Part 1

1. Use the special tool to install the oil seals to the differential bearing retainer and transaxle case.




CAUTION: Align the oil seal with the case positioning boss so that its flange notch faces upward when it is installed on the vehicle.




2. Use the special tool to install the rear output shaft oil seal. (AWD)




3. Use the special tool to press-fit the outer race in the transaxle case.




4. Install the front output shaft assembly. (AWD)




5. Position the solder measuring approx. 10 mm (0.39 in.) long by 1.6 mm (0.063 in.) in diameter in the front bearing retainer in the position shown in the figure and then install the outer race. (AWD)




6. Install the front bearing retainer and tighten the bolt to the specified torque. (AWD)

Front bearing retainer mounting bolts: 49 Nm (35 ft.lbs.)

7. Loosen the bolts and remove the front bearing retainer. (AWD)




8. Remove the outer race from the front bearing retainer and remove the solder. If the solder does not break, go on to steps 5-8 with large diameter solder. Measure the thickness of the crushed solder with a micrometer and select a spacer with the correct thickness so that the preload reaches the standard value. (AWD)

Standard value: 0.055-0.115 mm (0.00217-0.00453 in.)

9. Install the spacer selected in the previous step and the outer race in the front bearing retainer. (AWD)
10. First install the front bearing retainer and apply sealant to the bolts and then tighten to the specified torque. (AWD)

Specified sealant: MOPAR Part No.4318031 or MOPAR Part No. 4318032 or equivalent.

Front bearing retainer mounting bolts: 49 Nm (35 ft.lbs.)




11. Using a bearing puller, support the viscous coupling and insert in the case. Then install the stopper ring. (AWD)




12. Use the special tool to install the outer race in the center bearing retainer. (AWD)




13. Install the center bearing retainer so the projection of the stopper bolt fits in the groove of the center bearing retainer. (AWD)




14. Install the center bearing retainer stopper bolt. (AWD)

Center bearing retainer stopper bolt: 5 Nm (4 ft.lbs.)




15. Install the special tool in the center differential and install the center differential in the transaxle case. (AWD)




16. Install the transfer shaft (FWD)




17. Place solder with a length of approximately 10 mm (0.39 in.) and diameter of 3 mm (0.12 in.) on the output bearing retainer at the position shown in the diagram and install the outer race.




18. Install the output bearing retainer and tighten the bolts to the specified torque.

Output bearing retainer mounting bolts: 24 Nm (18 ft.lbs.)

19. Loosen the bolts and remove the output bearing retainer.




20. Remove the outer race from the output bearing retainer and remove the solder. If the solder is not crushed, repeat steps 17-19. Measure the thickness of the crushed solder using a micrometer and select a spacer with a thickness that will provide the standard value for the preload.

Standard value: 0.075-0.135 mm (0.00295-0.00531 in.)

21. Install the spacer selected in the previous item and the outer race on the output bearing retainer.




22. Install a new O-ring around the outer circumference of the outer bearing retainer.
23. Coat the O-ring with automatic transmission fluid and tighten the output bearing retainer mounting bolts to the specified torque.

Output bearing retainer mounting bolts: 24 Nm (18 ft.lbs.)




24. Insert the output flange into the case and install a snap ring around the bearing.




25. Install the bearing retainer using new bolts.

Bearing retainer mounting bolts: 20 Nm (15 ft.lbs.)




26. Caulk the heads of the bolts.




27. Apply a coating of petrolatum to thrust bearing # 10 and attach to the planetary carrier.




28. Assemble the planetary carrier.




29. Assemble the forward sun gear, thrust race # 9, thrust bearing # 8 and reverse sun gear.




30. Install both sun gears assembled in the previous item into the planetary carrier.




31. Assemble the reaction plate, brake disc and brake plate.







Identification of thrust bearings, thrust races and thrust washers.




32. Assemble the pressure plate used in disassembly and install the return spring.

CAUTION: Position the return spring correctly.




33. Apply a coating of petrolatum jelly to the wave spring and attach it to the center support.




34. Mount the special tool on the center support, install 2 new O-rings and push into the transaxle case.

CAUTION:

1. Coat the O-rings with automatic transmission fluid and align the oil holes.
2. Do not move the wave spring out of position.




35. Install the snap ring.




36. Use a feeler gauge and measure the end play of the low/reverse brake. Adjust to the standard value by selecting the proper pressure plate.

Standard value: 1.0-1.2 mm (0.039-0.047 in.)