Overhaul - Automatic Transmission: Assembly
NOTE:
If the transaxle assembly is being reconditioned (clutch/seal replacement) or replaced, it is necessary to perform the Quick Learn Procedure using the DRBIII(R) Scan Tool (Refer to
STANDARD PROCEDURE
).
- Install the output bearing cups, use Special Tool # 5050A (Fig 1 ).
- Install low/reverse piston retainer gasket (Fig 2 ).
- Install low/reverse piston retainer (Fig 3 ).
- Install low/reverse piston retainer-to-case screws (Fig 4 ) and torque to 5 N.m (45 in.lbs.).
- Install low/reverse clutch piston (Fig 5 ).
- Assemble guide bracket assembly as shown in (Fig 6 ) (Fig 7 ).
- Install guide bracket pivot shaft (Fig 8
).
CAUTION: When installing, be sure guide bracket and split sleeve touch the rear of the transaxle case.
- Install park sprag pivot retaining screw (Fig 9 ) and torque to 5 N.m (45 in.lbs.).
- Install low/reverse piston belleville spring into position (Fig 10 ).
- Install and load low/reverse spring compressor tool as shown in (Fig 11 ) (Fig 12 ) to facilitate snap ring installation.
- Install snap ring and remove compressor tool (Fig 13 ).
- Install rear carrier front bearing cone (Fig 14 ).
- Check output bearing preload. Output bearing preload must be checked and/or adjusted if any of the following items have been replaced:
- Output shaft (rear carrier assembly)
- Output, shaft bearings
- Transaxle case
- PRELOAD CHECK/SHIM SELECTION: Install rear output shaft bearing cone and special tool 6618A (Fig 15 ).
- Install special tool 6618A (Fig 16 ). Lightly tighten retaining screws. Screws should be below the plate surface, but do not snug screws.
- 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.
- Install shim on output shaft (Fig 17 ). 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. Refer to Output Shaft Rear Shim Chart for available sizes .
- Install output shaft/rear carrier into rear bearing. The shaft must be pressed into position. Use special tool MD-998911 (Disc) and C- 4171 and C4171-2 (Handle) to press shaft into rear bearing (Fig 18 ).
- Do not re-use old transfer shaft nut or output shaft nut because the removed stake weakens the nut flange . Using special tools 6497 and 6498, install new output shaft nut. Do not reuse old output shaft nut. Tighten new output shaft nut to 271 N.m (200 ft. lbs.).
- Check the turning torque of the output shaft (Fig 19 ). 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. If turning torque is less than 1 in. lb., install a thinner shim. Make sure there is no end play.
- The new nut must be staked after the correct turning torque is obtained (Fig 20
) (Fig 21
). Use special tool 6639 to stake output shaft nut and special tool 6589 to stake transfer shaft.CAUTION: Failure to stake shaft nuts could allow the nuts to back-off during use.
- Apply Mopar(R) ATF RTV (MS-GF41) as shown in (Fig 22
). Install main sump baffle to transaxle case (Fig 23
) and torque screw to 5 N.m (45 in.lbs.).
CAUTION: When reinstalling drive chains, the blue link must face outward.
- Install output sprocket spacer (Fig 24
).
CAUTION: The chain sprockets have a slip fit onto the shafts. Apply only a slight amount of pressure to the chain spreader to release the chain pressure. If chain sprockets are not spread slightly, installation will be difficult.
- Install transfer chain and sprockets to transfer shaft and output shaft (Fig 25 ).
- Remove chain spreader (Fig 26 ).
- Install transfer shaft sprocket snap rings and wave washers (Fig 27
) (Fig 28
).
CAUTION: Be sure to reinstall the chain snubber and chain oiler when reassembling.
- Install transfer chain snubber (Fig 29 ) and torque screws to 5 N.m (45 in.lbs.).
- Install chain oiler (Fig 30 ) and torque screw to 5 N.m (45 in.lbs.).
- Stand trans upright on bellhousing
- Install chain cover (Fig 31 ). Chain cover must be free of old sealant, dirt and oil before applying new sealant . Apply a 1/8 inch bead of Mopar(R) ATF RTV (MS-GF41) to flange of cover.
- Install low/reverse clutch pack (Fig 32 ). Leave uppermost disc out to facilitate snap ring installation.
- Install low/reverse reaction plate snap ring (Fig 33 ).:
- Install one low/reverse clutch disc (Fig 34 ).
- Install low/reverse reaction plate with flat side up (Fig 35 ).
- Install tapered snap ring (tapered side out) as shown in (Fig 36 ) (Fig 37 ).
- Measure low/reverse clutch pack. Set up dial indicator as shown in (Fig 38 ). Press down clutch pack with finger and zero dial indicator. Record measurement, in four (4) places and take average reading. Low/Reverse clutch pack clearance is 0.86 to 1.52 (0.034 to 0.060 inch).
- Select the proper low/reverse reaction plate to achieve specifications:LOW/REVERSE REACTION PLATE CHART
PART NUMBER THICKNESS 4799846AA 5.88 mm (.232 in.) 4799847AA 6.14 mm (.242 in.) 4799848AA 6.40 mm (.252 in.) 4799849AA 6.66 mm (.262 in.) 4799855AA 6.92 mm (.273 in.) - Install 2/4 clutch pack (Fig 39
). Stagger 2/4 clutch disc pads as shown in (Fig 40
).
NOTE: When installing the 2-4 clutch plates and discs, the orientation should be alternated so the pilot pads of adjacent plates do not align, refer to (Fig 40 ).
- Install 2/4 clutch belleville spring (Fig 41 ) (Fig 42 ).
- Install 2/4 clutch retainer (Fig 43 ).
- Set up Tool 5058 as shown in (Fig 44 ). Compress 2/4 clutch just enough to facilitate snap ring installation.
- Measure 2/4 clutch clearance: Set up dial indicator as shown in (Fig 45 ). Press down clutch pack with finger and zero dial indicator. Record measurement in four (4) places and take average reading. 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. There is no adjustment for the 2/4 clutch clearance.
- Install the #7 needle bearing to the rear sun gear (Fig 46 ). 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.
- Install rear sun gear and #7 needle bearing (Fig 47 ).
- Install front carrier/rear annulus assembly and #6 needle bearing (Fig 48 ).
- Install front sun gear assembly and #4 thrust washer (Fig 49 ).
- Determine proper #4 thrust plate thickness.
- Select the thinnest #4 thrust plate thickness.
- Install #4 thrust plate (Fig 50 ) using petrolatum to hold into position.
- Install input clutch assembly. Ensure the input clutch assembly is completely seated by viewing position through input speed sensor hole (Fig 51 ). If view through input speed sensor hole is not as shown in ( Fig 51 ), the input clutches assembly is not seated properly.
- Remove the oil pump o-ring (Fig 52 ) and install oil pump and gasket to transaxle. 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.
- Measure the input shaft end play with the transaxle in the vertical position. This will ensure that the measurement will be accurate.
- Set up and measure endplay using End Play Set 8266 and Dial Indicator Set C3339 as shown in (Fig 53 ).
- Measure input shaft end play. Input shaft end play must be .005 to .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.
- See chart to select the proper No. 4 thrust plate.NO. 4 THRUST PLATE CHART
PART NUMBER THICKNESS 3836237AB 1.73mm (0.068 in.) 4431666AB 1.80mm (0.071 in.) 3836238AB 1.96mm (0.077 in.) 4431667AB 2.03mm (0.080 in.) 3836239AB 2.16mm (0.085 in.) 4431668AB 2.24mm (0.088 in.) 3836240AB 2.39mm (0.094 in.) 4431669AB 2.46mm (0.097 in.) 3836241AB 2:62mm (0.103 in.) 4446670AB 2.67mm (0.105 in.) 4446671AB 2.90mm (0.114 in.) - Remove oil pump, gasket, and input clutch assembly to gain access to and install proper #4 thrust plate.
CAUTION: If view through input speed sensor hole is not as shown in (Fig 51 ), the input clutches assembly is not seated properly. - Install input clutch assembly with proper thrust plate (Fig 54 ).
- Install #1 caged needle bearing (Fig 55 ).
- Replace cooler by-pass valve if transmission failure has occurred (Fig 56
).CAUTION: By-pass valve must be replaced if transmission failure occurs.NOTE: To align oil pump, gasket, and case during installation, use threaded dowels or phillips screwdrivers.
- Install oil pump gasket (Fig 57 ).
- Install oil pump and torque oil pump-to-case bolts to 28 N.m (250 in.lbs.) (Fig 58 ).
- Install long stub shaft and bearing to housing (Fig 59
).
NOTE: Install new halfshaft retainer clips.
- Install long stub shaft bearing retaining snap ring (Fig 60 ). Replace halfshaft retainer clips.
- Install low/reverse accumulator as shown in (Fig 61 ).
- Install low/reverse accumulator plug (Fig 62 ).
- Install low/reverse accumulator snap ring (Fig 63 ).
- Install underdrive and overdrive accumulators as shown in (Fig 64
) (Fig 65
) (Fig 66
).
CAUTION: Do not handle the valve body by the manual shaft. Damage could result.
- Install valve body into place as shown in (Fig 67 ).
- Install seven (7) valve body-to-case bolts (Fig 68 ) and torque to 12 N.m (105 in.lbs.).
- Install transaxle oil filter (Fig 69 ).
- Install transaxle oil pan (Fig 70
) with a bead of Mopar(R) ATF RTV (MS-GF41). Torque oil pan-to-case bolts to 23 N.m (17 ft. lbs.).
Install both speed sensors from transaxle case (Fig 71 ). Torque speed sensors to 27 N.m (20 ft. lbs.).
- As a final check of the transaxle, measure the input shaft end play. This will indicate when a #4 thrust plate change is required. The number 4 thrust plate is located behind the overdrive clutch hub. Attach a dial indicator to transaxle bell housing with its plunger seated against end of input shaft (Figure ). Move input shaft in and out to obtain end play reading. End play specifications are 0.13 to 0.64 mm (0.005 to 0.025 inch). If not within specifications, make the necessary thrust plate adjustment.