Part 2

31. TRANSFER GEAR BEARING ADJUSTMENT





a. Install a 4.66 mm (0.184 inch) gauging shim on the transfer shaft (Fig. 121).
b. Install transfer shaft gear using Tool 6261. Using Tool 6259, install transfer shaft gear retaining nut to 271 Nm (200 ft. lbs.).
c. Measure end play. Attach Tool L4432 to the transfer gear.
d. Mount a steel ball with grease into the end of the transfer shaft.
e. Push and pull the gear while rotating back and forth to ensure seating of the bearing rollers.
f. Using a dial indicator, measure transfer shaft end play.
g. Refer to the transfer shaft bearing shim chart for the required shim combination to obtain the proper bearing setting.
h. Use Tool 6259 to remove the retaining nut and washer. Remove the transfer shaft gear using Pool L4407A.
i. Remove the gauging shim (Fig. 121) and install the proper shim indicated by the chart.








TRANSFER SHAFT BEARING SHIM CHART





32. Install the transfer shaft gear using Tool 6261 (Fig. 122).

CAUTION: Install a NEW retaining nut, as the original nut MUST NOT be reused.

33. Install the new retaining nut and washer.





34. Using Tool 6259, torque transfer gear retaining nut to 271 Nm (200 ft. lbs.) (Fig. 123).
35. Measure transfer shaft end play. Transfer shaft end play should be within 0.05 - 0.10 mm (0.002 - 0.004 inch). If the end play is too high, install a 0.04 mm (0.0016 inch) thicker shim. If the end play is too low, install a 0.04 mm (0.0016 inch) thinner shim. Repeat until 0.05 - 0.10 mm (0.002 - 0.004 inch) end play is obtained.





36. Install a bead of Mopar Silicone Rubber Adhesive Sealant to transfer gear cover (Fig. 124).





37. Install transfer gear cover-to-case bolts and torque to 20 Nm (175 in. lbs.) torque (Fig. 125).





38. Install low/reverse clutch pack (Fig. 126). Leave uppermost disc out until snap ring is installed.





39. Install low/reverse reaction plate flat snap ring (Fig. 127).





40. Install remaining low/reverse clutch disc (Fig. 128).





41. Install low/reverse reaction plate with flat side up (Fig. 129).








42. Install tapered snap ring (with tapered side out) as shown in (Fig. 130) (Fig. 131).





43. Set up dial indicator as shown in (Fig. 132) to measure low/reverse clutch clearance. Press down on clutch pack with finger and zero dial indicator. Low/Reverse clutch pack clearance is 0.89 - 1.47 mm (0.035 - 0.058 inch). Select the proper low/reverse reaction plate to achieve specifications:





LOW/REVERSE REACTION PLATE CHART








44. Install 2/4 clutch pack (Fig. 133), staggering clutch plate pads as shown in (Fig. 134).







45. Orient 2/4 clutch return spring to retainer as shown in (Fig. 135), and install to transaxle (Fig. 136).





46. Using tool 5058, compress 2/4 clutch return spring just enough to install snap ring (Fig. 137).
47. Install snap ring.





48. Set up dial indicator as shown in (Fig. 138) and measure 2/4 clutch clearance. Press down on clutch pack with finger and zero dial indicator. 2/4 clutch pack clearance is 0.76 - 2.64 mm (0.030 - 0.104 inch). If clearance is outside this range, the clutch is assembled improperly. There is no adjustment for 2/4 clutch clearance.





49. Install rear sun gear and # 7 needle bearing (Fig. 139).





50. Install front carrier/rear annulus assembly and # 6 needle bearing (Fig. 140).





51. Install front sun gear assembly and # 4 thrust washer (Fig. 141).
52. DETERMINING # 4 THRUST PLATE THICKNESS / INPUT SHAFT END PLAY:





a. Select the thinnest # 4 thrust plate thickness and install to input clutch assembly (Fig. 142). Use petrolatum to retain





b. Install input clutch assembly into position and verify that it is completely seated by viewing through input speed sensor hole. If view through input speed sensor hole is not as shown in (Fig. 143), the input clutch assembly is not seated properly.





c. Remove oil pump O-ring (Fig. 144). Be sure to reinstall oil pump O-ring after selecting the proper # 4 thrust plate.





d. Set up input shaft for measurement with Indicator Set C3339 and End Play Set 8266 Gas shown in (Fig. 145).
e. Measure the input shaft end play with the transaxle in the vertical position. Input shaft end play must within 0.005 to 0.025 inch. For example, if end play reading is 0.055 inch, select No. 4 Thrust Plate which is 0.071 to 0.074 thick. This should provide an input shaft end play reading of 0.020 inch which is within specifications.
f. Refer to the No. 4 thrust plate chart to select the proper No.4 thrust plate:





NO. 4 THRUST PLATE CHART





53. Install input clutch assembly (Fig. 146).





54. Install # 1. caged needle bearing (Fig. 147).

CAUTION: The cooler bypass valve must be replaced if transaxle failure has occurred. Do not attempt to reuse or clean old valve.





55. Install cooler bypass valve with O-ring end towards rear of case (Fig. 148).





56. Install oil pump gasket (Fig. 149).





57. Install oil pump assembly (Fig. 150).





58. Install oil pump-to-case bolts and torque to 27 Nm (20 ft. lbs.) (Fig. 151).





59. Install low/reverse accumulator (Fig. 152).





60. Install low/reverse accumulator plug (Fig. 153).





61. Install low/reverse accumulator snap ring (Fig. 154).

NOTE: Depending on engine application, some accumulators will have two springs, and others will have one spring. The springs are color-coded for application and year.











62. Install underdrive and overdrive accumulators (Fig. 155) (Fig. 156) (Fig. 157).





63. Install valve body to transaxle (Fig. 158). Rotate manual valve shaft fully clockwise to ease installation. Make sure park rod rollers are positioned within park guide bracket.





64. Install and torque valve body-to-case bolts to 12 Nm (105 in. lbs.) (Fig. 159).





65. Install oil filter and new O-ring (Fig. 160).





66. Apply an 1/8" bead of Mopar Silicone Rubber Adhesive Sealant to oil pan and immediately install to case (Fig. 161).
67. Install oil pan-to-case bolts and torque to 19 Nm (165 in. lbs.).





68. Install solenoid/pressure switch assembly and gasket to case (Fig. 162).





69. Install and tighten solenoid/pressure switch assembly-to-transaxle case bolts to 12 Nm (110 in. lbs.) (Fig. 163).
70. Install and torque input and output speed sensors to case to 27 Nm (20 ft. lbs.).