Part 2

41. Install the spacer (2), so that the spacer covers the lower splines of the output shaft, and install the selectable end play washer (1) onto the output shaft and park lock gear assembly.
42. Install the extension housing with a new gasket, while aligning park brake shaft and the transmission range selector shaft, onto the transmission case.
43. Install and tighten the extension housing bolts. Tighten bolts to 37 Nm (27 ft.lbs.)

NOTE: End- play readings that are below specification (smaller gap) may indicate that a bearing is out of position or that the transmission might have been set-up incorrectly.

NOTE: The selectable output shaft end-play washers are identified by an alpha numeric numeral stamped onto the face of the washer.










44. Install a NEW nut on the output shaft and install the Dial Indicator (2).
45. With the transmission in a vertical position, and using a pry tool (1) on the output shaft nut measure and record the output shaft end-play. The output shaft end-play clearance is 0.50-0.90 mm (0.019-0.035 in.). Assemble and disassemble as necessary to achieve the correct output shaft end-play clearance.

2WD and 4WD EXTENSION HOUSING INTERNAL SELECTABLE END-PLAY WASHERS
- I = 1.00mm (0.039 in.)
- J = 1.20 mm (0.047 in.)
- K = 1.40 mm (0.055 in.)
- L = 1.60 mm (0.063 in.)
- M = 1.80 mm (0.071 in.)
- N = 2.00 mm (0.079 in.)

46. Remove the Dial Indicator (2) set up.

4WD OUTPUT SHAFT END PLAY CHECK

NOTE: The 4WD extension housing has two selectable output shaft end-play washers, fore and aft of the output shaft bearing, therefore the output shaft end-play checking procedure must be preformed twice. The external selectable end-play washer and snap ring is in place to prevent excess forward pressure on the NO.9 thrust bearing while the 4WD transfer case is bolted to the extension housing.




Figure 36 - EXTENSION HOUSING
1. Install the 4WD extension housing with a new gasket, while aligning park brake shaft and the transmission range selector shaft, onto the transmission case. Tighten bolts to 37 Nm (27 ft.lbs.)




Figure 37 - 4WD OUTPUT SHAFT END PLAY





2. Install Adapter (1) and the handle from End-Play Tool Set and Dial Indicator (2).
3. With the transmission in a vertical position, measure and record the output shaft end-play. The output shaft end-play clearance is 0.50-0.90 mm (0.019-0.035 in.), Assemble and disassemble as necessary to achieve the correct output shaft end-play clearance.










4. Install the selectable output shaft end-play washer and the external snap ring (1).




Figure 39 - 4WD OUTPUT SHAFT END PLAY





5. Using Adapter (1) and the handle from End-Play Tool Set and Dial Indicator (2), while the transmission is still in a vertical position measure and record the output shaft end-play. The output shaft end-play clearance is 0.00 - 0.24 mm (0.000-0.009 in.). Assemble and disassemble as necessary to achieve the correct output shaft end-play clearance.










4WD EXTERNAL EXTENSION HOUSING SELECTABLE END PLAY WASHERS
- I = 1.0 mm (0.039 in.)
- J = 1.20 mm (0.047 in.)
- K = 1.40 mm (0.055 in.)
- L = 1.60 mm (0.063 in.)
- M = 1.80 mm (0.071 in.)
- N = 2.0. mm (0.079 in.)
- O = 2.20 mm (0.087 in.)
- P = 2.40 mm (0.094 in.)

6. Remove the Dial Indicator set up.
7. Install the output shaft seal retainer (1) and the bolts. Tighten the bolts to 17 Nm (12.5 ft.lbs.).
8. Install a new output shaft seal using Installer tool.




Figure 41 - OUTPUT SHAFT FLANGE





9. Install a new output shaft seal into the 2WD extension housing using Installer tool.
10. Install the output shaft flange (1) and O-ring seal (2).




Figure 42 - OUTPUT SHAFT NUT





NOTE: Do not exceed the specified torque value on the output shaft nut.

11. Install the NEWoutput shaft flange nut and tighten to 210 Nm (155 ft.lbs.).
12. Using a small chisel, stake the output shaft flange nut into the void on the output shaft.

CAUTION: While installing the trust washers and bearings be certain they are orientated correctly to the transmission component. A thrust bearing must be installed correctly or transmission failure may occur.




Figure 43 - THRUST WASHER AND BEARING ORIENTATION BEFORE BULKHEAD








Figure 44 - K3 SUPPORT SEAL RINGS





13. Apply trans jell or petroleum jelly onto the seal rings. Install the K3 support seal rings.




Figure 45 - K3 HUB REAR THRUST BEARING NO.8
14. Lubricate with trans jell or petroleum jelly and install the number eight thrust bearing.




Figure 46 - K3 CLUTCH
15. Install the K3 clutch into the transmission case.




Figure 47 - P1 ANNULUS THRUST BEARING NO. 7





16. Lubricate with trans jell or petroleum jelly and install the number seven thrust bearing.




Figure 48 - P1 ANNULUS GEAR
17. Install the P1 annulus gear into the transmission case.




Figure 49 - P1 THRUST BEARING NO. 6





18. Lubricate with trans jell or petroleum jelly and install the number six thrust bearing.




Figure 50 - P1 CARRIER
19. Install the P1 planetary carrier into the transmission case.




Figure 51 - P1 CARRIER BOLTS





20. Install the P1 planetary carrier and the bolts (1) into the transmission case and hand tighten.




Figure 52 - CARRIER SNAP RING

NOTE: The tapered edge of the snap ring faces outward. The "hooked" ends of the snap ring should be to the window side of the PTO.

21. Install the P1 planetary carrier snap ring into the transmission case. Tighten the bolts to 28 Nm (21 ft.lbs.).




Figure 53 - FRONT SUN PTO REAR THRUST BEARING NO. 5
22. Lubricate with trans jell or petroleum jelly and install thrust bearing number five.




Figure 54 - FRONT SUN / PTO DRIVE GEAR
23. Install the front sun / PTO drive gear into the transmission case.




Figure 55 - FRONT SUN/PTO FRONT THRUST BEARING No. 4
24. Lubricate with trans jell or petroleum jelly and install thrust bearing number four.




Figure 56 - K2 HUB THRUST BEARING NO. 3





25. Lubricate with trans jell or petroleum jelly and install thrust bearing number three.




Figure 57 - K2 HUB
26. Install the K2 clutch hub into the transmission case.




Figure 58 - K1 THRUST BEARING NO. 2





27. Lubricate with trans jell or petroleum jelly and install thrust bearing number two.





28. Install the K1 clutch hub and thrust bearing into the transmission case.




Figure 60 - K1 AND K2 CLUTCHES





29. Apply trans jell or petroleum jelly onto the input shaft seal rings and install the K2 clutch assembly (3) onto the K1 clutch / input shaft assembly (1) with selectable input shaft end-play thrust bearing number one (2) and thrust washer (3) in place.




Figure 61 - K2 RETAINER
30. Install the K2 clutch assembly and the K1 clutch / input shaft assembly into the transmission case.

CAUTION: If the oil pump is being replaced, the valve body must also be replaced. Failure to follow these instructions will damage the transmission.

NOTE: Be certain the input shaft seal rings are in place as well as the seal ring on the oil pump hub.




Figure 62 - OIL PUMP NYLON THRUST WASHER





31. Lubricate with trans jell or petroleum jelly and install the nylon thrust washer (1) onto the oil pump.

NOTE: Two pin punches inserted through the oil pump mounting holes will aid in the installation of the oil pump.




Figure 63 - OIL PUMP REMOVAL
32. Install a new torque converter hub seal into the oil pump using Installation tool.
33. Lubricate the oil pump o-ring with MOPAR(R) AS68RC ATF.
34. Install the oil pump with a new gasket onto the transmission case.
35. Apply a light coating of MOPAR(R) thread sealant onto the oil pump bolts and install the bolts. Tighten bolts in a crisscross fashion to 21 Nm (15.5 ft.lbs.).




Figure 64 - INPUT SHAFT END PLAY








Figure 65 - K1 AND K2 CLUTCHES





NOTE: The input shaft end-play clearance may be checked with or without the torque converter housing in place.

NOTE: The input shaft end-play clearance is adjusted by means of the selectable NO. 1 thrust bearing race (2). The Thrust Washer (3) is non selectable.

36. Install the Dial Indicator Set and Input Shaft Spline Socket to check the input shaft end-play clearance.

The input shaft end-play clearance for both 2WD and 4WD is 0.50-0.90 mm (0.019-0.035 in. ). If the clearance is not within tolerance choose the correct selectable thrust bearing race.

- Bearing race number one = 0.81 mm (0.031 in.)
- Bearing race number two = 1.10 mm (0.043 in.)
- Bearing race number three = 1.60 mm (0.063 in.)

37. Assemble and disassemble as necessary to achieve the input shaft end-play clearance.
38. Remove the Dial Indicator (2) set up.




Figure 66 - OVERHEAD VIEW

NOTE: These dimensions are at time of production.






39. Install the three accumulator springs first and then the three accumulator valves (1), (2) ,(3).
40. Install the valve bodyValve Body - Installation.




Figure 67 - TC HOUSING
41. Install the torque converter housing to the transmission case.
42. Install the torque converter housing bolts and tighten to 64 Nm (47 ft.lbs.)




Figure 68 - COOLER LINES





43. Apply trans jell or petroleum jelly onto the cooler line seals and install the cooler line fittings (3) into the transmission case.
44. Tighten the cooler line fittings (3) to 44 Nm (32 in.lbs.)
45. Apply trans jell or petroleum jelly onto the Jiffy Tite fitting seals and install the Jiffy Tite fittings (2) onto the cooler line fittings.
46. Tighten Jiffy Tite fittings (2) to 25 Nm (18 ft.lbs.)
47. Install the ATF output temperature sensor (1) onto the output cooler line fitting.
48. Tighten the ATF output temperature sensor (1) to 34 Nm (25 ft.lbs.)




Figure 69 - PTO DUST COVER
49. Install a new gasket onto the PTO cover and apply a light coating of MOPAR(R) thread sealant onto the PTO cover bolts, install the bolts. Tighten the PTO cover bolts to 15 Nm (11 ft.lbs.).





50. Lubricate the o-ring with AS68RC ATF and install a new breather hose fitting into the transmission case.



Figure 71 - SEAL INSTALLATION
51. Lubricate the manual shift lever seals (one on each side of the transmission) with trans jell or petroleum jelly and install the seal into the transmission case.




Figure 72 - FILL TUBE





52. Lubricate the transmission fill tube O-ring (1) with trans jell or petroleum jelly and install the fill tube into the transmission case.
53. Install the transmission fill tube to case bolt (if equipped) and tighten bolt to 12.5 Nm (9 ft.lbs.).
54. Install the transmission range sensorTransmission Range Sensor - Installation
55. Install the manual shift lever onto the transmission manual shift lever shaft. Tighten the inside nut to 12.5 Nm (9 ft.lbs.). While holding the inside nut tighten the outside nut to 12.5 Nm (9 ft.lbs.).




Figure 73 - OUTPUT SPEED SENSOR
56. Apply trans jell or petroleum jelly onto the output speed sensor seal and install the output speed sensor into the transmission case.
57. Install the output speed sensor bolt. Tighten the output speed sensor bolt to 8 Nm (70 in.lbs.).




Figure 74 - INPUT SPEED SENSOR
58. Apply trans jell or petroleum jelly onto the input speed sensor seal and install the input speed sensor into the transmission case.
59. Install the input speed sensor bolt. Tighten the input speed sensor bolt to 8 Nm (70 in.lbs.).

WARNING: Be certain the transmission is secure when installing the torque converter, the torque converter is very heavy. Failure to follow these instructions may result in personal injury or may be fatal.




Figure 75 - TORQUE CONVERTER REMOVAL
60. Apply trans jell or petroleum jelly onto the input shaft ring seals and torque converter hub seal.
61. Install the torque converter onto the input shaft while applying inward pressure and rotating back and forth at the same time in order to align the input shaft splines and the two teeth on the oil pump drive gear.
62. Install a C-clamp or similar devise to secure the torque converter into the torque converter housing.