Assembly
ASSEMBLYCAUTION: If transaxle failure has occurred, it is necessary to flush the transaxle oil cooler and lines to remove debris and particles that could contaminate and/or fail a new or rebuilt unit.
NOTE: This procedure does not include assembly of final drive (differential) components.
NOTE: This procedure does not include assembly of transfer system (transfer shaft and output shaft) components.
1. Install # 11 thrust washer (Fig. 59).
2. Install low/reverse band (Fig. 60). Do not install strut or adjust at this time.
3. Assemble Tool L-4440 to overrunning clutch as shown in (Fig. 61).
4. Orient springs as shown on left side of (Fig. 62).
5. Install overrunning clutch/tool assembly to transaxle and remove Tool L-4440.
6. Install # 10 thrust washer to rear of rear planetary gear assembly. Use petrolatum to retain and secure during installation.
7. Install rear planetary gear assembly (Fig. 63).
8. Install # 9 thrust washer (Fig. 64). Use petrolatum to secure.
9. Install sun gear driving shell (Fig. 65).
10. Install front planetary gear assembly (Fig. 66).
11. Install front planetary gear snap ring (Fig. 67).
12. Install # 3 thrust washer (Fig. 68). Refer to end play specification recorded during transaxle disassembly to determine whether or not replacement is necessary.
13. Install rear clutch assembly (Fig. 69). Ensure that all clutch discs are engaged to front planetary gear splines or transaxle failure will result.
14. Install # 2 thrust washer (Fig. 69).
15. Install front clutch assembly (Fig. 70). Ensure that all clutch discs are engaged to rear clutch retainer splines or transaxle failure will result.
16. Install kickdown band (Fig. 71). Do not install strut or adjust at this time.
17. Install oil pump gasket (Fig. 72).
18. Inspect # 1 thrust washer (on reaction support) and replace as necessary.
19. Install oil pump to transaxle (Fig. 73). Torque bolts to 31 Nm (275 in. lbs.).
20. Set up tools as shown in (Fig. 74) to measure input shaft end play. Input shaft end play should be within 0.19 - 1.50 mm (0.008 - 0.060 inch).
21. Install park pawl, spring, and pivot shaft (Fig. 75)
22. Install rod support and bolts (Fig. 76). Torque bolts to 28 Nm (250 in. lbs.). (Fig. 77).
23. Assemble kickdown servo as shown in (Fig. 78).
24. Install kickdown servo piston assembly and return spring (Fig. 79).
25. Install kickdown servo rod guide (Fig. 80). Place snap ring into position for installation.
26. Install snap ring (Fig. 81).
27. Install kickdown band strut.
28. Torque kickdown band adjusting screw (Fig. 82) to 8 Nm (72 in. lbs.) torque. Back off adjusting screw 2 1/4 turns. Torque lock nut to 47 Nm (35 ft. lbs.).
29. Install accumulator piston and spring (Fig. 83).
30. Install accumulator plate (Fig. 84) and place snap ring into position for installation.
31. Install accumulator snap ring (Fig. 85).
32. Install low/reverse servo piston, spring, and retainer (Fig. 86).
33. Install low/reverse piston snap ring (Fig. 87).
34. Install low/reverse band strut.
35. Adjust low/reverse band. Tighten adjusting nut (Fig. 88) to 5 Nm (41 in. lbs.) torque. Back off adjusting nut 3 turns. Torque lock nut to 14 Nm (125 in. lbs.).
36. Install valve body assembly (Fig. 89). Make sure governor tubes are properly engaged to the transaxle case and valve body.
37. Install and torque valve body-to-transaxle case bolts (Fig. 90) to 12 Nm (105 in. lbs.) torque.
38. Install cooler bypass valve and seal (Fig. 91). Torque bolts to 5 Nm (40 in. lbs.).
39. Install park rod into position and retain with e-clip (Fig. 92).
40. Install oil filter and gasket into position (Fig. 93).
41. Install oil filter-to-valve body screws (Fig. 94) and torque to 5 Nm (45 in. lbs.) torque.
42. Install an 1/8" bead of Mopar Silicone Rubber Adhesive Sealant to the transaxle oil pan (Fig. 95). Install oil pan to case and immediately install and torque oil pan-to-case bolts (Fig. 96) to 19 Nm (165 in. lbs.) torque.