Steps 26 thru 55
42LE - Automatic TransaxleAssembly Con't
Steps 26 - 55
26. Install low/reverse reaction plate with flat side up (Fig. 112).
27. Install tapered snap ring (tapered side out) as shown in (Fig. 113) (Fig. 114).
28. Measure low/reverse clutch pack. Set up dial indicator as shown in (Fig. 115). 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).
29. Select the proper low/reverse reaction plate to achieve specifications:
LOW/REVERSE REACTION PLATE CHART:
30 Install 2/4 clutch pack (Fig. 116). Stagger 2/4 clutch disc pads as shown in (Fig. 117).
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. 117).
31 Install 2/4 clutch belleville spring (Fig. 118) (Fig. 119).
32. Install 2/4 clutch retainer (Fig. 120).
33. Set up Tool 5058 as shown in (Fig. 121). Compress 2/4 clutch just enough to facilitate snap ring installation.
34. Measure 2/4 clutch clearance: Set up dial indicator as shown in (Fig. 122). 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.
35. Install the #7 needle bearing to the rear sun gear (Fig. 123). 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.
36. Install rear sun gear and #7 needle bearing (Fig. 124).
37. Install front carrier/rear annulus assembly and #6 needle bearing (Fig. 125).
38. Install front sun gear assembly and #4 thrust washer (Fig. 126).
39. Determine proper #4 thrust plate thickness.
a. Select the thinnest #4 thrust plate thickness.
b. Install #4 thrust plate (Fig. 127) using petrolatum to hold into position.
c. Install input clutch assembly Ensure the input clutch assembly is completely seated by viewing position through input speed sensor hole (Fig. 128). If view through input speed sensor hole is not as shown in (Fig. 128), the input clutches assembly is not seated properly.
d. Remove the oil pump o-ring (Fig. 129) 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.
e. Measure the input shaft end play with the transaxle in the vertical position. This will ensure that the measurement will be accurate.
f. Set up and measure endplay using End Play Set 8266 and Dial Indicator Set C3339 as shown in (Fig. 130).
g. Measure input shaft end play. Input shaft end play must be 0.005 to 0.025 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.
NO. 4 THRUST PLATE CHART:
h. See chart to select the proper No. 4 thrust plate.
i. 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. 128), the input clutches assembly is not seated properly.
40. Install input clutch assembly with proper thrust plate (Fig. 131).
41. Install #1 caged needle bearing (Fig. 132).
42. Replace cooler by-pass valve if transmission failure has occurred (Fig. 133).
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.
43. Install oil pump gasket (Fig. 134).
44. Install oil pump and torque oil pump-to-case bolts to 28 Nm (250 inch lbs.) (Fig. 135).
45. Install long stub shaft and bearing to housing (Fig. 136).
NOTE: Install new halfshaft retainer clips.
46. Install long stub shaft bearing retaining snap ring (Fig. 137). Replace halfshaft retainer clips.
47. Install low/reverse accumulator as shown in (Fig. 138).
48. Install low/reverse accumulator plug (Fig. 139).
49. Install low/reverse accumulator snap ring (Fig. 140).
50. Install underdrive and overdrive accumulators as shown in (Fig. 141) (Fig. 142) (Fig. 143).
CAUTION: Do not handle the valve body by the manual shaft. Damage could result.
51. Install valve body into place as shown in (Fig. 144).
52. Install seven (7) valve body-to-case bolts (Fig. 145) and torque to 12 Nm (105 inch lbs.).
53. Install transaxle oil filter (Fig. 146).
54. Install transaxle oil pan (Fig. 147) with a bead of Mopar ATF RTV (MS-GF41). Torque oil pan-to-case bolts to 23 Nm (17 ft. lbs.).
Install both speed sensors from transaxle case (Fig. 148). Torque speed sensors to 27 Nm (20 ft. lbs.).
55. 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. 149). 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.