6F24 Automatic Transmission (Service Information): Assembly: AWD
NOTE:
Thoroughly clean all components to remove metallic and fibrous materials that may have contaminated the transaxle during a component failure.
NOTE:
Inspect all components for excessive ware, spalled surfaces, or other obvious damage. Replace only damaged components that are serviceable with genuine Mopar Parts.
- Place the transfer drive assembly (1) into position in the transaxle case.
- Install three bolts (2) to hold transfer drive assembly (1) to the transaxle housing. Refer to SPECIFICATIONS .
- Install NEW inside and outside D-ring seals into the low & reverse brake piston (1).
- Using specified transaxle fluid, lubricate the low & reverse brake piston (1) D-ring seals.
- Place low & reverse brake piston (1) in position in transaxle housing.
- Push low & reverse brake piston downward into cylinder bore in the transaxle housing.
- Place low & reverse brake piston spring retainer in position on the lo-reverse brake piston.
- Install spring compressor tools (special tool #5058A-3, Screw, Forcing) in position on transaxle.
- Insert screw through center hole in spring compressor (special tool #8621, Compressor, Spring).
Insert the screw through the transfer gear and into the threaded cross bar across the bell housing opening.
- Compress the low/reverse spring retainer.
- Install the snap ring (1) to hold the low/reverse brake spring retainer to the low/reverse brake piston.
- Place the front annulus gear (1) in position in the low/reverse brake assembly.
- Place the front annulus gear thrust bearing and race (1) in position on the front annulus gear (2) hub.
- Place the front planetary gear (1) in position on the front annulus gear assembly (2).
- Insert the front sun gear (1) into front planetary gear assembly.
- Place the bearing (2) and race (1) set in position on the planetary gear hub.
- Insert the middle sun gear (1) in position in the in position on the front sun gear (2).
- Place the thrust washer (1) in position on the front planetary gear hub.
- Place the middle/rear planetary gear assembly (1) in position in the planetary gear hub.
- Place the rear annulus gear (1) in position on the middle/rear planetary gear assembly.
- Install the snap ring (2) to hold the rear annulus gear (1) into the front annulus gear hub.
- Insert the snap ring into the groove in the middle/rear planetary gear.
- Place the one way clutch inner race (1) in position on the middle/rear planetary gear.
- Using long nose pliers (3), compress snap ring (1) to hold the one way clutch race (2) to the middle/rear planetary gear.
- Install the low & reverse brake pressure plate (1), cushion plate (2), plates 3) discs (4), and the reaction plate (5), in order, into the transaxle.
- Install the snap ring (1) to hold low/reverse brake into the lowest snap ring land (2) in the transaxle.
- Lining up the two narrow lugs on the OWC to the two narrow slots on the transaxle housing insert the OWC (1) into the transaxle. Press down until it is seated. The OWC should rotate in a counterclockwise direction only.
- Install the snap ring (1) to hold the OWC to the transaxle housing
- Turn transaxle over to gain access to the front of the transaxle.
- Install the transfer driven gear (1) assembly in position in the transaxle (2).
- Install the park sprag support shaft (1) in position in the transaxle housing.
- Insert the park sprag (1) in position in the transaxle housing.
- Install the park sprag spring and shaft (1) in position in the transaxle housing.
- Using a suitable hook tool (1), lift the park sprag spring (2) onto the park sprag.
- Install bolts to hold the park rod guide (1) in position on the transaxle housing.
- Place the underdrive brake retainer (2) in position on the transaxle housing (1).
- Install bolts (2) to hold the underdrive brake retainer (1) to the transaxle housing. Refer to SPECIFICATIONS .
- Place the underdrive brake chamber in position on the transaxle housing.
- Install bolts (1) to hold the underdrive brake chamber (2) to the transaxle housing. Refer to SPECIFICATIONS .
- Install NEW D-ring outer seal and the O-ring inner seal in the lands on the underdrive piston.
- Install the underdrive brake piston (1) in position on the underdrive brake piston chamber.NOTE:
The location tabs (2) on the underdrive brake piston should be oriented toward the valve body opening in the transaxle.
- Push underdrive brake piston (3) downward until it seats in the underdrive brake chamber.
- Place the underdrive spring retainer (1) in position on the underdrive brake piston (2).
- Insert the bolt (3) for tool (special tool #5058A, Compressor, Spring) through tool (special tool #10426, Compressor, Underdrive Spring).
- Insert the tool (special tool #5058A-3, Screw, Forcing) bolt (3) with the spring compressor through the center of the transaxle (1) and out the back into the threaded center bore of the tool cross bar (2) spanning the back of the transaxle.
Compress the underdrive springs (3) to gain access to the snap ring land.
- Install the snap ring (1) to hold the underdrive spring plate to the underdrive brake hub.
- Remove the spring compressor tool from the transaxle.
- Turn the transaxle over to gain access to the rear cover.
- Place the thrust bearing (1) and race set into of the center of the middle/rear planetary gear assembly (2).
- Place the thrust washer (1) in position on the middle/rear planetary gear.
- Install the overdrive clutch assembly (1) onto the one way clutch race (2).
- Install thrust bearing (1) onto the overdrive clutch hub (2) assembly with the rollers facing upward.
- Install the four seals (2) into transfer ports in transaxle housing.
- Install the two split seal ring seals (2) into the lands in the rear cover (1) hub.
- Using assembly lube applied in the seat area of the rear cover (3), Install the selective spacer (1) onto the rear cover (2).
- Apply a 3 mm (0.120 in.) bead of Dupont® Loctite™ 5460 Pink Flange Sealant or equivalent around the perimeter of the rear cover.
- Place the rear cover (1) in position on the transaxle.
- Install bolts to hold the rear cover (1) to the transaxle. Refer to SPECIFICATIONS .
- Turn transaxle over to gain access to the underdrive brake.
- Place underdrive brake plates and discs in position in underdrive brake drum.
- Install large snap ring (3) to hold underdrive brake (1) into the underdrive brake drum.
- Install underdrive brake hub (1) assembly in position on transaxle.
- Install thrust washer (2) in position on the underdrive brake hub.
- Install the 3/5/R clutch and 2/6 brake hub (1) assembly in position on the underdrive clutch.
- Install the thrust bearing (2) in position on the 3/5/R clutch and 2/6 brake hub.
- Install the 3/5/R clutch assembly (1) in position in the 3/5/R and 2/6 brake hub (2) assembly.
- Install 2/6 brake select thickness reaction plate (1) in position in the 2/6 brake hub.
- Install the 2/6 brake alternating the (1) plates (3) and discs (2) in position in the 2/6 brake hub.
- Install 2/6 brake wave plate (1) in position in the 2/6 brake hub.
- Install two split ring seals (2) in the seal lands (2) in the input shaft (1).
- Install two split seal rings (3) in the lands (2) in fluid pump (1) hub.
- Apply a 3 mm (0.120 in.) bead of Dupont® Loctite™ 5460 Pink Flange Sealant or equivalent around the perimeter of the fluid pump sealing surface.
- Using assembly lube, install the plastic thrust washer (2) in position on the underside of the fluid pump (1). There are three nubs that insert into holes in the fluid pump hub to prevent the thrust washer from rotating.
- Place the fluid pump (2) in position on the transaxle housing (1).
- Install bolts (1) to hold fluid pump (3) to the trans axle housing (2). Refer to SPECIFICATIONS .
- Install NEW o-ring seal in position in the groove in the fluid pump housing.
- Place the fluid filter (2) in position in the transaxle housing (1).
- Install bolts (1) to hold the fluid filter to the fluid pump (3) housing. Refer to SPECIFICATIONS .
- Install seals in position in four small transfer ports (2) in the transaxle housing (1).
- Install seal in position in the large transfer port (1) in the axle housing (2).
- Place the differential assembly in position in the transaxle housing.
- Apply a 3 mm (0.120 in.) bead of Dupont® Loctite™ 5460 Pink Flange Sealant or equivalent around the perimeter of the transaxle housing.
- If fluid guides and tube were removed during cleaning, install related components in the transaxle housing. Refer to SPECIFICATIONS .
- Place the bell housing (1) in position on the transaxle (2).
- Install five bolts (1) on inside of the bell housing. Refer to SPECIFICATIONS .
- Install six bolts (2) in the bottom of the transaxle housing. Refer to SPECIFICATIONS .
- Install five bolts from the back (2) and four bolts from the top (1) of the transaxle housing. Refer to SPECIFICATIONS .
- If seal required replacement, install the NEW lip seal in the manual shaft hole in the transaxle housing.
- Insert the park rod (1) into the park rod guide.
- Insert the manual shaft (1) into the bearing in the transaxle.
- Push manual shaft (1) upward until park rod (2) engages the detent comb.
- Rotate manual shaft (1) clockwise to lock the staked nub on the park rod (2) in the key hole slot (3) in the manual shaft detent comb.
- Install the pin (2) to hold the manual shaft (1) in the transaxle into the hole in the pan gasket flange.
- Place the main wire harness and sensors (1) in position on the transaxle.
- Push the wire connector outward through to hole in the transaxle housing.
- Place the wire connector (1) hold down bracket (2) in position on the transaxle.
- Install bolt to hold the wire connector (1) hold down bracket (2) to the top of transaxle housing. Refer to SPECIFICATIONS .
- Insert the speed sensors in position in the transaxle housing.
- Install bolts (1) to hold the speed sensors and main wire harness to transaxle. Refer to SPECIFICATIONS .
- Install the two seals into the transfer ports in transaxle housing.
- The manual valve is loose after the valve body is removed and may fall out during installation.
Place the valve body (2) in position on the transaxle (1). Guide the pin on the manual valve into the slot in the manual shaft detent comb.
- Install bolts, 7 short (1) and 1 long (2) bolts, to hold the valve body to the transaxle. Refer to SPECIFICATIONS .
- Place the detent spring (2) in position on the valve body (1).
- Install the screw to hold the manual shaft detent spring (1) to the valve body (2). Refer to SPECIFICATIONS .
- Starting at the top solenoid valve, push inward at each solenoid (2) until the connector (3) is engaged.
- Install bolts to hold the solenoid valve connector (2) to the valve body (1). Refer to SPECIFICATIONS .
- Insert the temperature sensor (1) into port in the valve body (2).
- Install bolt to hold fluid temperature sensor (1) to the valve body (2). Refer to SPECIFICATIONS .
- Install a NEW gasket on the pan and place the pan (1) in position on the transaxle (2).
- Install bolts to hold the valve body pan (2) to the transaxle (1). Refer to SPECIFICATIONS .
- Place the cooler tubes (2) in position on the transaxle (1).
- Install bolt to hold the cooler tube (2) bracket to the transaxle (1). Refer to SPECIFICATIONS .
- Install banjo bolts (2) to hold the cooler tubes (1) to the transaxle. Refer to SPECIFICATIONS .
- Place the vent tube (3) in position on the transaxle (1).
- Install bolt to hold the vent tube bracket (2) to the transaxle housing. Refer to SPECIFICATIONS .
- Push the vent hose end (1) onto of the nipple on the vent adaptor (2).
- Using common pliers (3), compress the hose spring clamp (2) and slide it up the vent hose (1) into position to hold the hose to the nipple.
- Place the TRS (1) in position on the transaxle.
- Install bolts to hold the TRS (1) to the transaxle housing. Refer to SPECIFICATIONS .
- Place the manual level (1) in position on the manual shaft.
- Insert a suitable pin punch (2) or equivalent through the manual lever into the TRS switch (1) to hold lever in place.
- Install the nut to hold the manual lever to the manual shaft. Refer to SPECIFICATIONS .
NOTE:
The transaxle can now be installed in a vehicle. Refer to INSTALLATION .