Part 2

ASSEMBLY

NOTE: Apply trans jell or petroleum jelly to all slide portions, rolling contacts surfaces, thrust surfaces etc. to prevent burnout during initial operation. Lubricate O-rings and O-ring seals with MOPAR(R) ATF +4. Soak all friction disks in MOPAR(R) ATF +4 for at least two hours before assembly of clutch packs.

NOTE: If the transmission assembly is being reconditioned (clutch/seal replacement) or replaced, it is necessary to perform the Quick Learn Procedure using the scan tool Quick Learn Procedure .










35. Measure 2/4 clutch clearance: Set up dial indicator (1) as shown. Press down clutch pack with finger and zero dial indicator. Record measurement in four (4) places and take average reading. The 2/4 clutch pack clearance is 0.76 to 2.64 mm (0.030 to 0.104 inch). If not within specifications, the clutch is not assembled properly or is excessively worn. There is no adjustment for the 2/4 clutch clearance.










36. Install the #7 needle bearing (1) to the rear sun gear (2). The number 7 needle bearing has three anti-reversal tabs and is common with the number 5 and number 2 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.










37. Install rear sun gear (2) and #7 needle bearing (1).










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










39. Install front sun gear assembly (1) and #4 thrust washer (2).










40. Determine proper #4 thrust plate thickness. Select the thinnest available #4 thrust plate.
41. Install #4 thrust plate (2) using petrolatum to hold into position.
42. Install input clutch assembly. Ensure the input clutch assembly is completely seated by viewing position through input speed sensor hole. If the speed sensor tone wheel is not centered in the opening, the input clutches assembly is not seated properly.










43. Remove the oil pump o-ring (2) and install oil pump and gasket to transmission. Use screw-in dowels or Phillips head screwdrivers to align pump to case. Be sure to reinstall O-ring on oil pump after selecting the proper No. 4 thrust plate.










44. Measure the input shaft end play with the transmission in the vertical position. This will ensure that the measurement will be accurate.
45. Set up and measure endplay using End Play Set 8266A (1, 2) and Dial Indicator Set C-3339A (3) as shown.
46. Measure input shaft end play. Input shaft end play must be 0.127 to 0.635 mm (0.005 to 0.025 inch). For example, if end play reading is 0.055 in. , select No. 4 Thrust Plate which is 0.071 to 0.074 in. thick. This should provide an input shaft end play reading of 0.020 in. , which is within specifications.










47. Remove oil pump, gasket, and input clutch assembly to gain access to and install proper #4 thrust plate.
48. Install input clutch assembly (1) with proper thrust plate.










49. Install #1 caged needle bearing (1).










CAUTION: By-pass valve MUST be replaced if a transmission failure has occurred.

50. Replace cooler by-pass valve (1) if transmission failure has occurred.










NOTE: To align oil pump, gasket, and case during installation, use threaded dowels or Phillips screwdrivers.

51. Install oil pump gasket (2).










52. Install oil pump (2) and torque oil pump-to-case bolts (1) to 30 Nm (265 in. lbs.). Do not reuse original oil pump bolts.










53. Install low/reverse accumulator (1) as shown.










54. Install low/reverse accumulator plug (2).










55. Install low/reverse accumulator snap ring (1).










56. Install underdrive (2) and overdrive (1) accumulators and springs.










CAUTION: Do not handle the valve body by the manual shaft. Damage could result.

57. Install valve body (1) into place as shown.










58. Install seven (7) valve body-to-case bolts (1) and tighten to 12 Nm (105 in.lbs.).










59. Install transmission oil filter (1). Tighten the bolts to 5 Nm (45 in. lbs.).










60. Install transmission oil pan (1) with a bead of Mopar(R) ATF RTV.










NOTE: Before installing the oil pan bolt in the bolt hole located between the torque converter clutch on and U/D clutch pressure tap circuits , it will be necessary to replenish the sealing patch on the bolt using MOPAR(R) Lock AND Seal Adhesive.

61. Install and tighten the oil pan-to-case bolts to 20 Nm (14.5 ft. lbs.).










NOTE: Before installing either speed sensor bolt, it will be necessary to replenish the sealing patch on the bolt using Mopar(R) Lock AND Seal Adhesive.

62. Install both speed sensors (1, 2) into the transmission case. Torque the speed sensor bolts to 9 Nm (80 in. lbs.).










63. As a final check of the transmission, measure the input shaft end play. This will indicate when a #4 thrust plate change is required. The #4 thrust plate is located behind the overdrive clutch hub. Attach a dial indicator C-3339A (3) to transmission bell housing with its plunger seated against end of input shaft. Install End Play tool 8266-2 (2) , 8266-8 (1) and move input shaft in and out to obtain end play reading. Input shaft end play must be 0.127 to 0.635 mm (0.005 to 0.025 inch). If not within specifications, make the necessary thrust plate adjustment.

64. Perform the following, if necessary:
a.








Install the extension shaft bearing (2) onto the extension shaft.

b.








Install the extension shaft bearing retaining ring (3) onto the extension shaft (1).

c.








Install the extension shaft (2) and bearing assembly (3) into the extension housing (1).

d.








Install the extension shaft bearing snap ring (3) into the extension housing.

e.








Verify that the extension shaft snap ring (3) is fully engaged in the snap ring groove.










65. Inspect the lube tube grommet (3) for damage. If the grommet lip is damaged, it will need to be replaced.










66. Place a bead of Mopar(R) ATF RTV on the rear surface of the transmission case for the extension housing.
67. Install the extension housing (2) onto the transmission case, 4X2 vehicles only.










NOTE: Before installing the lowermost four extension housing bolts , it will be necessary to replenish the sealing patch on the bolts using MOPAR(R) Lock AND Seal Adhesive.

68. Install the bolts that hold the extension housing onto the transmission case. Be sure to install any stud bolts to their original locations. Tighten the bolts to 54 Nm (40 ft.lbs.).