Part 2

ASSEMBLY





Figure 27 Install Transfer Shaft






28. Using Remover/Installer 5049A (1) (Figure 27), install transfer shaft (2).




Figure 28 Install Transfer Shaft Bearing Snap Ring






29. Using Snap Ring Pliers 6051 (1) (Figure 28), install transfer shaft bearing snap ring (2).




Figure 29 Install Transfer Shaft Bearing Cup Into Retainer






30. Using an arbor press (1) (Figure 29) install transfer shaft bearing cup into retainer using Installer 6061 (3). Use removed bearing cup to support retainer (4).




Figure 30 Remove Bearing Cup Retainer






31. Install bearing cup retainer (2) (Figure 30) to transaxle.




Figure 31 Install Transfer Gear Bearing Cone






32. Install new transfer gear bearing cone (3) (Figure 31) to transfer gear (4) using Installer 5052 (5).




Figure 32 Install Transfer Shaft Gear and (Select) Shim






33. TRANSFER GEAR BEARING ADJUSTMENT:

a. Install a 4.66 mm (0.183 in.) gauging shim on the transfer shaft (Figure 32).
b. Install transfer shaft gear using Installer 6261. Using Holder 6259, install transfer shaft gear retaining nut to 271 Nm (200 ft. lbs.).
c. Measure end play. Attach Gear Checking Plate 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 Holder 6259 to remove the retaining nut and washer. Remove the transfer shaft gear using Gear Puller L4407A.
i. Remove the gauging shim and install the proper shim indicated by the chart.

Transfer Shaft Bearing Shim Chart (Part 1):

Transfer Shaft Bearing Shim Chart (Part 2):

Figure 33 Install Transfer Shaft Gear






34. Install the transfer shaft gear (4) (Figure 33) using Installer 6261 (2).




Figure 34 Tighten Transfer Gear Nut to 271 Nm (200 ft. lbs.)







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

35. Install the new retaining nut and washer.
36. Using Holder 6259 (4) (Figure 34), torque transfer gear retaining nut to 271 Nm (200 ft. lbs.).




Figure 35 Install Rear Cover






37. Measure transfer shaft end play. Transfer shaft end play should be within 0.05-0.10 mm (0.002-0.004 in.). If the end play is too high, install a 0.04 mm (0.0016 in.) thicker shim. If the end play is too low, install a 0.04 mm (0.0016 in.) thinner shim. Repeat until 0.05-0.10 mm (0.002-0.004 in.) end play is obtained.
38. Install a bead of Mopar(R) ATF RTV (MS-GF41) (2) (Figure 35) to transfer gear cover (1).




Figure 36 Install Rear Cover Bolts






39. Use sealant on bolts (3) (Figure 36), install transfer gear cover-to-case bolts (1) and torque to 20 Nm (175 in. lbs.) torque.




Figure 37 Install Low/Reverse Clutch Pack






40. Install low/reverse clutch pack (1, 2) (Figure 37). Leave uppermost disc out until snap ring is installed.




Figure 38 Install Low/Reverse Reaction Plate Snap Ring






41. Install low/reverse reaction plate flat snap ring (2) (Figure 38) insure you do not scratch clutch plate (3).




Figure 39 Install One Disc

1 - ONE DISC FROM LOW/REVERSE CLUTCH

42. Install remaining low/reverse clutch disc (1) (Figure 39).




Figure 40 Install Low/Reverse Reaction Plate

1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP)

43. Install low/reverse reaction plate with flat side up (1) (Figure 40).




Figure 41 Tapered Snap Ring Instructions

44. Use as a reference while installing tapered snap ring (Figure 41).




Figure 42 Snap Ring Installed






45. Install tapered snap ring (with tapered side up) (2) (Figure 42).




Figure 43 Check Low/Reverse Clutch Clearance






46. Set up dial indicator (1) (Figure 43) 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 in.). Set up indicator and record measurement in four places. Take average of readings and select the proper low/reverse reaction plate to achieve specifications.

Low/Reverse Reaction Plate Chart:

Figure 44 Install 2/4 Clutch Pack






47. Install 2/4 clutch pack (1, 2) (Figure 44).




Figure 45 Proper Orientation of 2/4 Clutch Retainer and Spring







NOTE: The 2/4 Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.

48. Orient 2/4 clutch return spring to retainer (3) (Figure 45).




Figure 46 2/4 Clutch Retainer






49. Install 2/4 clutch retainer to transaxle (1, 2) (Figure 46).




Figure 47 Install 2/4 Clutch Retainer Snap Ring






50. Using Compressing Tool 5058-A (1) (Figure 47), compress 2/4 clutch return spring just enough to install snap ring (3).
51. Install snap ring.




Figure 48 Check 2/4 Clutch Clearance






52. Set up dial indicator (1) (Figure 48) 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 in.). 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.