Part 2

ASSEMBLY






36. Install input clutch assembly into position and verify that it is completely seated by viewing through input speed sensor hole (3). If view through input speed sensor hole is not as shown in the view, the input clutch assembly (2) is not seated properly.










37. Remove oil pump O-ring (2). Be sure to reinstall oil pump O-ring after selecting the proper number four thrust plate.
38. Install pump and gasket to transmission. Install and torque bolts.










39. Set up input shaft for measurement with Indicator Set C-3339A (3) and End Play Set 8266A (1,2).
40. Measure the input shaft end play with the transaxle in the vertical position. Input shaft end play must be within 0.13-0.64 mm (0.005 to 0.025 in.) For example, if end play reading is 0.055 in. select number four Thrust Plate which is 0.071-0.074 in. thick. This should provide an input shaft end play reading of 0.020 in. which is within specifications.
41. Refer to the number four thrust plate chart NO. 4 THRUST PLATE CHART to select the proper number four thrust plate.

NO. 4 THRUST PLATE CHART















42. Install input clutch assembly (1).










43. Install number one caged needle bearing (1) note: tinged 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.






44. Install cooler bypass valve (1) with O-ring end towards rear of case.





45. Install oil pump gasket (1).





46. Install oil pump (2).
47. Install oil pump-to-case bolts (1) and tighten 30 Nm (265 in. lbs.).










48. Install output gear stirrup (1) with serrated side out.










49. Install retaining strap (1).
50. Install strap bolts (3) but do not tighten at this time.










51. Rotate stirrup (2) clockwise against flats of retaining bolt.










52. Tighten stirrup strap bolts to 23 Nm (200 in. lbs.).










53. Bend tabs (1) on strap up against flats of bolts.





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





55. Install the differential cover.





56. Install the differential cover bolts (1) and tighten to 61 Nm (45 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 16 Nm (140 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-4995A (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-3339A (1) onto End Play Tool 9951.
75. Use moderate downward pressure on End Play Tool 9951 and zero Dial Indicator C-3339A.
76. Use moderate upward pressure on End Play Tool 9951 and take reading from Dial Indicator C-3339A.
77. Remove End Play Tool 9951 and zero Dial Indicator C-3339A.
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 Underdrive Compounder Assembly - Assembly and retest.
80. Using Mopar lock AND 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 61 Nm (45 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 Transmission Range Sensor - 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 12 Nm (105 in. lbs.).





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





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





115. Install the fluid filter oil pan, use a bead of MOPAR(R) ATF RTV (MS-GF41).
116. Install the fluid filter oil pan bolts and tighten to 12 Nm (105 in. lbs.).





117. If equipped install the Front Sound Dampener Cover (2) and the fasteners (1).





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





119. If equipped install the Top Sound Dampener Cover (1).