8HP45 Automatic Transmission - Assembly

ASSEMBLY

Special Tools:










CAUTION: A unique transmission fluid has been developed for the 8HP45 transmission. This fluid is NOT compatible with ATF+4 or any other current Chrysler transmission fluid. For specifics about this unique fluid see FLUIDS, LUBRICANTS AND GENUINE PARTS .

CAUTION: The Transmission Control Module (TCM), or Transmission Control Module Assembly (TCMA) is extremely sensitive to Electrostatic Discharge (ESD). Always use a ground strap and follow the ESD guidelines in ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES . Failure to follow these instructions may result in damage to the TCM/TCMA.

NOTE: If the transmission is being reconditioned (clutch/seal replacement) or replaced, it is necessary to perform the TCM Adaptation Procedure 8HP45





1. Insert the P4 annulus (3) into the P4 annulus drum (2).
2. Install the snap ring (1) into the P4 annulus drum (2).





3. Install the P4 planetary carrier\output shaft (2) into the P4 annulus drum (1).





4. Position the bearings on the top and the bottom of C clutch (1).
5. Install the C clutch (1) into the P4 sun gear/C/E clutch retainer (2).





6. Install the needle bearing (2) onto the E clutch (1).
7. Install the E clutch (1) into the P4 sun gear/C/E clutch retainer (3).





8. Install the snap ring (1) into the P4 sun gear/C/E clutch retainer (2).





9. Install the P3 annulus (1) into the P4 sun gear/C/E clutch retainer (2).





10. Install the snap ring (1) into the P4 sun gear/C/E clutch retainer (2).





11. Install the P4 sun gear/C/E clutch retainer (1) into the D clutch drum (2).





12. Install the needle bearing onto the planetary carrier.
13. Install the P3 planetary carrier (2) in the D clutch drum.
14. Install the snap ring (1).





15. Install the D clutch drum (1) into the P4 annulus drum (2).





16. Install the P2 annulus\P3 sun gear (1) onto the drum assembly (2).





17. Install the needle bearing (2) and washer.
18. Install the input shaft with P2 planetary carrier (1) into the drum assembly.





19. Install P1/P2 sun gear into the bottom of the P1 planetary carrier (3).
20. Install the P1 planetary carrier (3).
21. Install the snap ring (1).





22. Install the needle bearing and holding plate (2) onto the P1 planetary carrier.
23. Install the washer onto the internal ring gear.
24. Install the P1 annulus\B clutch hub assembly (1) onto the P4 annulus drum.
25. Install the O-ring and five squared O-rings.





26. Install the clutch pack (2).






NOTE: The (10373) (3) is a combination tool that is reversed to install the oil dam and output shaft inner needle bearing. For use to install the output shaft inner needle bearing, use the thick walled side (2) of the tool against the bearing.

27. Using (10373) (3) and (C-4171) (1), install the output shaft inner needle bearing.
28. Install the snap ring.






NOTE: The (10373) (3) is a combination tool that is reversed to install the oil dam and output shaft inner needle bearing. For use to install the oil dam, use the thin walled side (2) of the tool against the oil dam.

29. Using (10373) (3) and (C-4171) (1), install the oil dam.
30. Install the snap ring.





31. Install the needle bearing (AWD) or ball bearing (RWD).
32. Install the snap ring (1).





33. Install the input/output shaft and P4 annulus drum assembly (1) into the case.





34. From outside the transmission case, install the park pawl shaft and install the park pawl (1) and spring (2).





35. Install the park pawl shaft plug (1) into the rear of the case and tighten to 35 Nm (26 ft. lb.).





36. Using (6936) (1), install the selector shaft seal (2).





37. Install the shaft (4), spring (2), and fork (1) into the case.
38. Install the roll pin into the selector shaft (4) using a suitable pin punch (3).





39. Install the park pawl lock rod (1) onto the fork (2).





40. Position the park pawl lock rod guide plate (2), install the three park pawl lock rod guide plate retaining screws (1) and tighten to 10 Nm (89 in. lb.).





41. Install the oil pump cover lip seal (3) on the oil pump cover (2).
42. Using (10375) (1), install the input shaft seal in the oil pump cover (2).





43. Position the oil pump housing (2) and oil pump cover (3) together.
44. Install the five bolts (1) and tighten to 5 Nm (44 in. lb.) plus 45°.





45. Insert the piston and the retaining ring (1) into the housing.





46. Position the oil pump housing assembly (4) in a suitable arbor press.
47. Using (8285) (1), press on the fingers of the piston retaining ring to remove tension, and install the two halves of the split retainer ring (2).





48. Install the hub (3).
49. Install the clutches and spacers (4).
50. Install the snap ring (2).
51. Install the outer ring (1) (below B-piston).





52. Position the B-piston alignment tab (2) above the notch and install B-piston (1) on the assembly.





53. Carefully position the oil pump housing assembly into the case.
54. Install the new input shaft O-ring.





55. Install the thirteen oil pump cover retaining bolts and tighten the oil pump cover as follows:
a. In order to seat the oil pump cover properly, pre tighten bolts one, seven and nine to 6 Nm (53 in. lb.).
b. Working in a clockwise pattern, beginning with number one, tighten to 10 Nm (89 in. lb.).
c. Working in a clockwise pattern, beginning with number one, tighten an additional 90°.






NOTE: The manual park release lever (2) can be reversed to release tension and ease the installation of the valve body assembly.

56. Temporarily install the manual park release lever (2) to release tension on the shift fork as follows:
a. Install the manual shift shaft lever (2) 180 degrees offset from its original position.
b. Install the nut (1) and hand tighten.
c. Turn the manual park release lever (2) and using a tie strap (3), secure the lever (2) into position so the park release fork is in the same position as it was before valve body assembly removal.





57. Install a new compression seal (3) into the transmission case.
58. Install the fluid port (1) with new O-rings to the transmission case.





59. Install the (10379) (1) in the transmission case as guides for the valve body assembly.

NOTE: Make sure the shift fork lines up properly.

60. Using the valve body alignment pins (1) to guide, position the valve body assembly to the transmission.

NOTE: After several bolts have been hand tightened, remove the guide pins (1).

61. Install the fourteen valve body assembly retaining bolts and hand tighten.





62. Using (10377) (1) carefully install the electrical harness insulator (2) into the transmission case (3).





63. Install the sensor (4) and the sensor retaining bolt (1) and hand tighten.
64. Latch the electrical connector insulator lock (2) by pushing in.
65. Install the valve body assembly end retainer bolts (3) and hand tighten.





66. Tighten the valve body assembly retaining bolts 1-18 in the sequence shown to 8 Nm (71 in. lbs.).





67. Remove the tie strap and return the manual release lever (1) to the original position.
68. Install the nut (2) and tighten to 10 Nm (89 in. lbs.).




69. Position the oil pan and gasket.
70. Install the thirteen oil pan retaining bolts and using the sequence shown and tighten to 10 Nm (89 in. lbs.).






NOTE: AWD only.

CAUTION: The seal must be installed flush with the case. Driving the seal deeper could damage the seal causing a leak.

71. Position the new output shaft seal (3) over the output shaft and against the transmission case.
72. Using (8481) install the output shaft seal.
73. Position the extension housing.
74. Install the seven transmission housing extension bolts (2) and tighten to 27 Nm (20 ft. lbs.).






NOTE: RWD only.

75. Install the transmission output shaft washer.

CAUTION: The seal must be installed flush with the case. Driving the seal deeper could damage the seal causing a leak.

76. Position the new output shaft seal (3) over the output shaft and against the transmission case.
77. Using (8481) install the output shaft seal.
78. Install the transmission rear dust seal (2).
79. Install the propeller shaft flange (1).





80. Install the new propeller shaft flange nut and washer using a 34 mm 12 point socket (3) and (C-3281) (2) to hold the flange (1). Tighten to 60 Nm (44 Ft. lbs.).
81. Stake the nut.





82. Install the torque converter (1) Torque Converter - Installation.
83. Before installing the transmission in the vehicle, pre-fill the transmission as outlined in FILL TRANSMISSION AFTER SERVICE . Transmission Fill After Service