Aw60T Automatic Transaxle (Service Information): Assembly: Assembly

Fig 1: Installing Bell Housing Side Transfer Shaft Bearing Race

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1. Install the bell housing side transfer shaft bearing race using (special tool #D-146, Installer, Bearing Cup) and (special tool #C-4171, Driver Handle, Universal)
2. Install the bell housing side differential side bearing race using (special tool #9617, Installer, Bearing Cup) and (special tool #C-4171, Driver Handle, Universal)
3. Install the case side differential bearing and shim using (special tool #8255, Installer) and a press.
4. Install the case side transfer shaft bearing race using Race Installer (special tool #10312, Installer, Bearing Cup) and (special tool #C-4171, Driver Handle, Universal).
   Fig 2: 1st Gear & Reverse Brake Piston O-Rings

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5. Install new  O-rings to the 1st gear and reverse brake piston.
   Fig 3: Oil Seal Rings

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6. Install new  oil seal rings.
   Fig 4: 1st Gear & Reverse Brake Piston

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7. Install the needle bearing to the case using an appropriately sized socket.
8. Install the 1st gear and reverse brake piston.
   Fig 5: 1st Gear & Reverse Brake Piston Thrust Washer

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9. Install the C2 clutch thrust washer (1).
   Fig 6: 1st Gear & Reverse Brake Return Spring

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10. Install the 1st gear and reverse brake return spring (1).
    Fig 7: 1st Gear & Reverse Brake Return Spring Snap Ring

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11. Install the snap ring (1)
    Fig 8: C2 Clutch Assembly

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12. Install the C2 clutch assembly (1).
    Fig 9: C2 Clutch Assembly Snap Ring

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13. Install the snap ring.
    Fig 10: B2 Disc Pack

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14. Install the B2 disc pack (1).
    Fig 11: B2 Disc Pack Snap Ring

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15. Install the snap ring (1).
    Fig 12: Thrust Needle Roller Bearing & Races

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16. Install the thrust washers and thrust bearing.
    Fig 13: Planetary Carrier & One Way Clutch

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17. Install the rear planetary carrier and one way clutch as a unit (1 and 2).
    Fig 14: Planetary Gears

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18. Install the large and small rear planetary gears (1).
    Fig 15: Planetary Gear Snap Ring

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19. Install the snap ring (1).
    Fig 16: Output Speed Sensor & Bolt

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20. Install the output speed sensor (2) and the speed sensor bolt (1). Tighten to Tighten to 6 N.m (53 in.lbs.).
    Fig 17: Counter Drive Gear Assembly

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21. Install the counter drive gear assembly (1).
22. Install the counter drive gear assembly bolts. Tighten to 62 N.m (46 ft.lbs.).
    Fig 18: Fluid Transfer Pipe & Bolts

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23. Install the fluid transfer pipe (2) and install the transfer pipe bolts (1), tighten to 6 N.m (53 in.lbs.).
    Fig 19: Installing Left Side Counter Gear Bearing

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24. Install the left side counter gear bearing using (special tool #C-3717, Sleeve)

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    Fig 20: Installing Right Side Counter Gear Bearing

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25. Install the right side counter gear bearing using (special tool #C-4040, Installer, Bearing)

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    Fig 21: Counter Gear Shaft & Differential

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26. Install the counter gear shaft (2) and the differential (1).
    Fig 22: Manual Lever

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27. Install the new  manual lever seal using (special tool #10141-5, Remover/Installer).
28. Install the manual lever (1).
    Fig 23: Plunger

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29. Install the plunger to the case.
    Fig 24: Actuator Rod

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30. Install the actuator rod (1).
    Fig 25: Actuator Rod & Manual Shift Lever

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31. Rotate the actuator rod (1) and turn the manual shift lever (2) so the rod key slot and tabs line up, connect.
    Fig 26: Parking Pawl, Spring & Pivot Assembly

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32. Install the parking pawl (2) and the spring and pivot assembly (1).
    Fig 27: Manual Shift Shaft Detent & Bolt

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33. Install the manual shift shaft the detent (2) and detent bolt (1). Tighten to 10 N.m (89 in.lbs.).
    Fig 28: Actuator Rod, Bracket & Bolts

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34. Connect the actuator rod (2) to the bracket (3). Install the parking pawl actuator bracket bolts (1). Tighten to 10 N.m (89 in.lbs.).
    Fig 29: Thrust Washers & Bearing

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35. Install the thrust washers (1) and bearings (2).
    Fig 30: Sun Gear Input Drum

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36. Install the sun gear input drum (1).
    Fig 31: C1 Clutch Assembly

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37. Install the C1 clutch assembly (1).
    Fig 32: Front Planetary Carrier & Input Shaft Annulus Gear Assembly

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38. Install the front planetary carrier and input shaft annulus gear assembly (1).
    Fig 33: B1 Brake/C3 Clutch Assembly

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39. Install the B1 brake / C3 clutch assembly (1).
    Fig 34: Thrust Washer

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40. Install the nylon thrust washer (1).
    Fig 35: B1 Brake Band

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41. Install the B1 band (1).
    Fig 36: B1 Band Bolt

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42. Install the B1 band bolt (1). Tighten to 167 N.m (123 ft.lbs.)
    Fig 37: B1 Brake Band Servo, Spring & Piston Rod

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43. Install the B1 band servo assembly (1-3), install new  O-rings.
    Fig 38: Oil Strainer & Bolts

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44. Install the oil strainer (2) and bolts (1). Tighten the bolts to 6 N.m (53 in.lbs.)
    Fig 39: Oil Pump

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45. Install the oil pump.
    Fig 40: Oil Pump Bolts

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46. Install the oil pump bolts (1). Tighten to 25 N.m (18 ft.lbs.).
47. Check that the input shaft turns smoothly, if not then remove the pump and reinstall.
    Fig 41: Measuring Vertical Input Shaft End Play

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48. Using a dial indicator, measure the vertical input shaft end play. The end play should be within 0.399-1.131mm (0.016-0.045 in.).
    Fig 42: Tube, Retention Tab & Bolt

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49. Install the tube (3), bolt (1) and retention tab (2). Tighten the bolt to 6 N.m (53 in.lbs.).
    Fig 43: Magnets

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50. Install the magnets (1) to the oil reservoir lock plate.
    Fig 44: Oil Reservoir Lock Plate & Bolts

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51. Install the oil reservoir lock plate and bolts (1 and 2). Tighten the bolts to 6 N.m (53 in.lbs.).
    Fig 45: Installing Transmission Gasket

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52. Install the new  transmission gasket after coating them with ATF.
    Fig 46: Case Halves

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53. Apply a uniform bead of MOPAR 3 Bond to the case halves
54. Assemble the case halves.
    Fig 47: Transaxle Case Bolts

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55. Install the transaxle case bolts. Note that the longer bolts are in positions (1).
    Fig 48: Transaxle Case Bolts Tightening Sequence

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56. Install the transaxle case bolts. Tighten to 30 N.m (22 ft.lbs.) following the sequence shown.
    Fig 49: Input Speed Sensor & Bolt

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57. Install the input speed sensor (2) to the case. Install the input speed sensor bolt (1), Tighten to 6 N.m (53 in.lbs.).
58. Install the external oil cooler. Refer to COOLER, TRANSMISSION OIL, INSTALLATION .
59. Install the valve body assembly. Refer to VALVE BODY, INSTALLATION .
60. Install the transmission control module. Refer to MODULE, TRANSMISSION CONTROL [EAJ], INSTALLATION or MODULE, TRANSMISSION CONTROL [EAB], INSTALLATION .