Steps 26 thru 50
41TE AUTOMATIC TRANSAXLEASSEMBLY (Cont.)
Steps 26 - 50
26. Using Tool 5049A, install transfer shaft (Fig. 108).
27. Using Tool 6051, install transfer shaft bearing snap ring (Fig. 109).
28. Install transfer shaft bearing cup into retainer using Tool 6061 (Fig. 110).
29. Install bearing cup retainer to transaxle (Fig. 111)
30. Install transfer gear bearing cone to transfer gear using Tool 5052 (Fig. 112).
31. TRANSFER GEAR BEARING ADJUSTMENT:
a. Install a 4.66 mm (0.184 inch) gauging shim on the transfer shaft (Fig. 113).
b. Install transfer shaft gear using Tool 6261. Using Tool 6259, install transfer shaft gear retaining nut to 271 Nm (200 ft. lbs.).
c. Measure end play. Attach Tool L4432 to the transfer gear.
d. Mount a steel ball with grease into the end of the transfer shaft.
e. Push and pull the gear while rotating back and forth to ensure seating of the bearing rollers.
f. Using a dial indicator, measure transfer shaft end play.
g. Refer to the transfer shaft bearing shim chart for the required shim combination to obtain the proper bearing setting.
h. Use Tool 6259 to remove the retaining nut and washer. Remove the transfer shaft gear using Tool L4407A.
i. Remove the gauging shim (Fig. 113) and install the proper shim indicated by the chart.
32. Install the transfer shaft gear using Tool 6261 (Fig. 114).
CAUTION: Install a NEW retaining nut, as the original nut MUST NOT be reused.
33. Install the new retaining nut and washer.
34. Using Tool 6259, torque transfer gear retaining nut to 271 Nm (200 ft. lbs.) (Fig. 115).
35. Measure transfer shaft end play. Transfer shaft end play should be within 0.05 - 0.10 mm (0.002 - 0.004 inch). If the end play is too high, install a 0.04 mm (0.0016 inch) thicker shim. If the end play is too low, install a 0.04 mm (0.0016 inch) thinner shim. Repeat until 0.05 - 0.10 mm (0.002 - 0.004 inch) end play is obtained.
36. Install a bead of Mopar ATF RTV (MS-GF41) to transfer gear cover (Fig. 116).
37. Install transfer gear cover-to-case bolts and torque to 20 Nm (175 in. lbs.) torque (Fig. 117).
38. Install low/reverse clutch pack (Fig. 118). Leave uppermost disc out until snap ring is installed.
39. Install low/reverse reaction plate flat snap ring (Fig. 119).
40. Install remaining low/reverse clutch disc (Fig. 120).
41. Install low/reverse reaction plate with flat side up (Fig. 121).
42. Install tapered snap ring (with tapered side up) as shown in (Fig. 122) (Fig. 123).
43. Set up dial indicator as shown in (Fig. 124) to measure low/reverse clutch clearance. Press down on clutch pack with finger and zero dial indicator. Low/Reverse clutch pack clearance is 0.89 - 1.47 mm (0.035 - 0.058 inch). Set up indicator and record measurement in four (4) places. Take average of readings and select the proper low/reverse reaction plate to achieve specifications.
LOW/REVERSE REACTION PLATE CHART:
44. Install 2/4 clutch pack (Fig. 125), staggering clutch plate pads as shown in (Fig. 126).
45. Orient 2/4 clutch return spring to retainer as shown in (Fig. 127), and install to transaxle (Fig. 128).
46. Using tool 5058, compress 2/4 clutch return spring just enough to install snap ring (Fig. 129).
47. Install snap ring.
48. Set up dial indicator as shown in (Fig. 130) and measure 2/4 clutch clearance. Press down on clutch pack with finger and zero dial indicator. 2/4 clutch pack clearance is 0.76 - 2.64 mm (0.030 - 0.104 inch). Set up indicator and record measurement in four (4) places. Take average of readings. If clearance is outside this range, the clutch is assembled improperly. There is no adjustment for 2/4 clutch clearance.
49. Install rear sun gear and # 7 needle bearing (Fig. 132).
NOTE: The number seven needle bearing has three anti-reversal tabs and is common with the number five and number two position. The orientation should allow the bearing to seat flat against the rear sun gear (Fig. 131). A small amount of petrolatum can be used to hold the bearing to the rear sun gear.
50. Install front carrier/rear annulus assembly and # 6 needle bearing (Fig. 133).