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TRANSAXLE CENTERLINETo assemble the transaxle centerline, refer to the following procedures.
Bearing Cup Installation Special Tool 5050A:
To install the output bearing cups, use Special Tool #5050A, or equivalent.
Install Piston Retainer Gasket:
Install Piston Retainer:
Install Retainer Attaching Screws:
Install Low/Reverse Clutch Piston:
Guide Bracket Disassembled:
Guide Bracket:
Install Guide Bracket Pivot Shaft:
Install Parking Sprag Pivot Retaining Screw:
Install Low/Reverse Piston Return Springs:
Low/Reverse Spring Compressor Tool:
Compressor Tool In Use:
Install Snap Ring:
Install Rear Carrier Front Bearing Cone:
CAUTION: When installing, be sure guide bracket and split sleeve touch the rear of the transaxle case.
OUTPUT SHAFT BEARING PRELOAD SHIM SELECTION
When assembling, the output bearing preload must be checked and/or adjusted if any of the following items have been replaced:
- Output shaft (rear carrier assembly)
- Output shaft bearings
- Transaxle case
Bearing Installation:
Shim Selection
1. Install rear output shaft bearing cone and special tool 6618A, or equivalent.
Special Tool Installed:
2. Install special tool 6618A, or equivalent. Lightly tighten retaining screws. Screws should be below the orate surface, but do not snug screws.
3. Turn case over on arbor press so that the plate is resting on the press base
CAUTION: The output shaft will extend through the hole of tool 6618A, or equivalent. Ensure your press table has clearance for the output shaft.
Shim Installation:
Output Bearing Shim Chart:
4. Install shim on output shaft. Apply small amount of petrolatum onto the shim to hold it in place. Use the original shim as a starting point. If original shim is not available, use the thickest shim available. Refer to Output Shaft Rear Shim Chart for available sizes.
Press Shaft Into Case:
5. Install output shaft/rear carrier into rear bearing. The shaft must be pressed into position. Use special tool MD-998911 (Disc) and C-4171 and C4171-2 (Handle), or equivalents to press shaft into rear bearing.
CAUTION: Do not reuse old transfer shaft nut or output shaft nut because the removed stake weakens the nut flange.
6. Using special tools 6497 and 6498, or equivalents, install new output shaft nut. Do not reuse old output shaft nut. Tighten new output shaft nut to 271 Nm (200 ft. lbs.).
Checking Turning Torque:
7. Check the turning torque of the output shaft. The shaft should have 1 to 8 inch lbs. of turning torque. If the turning torque is higher than 8 inch lbs., install a thicker shim. If the turning torque is less than 1 inch lbs., install a thinner shim. Make sure there is no end play.
CAUTION: Failure to stake shaft nuts could allow the nuts to back-off during use.
Staking Output Shaft Nut:
Correctly Staked Nut:
8. The new nut must be staked after the correct turning torque is obtained. Use special tool 6639, or equivalent to stake output shaft nut and special tool 6589, or equivalent to stake transfer shaft.
Correctly Applied Sealant:
When reinstalling main sump baffle apply MOPAR Silicone Sealant as shown.
Main Sump Vent Baffle Location:
Output Shaft Spacer:
Install main sump baffle to transaxle case.
CAUTION: When reinstalling drive chains, the blue link must face outward.
Install Chains And Both Sprockets As An Assembly:
Remove Chain Spreader:
Install Transfer Shaft Sprocket Snap Ring And Wave Washer:
Install Output Shaft Sprocket Snap Ring And Wave Washer:
CAUTION: The chain sprockets have a slip fit onto the shafts. Apply only a slight amount of pressure to the chain spreader to release the chain pressure. If chain sprockets are not spread slightly, installation will be difficult.
Install Chain Snubber:
Install Chain Oiler:
CAUTION: Be sure to reinstall the chain snubber and chain oiler when reassembling.
Stand trans upright on bellhousing
Install Chain Cover:
Chain cover must be free of old sealant, dirt and oil before applying new sealant. Apply a 1/8 inch bead of sealant to flange of cover.
Install Low/Reverse Clutch Pack:
Install Low/Reverse Reaction Plate Snap Ring:
Install One Disc:
Install Low/Reverse Reaction Plate:
Tapered Snap Ring Instructions:
Snap Ring Installed:
Check Low/Reverse Clutch Clearance:
Press down clutch pack with finger and zero dial indicator. Low/Reverse clutch pack clearance is 0.89 to 1.47 (0.035 to 0.058 inch).
Low/Reverse Reaction Plate Chart:
Select the proper low/reverse reaction plate to achieve specifications:
Install 2/4 Clutch Pack:
Stagger 2/4 Clutch Plate Pads:
NOTE: When installing the 2-4 clutch plates and discs, the orientation should be alternated so the pilot pads of adjacent plates do not align, refer image.
Install 2/4 Clutch Return Spring:
Proper Orientation Of 2/4 Clutch Retainer And Spring:
Install 2/4 Clutch Retainer:
Install 2/4 Clutch Retainer Snap Ring:
Check 2/4 Clutch Clearance:
Press down clutch pack with finger and zero dial indicator. The 2/4 clutch pack clearance is 0.63 to 2.51 mm (0.025 to 0.099 inch). If not within specifications, the clutch is not assembled properly. There is no adjustment for the 2/4 clutch clearance.
Number 7 Bearing:
Install Front Carrier And Rear Annulus Assembly:
Install Front Carrier And Rear Annulus Assembly:
Install Front Sun Gear Assembly:
The number 7 needle bearing has antireversal 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.