Steps 6-8

6. 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 Nm (200 ft. lbs.).

Fig. 242:

7. Check the turning torque of the output shaft (Fig. 242). The shaft should have 1 to 8 inch lbs. of turning torque. If the turning torque is higher than 8 inch lbs., install a thicker shim. If the turning torque is less than 1 inch lbs., install a thinner shim. Make sure there is no end play.

CAUTION: Failure to stake shaft nuts could allow the nuts to back-off during use.

Fig. 243:

Fig. 244:

8. The new nut must be staked after the correct turning torque is obtained (Fig. 243). Use special tool. 6639 to stake output shaft nut and special tool 6589 to stake transfer shaft.

Fig. 245:

When reinstalling main sump baffle apply MOPAR Silicone Sealant as shown in (Fig. 245).

Fig. 246:

Install main sump baffle to transaxle case (Fig. 246).

Fig. 247:

Fig. 248:

Fig. 249:

Fig. 250:

Fig. 251:

CAUTION:
- When reinstalling drive chains, the blue link must face outward.
- 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.

Fig. 252:

Fig. 253:

CAUTION: Be sure to reinstall the chain snubber and chain oiler when reassembling.

Fig. 254:

Fig. 255:

Fig. 256:

Fig. 257:

Fig. 258:

Fig. 259:

Fig. 260:

Fig. 261:

Stand trans upright on bellhousing.
Chain cover must be free of old sealant, dirt and oil before applying new sealant. Apply a 1/8 inch bead of sealant to flange of cover.
Press down clutch pack with finger and zero dial indicator. Low/Reverse clutch pack clearance is 0.89 to 1.04 (0.035 to 0.042 inch).

Low/reverse Reaction Plate Chart:

Low/Reverse Reaction Plate Chart

Fig. 262:

Select the proper low/reverse reaction plate to achieve specifications:

Fig. 263:

Fig. 264:

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. 263).

Fig. 265:

Fig. 266:

Fig. 267:

Fig. 268:

Press down clutch pack with finger and zero dial indicator. 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.

Fig. 269:

Fig. 270:

The number 7 needle bearing has 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 (Fig. 269). A small amount of petrolatum can be used to hold the bearing to the rear sun gear.

DETERMINING No. 4 THRUST PLATE THICKNESS-INPUT SHAFT END PLAY

Fig. 271:

Fig. 272:

Fig. 273:

Fig. 274:

To determine the proper thickness of the No. 4 thrust plate, select the thinnest No. 4 thrust plate. Using petrolatum (Fig. 273) to hold thrust plate in position, install input clutch assembly. Be sure the input clutch assembly is completely seated (Fig. 274),

CAUTION: If view through input speed sensor hole is not as shown above, the input clutches assembly is not seated properly.

Fig. 275:

Remove the oil pump O-ring (Fig. 275). You will be able to install and remove the oil pump and gasket very easily to select the proper No. 4 thrust plate.

NOTE: Use screw-in dowels or phillips-head screwdrivers to align pump to case.

CAUTION: Be sure to reinstall O-ring on oil pump after selecting the proper No. 4 thrust plate.

Fig. 276:

Measure the input shaft end play with the transaxle in the vertical position. This will ensure that the measurement will be accurate.

NOTE: Input shaft end play must be 0.005 to 0.025 inch.

No.4 Thrust Plate Chart:

No.4 Thrust Plate Chart

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.

Fig. 277:

Fig. 278:

Reinstall the input clutches assembly with the selected thrust plate.

Fig. 279:

Fig. 280:

Fig. 281:

Fig. 282:

Fig. 283:

CAUTION: By-pass valve must be replaced if transmission failure occurs.

NOTE: To align oil pump during installation, use threaded dowels or phillips screwdrivers.

Fig. 284:

Fig. 285:

Fig. 286:

Fig. 287:

NOTE: Install new driveshaft retainer clips to driveshafts.

Fig. 288:

Fig. 289:

Fig. 290:

Fig. 291:

Fig. 292:

Fig. 293:

Fig. 294:

CAUTION: Do not handle the valve body by the manual shaft. Damage could result.

Fig. 295:

Install both speed sensors from transaxle case (Fig. 295).

Fig. 296:

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 (Fig. 296). 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.