Assembly (Part 2)

Fig. 130 Install 2/4 Clutch Retainer Snap Ring:

50) Using Compressing Tool 5058-A (1) (Fig. 130), compress 2/4 clutch return spring just enough to install snap ring (3).
51) Install snap ring.

Fig. 131 Check 2/4 Clutch Clearance:

52) Set up dial indicator (1) (Fig. 131) 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). Set up indicator and record measurement in four (4)places. Take average of readings. If clearance is outside this range, the clutch is assembled improperly. There is no adjustment for 2/4 clutch clearance.

Fig. 132 Number 7 Bearing:

NOTE: The number seven needle (1) (Fig. 132) bearing has three anti-reversal tabs and is common with the number five and number two position. The orientation should allow the bearing to seat flat against the rear sun gear. A small amount of petrolatum can be used to hold the bearing to the rear sun gear (2).

Fig. 133 Install Rear Sun Gear and #7 NeedleBearing:

53) Install rear sun gear (2) (Fig. 133) and #7 needle bearing (1).

Fig. 134 Install Front Carrier and Rear AnnulusAssembly:

54) Install front carrier/rear annulus assembly (2) (Fig. 134) and #6 needle bearing (1).

Fig. 135 Install Front Sun Gear Assembly:

55) Install front sun gear assembly (1) (Fig. 135) and #4 thrust washer (2).

Fig. 136 Select Thinnest No. 4 Thrust Plate:

56) Select the thinnest #4 thrust plate thickness (2) (Fig. 136) and install to input clutch assembly Use petrolatum to retain (3).

Fig. 137 View Through Input Speed Sensor Hole:

57) Install input clutch assembly into position and verify that it is completely seated by viewing through input speed sensor hole (2) (Fig. 137). If view through input speed sensor hole is not as shown in the below view, the input clutch assembly is not seated properly.

Fig. 138 Remove Oil Pump O-Ring:

58) Remove oil pump O-ring (2) (Fig. 138). Be sure to reinstall oil pump O-ring after selecting the proper #4 thrust plate.
59) Install pump and gasket to transmission. Install and torque bolts.

Fig. 139 Measure Input Shaft End Play Using EndPlay Set 8266:

60) Set up input shaft for measurement with Indicator Set C3339 (2) and End Play Set 8266 (1) (Fig. 139).
61) Measure the input shaft end play with the transaxle in the vertical position. Input shaft end play must be 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.
62) Refer to the No. 4 thrust plate chart NO. 4 THRUST PLATE CHART to select the proper No. 4 thrust plate.

NO. 4 THRUST PLATE CHART:

Fig. 140 Install Input Clutch Assembly:

63) Install input clutch assembly (1) (Fig. 140).

Fig. 141 Install Caged Needle Bearing:

64) Install #1 caged needle bearing (1) (Fig. 141) note: tanged side out (2).

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

Fig. 142 Install Cooler Bypass Valve:

65) Install cooler bypass valve (1) (Fig. 142) with O-ring end towards rear of case.

Fig. 143 Install Oil Pump Gasket:

66) Install oil pump gasket (1) (Fig. 143).

Fig. 144 Install Oil Pump:

67) Install oil pump (1) (Fig. 144).

Fig. 145 Install Pump-to-Case Bolts:

68) Install oil pump-to-case bolts (1) (Fig. 145) and torque to 27 Nm (20 ft. lbs.).

Fig. 146 Install Low/Reverse Accumulator:

69) Install low/reverse accumulator (1) (Fig. 146).

Fig. 147 Install Low/Reverse Accumulator Plug(Cover):

70) Install low/reverse accumulator plug (2) (Fig. 147).

Fig. 148 Install Low/Reverse Accumulator SnapRing:

71) Install low/reverse accumulator snap ring (1) (Fig. 148).

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.

Fig. 149 Underdrive and Overdrive Accumulators:

72) Install underdrive and overdrive accumulators (1, 2) (Fig. 149).

Fig. 150 Install Valve Body:

73) Install valve body (1) (Fig. 150) to transaxle. Rotate manual valve shaft fully clockwise to ease installation. Make sure park rod rollers are positioned within park guide bracket.

Fig. 151 Install Valve Body-to-Case Bolts:

74) Install and torque valve body-to-case bolts (1) (Fig. 151) to 12 Nm (0.05 inch lbs.).

Fig. 152 Install Oil Filter:

75) Install oil filter (1) (Fig. 152) and new O-ring (2).

Fig. 153 Install Oil Pan:

76) Apply an 1/8" bead of Mopar ATF RTV (MSGF41) (2) (Fig, 153) to oil pan (1) and immediately install to case.
77) Install oil pan-to-case bolts and torque to 19 Nm (165 inch lbs.).

Fig. 154 Solenoid/Pressure Switch Assembly andGasket:

78) Install solenoid/pressure switch assembly (1) (Fig. 154) and gasket (2) to case.

Fig. 155 Solenoid Pack-to-Transaxle Bolts:

79) Install and tighten solenoid/pressure switch assembly-to-transaxle case bolts (1) to 12 Nm (110 inch lbs.) (Fig. 155).
80) Install and torque input and output speed sensors to case to 27 Nm (20 ft. lbs.).