Steps 36-70
40TE TRANSAXLEASSEMBLY (STEPS 36-70)
36. Install a bead of Mopar(R) ATF RTV (MS-GF41) to transfer gear cover (Fig. 115).
37. Install transfer gear cover-to-case bolts and torque to 20 Nm (175 inch lbs.) torque (Fig. 116).
38. Install low/reverse clutch pack (Fig. 117). Leave uppermost disc out until snap ring is installed.
39. Install low/reverse reaction plate flat snap ring (Fig. 118).
40. Install remaining low/reverse clutch disc (Fig. 119).
41. Install low/reverse reaction plate with flat side up (Fig. 120).
42. Install tapered snap ring (with tapered side up) as shown in (Fig. 121) (Fig. 122).
43. Set up dial indicator as shown in (Fig. 123) 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 nun (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.
44. Install 2/4 clutch pack (Fig. 124).
NOTE: The 2/4 Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.
45. Orient 2/4 clutch return spring to retainer as shown in (Fig. 125), and install to transaxle (Fig. 126).
46. Using tool 5058, compress 2/4 clutch return spring just enough to install snap ring (Fig. 127).
47. Install snap ring.
48. Set up dial indicator as shown in (Fig. 128) 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. 130).
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. 129). 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. 131).
51. Install front sun gear assembly and #4 thrust washer (Fig. 132).
52. DETERMINING #4 THRUST PLATE THICKNESS /INPUT SHAFT END PLAY
a. Select the thinnest #4 thrust plate thickness and install to input clutch assembly (Fig. 133). Use petrolatum to retain.
b. Install input clutch assembly into position and verify that it is completely seated by viewing through input speed sensor hole. If view through input speed sensor hole is not as shown in (Fig. 134), the input clutch assembly is not seated properly
c. Remove oil pump O-ring (Fig. 135). Be sure to reinstall oil pump O-ring after selecting the proper #4 thrust plate.
d. Install pump and gasket to transmission. Install and torque bolts.
e. Set up input shaft for measurement with Indicator Set C3339 and End Play Set 8266 as shown in (Fig. 136).
f. Measure the input shaft end play with the transaxle in the vertical position. Input shaft end play must be within 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.
g. Refer to the No. 4 thrust plate chart to select the proper No. 4 thrust plate:
NO. 4 THRUST PLATE CHART
53. Install input clutch assembly (Fig. 137).
54. Install #1 caged needle bearing (Fig. 138).
CAUTION: The cooler bypass valve must be replaced if transaxle failure has occurred. Do not attempt to reuse or clean old valve.
55. Install cooler bypass valve with O-ring end towards rear of case (Fig. 139).
56. Install oil pump gasket (Fig. 140).
57. Install oil pump assembly (Fig. 141).
58. Install oil pump-to-case bolts and torque to 27 Nm (20 ft. lbs.) (Fig. 142).
59. Install low/reverse accumulator (Fig. 143).
60. Install low/reverse accumulator plug (Fig. 144).
61. Install low/reverse accumulator snap ring (Fig. 145).
NOTE: Depending on engine application, some accumulators will have two springs, and others will have one spring. The springs are color-coded for application and year.
62. Install underdrive and overdrive accumulators and springs (Fig. 146).
63. Install valve body to transaxle (Fig. 147). Rotate manual valve shaft fully clockwise to ease installation. Make sure park rod rollers are positioned within park guide bracket.
64. Install and torque valve body-to-case bolts to 12 Nm (105 inch lbs.) (Fig. 148).
65. Install oil filter and new O-ring (Fig. 149).
66. Apply an 1/8" bead of Mopar(R) ATF RTV (MSGF41) to oil pan and immediately install to case (Fig. 150).
67. Install oil pan-to-case bolts and torque to 19 Nm (165 inch lbs.).
68. Install solenoid/pressure switch assembly and gasket to case (Fig. 151).
69. Install and tighten solenoid/pressure switch assembly-to-transaxle case bolts to 12 Nm (110 inch lbs.) (Fig. 152).
70. Install and torque input and output speed sensors to case to 27 Nm (20 ft. lbs.).