Steps 41 - 80
41TE AUTOMATIC TRANSAXLEASSEMBLY STEPS 41 - 80
Fig.117 Install Low/Reverse Reaction Plate Snap Ring:
(41) Install low/reverse reaction plate flat snap ring (2) (Fig. 117) insure you do not scratch clutch plate (3).
Fig.118 Install One Disc:
(42) Install remaining low/reverse clutch disc (1) (Fig. 118).
Fig.119 Install Low/Reverse Reaction Plate:
(43) Install low/reverse reaction plate with flat side up (1) (Fig. 119).
Fig.120 Tapered Snap Ring Instructions:
(44) Use as a reference while installing tapered snap ring (Fig. 120).
Fig.121 Snap Ring Installed:
(45) Install tapered snap ring (with tapered side up) (2) (Fig. 121).
Fig.122 Check Low/Reverse Clutch Clearance:
(46) Set up dial indicator (1) (Fig. 122) 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 places. Take average of readings and select the proper low/reverse reaction plate to achieve specifications.
LOW/REVERSE REACTION PLATE CHART:
Fig.123 Install 2/4 Clutch Pack:
(47) Install 2/4 clutch pack (1,2) (Fig. 123).
NOTE: The 2/4 Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.
Fig.124 Proper Orientation Of 2/4 Clutch Retainer And Spring:
(48) Orient 2/4 clutch return spring to retainer (3) (Fig. 124).
Fig.125 2/4 Clutch Retainer:
(49) Install 2/4 clutch retainer to transaxle (1,2) (Fig. 125).
Fig.126 Install 2/4 Clutch Retainer Snap Ring:
(50) Using Compressing Tool 5058-A (1) (Fig. 126), compress 2/4 clutch return spring just enough to install snap ring (3).
(51) Install snap ring.
Fig.127 Check 2/4 Clutch Clearance:
(52) Set up dial indicator (1) (Fig. 127) 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.
Fig.128 Number 7 Bearing:
NOTE: The number seven needle (1) (Fig. 128) 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. A small amount of petrolatum can be used to hold the bearing to the rear sun gear (2).
Fig.129 Install Rear Sun Gear And #7 Needle Bearing:
(53) Install rear sun gear (2) (Fig. 129) and #7 needle bearing (1).
Fig.130 Install Front Carrier And Rear Annulus Assembly:
(54) Install front carrier/rear annulus assembly (2) (Fig. 130) and #6 needle bearing (1).
Fig.131 Install Front Sun Gear Assembly:
(55) Install front sun gear assembly (1) (Fig. 131) and #4 thrust washer (2).
Fig. 132 Select Thinnest No.4 Thrust Plate:
(56) Select the thinnest #4 thrust plate thickness (2) (Fig. 132) and install to input clutch assembly Use petrolatum to retain (3).
Fig. 133 View Through Input Speed Sensor Hole:
(57) Install input clutch assembly into position and verify that it is completely seated by viewing through input speed sensor hole (2) (Fig. 133). If view through input speed sensor hole is not as shown in the below view, the input clutch assembly is not seated properly.
Fig.134 Remove Oil Pump O-Ring:
(58) Remove oil pump O-ring (2) (Fig. 134). Be sure to reinstall oil pump O-ring after selecting the proper #4 thrust plate.
(59) Install pump and gasket to transmission. Install and torque bolts.
Fig.135 Measure Input Shaft End Play Using End Play Set 8266:
(60) Set up input shaft for measurement with Indicator Set C3339 (2) and End Play Set 8266 (1) (Fig. 135).
(61) 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.
(62) Refer to the No. 4 thrust plate chart NO. 4 THRUST PLATE CHART to select the proper No. 4 thrust plate.
No.4 Thrust Plate Chart:
NO. 4 THRUST PLATE CHART
Fig. 136 Install Input Clutch Assembly:
(63) Install input clutch assembly (1) (Fig. 136).
Fig.137 Install Caged Needed Bearing:
(64) Install #1 caged needle bearing (1) (Fig. 137) note: tanged side out (2).
CAUTION: The cooler bypass valve must be replaced if transaxle failure has occurred. Do not attempt to reuse or clean old valve.
Fig.138 Install Cooler Bypass Valve:
(65) Install cooler bypass valve (1) (Fig. 138) with O-ring end towards rear of case.
Fig.139 Install Oil Pump Gasket:
(66) Install oil pump gasket (1) (Fig. 139).
Fig.140 Install Oil Pump:
(67) Install oil pump (1) (Fig. 140).
Fig.141 Install Pump-to-Case Bolts:
(68) Install oil pump-to-case bolts (1) (Fig. 141) and torque to 27 Nm (20 ft. lbs.).
Fig.142 Install Low/Reverse Accumulator:
(69) Install low/reverse accumulator (1) (Fig. 142).
Fig.143 Install Low/Reverse Accumulator Plug (Cover):
(70) Install low/reverse accumulator plug (2) (Fig. 143).
Fig.144 Install Low/Reverse Accumulator Snap Ring:
(71) Install low/reverse accumulator snap ring (1) (Fig. 144).
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.145 Underdrive And Overdrive Accumulators:
(72) Install underdrive and overdrive accumulators (1, 2) (Fig. 145).
Fig.146 Install Valve Body:
(73) Install valve body (1) (Fig. 146) to transaxle. Rotate manual valve shaft fully clockwise to ease installation. Make sure park rod rollers are positioned within park guide bracket.
Fig.147 Install Valve Body-to-Case Bolts:
(74) Install and torque valve body-to-case bolts (1) (Fig. 147) to 12 Nm (105 inch lbs.).
Fig.148 Install Oil Filter:
(75) Install oil filter (1) (Fig. 148) and new O-ring (2).
Fig.149 Install Oil Pan:
(76) Apply an 1/8" bead of Mopar ATF RTV (MS-GF41) (2) (Fig, 149) to oil pan (1) and immediately install to case.
(77) Install oil pan-to-case bolts and torque to 19 Nm (165 inch lbs.).
Fig.150 Solenoid/Pressure Switch Assembly And Gasket:
(78) Install solenoid/pressure switch assembly (1) (Fig. 150) and gasket (2) to case.
Fig.151 Solenoid Pack-to-Transale Bolts:
(79) Install and tighten solenoid/pressure switch assembly-to-transaxle case bolts (1) to 12 Nm (110 inch lbs.) (Fig. 151).
(80) Install and torque input and output speed sensors to case to 27 Nm (20 ft. lbs.).