Assembly
ASSEMBLYClean and inspect all valve body components for damage or wear.
CAUTION: Do not force valves or plugs into place during reassembly. If the valve body bores, valves, and plugs are free of distortion or burrs, the valve body components should all slide into place easily. In addition, do not overtighten the transfer plate and valve body screws during reassembly. Overtightening can distort the valve body resulting in valve sticking, cross leakage and unsatisfactory operation. Tighten valve body screws to recommended torque only.
1. Lubricate valve body bores, valves and plugs with Mopar ATF Plus 4, Type 9602, transmission fluid.
2. Install regulator valve line pressure plug, pressure plug sleeve, regulator valve throttle pressure plug, and spring into valve body (Fig. 234). Verify valve components slide freely.
3. Install regulator valve end plate on valve body (Fig. 234).
4. Install kickdown limit valve and spring in kickdown limit valve body (Fig. 234). Verify valve components slide freely.
5. Compress spring into kickdown limit valve body.
6. Install retainer in grooves at end of kickdown limit valve body (Fig. 234).
7. Install throttle pressure plug in kickdown limit valve body (Fig. 234).
8. Install 1-2 shift valve and spring into valve body (Fig. 234).
9. Install 2-3 shift valve and spring into valve body (Fig. 234).
10. Install 1-2 shift control valve and spring into valve body (Fig. 234).
11. Verify valve components slide freely.
12. Place kickdown limit valve body and end plate in position on valve body and compress springs (Fig. 234).
13. Install screws to attach kickdown limit valve body to valve body (Fig. 234).
14. Install shuttle valve throttle plug, primary spring and shuttle valve into valve body (Fig. 234). Verify valve components slide freely.
15. Install 1-2 and 2-3 shift valve governor plugs into valve body (Fig. 234). Verify valve components slide freely.
16. Place governor plug end plate in position on valve body and compress spring.
17. Install screws to attach governor plug end plate to valve body (Fig. 234).
18. Assemble shuttle valve spring and guides (Fig. 234). Place spring and guides in position on shuttle valve stem.
19. Compress spring and install E-clip in groove on shuttle valve stem (Fig. 237).
20. Place shuttle valve end plate in position on valve body (Fig. 238).
21. Install screws to attach shuttle valve end plate to valve body (Fig. 238).
22. Install rear clutch servo and rear servo check balls in proper cavities in transfer plate (Fig. 239).
23. Insert filter into opening in separator plate (Fig. 240).
24. Place separator plate in position on transfer plate and install screws to attach separator plate to transfer plate (Fig. 240).
25. Place one 11/32 inch check ball and six 1/4 inch check balls in the proper cavities in the valve body (Fig. 241).
26. Place transfer plate in position on valve body (Fig. 242).
27. Install screws to attach transfer plate to valve body (Fig. 242).
28. Turn valve body over to expose the separator plate.
29. Insert converter clutch valve and spring into converter clutch valve module (Fig. 243). Verify valve components slide freely.
30. Insert spring and fail-safe valve into converter clutch valve module (Fig. 243). Verify valve components slide freely.
31. Place cover plate in position on converter clutch valve module (Fig. 243).
32. Install screws to attach cover to converter clutch valve module (Fig. 243).
33. Insert connecting tube into converter clutch valve module (Fig. 243).
34. Insert connecting tube into valve body opening (Fig. 244).
35. Place converter clutch valve module in position on separator plate. Install screws to attach converter clutch module to valve body (Fig. 244).
36. If necessary, install a new O-ring on converter clutch solenoid (Fig. 245).
37. Insert converter clutch solenoid into transfer plate (Fig. 245).
38. Install screw to attach solenoid to transfer plate (Fig. 245).
39. If necessary, insert park rod end into manual lever and install E-clip (Fig. 246).
40. Insert detent spring and ball into opening in valve body and install Retainer Tool 6583 (Fig. 247).
41. Install manual valve into valve body (Fig. 248).
42. Insert throttle lever through transfer plate side of valve body and upward (Fig. 249).
43. Insert throttle lever into groove in manual valve (Fig. 250).
44. Install seal, washer, and E-clip to retain manual shaft to valve body (Fig. 249).
45. Install switch valve and spring, pressure regulator valve and spring, kickdown valve and spring, and throttle valve into valve body (Fig. 251).
46. Place adjusting screw bracket and line pressure adjusting screw in position on valve body and compress springs (Fig. 251).
47. Install screws to attach adjuster bracket to valve body.