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8HP95 Automatic Transmission (Service Information): Assembly

CAUTION:

A unique transmission fluid has been developed for this transmission. This fluid is NOT compatible with ATF+4 or any other current FCA US LLC transmission fluid. For specifics about this unique fluid see FLUIDS, LUBRICANTS AND GENUINE PARTS.

CAUTION:

The Transmission Control Module (TCM), or Transmission Control Module Assembly (TCMA) is extremely sensitive to Electrostatic Discharge (ESD). Always use a ground strap and follow the ESD guidelines in ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES. Failure to follow these instructions may result in damage to the TCM/TCMA.

NOTE:

If the transmission is being reconditioned (clutch/seal replacement) or replaced, it is necessary to perform the Transmission Control Module (TCM) Adaptation Procedure. Refer to TRANSMISSION CONTROL MODULE (TCM) ADAPTATION .

GC0152178Courtesy of CHRYSLER GROUP, LLC
  1. Insert the P4 annulus (3) into the P4 annulus drum (2).
  2. Install the snap ring (1) into the P4 annulus drum (2).
    GC0152270Courtesy of CHRYSLER GROUP, LLC
  3. Install the P4 planetary carrier\output shaft (2) into the P4 annulus drum (1).
    GC0152177Courtesy of CHRYSLER GROUP, LLC
  4. Position the bearings on the top and the bottom of C clutch (1).
  5. Install the C clutch (1) into the P4 sun gear/C/E clutch retainer (2).
    GC0152176Courtesy of CHRYSLER GROUP, LLC
  6. Install the needle bearing (2) onto the E clutch (1).
  7. Install the E clutch (1) into the P4 sun gear/C/E clutch retainer (3).
    GC0152175Courtesy of CHRYSLER GROUP, LLC
  8. Install the snap ring (1) into the P4 sun gear/C/E clutch retainer (2).
    GC0152174Courtesy of CHRYSLER GROUP, LLC
  9. Install the P3 annulus (1) into the P4 sun gear/C/E clutch retainer (2).
    GC0152173Courtesy of CHRYSLER GROUP, LLC
  10. Install the snap ring (1) into the P4 sun gear/C/E clutch retainer (2).
    GC0152170Courtesy of CHRYSLER GROUP, LLC
  11. Install the P4 sun gear/C/E clutch retainer (1) into the D clutch drum (2).
    GC0152274Courtesy of CHRYSLER GROUP, LLC
  12. Install the needle bearing onto the planetary carrier.
  13. Install the P3 planetary carrier (2) in the D clutch drum.
  14. Install the snap ring (1).
    GC0152172Courtesy of CHRYSLER GROUP, LLC
  15. Install the D clutch drum (1) into the P4 annulus drum (2).
    GC0152151Courtesy of CHRYSLER GROUP, LLC
  16. Install the P2 annulus\P3 sun gear (1) onto the drum assembly (2).
    GC0152150Courtesy of CHRYSLER GROUP, LLC
  17. Install the needle bearing (2) and washer.
  18. Install the input shaft with P2 planetary carrier (1) into the drum assembly.
    GC0152148Courtesy of CHRYSLER GROUP, LLC
  19. Install P1/P2 sun gear into the bottom of the P1 planetary carrier (3).
  20. Install the P1 planetary carrier (3).
  21. Install the snap ring (1).
    GC0152146Courtesy of CHRYSLER GROUP, LLC
  22. Install the needle bearing and holding plate (2) onto the P1 planetary carrier.
  23. Install the selectable shim to the P1 annulus/B clutch hub.
  24. Install the P1 annulus\B clutch hub assembly (1) onto the P4 annulus drum.
  25. Install the O-ring and five squared O-rings.
    GC0152139Courtesy of CHRYSLER GROUP, LLC
  26. Install the clutch pack (2).
    GC0170185Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The (special tool #10373A, Installer, Output Needle Bearing/Rear Oil Dam) (1) is a combination tool that is reversed to install the oil dam and output shaft inner needle bearing. For use to install the output shaft inner needle bearing, use the thick walled side of the tool against the bearing.

  27. Using (special tool #10373A, Installer, Output Needle Bearing/Rear Oil Dam) (1) and (special tool #C-4171, Driver Handle, Universal) (2), install the output shaft inner needle bearing.
  28. Install the snap ring.
    GC0170185Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The (special tool #10373A, Installer, Output Needle Bearing/Rear Oil Dam) (1) is a combination tool that is reversed to install the oil dam and output shaft inner needle bearing. For use to install the oil dam, use the thin walled side of the tool against the oil dam.

  29. Using (special tool #10373A, Installer, Output Needle Bearing/Rear Oil Dam) (1) and (special tool #C-4171, Driver Handle, Universal) (2), install the oil dam.
  30. Install the snap ring.
    GC0152266Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    AWD shown in the illustration, RWD similar.

  31. Install the ball bearing.
  32. Install the snap ring (1).
    GC0154476Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The transmission must be in a upright position when the input/output shaft and the P4 annulus drum assembly (1) is installed.

  33. Install the input/output shaft and P4 annulus drum assembly (1) into the case.
    GC0152144Courtesy of CHRYSLER GROUP, LLC
  34. From outside the transmission case, install the park pawl shaft and install the park pawl (1) and spring (2).
    GC0152143Courtesy of CHRYSLER GROUP, LLC
  35. Install the park pawl shaft plug (1) into the rear of the case and tighten to the proper torque specifications. Refer to TORQUE SPECIFICATIONS .
    GC0152279Courtesy of CHRYSLER GROUP, LLC
  36. Using (special tool #6936, Spacer) (1), install the Manual Park Release (MPR) shaft seal (2).
    GC0152142Courtesy of CHRYSLER GROUP, LLC
  37. Install the shaft (4), spring (2), and fork (1) into the case.
  38. Install the roll pin into the MPR shaft (4) using a suitable pin punch (3).
    GC0152141Courtesy of CHRYSLER GROUP, LLC
  39. Install the park pawl lock rod (1) onto the fork (2).
    GC0152140Courtesy of CHRYSLER GROUP, LLC
  40. Position the park pawl lock rod guide plate (2), install the three park pawl lock rod guide plate retaining screws (1) and tighten to the proper torque specifications. Refer to TORQUE SPECIFICATIONS .
    GC0152287Courtesy of CHRYSLER GROUP, LLC
  41. Install the oil pump cover lip seal (3) on the oil pump cover (2).
    GC0154563Courtesy of CHRYSLER GROUP, LLC
  42. If removed, install a NEW  oil pump needle bearing using (special tool #10376, Installer, Input Shaft Needle Bearing) and (special tool #C-4171, Driver Handle, Universal).
    GC0154353Courtesy of CHRYSLER GROUP, LLC
  43. If removed, install the inner oil pump needle bearing using (special tool #10382, Installer, Oil Pump Housing Needle Bearing) and (special tool #C-4171, Driver Handle, Universal)
  44. Using (special tool #10375, Installer, Oil Pump Cover Oil Seal) (1), install the input shaft seal in the oil pump cover (2).
    GC0152253Courtesy of CHRYSLER GROUP, LLC
  45. Position the oil pump housing (2) and oil pump cover (3) together.
  46. Install the five bolts (1) and tighten to the proper torque specifications. Refer to TORQUE SPECIFICATIONS .
    GC0152254Courtesy of CHRYSLER GROUP, LLC
  47. Insert the piston and the retaining ring (1) into the housing.
    GC0152251Courtesy of CHRYSLER GROUP, LLC
  48. Position the oil pump housing assembly (4) in a suitable arbor press.
  49. Using (special tool #8285, Compressor, Spring) (1), press on the fingers of the piston retaining ring to remove tension, and install the two halves of the split retainer ring (2).
    GC0152250Courtesy of CHRYSLER GROUP, LLC
  50. Install the hub (3).
  51. Install the clutches and spacers (4).
  52. Install the snap ring (2).
  53. Install the outer ring (1) (below B-piston).
    GC0152288Courtesy of CHRYSLER GROUP, LLC
  54. Position the B-piston alignment tab (2) above the notch and install B-piston (1) on the assembly.
    GC0152105Courtesy of CHRYSLER GROUP, LLC
  55. Carefully position the oil pump housing assembly into the case, firmly press the oil pump into place before drawing it in with the bolts.
    NOTE:

    Check the transmission end play before installing the new oil pump bolts, in case adjustment is needed.

  56. Install the NEW  input shaft O-ring.
    GC0152246Courtesy of CHRYSLER GROUP, LLC
  57. Install the thirteen oil pump cover retaining bolts and tighten the oil pump cover as follows:
    1. In order to seat the oil pump cover properly, pre tighten bolts one, seven and nine to 6 N.m (53 in. lb.).
    2. Working in a clockwise pattern, beginning with number one, tighten to 10 N.m (89 in. lb.).
    3. Working in a clockwise pattern, beginning with number one, tighten an additional 90°.
    GC0152275Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The MPR lever (2) can be reversed to release tension and ease the installation of the valve body assembly.

  58. Temporarily install the MPR lever (2) to release tension on the shift fork as follows:
    1. Install the MPR lever (2) 180 degrees offset from its original position.
    2. Install the nut (1) and hand tighten.
    3. Turn the MPR lever (2) and using a tie strap (3), secure the lever (2) into position so the park release fork is in the same position as it was before valve body assembly removal.
    GC0152241Courtesy of CHRYSLER GROUP, LLC
  59. Install a new compression seal (3) into the transmission case.
  60. Install the fluid port (1) with NEW  O-rings to the transmission case.
    GC0152262Courtesy of CHRYSLER GROUP, LLC
  61. Install the (special tool #10379, Pins, Valve Body Alignment) (1) in the transmission case as guides for the valve body assembly.
    NOTE:

    Make sure the shift fork lines up properly.

  62. Using the valve body alignment pins (1) to guide, position the valve body assembly to the transmission.
    NOTE:

    After several bolts have been hand tightened, remove the guide pins (1).

  63. Install the fourteen valve body assembly retaining bolts and hand tighten.
    GC0152117Courtesy of CHRYSLER GROUP, LLC
  64. Using (special tool #10377, Remover/Installer, Guide Sleeve) (1) carefully install the electrical harness insulator (2) into the transmission case (3).
    GC0152103Courtesy of CHRYSLER GROUP, LLC
  65. Install the sensor (4) and the sensor bolt (1) and hand tighten.
  66. Latch the electrical connector insulator lock (2) by pushing in.
    GC0154626Courtesy of CHRYSLER GROUP, LLC
  67. If equipped, install the Hydraulic Impulse Storage Unit (H.I.S.).
  68. Tighten the bolts (2 and 3) to the proper torque specifications. Refer to TORQUE SPECIFICATIONS .
  69. Install the valve body assembly end bolts (3) and hand tighten.
    GC0169780Courtesy of CHRYSLER GROUP, LLC
  70. Tighten the valve body assembly retaining bolts 1-18 in the sequence shown in the illustration to 6 Nm (53 in.-lbs.).
    GC0152243Courtesy of CHRYSLER GROUP, LLC
  71. Remove the tie strap and return the Manual Park Release (MPR) lever (1) to the original position.
  72. Install the MPR lever nut (2) and tighten to the proper torque specifications. Refer to TORQUE SPECIFICATIONS .
    GC0170496Courtesy of CHRYSLER GROUP, LLC
  73. Install the NEW  transmission oil filter (1).
    GC0170254Courtesy of CHRYSLER GROUP, LLC
  74. Install the 13 transmission oil pan bolts and tighten to 10 N.m (89 in. lbs.) in a crisscross pattern.
    GC0170154Courtesy of CHRYSLER GROUP, LLC
  75. Verify the transmission oil pan plug (1) is installed.
    GC0170254Courtesy of CHRYSLER GROUP, LLC
  76. Position the oil pan (2) and gasket.
  77. Install the 13 transmission oil pan bolts (1) using crisscross pattern and tighten to 4 N.m (35 in. lbs.) + 45°.
  78. Install the transmission output shaft washer.
    CAUTION:

    The seal must be installed flush with the case. Driving the seal deeper could damage the seal causing a leak.

  79. Position the new output shaft seal over the output shaft and against the transmission case.
  80. Using (special tool #8481, Installer, Gear) install the output shaft seal.
  81. Install the transmission rear dust seal.
    GC0169779Courtesy of CHRYSLER GROUP, LLC
  82. Install the drive shaft flange (1).
  83. Install the NEW  transmission output flange nut (2) and washer using a 34 mm 12 point socket and (special tool #C-3281, Holder, Flange) (2). Tighten to the proper torque specifications. Refer to TORQUE SPECIFICATIONS .
  84. Stake (3) the transmission output flange nut.
    GC0152102Courtesy of CHRYSLER GROUP, LLC
  85. Install the torque converter (1). Refer to TORQUE CONVERTER, INSTALLATION .
  86. Before installing the transmission in the vehicle, pre-fill the transmission as outlined in FILL TRANSMISSION AFTER SERVICE. Refer to FLUID AND FILTER, STANDARD PROCEDURE .
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