Part 2

ASSEMBLY

CAUTION: Apply CVT fluid when installing the bushing.

63. Install the bushing (1)(Figure 48) into the valve body assembly.





64. Tighten the mounting bolts of the valve body assembly to 8 Nm (70 in. lbs).





65. Install the manual lever (1)(Figure 50) onto the manual shaft. Install and tighten the mounting nut to 22 Nm 194 in. lb.





66. Install the bracket (1)(Figure 51) onto the valve body assembly. Install and tighten the mounting bolts to 8 Nm (70 in. lbs.).






CAUTION: Do not re-use the o-ring. Apply CVT fluid when installing the o-ring.

67. Install the new o-ring (1)(Figure 52) onto the new oil strainer.





68. Install the new oil strainer (1)(Figure 53) onto the valve body assembly. Install and tighten the mounting bolts to 8 Nm (70 in. lbs.).






CAUTION: Do not re-use the oil pan gasket. Remove any moisture, oil, and used gasket material from the surface where the new gasket is to be installed. When installing the oil pan gasket, align the dowel pin with the dowel pin hole in the oil pan gasket.

69. Install the oil pan gasket (1)(Figure 54) onto the transaxle case.






CAUTION: When installing the oil pan, align the dowel pin of the transaxle case with the dowel pin hole of the oil pan.

70. Install the oil pan on the transaxle case (1)(Figure 55). Install and tighten the mounting bolts to 8 Nm (70 in. lbs.).





71. Install the snap ring (1)(Figure 56) onto the terminal body.






CAUTION: Do not re-use the seal rings. Apply Vaseline or assembly lube when installing the seal rings.

72. Install the new seal rings (1)(Figure 57) onto the reaction shaft support.





73. Install the reaction shaft support (1)(Figure 58) onto the transaxle case temporarily with the mounting bolts.





74. Install the baffle plate (1)(Figure 59) temporarily with the mounting bolts.





75. Install the baffle plate (1)(Figure 60). Install and tighten the mounting bolts to 6 Nm (52 in. lbs.).





76. Install the bracket (1)(Figure 61) as shown. Tighten the mounting bolts of the oil pump cover, baffle plate, and brackets to 26 Nm (19 in. lbs.).





77. Install the snap ring (1)(Figure 62) into the oil pump.






CAUTION: Be sure to align the pawl of the thrust washer with the alignment hole of the oil pump cover. Apply Vaseline or assembly lube when installing the thrust washer.

78. Install the thrust washer (1)(Figure 63) onto the oil pump cover.






CAUTION: When necessary to replace any of the driven sprocket, oil pump chain, or drive sprocket, replace all components as a matched set. Pull the driven sprocket up softly and check that the driven sprocket is securely installed.

79. Expand the snap ring (1).
80. Install the driven sprocket, oil pump chain (2) and drive sprocket (3).





81. The required clearance for the oil pump drive sprocket is 0.10-0.23 mm (0.004-0.009 in.). Measure the clearance (1)(Figure 65) between the oil pump drive sprocket (4) and the converter housing (5) in the following procedure:






NOTE: Gauge Bar can be used for doing the following measurement.

82. Measure the distance (1-2)(Figure 66) from the edge of the transaxle case to the select shim installation surface of the drive sprocket. This is the oil pump drive sprocket measurement one.






NOTE: Gauge Bar can be used for doing the following measurement.

83. Measure the distance (1-2)(Figure 67) from the edge of the converter housing to the surface touching the select shim contact surface. This is the oil pump drive sprocket measurement two.
84. Calculate the thickness of the required select shim with the following formula: The select shim is equal to the oil pump drive sprocket measurement one, plus the oil pump drive sprocket measurement two, minus 0.16 mm (0.0065 in.).





85. Install the chosen select shim (1)(Figure 68) onto the drive sprocket.





86. Install the baffle plate (1)(Figure 69) over the oil pump driven sprocket. Install and tighten the mounting nut to 6 Nm (52 in. lbs.).






CAUTION: Do not re-use the o-ring. Apply CVT fluid when installing the o-ring.

87. Install the new o-ring (1)(Figure 70) onto the input shaft.





88. Install the differential assembly (1)(Figure 71) into the transaxle case.





89. Install the reduction gear assembly (1)(Figure 72) into the transaxle case.






CAUTION: Do not re-use the converter housing oil seal (1). Apply CVT fluid when installing the converter housing oil seal (1).

90. Install the converter housing oil seal (1)(Figure 73) into the converter housing with Installer.





91. Apply MOPAR gasket sealer (1)(Figure 74) on the converter housing installation surface of the transaxle case.

CAUTION: Remove moisture, oil, and used sealant from the sealant application surface. Make sure that the starting point and the ending point are between two bolt holes.






92. Install the converter housing on the transaxle case and tighten the bolts to 45 Nm (33 ft. lbs.).





93. Install the transmission range sensor (TRS) (1)(Figure 76) over the manual shaft and onto the transaxle case.






CAUTION: Do not re-use the TRS transmission range sensor.

94. Put the manual shaft in the N position (3)(Figure 77). Install Park Neutral Switch Adjustment Tool (2) and adjust the position of the TRS (1).





95. Install and tighten the mounting bolts of the TRS to 6 Nm (49 in. lbs.).
96. Remove the TRS alignment tool from the TRS.





97. Install the shift lever (1)(Figure 79) onto the manual shaft. Install and tighten the mounting nut to 17 Nm (150 in. lbs.).






CAUTION: Do not re-use the o-ring. Apply CVT fluid when installing the o-ring.

98. Install the o-ring (1)(Figure 80) onto the input speed sensor.





99. Install the input speed sensor (1)(Figure 81) into the transaxle case. Install and tighten the mounting bolt to 6 Nm (52 in. lbs.).






CAUTION: Do not re-use the o-ring. Apply CVT fluid when installing the o-ring.

100. Install the new o-ring (1)(Figure 82) onto the output speed sensor.






CAUTION: Be sure to install the select shim between the secondary speed sensor and the converter housing before installing the secondary speed sensor.

101. Install the output speed sensor (1)(Figure 83) into the converter housing. Install and tighten the mounting bolt to 6 Nm (52 in lbs.).






CAUTION: Apply CVT fluid on the seal part when installing the CVT fluid filter.

102. Install the CVT fluid filter (1)(Figure 84) into the transaxle case.






CAUTION: Do not re-use the o-ring. Apply CVT fluid when installing the o-ring.

103. Install the new o-ring (1) onto the CVT fluid filter.





104. Install the CVT fluid cooler (1)(Figure 86) onto the transaxle case. Install and tighten the mounting bolts to 4 Nm (37 in.lbs.).





105. Remove the Transmission Service Stand (1) from the Belt side of the transmission case.






NOTE: Gauge Bar can be used for doing the following measurement.

NOTE: When conducting measurements, measure two or more places and calculate the average value.

106. Install the torque converter on the transaxle and measure the dimension (1)(Figure 88) to see if it is at least 13 mm. If the measurement is less than 13 mm, the torque converter is not fully installed.

NOTE: Use the designated brand of CVT fluid. Use of other brands of CVT fluid other than the designated brand will deteriorate the driveability and the durability of the CVT, and will cause damage to the CVT.

107. Fill the transaxle with CVT fluid. CVT Automatic - Transmission Fill.