Repair Procedure Steps 1 Thru 60

1. Open the hood.

2. Disconnect and isolate the battery negative cable.

NOTE:
Journey/Sebring/Avenger models continue to next step Town & Country Models proceed to Step # 14.

NOTE:
The front splash shield is a two piece assembly

3. Remove push pins that secure the left front splash shield.

4. Remove fasteners that secure the left front splash shield.

5. Remove the left front splash shield.

6. Remove the air cleaner housing Refer to the information provided in DealerCONNECT > TechCONNECT > Service Information > 09 Engine > Air intake System > Body Air Cleaner > Removal.

7. Support the transaxle with a floor jack.





8. Remove the bolts at the left transmission mount (Fig 1).

9. Remove the floor jack from the transmission.

10. Raise the vehicle on the hoist.





11. Support the engine with a screw jack (Fig. 2).





12. Remove the fore/aft member mount through bolt (Fig. 3).

13. Lower transaxle Allow the transaxle to rest on the fore/aft member Proceed to Step # 17.

14. Remove the Battery Refer to TechCONNECT > Service Information > 08 Electrical > Engine Systems > Battery Systems > Battery > Removal for additional information.





15. Disconnect the radiator overflow hose from the radiator filler neck. Then remove the engine coolant overflow bottle. The bottle is secured to the radiator support by bayonet style attachments. Remove the coolant recovery container by pulling the coolant bottle upwards off of the radiator fan shroud (Fig. 4).

16. On 3.8L Town and Country/Grand Caravan models remove the exhaust crossover pipe Refer to Tech CONNECT > Service Information > 11 - Exhaust Systems > Pipe Exhaust Crossover > Removal for additional information.

17. Place a drain pan under the transmission.





18. Disconnect oil cooler lines from transaxle using Trans Cooler Line Disconnect tool 8875A. Allow the residual transmission fluid to drain into the drain pan then move the lines out of the way (Fig 5).





19. Remove shift cable from manual valve lever (Fig. 6).





20. Remove the solenoid pack connector at valve body oil pan (Fig. 7).

21. On Town and Country/Grand Caravan models remove the engine coolant heater tube hold down clamp bolt located at the left side of the engine. Then remove the engine coolant heater tube hold down clamp bolt attached at the front of the engine Position the engine coolant heater tube out of the way.





22. Remove the three valve body oil pan sound deadener retaining clips (Fig 8) and remove the sound deadener.





23. Take note of each sound deadener stud location (should be three) (Fig 9) for reference later and remove each stud.

24. Remove the wire harness retaining clip from the valve body oil pan (Fig. 9).

25. Remove the top valve body oil pan bolts.

26. Raise the vehicle on a hoist.

27. If the vehicle is equipped with wheel center caps that cover the wheel nuts remove the left front wheel's cap with an appropriate removal tool utilizing the notch located between the wheel and the outer edge of the cap Use care not to damage the wheel coating.

28. Remove the left front wheel's five wheel mounting (lug) nuts from studs.

29. Remove the left front tire and wheel assembly from hub.





30. Remove the two bolts securing disc brake caliper and adapter bracket to the steering knuckle (Fig. 10).

31. Remove the disc brake caliper and adapter bracket from the knuckle and rotor as an assembly (Fig. 10). Hang the assembly out of the way using wire or a bungee cord. Use care not to overextend the brake hose when doing this.

32. Turn the wheel fully to the left.





33. If equipped, remove the bolt at the ground cable (Fig. 11).

34 If equipped remove the ground cable clip at the valve body pan and move the ground cable away from the valve body pan.

35. Position a drain pan under the lower oil pan.

36. Loosen the lower pan bolts and tap the pan at one corner to break it loose allowing fluid to drain then remove the oil pan.

37. Remove nuts at the oil filter and discard the filter.

38. Remove the lower valve body oil pan bolts.

39 Remove the valve body oil pan.





40. Remove the electrical connector at the valve body (Fig. 12).





41. Remove screw at detente arm then remove the arm (Fig. 13).





42. Remove the twenty one valve body to case bolts (Fig. 14).

NOTE:
One valve body attaching screw is hidden by the manual valve rooster comb.








43. Pull the valve body away from the underdrive compounder oil transfer tubes (Fig. 15) and lift up on valve body to clear the manual valve pin past the slot in the rooster comb (Fig. 16).








44. Separate the underdrive compounder transfer tubes (Fig 17) from the underdrive compounder and remove the tubes (Fig. 18).





45. Remove transfer gear cover-to-case bolts (Fig 19).

46. Remove transfer gear cover (Fig 19).





47. Remove the oil scavenger (Fig 20).

CAUTION:
THE SCAVENGER IS SECURED TO THE TRANSMISSION CASE WITH SMALL TABS THESE SMALL TABS BREAK EASILY USE EXTREME CARE WHEN REMOVING THE SCAVENGER FROM THE TRANSMISSION.





48. Grind the staked tabs from the transfer gear (underdrive compounder side) (Fig. 21).

CAUTION:
TAKE CARE TO NOT DAMAGE THE TRANSFER SHAFT THREADS.





49. Install the Gear Holder 9739 onto the transfer gear (underdrive compounder side) and remove the nut (Fig 22).





50. Remove the snap ring at the underdrive compounder assembly (Fig 23).

NOTE:
The underdrive compounder snap ring is tapered Please note the direction of the snap ring taper before removal so that upon reassembly it will be installed properly,





51. Using an Impact Driver loosen all transfer gear bearing retainer screws Then remove the four bolts shown in (Fig 24).





52. Install puller adapter 9908 to the compounder bearing retainer (Fig. 25).

53. Install Slide Hammer C3752 to puller adapter 9908 and pull the underdrive compounder assembly from the case (Fig. 25).





54. Remove the underdrive compounder assembly (Fig. 26).

55. Remove the slide hammer from the adapter 9908 and clamp the adapter into a vise to support the underdrive compounder during the disassembly process.

NOTE:
The planetary gear set/output hub may still be in the transmission case. If the planetary gear set/output hub is in the transmission remove it and proceed to Step # 57. If not proceed to the next step.





56. Remove the planetary gear set / output hub.





57. Remove the helical shim (Fig. 28).

NOTE:
If the helical shim is not on the sun gear, then it may still be located in the planetary gear set. It will not be necessary to remove the helical shim from the planetary gear set/output hub.





58. Using Special Tools 6680-2 and 6680-3 (wiring terminal picks) or two small picks remove retaining clip from transfer/underdrive shaft (Fig. 29).

NOTE:
A new retaining clip will be used during assembly.

59. Remove the sun gear from the shaft.





60. Remove the split bearing using a small pick (Fig 30).