Repair Procedure Steps 61 Thru 154
61. Remove the underdrive compounder direct clutch from the low clutch (Fig. 31).
62. Remove the thrust bearing from the transfer shaft (Fig. 32).
63. Remove the overrunning clutch from the low clutch (Fig. 33).
64. Carefully clamp the underdrive compounder low clutch into a soft jaw vise.
CAUTION:
TAKE CARE NOT TO OVERTIGHTEN THE VISE AS DAMAGE TO THE UNDERDRIVE COMPOUNDER LOW CLUTCH MAY RESULT.
65. Remove Puller Adapter 9908 from the low clutch (Fig. 34).
66. Remove remaining fasteners securing the transfer shaft bearing retainer and remove the retainer (Fig 35).
67. Remove the transfer shaft from the low clutch (Fig. 36).
68. Using Bearing Splitter 1130 and a press remove the transfer shaft bearing (Fig. 37).
69. Using Installer 6756 and a Press install the transfer shaft bearing (p/n 68051332AA) onto the transfer shaft (Fig. 38).
70. Using Press Puller 0-293-PA, Adaptors 9738 and Press Plug 9678 remove compounder transfer gear bearing cone (Fig 39).
71. Install the transfer gear bearing cone (p/n 68051332AA) using Installer 6756 (Fig 46).
72. Using a suitable tool drive both transfer shaft bearing races from the transfer shaft bearing retainer (Fig 41) and (Fig 42).
73. Install new bearing races into the transfer shaft bearing retainer using Bearing Race Installer 9952 and Drive Handle C4171 (Fig 43) and (Fig 44).
74. Install the transfer shaft onto the low clutch (Fig 36).
75. Lube the transfer shaft and transfer gear bearings with clean ATF+4 transmission fluid.
76. Install transfer shaft bearing retainer onto the low clutch.
77. Install all of the bearing retainer screws and tighten to 12 Nm (105 in.lbs).
78. Install the selectable shim (Fig. 45).
NOTE:
The selectable shim will determine turning torque.
79. Install the transfer gear (Fig. 46) onto the transfer shaft and Holder 9739 onto the transfer gear.
80. Install the transfer gear nut (Fig 47).
81. Clamp Holder 9739 into a vise as shown in (Fig. 48) tighten transfer gear nut to 271 Nm (200 if lbs).
82. Remove Holder 9739 from transfer gear.
83. Carefully clamp the underdrive compounder low clutch into a soft jaw vise.
CAUTION:
TAKE CARE NOT TO OVERTIGHTEN THE VISE AS DAMAGE TO THE UNDERDRIVE COMPOUNDER LOW CLUTCH MAY RESULT.
84. Rotate the transfer gear four complete revolutions clockwise then four complete revolutions counter clockwise to seat the new bearings.
85. Check turning torque using an inch pound torque wrench. Initial break away torque should be disregarded. Turning torque should be between 4.0 to 12.0 in-lbs (drag) If more than 12.0 in-lbs (drag) choose a larger shim and recheck turning torque. If less than 4.0 in-lbs (drag) choose a smaller shim and recheck turning torque (Fig. 49).
86. Install Holder 9739 onto transfer gear and clamp the holder into a vise.
87. Remove transfer gear nut and gear.
88. Install the Bearing Retainer Assembly Adapter 9903 onto the low clutch (Fig 34).
89. Clamp the adapter into a vise to support the underdrive compounder during assembly process.
90. Install the overrunning clutch into the low clutch (Fig 33).
91. Install the thrust bearing onto the transfer shaft (Fig 32).
92. Install the direct clutch onto the low clutch (Fig 31).
93. Install the split bearing and lock into place (Fig 30).
94. Install the sun gear onto the shaft.
95. Install the new retaining clip (p/n 5078635AA) onto the transfer / underdrive shaft (Fig. 29).
96. If necessary install the helical shim (Fig 28).
97. Install the planetary gear set / output hub onto the direct clutch (Fig 27).
98. Install the underdrive compounder assembly into the transaxle case (Fig 26).
99. Remove Adapter 9908 from the compounder bearing retainer.
100. Install all the bolts at the compounder bearing retainer and tighten to 12 N.m (105 in. lbs.).
101. Install snap ring at top of the compounder bearing retainer (Fig 50).
NOTE:
The underdrive compounder snap ring is tapered The tapered side of the snap ring must face outward (flat side toward transmission case).
102. Make sure select fit shim is located on the transfer shaft prior to installing the transfer gear (Fig 51).
103. install transfer gear onto transfer shaft.
104. install Holder 9739 onto the transfer gear (underdrive compounder side) (Fig 22).
105. Install a new transfer gear (underdrive compounder side) nut (p/n 6508521AA) and tighten to 271 Nm (200 ft.lbs.).
106. Use Staking Tool 9721 and stake the new nut.
107. Clean the transfer gear cover sealing surface and mating surface.
108. Install the oil scavenger (Fig 20).
109. Spread a bead of MOPAR(R) ATF RTV (p/n 05010884AA) (MS-GF41) onto the transfer gear cover sealing surface.
110. Install transfer gear cover-to-case bolts and tighten to 12 N.m (105 in.lbs.) (Fig 19).
111. Install the underdrive compounder transfer tubes (Fig 17) into the underdrive compounder.
112. Position the valve body near the underdrive compounder oil transfer tubes and slide the valve body manual valve pin into the slot in the rooster comb (Fig 16) Then slide the valve body onto the underdrive compounder transfer tubes (Fig 15).
113. Install the twenty one valve body to case bolts and tighten to 6 N.m (50 in.lbs.) (Fig. 14).
NOTE:
Valve body to case bolt torque is critical during the valve body installation. Failure to torque bolts could result in the improper operation.
114. Install the detente arm onto the pin at the valve body (Fig 13).
1i5. Install the screw at the detente arm and tighten to 6 N.m (50 in. lbs.).
116. Install the electrical connector at the valve body (Fig. 12).
117. Install a new transmission oil filter and nuts tighten to 5 N.m (40 in.lbs.).
118. Clean the oil pan and magnet.
119. Spread a bead of MOPAR(R) ATF RTV (p/n 05010884AA) (MS-GF41) onto the oil pan sealing surface.
120. Install the transmission oil pan onto the transmission and tighten oil pan bolts to 6 N.m (50 in.lbs.)
121. Install the valve body oil pan use a bead of MOPAR(R) ATF RTV (p/n 05010884AA) (MS-GF41).
122. Install the valve body oil pan bolts and tighten to 12 N.m (105 in.lbs.)
NOTE:
Install the three oil pan studs in the locations recorded from Step # 23.
123. If equipped install the ground cable and tighten the bolt (Fig 11).
124. If equipped install the ground cable clip at the valve body pan (Fig 11).
NOTE:
Journey/Sebring/Avenger models continue to next step Town & Country Models, proceed to Step # 129.
125. Place splash shield up to wheelhouse opening.
126. Install push pins.
127. Install fasteners.
128. Install the left front splash shield.
129. Install the disc brake caliper and adapter bracket assembly over the brake rotor and knuckle (Fig 10).
130. Install the mounting bolts securing the caliper adapter bracket to the knuckle (Fig 10). Tighten the bolts to 169 N.m (125 ft.lbs.).
131. Position the tire and wheel assembly on the wheel mounting studs using the hub pilot as a guide Place and hold the wheel flush up against the mounting surface.
132. Install and lightly snug all five wheel mounting (lug) nuts. Do not tighten at this time.
133. Lower the vehicle.
134. Progressively tighten all wheel mounting nuts in the proper sequence shown. Tighten nuts to a final torque of 135 N.m (100 ft.lbs.).
135. If applicable install the wheel center cap.
136. Install the wire harness retaining clip onto the valve body oil pan (Fig. 9).
137. Position the sound deadener over the valve body oil pan.
138. Install the three valve body oil pan sound deadener retaining clips (p/n 06100840) (Fig 8).
139. On Town and Country/Grand Caravan models reposition the engine coolant heater tube and secure the tube with the hold down clamp bolt located at the left side of the engine and the hold down clamp bolt attached at the front of the engine.
140. Attach the solenoid pack connector at valve body oil pan and secure it with the connector lock (Fig 7).
141. Install the shift cable onto the manual lever (Fig. 6).
142. Reconnect the oil cooler lines onto the transaxle (Fig. 5). Town and Country/Grand Caravan models, proceed to the next step. Journey/Sebring/Avenger models, proceed to Step # 146.
143. On 3.8L Town and Country/Grand Caravan models, install the exhaust crossover pipe. Refer to Tech CONNECT > Service Information > 11 - Exhaust Systems > Pipe, Exhaust Crossover > Installation for additional information.
144. Reconnect the radiator overflow hose onto the radiator filler neck. Then, install the engine coolant recovery bottle (Fig 4).
145. Install the Battery. Refer to TechCONNECT > Service Information > 08 - Electrical > Engine Systems > Battery Systems > Battery > Installation for additional information. Then, proceed to Step # 154.
146. Raise the vehicle and support the engine with a screw jack (Fig. 2).
147. Install the fore/aft member through bolt and tighten to 50 Nm (37 ft lbs) (Fig. 3).
148. Remove the screw jack supporting the engine.
149. Lower the vehicle.
150. Support the transaxle with a floor jack
151. install the bolts at the left transmission mount and tighten to 100 Nm (74 ft.lbs.) (Fig. 1).
152. Remove the floor jack from the transmission.
153. Reconnect the battery negative cable.
154. Top off transmission fluid using the information provide in DealerCONNECT > TechCONNECT > Service Info > 21 Transmission and Transfer Case > Fluid > Standard Procedure > FLUID LEVEL AND CONDITION CHECK.