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Service Information: Assembly

NOTE: If the transmission is being reconditioned (clutch/seal replacement) or replaced, it is necessary to perform the TCM Adaptation Procedure using the scan tool (Refer to ELECTRICAL/ELECTRONIC CONTROL MODULES/TRANSMISSION CONTROL MODULE - STANDARD PROCEDURE) .
Fig 1: Identifying B2, B3 and Parking Gear
GC0012711Courtesy of DAIMLERCHRYSLER CORP.
1 - SNAP-RING 5 - PARK GEAR
2 - HOLDING CLUTCH B3 DISCS 6 - TRANSMISSION HOUSING
3 - SPRING WASHER 7 - BOLTS - M8X60
4 - HOLDING CLUTCH B2
  1. Insert parking lock gear (5). See Fig 1.
  2. Install multiple-disc holding clutch B2 (4) in transmission housing (6). See Fig 1.
  3. Screw in both Torx socket bolts (7). Tighten the bolts to 16 N.m (141 in.lbs.).
    Fig 2: Measure B3 Clutch Clearance
    GC0012722Courtesy of DAIMLERCHRYSLER CORP.
    1 - OUTER DISC - 6.5 MM (0.256 IN.) 5 - PISTON
    2 - OUTER DISCS - 1.8 MM (0.071 IN.) 6 - FRICTION DISCS
    3 - OUTER DISCS - 1.8 MM (0.071 IN.) 7 - SNAP-RING
    4 - SPRING WASHER 8 - B3 DISC CARRIER
    NOTE: During the measurement the snap ring (7) must contact the upper bearing surface of the groove in the outer multiple-disc carrier (8). See Fig 2.
    NOTE: Pay attention to sequence of discs. If the original clutch discs are reused, be sure to return the disc identified on disassembly as belonging on top of the spring washer (4) to its original location. Place new friction multiple-discs in ATF fluid for one hour before installing.
    CAUTION: Apply only light pressure (less than 10 N (3 lbs.) of force) to the clutch pack when measuring the clutch clearance with the feeler gauge. Applying excessive force to the clutch will give an incorrect reading and lead to a transmission failure.
  4. Insert and measure spring washer (4) and multiple-disc pack B3 (2, 6). See Fig 2.
    • Put multiple-discs for multiple-disc holding clutch B3 together in the sequence shown in the illustration and insert individually.
    • Using a feeler gauge, determine the play "L" at three points between the snap ring (7) and outer multiple-disc (1). B3 clutch clearance should be 1.0-1.4 mm (0.039-0.055 in.). Adjust the clearance as necessary.
    • Adjust with snap-ring (7), if necessary. Snap-rings are available in thicknesses of 3.2 mm (0.126 in.), 3.5 mm (0.138 in.), 3.8 mm (0.150 in.), 4.1 mm (0.162 in.), 4.4 mm (0.173 in.), and 4.7 mm (0.185 in.).
    Fig 3: Check K1 Feed Hole
    GC0012718Courtesy of DAIMLERCHRYSLER CORP.
    1 - K1 CLUTCH FEED HOLE
  5. Check that the K1 clutch feed hole (1) in the inner hub of clutch B1 is free before installing clutch B1. See Fig 3.
    Fig 4: Removing/Installing Holding Clutch B1 and Oil Pump
    GC0012709Courtesy of DAIMLERCHRYSLER CORP.
    1 - BOLTS - M6X32 4 - BOLTS - M8X35
    2 - CONVERTER HOUSING 5 - HOLDING CLUTCH B1
    3 - INTERMEDIATE PLATE 6 - OIL PUMP
  6. Place intermediate plate (3) on converter housing (2) and align.
    NOTE: The intermediate plate can generally be used several times. The plate must not be coated with additional sealant
  7. Install the holding clutch B1 (5) onto the converter housing and intermediate plate. Installed position of clutch B1 in relation to converter housing is specified by a plain dowel pin in clutch B1 (arrow). See Fig 4.
  8. Install the bolts to hold clutch B1 (5) to the converter housing. See Fig 4.
  9. Securely tighten multiple-disc holding clutch B1 (5) on converter housing (2) to 10 N.m (89 in.lbs.).
    Fig 5: Identifying Oil Pump Seals
    GC0012721Courtesy of DAIMLERCHRYSLER CORP.
    1 - INNER OIL SEAL
    2 - OUTER OIL SEAL
  10. Install new torque converter hub seal (1) into the oil pump using Seal Installer 8902A. See Fig 5.
  11. Install new oil pump outer o-ring seal onto oil pump. See Fig 5.
  12. Install oil pump (6) and securely tighten. Tighten the oil pump bolts to 20 N.m (177 in.lbs.).
    Fig 6: Identifying K1, K2 and K3 Clutches
    GC0012708Courtesy of DAIMLERCHRYSLER CORP.
    1 - DRIVING CLUTCH K1 5 - THRUST WASHER
    2 - SUN GEAR OF FRONT PLANETARY GEAR SET 6 - FRONT PLANETARY GEAR SET, DRIVING CLUTCH K2, AND INPUT SHAFT
    3 - DRIVING CLUTCH K3, OUTPUT SHAFT , AND CENTER AND REAR PLANETARY GEAR SETS 7 - SEALING RINGS
    4 - THRUST NEEDLE BEARING
  13. Using grease, insert sealing rings (7) in the groove so that the joint remains together. See Fig 6.
  14. Install the K1 (1) clutch onto the B1 clutch. See Fig 6.
  15. Install input shaft with clutch K2 (6) and front gear set (1). See Fig 6.
  16. Install front washer (5) and thrust needle bearing (4). See Fig 6.
  17. Install output shaft with center and rear gear set and clutch K3 (3). See Fig 6.
    Fig 7: Measure from Transmission Housing to Park Gear
    GC0012719Courtesy of DAIMLERCHRYSLER CORP.
    1 - GAUGE BAR 6311
    2 - PARK GEAR
  18. Using grease, install both Teflon rings in the groove at the rear of the output shaft so that the joint stays together.
  19. Mount transmission housing on converter housing.
  20. Screw in Torx socket bolts through the transmission housing into the converter housing. Tighten the bolts to 20 N.m (177 in.lbs.).
    NOTE: Verify that there are no nicks or other irregularities in the surface of the transmission case that will cause an inaccurate measurement.
  21. Measure end-play between park pawl gear and grooved ball bearing in order to select the proper geartrain end-play shim.
  22. Place Gauge Bar 6311 (1) on transmission housing. Using a depth gauge, measure from the gauge bar (1) to the parking lock gear (2). See Fig 7.
    Fig 8: Measure from Transmission Housing to Rear Bearing Contact Surface
    GC0012720Courtesy of DAIMLERCHRYSLER CORP.
    1 - GAUGE BAR 6311
    2 - OUTPUT SHAFT BEARING CONTACT SURFACE
  23. Using a depth gauge, measure from the Gauge Bar 6311 (1) to the contact surface of the output shaft bearing (2) in the transmission housing. See Fig 8
  24. Subtract the first figure from the second figure to determine the current end-play of the transmission. Select a shim such that the end-play will be 0.3-0.5 mm (0.012-0.020 in.). Shims are available in thicknesses of 0.2 mm (0.008 in.), 0.3 mm (0.012 in.), 0.4 mm (0.016 in.), and 0.5 mm (0.020 in.).
  25. Install the selected end-play shim.
    Fig 9: Installing Output Shaft Bearing
    GC0012724Courtesy of DAIMLERCHRYSLER CORP.
    1 - BEARING INSTALLER 9287
    2 - BEARING
    3 - TRANSMISSION CASE
  26. Screw in Torx socket bolts through the converter housing into the transmission housing. Tighten the bolts to 20 N.m (177 in.lbs.).
  27. Install output shaft bearing (2) in rear transmission housing. Using Bearing Installer 9287 (1), install the output shaft bearing (2) into the transmission housing. See Fig 9.The closed side of the plastic cage must point towards the parking lock gear. 
    Fig 10: Removing/Installing Rear Output Shaft Retaining Ring
    GC0012713Courtesy of DAIMLERCHRYSLER CORP.
    1 - RETAINING RING
    2 - OUTPUT SHAFT BEARING
  28. Install the retaining ring (1). See Fig 10. Ensure that the retaining ring is seated correctly in the groove.
  29. Check that there is no play between the bearing and the retaining ring using feeler gauge.
  30. There must be no play between the retaining ring and the bearing. If the ring cannot be installed, a thinner ring must be used. If there is play between the ring and the bearing, a thicker ring must be installed. Retaining rings are available in thicknesses of 2.0 mm (0.079 in.), 2.1 mm (0.083 in.), and 2.2 mm (0.087 in.).
    Fig 11: Checking Input Shaft End Play
    GC0012714Courtesy of DAIMLERCHRYSLER CORP.
    1 - TOOL 8266-8
    2 - TOOL 8266-18
    3 - TOOL C-3339
  31. Rotate the transmission so that the bellhousing is pointed upward and ensuring that the output shaft is allowed to move freely.
  32. Measure input shaft end-play. See Fig 11.
    NOTE: If end-play is incorrect, transmission is incorrectly assembled, or the geartrain end-play shim is incorrect. The geartrain end-play shim is selective.
    • Attach Adapter 8266-18 (2) to Handle 8266-8 (1).
    • Attach dial indicator C-3339 (3) to Handle 8266-8 (1).
    • Install the assembled tool onto the input shaft of the transmission and tighten the retaining screw on Adapter 8266-18 to secure it to the input shaft.
    • Position the dial indicator plunger against a flat spot on the oil pump and zero the dial indicator.
    • Move input shaft in and out and record reading. End play should be 0.3-0.5 mm (0.012-0.020 in.). Adjust as necessary.
    Fig 12: Install Output Shaft Seal
    GC0012725Courtesy of DAIMLERCHRYSLER CORP.
    1 - SEAL INSTALLER 8902A
    2 - TRANSMISSION CASE
  33. Install the output shaft washer onto the output shaft.
  34. Install a new transmission rear seal into the transmission case with Seal Installer 8902A (1). See Fig 12.
    Fig 13: Align Staking Tool
    GC0012723Courtesy of DAIMLERCHRYSLER CORP.
    1 - PROPELLER SHAFT FLANGE
    2 - STAKING TOOL 9078
    3 - ALIGNMENT PIN
    4 - OUTPUT SHAFT NOTCH
  35. Place the transmission in PARK to prepare for the installation of the output shaft nut.
  36. Inspect the seal protector on the rear of the output shaft flange. Replace the seal protector if damaged. the seal protector can be removed using a suitable pry tool and installed with a suitable tube style tool.
  37. Install the propeller shaft flange onto the output shaft and install an new flange nut. Tighten the flange nut, with a 30 mm 12 point socket, to 200 N.m (148 ft.lbs.).
  38. Place the Staking Tool 9078 (2) and Driver Handle C-4171 onto the output shaft.
  39. Rotate the Staking Tool 9078 (2) until the alignment pin (3) engages the output shaft notch (4). See Fig 13.
    Fig 14: Stake Output Shaft Nut
    GC0012726Courtesy of DAIMLERCHRYSLER CORP.
    1 - STAKING TOOL 9078
    2 - PROPELLER FLANGE
    3 - STAKING PIN
  40. Press downward on the staking tool (1) until the staking pin (3) contacts the output shaft nut flange (2). See Fig 14.
  41. Strike the Driver handle C-4171 with a suitable hammer until the output shaft nut is securely staked to the output shaft.
    Fig 15: Removing/Installing Electrohydraulic Unit
    GC0012712Courtesy of DAIMLERCHRYSLER CORP.
    1 - HEAT SHIELD
    2 - ELECTROHYDRAULIC UNIT
    3 - BOLT
    4 - OIL FILTER
    5 - OIL PAN
    6 - CLAMPING ELEMENT
    7 - BOLT
    8 - 13-PIN PLUG CONNECTOR
    9 - BOLT
    10 - ADAPTER PLUG
  42. Install electrohydraulic unit (2). Tighten the bolts to 8 N.m (71 in.lbs.).
  43. Install oil filter (4). See Fig 15.
  44. Install oil pan (5). See Fig 15. Tighten the bolts to 8 N.m (71 in.lbs.).
  45. Install the adapter plug (10). See Fig 15. Tighten the bolt (9) to 2.5 N.m (22 in. lbs.).
    Fig 16: Removing/Installing Torque Converter
    GC0012710Courtesy of DAIMLERCHRYSLER CORP.
    1 - TORQUE CONVERTER
    2 - CONVERTER HOUSING
  46. Install the torque converter. See Fig 16.
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