Drivetrain - A/T Transfer Gear Bearing Noise
NUMBER: 21-007-10 REV. AGROUP: Transmission and Transfer Case
DATE: October 23, 2010
THIS SERVICE BULLETIN IS ALSO BEING RELEASED AS RAPID RESPONSE TRANSMITTAL 10-060. ALL APPLICABLE VIN's HAVE BEEN LOADED.
THIS BULLETIN SUPERSEDES SERVICE BULLETIN 21-007-10, DATED OCTOBER 9, 2010, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE IDENTIFYING SERVICE BULLETIN REPAIR PROCEDURES FOR VEHICLES EXHIBITING THE CONDITION THAT HAVE BEEN SOLD.
THIS PROCEDURE IS TO BE USED ON UNSOLD VEHICLES ONLY. IF THE VEHICLE IS SOLD, DO NOT USE THIS PROCEDURE. **PROCEDURES FOR SOLD VEHICLES IS AVAILABLE THROUGH SERVICE BULLETIN 21-008-10 RELEASED OCTOBER 23, 2010.
THIS SERVICE BULLETIN IS ONE OF THREE UNIQUE BULLETINS RELATED TO THE SUBJECT. THIS BULLETIN AFFECTS VEHICLES IN GROUP C ONLY. GROUP C VEHICLES ARE VEHICLES THAT HAD TRANSFER GEAR BEARING TURNING TORQUE SET IN THE RANGE OF 21-25 INCH POUNDS. REPAIR PROCEDURES FOR GROUP B VEHICLES IS RELEASED IN SERVICE BULLETIN 21-006-10 AND REPAIR PROCEDURES FOR GROUP A VEHICLES IS RELEASED IN SERVICE BULLETIN 21-005-10. THIS REPAIR PROCEDURE IS TO BE ONLY USED ON UNSOLD VEHICLES ASSOCIATED WITH THIS SERVICE BULLETIN AND RAPID RESPONSE TRANSMITTAL.
SUBJECT:
Transfer Gear Bearing Noise
OVERVIEW:
This bulletin involves installing a transfer gear bearing select fit shim that is five sizes thicker for unsold vehicles.
MODELS:
2010 JC Journey
2010 JS Sebring/Avenger
2010 RT Town & Country/Grand Caravan
NOTE:
This bulletin applies to select vehicles equipped with a 62TE automatic transmission (sales code DG2) built from January 1, 2010 (MDH 0101XX) through July 28, 2010 (MDH 0728XX) and with incorrect bearing preload. All involved vehicle VIN's will be loaded into the VIP System. The VIN list is available on DealerCONNECT for all affected dealers. The VIN list has been inserted in the service tab under Rapid Response Transmittals.
DISCUSSION:
Some vehicles may have been built with transmission transfer gear bearings that were built with incorrect bearing preload. Incorrect bearing preload may result in transfer gear bearing noise.
DIAGNOSIS:
Perform Repair Procedure for all affected unsold vehicles.
NOTE:
Not every vehicle equipped with the 62TE built from January 1, 2010 through July 28, 2010 is affected by this issue. Only vehicles identified on the VIN list may have incorrect transfer gear bearing preload.
PARTS REQUIRED:
SPECIAL TOOLS/EQUIPMENT REQUIRED:
GROUP C REPAIR PROCEDURE:
1. Turn the steering wheel to the far left.
2. Open hood.
3. Raise the vehicle on the hoist.
4. If the vehicle is equipped with wheel center caps that cover the wheel nuts, remove the left front wheel's cap with an appropriate removal tool utilizing the notch located between the wheel and the outer edge of the cap. Use care not to damage the wheel coating.
5. Remove the left front wheel's five wheel mounting (lug) nuts from their studs.
6. Remove the left front tire and wheel assembly from hub.
7. Remove the two bolts securing the left disc brake caliper and adapter bracket to the steering knuckle (Fig 1) (right side brake assembly shown).
8. Remove the disc brake caliper and adapter bracket from the knuckle and rotor as an assembly 0 Hang the assembly out of the way using wire or a bungee cord. Use care not to overextend the brake hose when doing this.
NOTE:
The front splash shield on some vehicles is a two piece assembly.
9. Remove push pins that secure the left front splash shield.
10. Remove fasteners that secure the left front splash shield.
11. Remove the left front splash shield.
NOTE:
Journey/Sebring/Avenger models continue to next step. Town & Country Models, proceed to Step # 21.
12. Journey/Sebring/Avenger models, lower the vehicle.
13. Remove the air cleaner housing. Refer to the information provided in DealerCONNECT > TechCONNECT > Service Information > 09 - Engine > Air intake System > Body, Air Cleaner > Removal.
14. Support the transaxle with a floor jack.
15. Remove the bolts at the left transmission mount and remove the mount (Fig. 2).
16. Remove the floor jack from the transmission.
17. Raise the vehicle on the hoist.
18. Support the engine with a screw jack (Fig. 3).
19. Remove the fore aft member mount through bolt (Fig. 4).
20. Lower transaxle. Allow the transaxle to rest on the fore aft member
21. Remove transfer gear cover-to-case bolts (2) (Fig. 5).
22. Remove transfer gear cover (Fig. 5).
23. Remove the oil scavenger (Fig. 6) by releasing the two lower tabs and sliding the scavenger away from the gears.
CAUTION:
The scavenger is secured to the transmission case by small tabs. These tabs break easily. Use extreme care when removing the scavenger from the transmission.
24. Grind the staked tabs from the transfer gear (underdrive compounder side) (Fig. 7).
25. Install the Gear Holder 9739 onto the transfer gear (underdrive compounder side) and remove the nut (Fig. 8).
26. Remove the transfer gear.
27. Remove the transfer gear bearing select fit shim (Fig. 9).
28. Using a micrometer, measure the select shim that was removed in
29. Refer to the following table and install the appropriate select shim onto the transfer gear shaft.
30. Install Holder 9739 onto the transfer gear (Fig 8).
31. Install a new transfer gear (underdrive compounder side) nut (p/n 6508521AA) and tighten to 271 N.m (200 ft.lbs.).
32. Use Staking Tool 9721 and stake the new nut.
33. Clean the transfer gear cover sealing surface and mating surface.
34. Install the oil scavenger (Fig. 6).
35. Spread a bead of MOPAR(R) ATF RTV (p/n 0501 0884AA) (MS-GF41) onto the transfer gear cover sealing surface.
36. Install transfer gear cover-to-case bolts (Fig. 5) and tighten to 12 N.m (105 in.lbs.).
NOTE:
Journey/Sebring/Avenger models continue to next step. Town & Country Models, proceed to Step # 46.
37. Support the engine with a screw jack (Fig. 3).
38. Install the fore aft member through bolt and tighten to 50 N.m (37 ft.lbs.) (Fig. 4).
39. Remove the screw jack.
40. Lower the vehicle.
41. Support the transaxle with a floor jack.
42. Install the bolts at the left transmission mount (Fig. 2) and tighten to 100 N.m (74 ft.lbs.).
43. Remove the floor jack from the transmission
44. Install the air cleaner housing. Refer to the information provided in DealerCONNECT > TechCONNECT > Service Information > 09 - Engine > Air intake System > Body, Air Cleaner > Installation.
45. Raise the vehicle on the hoist.
46. Place splash shield up to wheelhouse opening.
47. Install push pins.
48. Install fasteners.
49. Install the left front splash shield.
50. Install the disc brake caliper and adapter bracket assembly over the brake rotor and knuckle (Fig. 1).
51. Install the mounting bolts securing the caliper adapter bracket to the knuckle (Tighten the bolts to 169 N.m (125 ft.lbs.).
52. 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.
53. Install and lightly snug all five wheel mounting (lug) nuts. Do not tighten at this time.
54. Lower the vehicle.
55. Progressively tighten all wheel mounting nuts in the proper sequence shown. Tighten nuts to a final torque of 135 N.m (100 ft.lbs.).
56. If applicable, install the wheel center cap.
57. 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.
POLICY:
Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
This bulletin is supplied as technical information only and is not an authorization for repair.