CONTROL MODULE - STANDARD PROCEDURE) .

Fig 1: Bearing Cup Installation Special Tool - 5050A

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Install the output bearing cups using Special Tool - 5050A. See Fig 1.

Fig 2: Removing/Installing Piston Retainer Gasket
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1 - GASKET HOLES MUST LINE UP

2 - LOW/REVERSE CLUTCH PISTON RETAINER GASKET
Install low/reverse piston retainer gasket (2). See Fig 2.

Fig 3: Removing/Installing Piston Retainer
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1 - LOW/REVERSE CLUTCH PISTON RETAINER

2 - GASKET

Install low/reverse piston retainer (1). See Fig 3.

Fig 4: Installing Piston Retainer Screws

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1 - LOW/REVERSE CLUTCH PISTON RETAINER

2 - SCREWDRIVER

3 - TORX-LOC SCREWS

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

Fig 5: Removing/Installing Low/Reverse Clutch Piston

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1 - LOW/REVERSE CLUTCH PISTON

2 - D-RING SEAL

3 - D-RING SEAL

NOTE: The Low/Reverse Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.

Install low/reverse clutch piston (1). See Fig 5.

Fig 6: Assembled Guide Bracket

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1 - GUIDE BRACKET

2 - ANTIRATCHET SPRING (MUST BE ASSEMBLED AS SHOWN IN ILLUSTRATION)

3 - PAWL

Assemble guide bracket (1) assembly as shown in illustration, if necessary. See Fig 6.

Fig 7: Removing/Installing Guide Bracket Pivot Pin
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1 - PIVOT PIN

2 - GUIDE BRACKET ASSEMBLY

CAUTION: When installing, be sure guide bracket and split sleeve touch the rear of the transmission case.
Install guide bracket pivot pin (1). See Fig 7.
Install park sprag pivot retaining screw and torque to 4.5 N.m (40 in. lbs.).

Fig 8: Removing/Installing Low/Reverse Piston Belleville Spring
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1 - LOW/REVERSE PISTON RETURN SPRING

2 - PISTON

Install low/reverse piston Belleville spring (1) into position. See Fig 8.

Fig 9: Compressor Tool In Use

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1 - LOW/REVERSE CLUTCH RETURN SPRING

2 - SNAP RING (INSTALL AS SHOWN IN ILLUSTRATION)

3 - TOOL 5058A-3

4 - TOOL 5059A

5 - SPECIAL TOOL 6057

Install and load low/reverse spring compressor tool (3, 4, 5) as shown to facilitate snap ring (2) installation. See Fig 9.

Fig 10: Installing Low/Reverse Clutch Snap Ring

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1 - SNAP RING OPENING MUST BE BETWEEN SPRING LEVERS (AS SHOWN IN ILLUSTRATION)

2 - SNAP RING PLIERS

3 - TOOL 6057

Install snap ring (1) and remove compressor tool. See Fig 10.

Fig 11: Installing Rear Carrier Front Bearing Cone

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1 - ARBOR PRESS

2 - SPECIAL TOOL C-4171

3 - SPECIAL TOOL 6052

4 - REAR CARRIER

Install rear carrier (4) front bearing cone. See Fig 11.

Fig 12: Installing Bearing And Support Plate
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1 - SPECIAL TOOL 6618-A

2 - REAR OUTPUT SHAFT BEARING

Check output bearing preload. Output bearing preload must be checked and/or adjusted if any of the following items have been replaced:
1. Output shaft (rear carrier assembly)
2. Output shaft bearings
3. Transmission case
PRELOAD CHECK/SHIM SELECTION: Install rear output shaft bearing cone and special tool 6618A (1). See Fig 12.

Fig 13: Installing Support Plate
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1 - SPECIAL TOOL 6618-A
Install special tool 6618A (1) Lightly tighten retaining screws. Screws should be below the plate surface, but do not snug screws. See Fig 13.
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.

Fig 14: Shim Installation
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1 - SHIM

2 - OUTPUT SHAFT
Install shim (1) on output shaft (2) 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. See Fig 14.

Fig 15: Pressing Shaft Into Rear Bearing
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1 - SPECIAL TOOL C-4171 AND C-4171-2

2 - SPECIAL TOOL MD-998911

Install output shaft/rear carrier into rear bearing. The shaft must be pressed into position. Use special tool MD-998911 (Disc) (2) and C- 4171 and C4171-2 (Handle) (1) to press shaft into rear bearing. See Fig 15.

Fig 16: Checking Turning Torque Of Output Shaft

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1 - TORQUE WRENCH

2 - SPECIAL TOOL 6498-A

3 - OUTPUT SHAFT NUT

CAUTION: Do not re-use old output shaft nut because the removed stake weakens the nut flange. Using special tools 6497 and 6498-A, install new output shaft nut. Tighten new output shaft nut to 271 N.m (200 ft. lbs.).

Check the turning torque (1) of the output shaft 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. See Fig 16. If turning torque is less than 1 in. lb, install a thinner shim. Make sure there is no end play.

Fig 17: Staking Output Shaft Nut

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1 - ARBOR PRESS

2 - STAKING TOOL - 6639

3 - NEW NUT

CAUTION: Failure to stake nut could allow the nut to back-off during use.

The new nut (3) must be staked after the correct turning torque is obtained Use special tool 6639 (2) to stake output shaft nut. See Fig 17.

Fig 18: View Of Properly Staked Nut
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1 - BOTTOMED IN SLOT

2 - CORRECTLY STAKED NUT
Verify that the nut has been properly staked (2) to the output shaft. See Fig 18.

Fig 19: Removing/Installing Low/Reverse Clutch Pack
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1 - CLUTCH PLATES (5)

2 - CLUTCH DISCS (5)

Install low/reverse clutch pack (1, 2) Leave uppermost disc out to facilitate snap ring installation. See Fig 19.

Fig 20: Removing/Installing Low/Reverse Reaction Plate Snap Ring

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1 - SCREWDRIVER

2 - LOW/REVERSE REACTION PLATE FLAT SNAP RING

3 - DO NOT SCRATCH CLUTCH PLATE

Install low/reverse reaction plate snap ring (2). See Fig 20.

Fig 21: Low/Reverse Clutch Disc
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1 - ONE DISC FROM LOW/REVERSE CLUTCH
Install one low/reverse clutch disc (1). See Fig 21.

Fig 22: Removing/Installing Low/Reverse Reaction Plate
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1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP)
Install low/reverse reaction plate (1) with flat side up. See Fig 22.

Fig 23: Installing Low/Reverse Clutch Snap Ring
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1 - SCREWDRIVER

2 - TAPERED SNAP RING (INSTALL AS SHOWN IN ILLUSTRATION)
Install a new tapered snap ring (2) (tapered side out). See Fig 23.

Fig 24: Proper Snap Ring Orientation
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Make sure that the snap ring ends are oriented as shown in illustration. See Fig 24.

Fig 25: Checking Low/Reverse Clutch Clearance

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1 - DIAL INDICATOR

2 - DIAL INDICATOR TIP TOOL 6268

3 - HOOK TOOL

Measure low/reverse clutch pack. Set up dial indicator (1) as shown in illustration. Press down clutch pack with finger and zero dial indicator. Record measurement in four (4) places and take average reading. See Fig 25. Low/Reverse clutch pack clearance is 0.84 to 1.60 mm (0.033 to 0.063 inch).
Select the proper low/reverse reaction plate to achieve specifications.

Fig 26: Removing/Installing 2/4 Clutch Pack
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1 - CLUTCH PLATE (4)

2 - CLUTCH DISC (4)
Install 2/4 clutch pack (1, 2). See Fig 26.

Fig 27: Removing/Installing 2/4 Clutch Return Spring
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1 - 2/4 CLUTCH RETURN SPRING

NOTE: The 2/4 Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.

Install 2/4 clutch Belleville spring (1). See Fig 27.

Fig 28: View Of Proper Orientation Of 2/4 Clutch Retainer And Spring

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1 - NOTE POSITION

2 - RETURN SPRING

3 - 2/4 CLUTCH RETAINER

Verify the proper orientation of the return spring (2) to the 2/4 retainer (3). See Fig 28.

Fig 29: Installing 2/4 Clutch Retainer
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1 - 2/4 CLUTCH RETAINER

Install 2/4 clutch retainer (1). See Fig 29.

Fig 30: Removing/Installing 2/4 Clutch Retainer Snap Ring

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1 - TOOL 5058

2 - SCREWDRIVER

3 - SNAP RING

4 - 2/4 CLUTCH RETAINER

NOTE: Verify that Tool 5058A (1) is centered properly over the 2/4 clutch retainer (4) before compressing. If necessary, fasten the 5058A bar to the bellhousing flange with any combination of locking pliers and bolts to center the tool properly.

Set up Tool 5058 (1) as shown in illustration. Compress 2/4 clutch just enough to facilitate snap ring installation. See Fig 30.

Fig 31: Checking 2/4 Clutch Clearance

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1 - DIAL INDICATOR

2 - HOOK TOOL

3 - DIAL INDICATOR TIP TOOL 6268

Measure 2/4 clutch clearance: Set up dial indicator (1) as shown in illustration. Press down clutch pack with finger and zero dial indicator. Record measurement in four (4) places and take average reading. See Fig 31. 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 or is excessively worn. There is no adjustment for the 2/4 clutch clearance.

Fig 32: Identifying Rear Sun Gear & No. 7 Needle Bearing
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1 - #7 BEARING

2 - REAR SUN GEAR
Install the #7 needle bearing (1) to the rear sun gear (2). See Fig 32. The number 7 needle bearing has three antireversal 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 33: View Of Rear Sun Gear And Needle Bearing
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1 - #7 NEEDLE BEARING

2 - REAR SUN GEAR

Install rear sun gear (2) and #7 needle bearing (1). See Fig 33.

Fig 34: Identifying Front Carrier/Rear Annulus And Needle Bearing

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1 - #6 NEEDLE BEARING

2 - FRONT CARRIER AND REAR ANNULUS ASSEMBLY (TWIST AND PULL OR PUSH TO REMOVE OR INSTALL).

Install front carrier/rear annulus assembly (2) and #6 needle bearing (1). See Fig 34.

Fig 35: View Of Front Sun Gear Assembly And #4 Thrust Washer
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1 - FRONT SUN GEAR ASSEMBLY

2 - #4 THRUST WASHER (FOUR TABS)

Install front sun gear assembly (1) and #4 thrust washer (2). See Fig 35.

Fig 36: Identifying #4 Thrust Plate

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1 - OVERDRIVE SHAFT ASSEMBLY

2 - #4 THRUST PLATE (SELECT)

3 - PETROLATUM FOR RETENTION

Determine proper #4 thrust plate thickness. Select the thinnest available #4 thrust plate.
Install #4 thrust plate (2) using petrolatum to hold into position. See Fig 36.
Install input clutch assembly. Ensure the input clutch assembly is completely seated by viewing position through input speed sensor hole. If the speed sensor tone wheel is not centered in the opening, the input clutches assembly is not seated properly.

Fig 37: Removing/Installing Oil Pump O-Ring
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1 - OIL PUMP ASSEMBLY

2 - O-RING

Remove the oil pump o-ring (2) and install oil pump and gasket to transmission. See Fig 37. 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 38: Measuring Input Shaft End Play Using End Play Set 8266

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1 - TOOL 8266-8

2 - TOOL 8266-2

3 - TOOL C-3339

Measure the input shaft end play with the transmission in the vertical position. This will ensure that the measurement will be accurate.
Set up and measure endplay using End Play Set 8266 (1, 2) and Dial Indicator Set C3339 (3) as shown in illustration. See Fig 38.
Measure input shaft end play. Input shaft end play must be 0.127 to 0.635 mm (0.005 to 0.025 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.

Fig 39: Removing/Installing Input Clutch Assembly
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1 - INPUT CLUTCH ASSEMBLY
Remove oil pump, gasket, and input clutch assembly to gain access to and install proper #4 thrust plate.
Install input clutch assembly (1) with proper thrust plate. See Fig 39.

Fig 40: Removing/Installing No. 1 Caged Needle Bearing
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1 - #1 CAGED NEEDLE BEARING

2 - NOTE: TANGED SIDE OUT
Install #1 caged needle bearing (1). See Fig 40.

Fig 41: Identifying Cooler By-Pass Valve
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1 - BYPASS VALVE

CAUTION: By-pass valve MUST be replaced if transmission failure occurs.
Replace cooler by-pass valve (1) if transmission failure has occurred. See Fig 41.
NOTE: To align oil pump, gasket, and case during installation, use threaded dowels or phillips screwdrivers.

Fig 42: Identifying Oil Pump Gasket
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1 - BELLHOUSING

2 - OIL PUMP GASKET
Install oil pump gasket (2). See Fig 42.

Fig 43: Removing/Installing Oil Pump Attaching Bolts
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1 - BOLTS

2 - OIL PUMP
Install oil pump (2) and torque oil pump-to-case bolts (1) to 30 N.m (265 in. lbs.). Do not reuse original oil pump bolts. See Fig 43.

Fig 44: Low/Reverse Accumulator Piston
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1 - ACCUMULATOR PISTON
Install low/reverse accumulator (1) as shown in illustration. See Fig 44.

Fig 45: Removing/Installing Low/Reverse Accumulator Plug
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1 - ADJUSTABLE PLIERS

2 - PLUG
Install low/reverse accumulator plug (2). See Fig 45.

Fig 46: Removing/Installing Low/Reverse Accumulator Snap Ring
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1 - SNAP RING

2 - LOW/REVERSE ACCUMULATOR
Install low/reverse accumulator snap ring (1). See Fig 46.

Fig 47: Identifying Underdrive And Overdrive Accumulators
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1 - OVERDRIVE PISTON AND SPRING

2 - UNDERDRIVE PISTON AND SPRING
Install underdrive (2) and overdrive (1) accumulators and springs. See Fig 47.

Fig 48: Removing/Installing Valve Body
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1 - VALVE BODY

CAUTION: Do not handle the valve body by the manual shaft. Damage could result.
Install valve body (1) into place as shown in illustration. See Fig 48.

Fig 49: Removing/Installing Valve Body Bolts
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1 - BOLTS
Install seven (7) valve body-to-case bolts (1) and torque to 12 N.m (105 in. lbs.). See Fig 49.

Fig 50: Removing/Installing Transmission Filter
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1 - TRANSMISSION FILTER
Install transmission oil filter (1) and o-ring Tighten the bolts to 5 N.m (45 in. lbs.). See Fig 50.
If necessary, install a new transmission fill tube grommet into the transmission case with Installer 8254.

Fig 51: Removing/Installing Transmission Oil Pan
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1 - TRANSMISSION OIL PAN

Install transmission oil pan (1) with a bead of Mopar® ATF RTV. See Fig 51.

Fig 52: Locating Oil Pan Bolts & Pressure Ports

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1 - FRONT DRIVESHAFT

2 - PRESSURE PORTS

3 - TRANSMISSION CASE

4 - TRANSMISSION OIL PAN

5 - SECOND TRANSMISSION OIL PAN BOLT ON LEFT SIDE

6 - FIRST TRANSMISSION OIL PAN BOLT

NOTE: Before installing the oil pan bolt in the bolt hole located between the torque converter clutch on and U/D clutch pressure tap circuits, it will be necessary to replenish the sealing patch on the bolt using Mopar® Lock & Seal Adhesive. See Fig 52.

Install and torque the oil pan-to-case bolts to 20 N.m (14.5 ft. lbs.).

Fig 53: Identifying Input and Output Speed Sensors and Transmission Range Sensor

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1 - INPUT SPEED SENSOR

2 - OUTPUT SPEED SENSOR

3 - TRANSMISSION RANGE SENSOR

NOTE: Before installing either speed sensor bolt, it will be necessary to replenish the sealing patch on the bolt using Mopar® Lock & Seal Adhesive.

Install both speed sensors (1, 2) into the transmission case. Torque the speed sensor bolts to 9 N.m (80 in. lbs.). See Fig 53.

Fig 54: Measuring Input Shaft End Play Using End Play Set 8266

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1 - TOOL 8266-8

2 - TOOL 8266-2

3 - TOOL C-3339

As a final check of the transmission, measure the input shaft end play. This will indicate when a #4 thrust plate change is required. The #4 thrust plate is located behind the overdrive clutch hub. Attach a dial indicator to transmission bell housing with its plunger seated against end of input shaft Move input shaft in and out to obtain end play reading. See Fig 54. Input shaft end play must be 0.127 to 0.635 mm (0.005 to 0.025 inch). If not within specifications, make the necessary thrust plate adjustment.

Fig 55: Locating Lube Tube & Grommet

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1 - HOUSING

2 - LUBE TUBE

3 - GROMMET

4 - PRY SLOTS

Inspect the lube tube grommet (2) for damage. If the grommet lip is damaged, it will need to be replaced. See Fig 55.

Fig 56: Installing Output Shaft Bearing

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1 - BEARING INSTALLER 9287

2 - BEARING

3 - TRANSMISSION CASE

Install output shaft bearing in the rear transmission housing. Using Bearing Installer 9287 (1), install the output shaft bearing (2) into the transmission housing. See Fig 56. The closed side of the plastic cage must point towards the transmission.

Fig 57: Removing/Installing Rear Output Shaft Retaining Ring
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1 - RETAINING RING

2 - OUTPUT SHAFT BEARING
Install the snap-ring into the groove in the output shaft.
Install the output shaft into the output shaft bearing.
Install the retaining ring (1) Ensure that the retaining ring is seated correctly in the groove. See Fig 57.
Install the output shaft washer onto the output shaft.

Fig 58: Install Output Shaft Seal
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1 - SEAL INSTALLER 8902A

2 - TRANSMISSION CASE
Install a new transmission rear seal into the transmission case with Seal Installer 8902A (1). See Fig 58.
Install the propeller shaft flange onto the output shaft and install an new flange nut finger tight.

Fig 59: Removing/Installing Extension Housing
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Install the extension housing (2) onto the transmission case. See Fig 59.

Fig 60: Removing/Installing Adapter/Extension Housing Bolts
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NOTE: Before installing the lowermost four extension housing bolts, it will be necessary to replenish the sealing patch on the bolts using Mopar® Lock & Seal Adhesive.

Install the bolts that hold the extension housing onto the transmission case. Be sure to install any stud bolts to their original locations. Tighten the bolts to 54 N.m (40 ft.lbs.). See Fig 60.

Fig 61: Align Staking Tool

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1 - PROPELLER SHAFT FLANGE

2 - STAKING TOOL 9078

3 - ALIGNMENT PIN

4 - OUTPUT SHAFT NOTCH

Verify that the transmission is in PARK in order to prepare for the installation of the output shaft nut. Tighten the flange nut to 120 N.m (88.5 ft.lbs.).
Stake the output shaft nut to the output shaft as follows. Place the Staking Tool 9078 (2) and Driver Handle C-4171 onto the output shaft.

Rotate the Staking Tool 9078 (2) until the alignment pin (3) engages the output shaft notch (4). See Fig 61.

Fig 62: Stake Output Shaft Nut

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1 - STAKING TOOL 9078

2 - PROPELLER FLANGE

3 - STAKING PIN

Press downward on the staking tool (1) until the staking pin (3) contacts the output shaft nut flange (2). See Fig 62.
Strike the Driver handle C-4171 with a suitable hammer until the output shaft nut is securely staked to the output shaft.