Part 2

ASSEMBLY

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

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) AS68RC ATF. Soak all friction discs in MOPAR(R) AS68RC ATF for at least two hours before assembly of clutch packs.


CAUTION: While installing the trust washers and bearings be certain they are orientated correctly to the transmission component. A thrust bearing must be installed correctly or transmission failure may occur.




THRUST WASHER AND BEARING ORIENTATION BEFORE BULKHEAD








K3 SUPPORT SEAL RINGS





51. Apply trans jell or petroleum jelly onto the seal rings. Install the K3 support seal rings.




K3 HUB REAR THRUST BEARING NO.8
52. Lubricate with trans jell or petroleum jelly and install the number eight thrust bearing.




K3 CLUTCH
53. Install the K3 clutch into the transmission case.




P1 ANNULUS THRUST BEARING NO. 7





54. Lubricate with trans jell or petroleum jelly and install the number seven thrust bearing.




P1 ANNULUS GEAR
55. Install the P1 annulus gear into the transmission case.




P1 THRUST BEARING NO. 6





56. Lubricate with trans jell or petroleum jelly and install the number six thrust bearing.




P1 CARRIER
57. Install the P1 planetary carrier into the transmission case.




P1 CARRIER BOLTS





58. Install the P1 planetary carrier and the bolts (1) into the transmission case and hand tighten.




CARRIER SNAP RING

NOTE: The tapered edge of the snap ring faces outward. The "hooked" ends of the snap ring should be to the window side of the PTO.

59. Install the P1 planetary carrier snap ring into the transmission case. Tighten the bolts to 28 Nm (21 ft.lbs.).




FRONT SUN PTO REAR THRUST BEARING NO. 5
60. Lubricate with trans jell or petroleum jelly and install thrust bearing number five.




FRONT SUN / PTO DRIVE GEAR
61. Install the front sun / PTO drive gear into the transmission case.




FRONT SUN/PTO FRONT THRUST BEARING No. 4
62. Lubricate with trans jell or petroleum jelly and install thrust bearing number four.




K2 HUB THRUST BEARING NO. 3





63. Lubricate with trans jell or petroleum jelly and install thrust bearing number three.




K2 HUB
64. Install the K2 clutch hub into the transmission case.




K1 THRUST BEARING NO. 2





65. Lubricate with trans jell or petroleum jelly and install thrust bearing number two.





66. Install the K1 clutch hub and thrust bearing into the transmission case.




K1 AND K2 CLUTCHES





67. Apply trans jell or petroleum jelly onto the input shaft seal rings and install the K2 clutch assembly (3) onto the K1 clutch / input shaft assembly (1) with selectable input shaft end-play thrust bearing number one (2) and thrust washer (3) in place.




K2 RETAINER
68. Install the K2 clutch assembly and the K1 clutch / input shaft assembly into the transmission case.

CAUTION: If the oil pump is being replaced, the valve body must also be replaced. Failure to follow these instructions will damage the transmission.

NOTE: Be certain the input shaft seal rings are in place as well as the seal ring on the oil pump hub.




OIL PUMP NYLON THRUST WASHER





69. Lubricate with trans jell or petroleum jelly and install the nylon thrust washer (1) onto the oil pump.

NOTE: Two pin punches inserted through the oil pump mounting holes will aid in the installation of the oil pump.




OIL PUMP REMOVAL
70. Install a new torque converter hub seal into the oil pump using Installation tool 9987.
71. Lubricate the oil pump o-ring with MOPAR(R) AS68RC ATF.
72. Install the oil pump with a new gasket onto the transmission case.
73. Apply a light coating of MOPAR(R) thread sealant onto the oil pump bolts and install the bolts. Tighten bolts in a crisscross fashion to 21 Nm (15.5 ft.lbs.).




INPUT SHAFT END PLAY








K1 AND K2 CLUTCHES





NOTE: The input shaft end-play clearance may be checked with or without the torque converter housing in place.

NOTE: The input shaft end-play clearance is adjusted by means of the selectable NO. 1 thrust bearing race (2). The Thrust Washer (3) is non selectable.

74. Install the Dial Indicator Set C-3339A and Input Shaft Spline Socket 8266-19 to check the input shaft end-play clearance.

The input shaft end-play clearance for both 2WD and 4WD is 0.50-0.90 mm (0.019-0.035 in. ). If the clearance is not within tolerance choose the correct selectable thrust bearing race.

- Bearing race number one = 0.81 mm (0.031 in.)
- Bearing race number two = 1.10 mm (0.043 in.)
- Bearing race number three = 1.60 mm (0.063 in.)

75. Assemble and disassemble as necessary to achieve the input shaft end-play clearance.
76. Remove the Dial Indicator (2) set up.




OVERHEAD VIEW

NOTE: These dimensions are at time of production.






77. Install the three accumulator springs first and then the three accumulator valves (1), (2) ,(3).
78. Install the valve bodyValve Body - Installation.




TC HOUSING
79. Install the torque converter housing to the transmission case.
80. Install the torque converter housing bolts and tighten to 64 Nm (47 ft.lbs.)




COOLER LINES





81. Apply trans jell or petroleum jelly onto the cooler line seals and install the cooler line fittings (3) into the transmission case.
82. Tighten the cooler line fittings (3) to 44 Nm (32 in.lbs.)
83. Apply trans jell or petroleum jelly onto the Jiffy Tight fitting seals and install the Jiffy Tight fittings (2) onto the cooler line fittings.
84. Tighten Jiffy Tight fittings (2) to 25 Nm (18 ft.lbs.)
85. Install the ATF output temperature sensor (1) onto the output cooler line fitting.
86. Tighten the ATF output temperature sensor (1) to 34 Nm (25 ft.lbs.)




PTO DUST COVER
87. Install a new gasket onto the PTO cover and apply a light coating of MOPAR(R) thread sealant onto the PTO cover bolts, install the bolts. Tighten the PTO cover bolts to 15 Nm (11 ft.lbs.).





88. Lubricate the o-ring with AS68RC ATF and install a new breather hose fitting into the transmission case.



SEAL INSTALLATION
89. Lubricate the manual shift lever seals (one on each side of the transmission) with trans jell or petroleum jelly and install the seal into the transmission case.




FILL TUBE





90. Lubricate the transmission fill tube O-ring (1) with trans jell or petroleum jelly and install the fill tube into the transmission case.
91. Install the transmission fill tube to case bolt (if equipped) and tighten bolt to 12.5 Nm (9 ft.lbs.).
92. Install the transmission range sensorTransmission Range Sensor - Installation
93. Install the manual shift lever onto the transmission manual shift lever shaft. Tighten the inside nut to 12.5 Nm (9 ft.lbs.). While holding the inside nut tighten the outside nut to 12.5 Nm (9 ft.lbs.).




OUTPUT SPEED SENSOR
94. Apply trans jell or petroleum jelly onto the output speed sensor seal and install the output speed sensor into the transmission case.
95. Install the output speed sensor bolt. Tighten the output speed sensor bolt to 8 Nm (70 in.lbs.).




INPUT SPEED SENSOR
96. Apply trans jell or petroleum jelly onto the input speed sensor seal and install the input speed sensor into the transmission case.
97. Install the input speed sensor bolt. Tighten the input speed sensor bolt to 8 Nm (70 in.lbs.).

WARNING: Be certain the transmission is secure when installing the torque converter, the torque converter is very heavy. Failure to follow these instructions may result in personal injury or may be fatal.




TORQUE CONVERTER REMOVAL
98. Apply trans jell or petroleum jelly onto the input shaft ring seals and torque converter hub seal.
99. Install the torque converter onto the input shaft while applying inward pressure and rotating back and forth at the same time in order to align the input shaft splines and the two teeth on the oil pump drive gear.
100. Install a C-clamp or similar devise to secure the torque converter into the torque converter housing.