Steps 1 - 40
41TE AUTOMATIC TRANSAXLEASSEMBLY STEPS 1 - 40
CAUTION: The cooler bypass valve must be replaced if transaxle failure has occurred. Do not attempt to reuse or clean old valve.
NOTE: If transaxle is being overhauled (clutch and/or seal replacement), the TCM Quick Learn Procedure must be performed. Testing and Inspection
Fig.80 Install Both Output Bearing Cups:
(1) Install both output bearing cups (1) (Fig. 80) using Installer 5050 (3).
Fig.81 Install Piston Retainer Gasket:
(2) Install low/reverse piston retainer gasket (2) (Fig. 81). Make sure gasket holes line up with case (1).
Fig.82 Install Piston Retainer:
(3) Install low/reverse piston retainer (1) (Fig. 82).
Fig.83 Install Piston Retainer Attaching Screws:
(4) Install low/reverse piston retainer-to-case screws (3) (Fig. 83) and torque to 5 Nm (45 inch lbs.).
NOTE: The Low/Reverse Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.
Fig.84 Install Low/Reverse Clutch Piston:
(5) Install low/reverse clutch piston (1) (Fig. 84).
Fig.85 Guide Bracket Disassembled:
(6) Use above figure as a reference while assembling park guide bracket assembly (Fig. 85).
Fig.86 Guide Bracket:
(7) Assemble park guide bracket assembly (Fig. 86).
Fig.87 Pivot Shaft And Guide Bracket:
(8) Install guide bracket (2) (Fig. 87) into position and insert pivot shaft (3).
Fig.88 Install Anchor Shaft And Plug:
(9) Install anchor shaft (1) (Fig. 88) and plug (3). Make sure guide bracket and split sleeve are in contact with the rear of the transaxle case.
Fig.89 Low/Reverse Piston Return Spring:
(10) Install low/reverse piston return spring (1) (Fig. 89).
Fig.90 Compressor Tool Is Use:
(11) Install low/reverse spring compressor into position (Fig. 90).
Fig.91 Install Snap Ring:
(12) Compress low/reverse piston and install snap ring (1) (Fig. 91).
Fig.91 Install Rear Carrier Bearing Cone:
(13) Install rear carrier bearing cone (3) (Fig. 92) using Installer 6053 (1).
Fig.93 Install Rear Carrier Assembly:
(14) Install rear carrier assembly (1) (Fig. 93) to transaxle case.
Fig.94 Install Output Gear Bearing Cone:
(15) Install output gear bearing cone using Installer 5052 (3) (Fig. 94).
(16) OUTPUT GEAR BEARING ADJUSTMENT:
(a) With output gear removed, install a 4.50 mm (0.177 inch) gauging shim on the rear carrier assembly hub, using grease to hold the shim in place.
(b) Using Holder 6259, install output gear and bearing assembly Torque to 271 Nm (200 ft. lbs.).
Fig.95 Checking Output Gear Bearings End Play:
(c) Measure bearing end play. Attach Gear Checking Plate L-4432 (1) (Fig. 95) to the gear.
(d) Push and pull the gear while rotating back and forth to ensure seating of bearing rollers.
(e) Using a dial indicator mounted to the transaxle case, measure output gear end play.
(f) Refer to the output gear bearing shim chart for the required shim to obtain proper bearing setting.
(g) Use Holder 6259 to remove the output gear retaining bolt and washer. To remove the output gear, use Gear Puller L4407A.
(h) Remove the gauging shim and install the proper shim determined by the chart. Use grease to hold the shim in place.
OUTPUT GEAR BEARING SHIM CHART:
Fig.96 Install Output Gear:
(17) Install the output gear (3) (Fig. 96) and bearing assembly using Installer 6261 (2).
Fig.97 Output Gear Bolt And Washer:
(18) Install NEW output gear retaining bolt (2) (Fig. 97) and washer (3).
Fig.98 Tighten Output Gear To 271 Nm (200 ft. lbs.):
(19) Using Holder 6259 (4) (Fig. 98), torque output gear (1) retaining bolt to 271 Nm (200 ft. lbs.).
Fig.99 Check Output Gear Bearings Turning Torque:
(20) Using an inch pound torque wrench (1) (Fig. 99), check output shaft turning torque. Output shaft turning torque should be within 3 - 8 inch lbs . If the turning torque is too high, install a 0.04 mm (0.0016 inch) thicker shim. If the turning torque is too low, install a 0.04 mm (0.0016 inch) thinner shim. Repeat until the proper turning torque of 3 - 8 inch lbs. is obtained.
Fig.100 Install Stirrup:
(21) Install output gear stirrup (1) (Fig. 100) with serrated side out.
Fig.101 Install Strap Bolts:
(22) Install retaining strap (1) (Fig. 101).
(23) Install strap bolts (3) but do not tighten at this time.
Fig.102 Turn Stirrup Clockwise Against Bolt Flats:
(24) Rotate stirrup (2) (Fig. 102) clockwise against flats of retaining bolt.
Fig.103 Torque Stirrup Strap Bolts:
(25) Torque stirrup strap bolts to 23 Nm (200 inch lbs.) (Fig. 103).
Fig.104 Bend Tabs On Strap Up Against Flats Of Bolts:
(26) Bend tabs (1) (Fig. 104) on strap up against flats of bolts.
Fig.105 Install Transfer Shaft Bearing Cone:
(27) Install new transfer shaft bearing cone (2) (Fig. 105) using Installer 6052 (1).
Fig.106 Install Transfer Shaft:
(28) Using Remover/Installer 5049A (1) (Fig. 106), install transfer shaft (2).
Fig.107 Install Transfer Shaft Bearing Snap Ring:
(29) Using Snap Ring Pliers 6051 (1) (Fig. 107), install transfer shaft bearing snap ring (2).
Fig.108 Install Transfer Shaft Bearing Cup Into Retainer:
(30) Using an arbor press (1) (Fig. 108) install transfer shaft bearing cup into retainer using Installer 6061 (3). Use removed bearing cup to support retainer (4).
Fig.109 Remove Bearing Cup Retainer:
(31) Install bearing cup retainer (2) (Fig. 109) to transaxle.
Fig.110 Install Transfer Gear Bearing Cone:
(32) Install new transfer gear bearing cone (3) (Fig. 110) to transfer gear (4) using Installer 5052 (5).
(33) TRANSFER GEAR BEARING ADJUSTMENT:
Fig.111 Install Transfer Shaft Gear And (Select) Shim:
(a) Install a 4.66 mm (0.184 inch) gauging shim on the transfer shaft (Fig. 111).
(b) Install transfer shaft gear using Installer 6261. Using Holder 6259, install transfer shaft gear retaining nut to 271 Nm (200 ft. lbs.).
(c) Measure end play. Attach Gear Checking Plate 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 Holder 6259 to remove the retaining nut and washer. Remove the transfer shaft gear using Gear Puller L4407A.
(i) Remove the gauging shim and install the proper shim indicated by the chart.
TRANSFER SHAFT BEARING SHIM CHART Part 1:
TRANSFER SHAFT BEARING SHIM CHART Part 2:
Fig.112 Install Transfer Shaft Gear:
(34) Install the transfer shaft gear (4) (Fig. 112) using Installer 6261 (2).
CAUTION: Install a NEW retaining nut, as the original nut MUST NOT be reused.
(35) Install the new retaining nut and washer.
Fig.113 Tighten Transfer Gear Nut To 271 Nm (200 ft. lbs.):
(36) Using Holder 6259 (4) (Fig. 113), torque transfer gear retaining nut to 271 Nm (200 ft. lbs.).
(37) 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.
Fig.114 Install Rear Cover:
(38) Install a bead of Mopar ATF RTV (MS-GF41) (2) (Fig. 114) to transfer gear cover (1).
Fig.115 Install Rear Cover Bolts:
(39) Use sealant on bolts (3) (Fig. 115), install transfer gear cover-to-case bolts (1) and torque to 20 Nm (175 inch lbs.) torque.
Fig.116 Install Low/Reverse Clutch Pack:
(40) Install low/reverse clutch pack (1,2) (Fig. 116). Leave uppermost disc out until snap ring is installed.