Steps 41 - 82
40TE AUTOMATIC TRANSAXLEASSEMBLY STEPS 41 - 82
Fig.118 Install Rear Cover Bolts:
(41) Install transfer gear cover-to-case bolts (1) (Fig. 118) and torque to 20 Nm (175 inch lbs.) torque.
Fig.119 Install Low/Reverse Clutch:
(42) Install low/reverse clutch pack (1,2) (Fig. 119). Leave uppermost disc out until snap ring is installed.
Fig.120 Install Low/Reverse Reaction Plate Snap Ring:
(43) Install low/reverse reaction plate flat snap ring (2) (Fig. 120).
Fig.121 Install One Disc:
(44) Install remaining low/reverse clutch disc (1) (Fig. 121).
Fig.122 Install Low/Reverse Reaction Plate:
(Install low/reverse reaction plate with flat side up (1) (Fig. 122).
Fig.123 Tapered Snap Ring Instructions:
(46) Proper Installation of snap ring (with tapered side up) (Fig. 123).
Fig.124 Snap Ring Installed:
(47) Install tapered snap ring (with tapered side up) (Fig. 124).
Fig.125 Check Low/Reverse Clutch Clearance:
(48) Set up dial indicator (1) (Fig. 125) and indicator tool 6268 (2) 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 (1) and record measurement in four places. Take average of readings and select the proper low/reverse reaction plate to achieve specifications.
LOW/REVERSE REACTION PLATE CHART:
Fig.126 Install 2/4 Clutch:
(49) Install 2/4 clutch pack (1,2) (Fig. 126).
NOTE: The 2/4 Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.
Fig.127 Proper Orientation Of 2/4 Clutch Retainer And Spring:
(50) Orient 2/4 clutch return spring (2) (Fig. 127) to retainer (1).
Fig.128 2/4 Clutch Retainer:
(51) Install 2/4 clutch return spring (2) (Fig. 128) into transaxle.
Fig.129 Install 2/4 Clutch Retainer Snap Ring:
(52) Using Compressor 5058 (1) (Fig. 129), compress 2/4 clutch return spring just enough to install snap ring. (53) Install snap ring (3).
Fig.130 Check 2/4 Clutch Clearance:
(54) Set up dial indicator (1), (Fig. 130) indicator tip 6268 (3) and hook tool (2), 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.
Fig.121 Number 7 Bearing:
(55) Install rear sun gear and #7 needle bearing (1) (Fig. 131).
Fig.132 Install Rear Sun Gear And #7 Needle Bearing:
NOTE: The number seven needle bearing (1) (Fig. 132) 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. A small amount of petrolatum can be used to hold the bearing to the rear sun gear.
Fig.133 Install Front Carrier/Rear Annulus Assembly:
(56) Install front carrier/rear annulus assembly (2) (Fig. 133) and #6 needle bearing (1).
Fig.134 Install Front Sun Gear Assembly:
(57) Install front sun gear assembly (1) (Fig. 134) and #4 thrust washer (2).
Fig.135 Select Thinnest No.4 Thrust Plate:
(58) Select the thinnest #4 thrust plate thickness and install to input clutch assembly (1) (Fig. 135). Use petrolatum to retain.
Fig.136 View Through Input Speed Sensor Hole:
(59) Install input clutch assembly into position and verify that it is completely seated by viewing through input speed sensor hole. View through input speed sensor hole (2) (Fig. 136), if not as shown in picture, the input clutch assembly is not seated properly.
Fig.137 Remove Oil Pump O-Ring:
(60) Remove oil pump O-ring (2) (Fig. 137). Be sure to reinstall oil pump O-ring after selecting the proper #4 thrust plate.
(61) Install pump and gasket to transmission. Install and torque bolts.
Fig.138 Measure Input Shaft End Play Using Tool 8266-Typical:
(62) Set up input shaft for measurement with Indicator Set C-3339 (2) and End Play Socket Set 8266 (1) (Fig. 138).
(63) 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 of0.020 inch which is within specifications.
(64) Refer to the No. 4 thrust plate chart to select the proper No. 4 thrust plate.
NO. 4 THRUST PLATE CHART:
Fig.139 Install Input Clutch Assembly:
(65) Install input clutch assembly (1) (Fig. 139).
Fig.140 Install No.1 Caged Needle Bearing:
(66) Install #1 caged needle bearing (1) (Fig. 140).
CAUTION: The cooler bypass valve must be replaced if transaxle failure has occurred. Do not attempt to reuse or clean old valve.
Fig.141 Install Cooler Bypass Valve:
(67) Install cooler bypass valve (1) (Fig. 141) with O-ring end towards rear of case.
Fig.142 Install Oil Pump Gasket:
(68) Install oil pump gasket (1) (Fig. 142).
Fig.143 Install Oil Pump:
(69) Install oil pump assembly (1) (Fig. 143).
Fig.144 Install Pump-to-Case Bolts:
(70) Install oil pump-to-case bolts (1) (Fig. 144) and torque to 27 Nm (20 ft. lbs.).
Fig.145 Low/Reverse Accumulator:
(71) Install low/reverse accumulator (1) (Fig. 145)
Fig.146 Install Low/Reverse Accumulator Plug:
(72) Install low/reverse accumulator plug (2) (Fig. 146).
Fig.147 Install Low/Reverse Accumulator Snap Ring:
(73) Install low/reverse accumulator snap ring (1) (Fig. 147).
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.
Fig.148 Underdrive And Overdrive Accumulators:
(74) Install underdrive (2) (Fig. 148) and overdrive (4) accumulators and springs.
Fig.149 Valve Body Removal/Installation:
(75) Install valve body (1) (Fig. 149) to transaxle. Rotate manual valve shaft fully clockwise to ease installation. Make sure park rod rollers are positioned within park guide bracket.
Fig.150 Install Valve Body-to-Case Bolts:
(76) Install and torque valve body-to-case bolts (1) (Fig. 150) to 12 Nm (105 inch lbs.).
Fig.151 Install Oil Filter And O-Ring:
(77) Install oil filter and new O-ring (1,2) (Fig. 151).
Fig.152 Install Oil Pan:
(78) Apply an 1/8" bead of Mopar ATF RTV (MS-GF41) (2) (Fig. 152) to oil pan (1) and immediately install to case.
(79) Install oil pan-to-case bolts and torque to 19 Nm (165 inch lbs.).
Fig.153 Solenoid/Pressure Switch Assembly And Gasket:
(80) Install solenoid/pressure switch assembly (1) (Fig. 153) and gasket to case (2).
Fig.154 Attaching Bolts:
(81) Install and tighten solenoid/pressure switch assembly-to-transaxle case bolts (1) (Fig. 154) to 12 Nm (110 inch lbs.).
(82) Install and torque input and output speed sensors to case to 27 Nm (20 ft. lbs.).