Part 2

56. Install the differential cover bolts (1) and tighten to 95 Nm (70 ft. lbs.).




57. Install the differential output bearing cover (2).
58. Install the differential output bearing cover bolts (1) and tighten to 12 Nm (105 in. lbs.).




NOTE: Remote pinion gear must NOT be installed while checking turning torque.

59. Using the Turning Torque Tool 9735 (1) and an inch pound torque wrench (2) check the differential turning torque, it should be 10 to 22 in-lbs (drag). If turning torque is more than 22 in-lbs (drag) decrease shim size behind the end cover and recheck. If turning torque is less than 10 in-lbs (drag) increase shim size.
60. After proper turning torque is achieved for the differential remove the differential from the case and set aside keeping the correct shim with the differential.




61. Install the remote pinion bearing cup in the case (small cup) using Installer 9730 and Handle C-4171.
62. Install the remote pinion bearing cup in the cover using Installer 9729 and Handle C-4171.
63. Install the remote pinion (2) into the transaxle case.




64. Install the remote pinion cover (2) into transaxle case.




65. Install the bolts (1) at the remote pinion cover (2) and tighten to 12 Nm (105 in. lbs.).




NOTE: Differential assembly must not be installed when checking for pinion drag torque.

66. Check turning torque using Differential Bearing Torque Tool C-4995 (2) and an inch pound torque wrench (1). Turning torque for the remote pinion gear should be 2 to 8 in-lbs (drag). If more than 8 in-lbs (drag) decrease shim size under the remote pinion bearing cover cup. If turning torque is less than 2 in-lbs (drag) increase the shim size under the remote pinion bearing cover cup.




67. Install Holder 9908 (2) onto the compounder bearing retainer to help in installation.
68. Install the compounder bearing retainer into the transaxle case.




69. Remove Holder 9908 from the compounder bearing retainer.
70. Install all the bolts at the compounder bearing retainer and tighten to 12 Nm (105 in. lbs.).




71. Install snap ring (1) at top of the compounder bearing retainer.




NOTE: Insure End Play Tool 9951 is not binding in support plate that is bolted to the case.

NOTE: Always use original shim to determine end play.

72. Remove plug at case (3).
73. Install compounder End Play Tool 9951 (2) through the hole in the front case.
74. Install Dial Indicator C-3339 (1) onto End Play Tool 9951.
75. Use moderate downward pressure on End Play Tool 9951 and zero Dial Indicator C-3339.
76. Use moderate upward pressure on End Play Tool 9951 and take reading from Dial Indicator C-3339.
77. Remove End Play Tool 9951 and zero Dial Indicator C-3339.
78. Adjust shim thickness in the underdrive unit to 0.010 to 0.020".
79. Install the correct (select) helical shim and assemble the underdrive compounder Assembly and retest.
80. Using Mopar lock & seal adhesive install plug back into case and tighten to 24 Nm (18 ft. lbs.).




81. Install the transfer gear (underdrive compounder side) cone using Installer 6756 (3).




82. Install Holder 9739 (1) onto the transfer gear (underdrive compounder side) (2).
83. Install a new transfer gear (underdrive compounder side) nut and tighten to 271 Nm (200 ft. lbs.).
84. Use Staking Tool 9721 and stake the new nut.




85. Install the differential, bearing cups, shim and oil slinger into case.




86. Use a bead of MOPAR(R) ATF RTV (MS-GF41).
87. Install the differential cover.




88. Install the differential cover bolts (1) and tighten to 95 Nm (70 ft. lbs.).




89. Use a bead of MOPAR(R) ATF RTV (MS-GF41).
90. Install the differential output bearing cover (2) and tighten bolts to 12 Nm (105 in. lbs.).
91. Install differential oil seals into the case using installer MD998334-01.




92. Install the oil scavenger (2).




93. Install the transfer gear cover (1), use a bead of MOPAR(R) ATF RTV (MS-GF41).�
94. Install transfer gear cover-to-case bolts (2) and tighten to 12 Nm (105 in. lbs.).




95. Install the park pawl tube (1) into case (2) making sure guide pin aligns with hole in case.




96. Install the snap ring (1) for the park pawl tube.




97. Install the park pawl (1) and the park pawl spring (2).




98. Install the park pawl shaft (1).




99. Install the park pawl shaft and park pawl pipe plug tighten to 27 Nm (20 ft. lbs.).




100. Install the set screw (1) for the park pawl shaft and tighten to 1 Nm (10 in. lbs.).
101. Install the manual lever, TRS and seal Installation.








102. Install all six accumulators (1, 2, 3, 5, 6 and 7) into case along with the accumulator return springs.
103. Install a new 2/4 clutch oil supply seal (4) into the case.




NOTE: Install transmission oil on the oil transfer tubes O-rings.

104. Install the oil transfer tubes (2) into the case/compounder.




105. Install valve body (1) onto the oil transfer tubes and manual valve (3) at the rooster comb.




106. Install the valve body bolts (1) and tighten to 7 Nm (50 in. lbs.).




107. Install the detent spring (2).
108. Install the bolt (3) holding the detent spring and tighten to 7 Nm (50 in. lbs.).
109. Install the electrical connector (1) at the range sensor (4).




110. Install the valve body oil pan, use a bead of MOPAR(R) ATF RTV (MS-GF41).
111. Install the valve body oil pan bolts and tighten to 6 Nm (53in. lbs.).




112. Install the pressure tap plug (2) at valve body pan and tighten to 9 Nm (45 in. lbs.).




113. Install the fluid filter seal (1) at the case.




114. Install the fluid filter (2).
115. Install the fluid filter mounting nuts and tighten to 5 Nm (40 in. lbs.).




116. Install the fluid filter oil pan, use a bead of MOPAR(R) ATF RTV (MS-GF41).
117. Install the fluid filter oil pan bolts and tighten to 6 Nm (53 in. lbs.).




118. Install the speed sensors (1, 2 and 3) and tighten bolts to 12 Nm (105 in. lbs.).