Assembly

CAUTION: Do not force the valves or plugs into place during reassembly. If the valve body bores and the valves and plugs are free of distortion or burrs, the valves and plugs should slide into place easily. In addition, do not overtighten the transfer plate and valve body screws during reassembly. Overtightening can distort the valve body resulting in valve sticking, cross leakage and unsatisfactory operation. Tighten the screws alternately and evenly to 4 Nm (35 inch lbs.) torque only.

1. Lubricate valve body bores, valves and plugs with Mopar (R) ATF Plus transmission fluid, or equivalent.





2. Insert rear clutch and rear servo check balls in transfer plate.





3. Install filter in separator plate.
4. Align and install separator plate on transfer plate.





5. Verify rear clutch check ball position before securing separator plate. Ball should be visible in fifth orifice at lower right side of separator plate as shown.
6. Install stiffener plate on separator plate. Then secure separator and stiffener plates to transfer plate with short attaching screws. Tighten screws to 4 Nm (35 inch lbs.) torque.





7. Position valve body so internal passages and check ball seats are facing upward. Then install check balls in valve body. There are a total of 7 check balls. Single large check ball has a diameter of approximately 11/32 inch. Remaining 6 check balls have a diameter of approximately 1/4 inch.





8. Align and install transfer/separator plate assembly on valve body. Install screws attaching transfer plate to valve body. Tighten screws alternately and in a diagonal pattern to 4 Nm (35 inch lbs.) torque.





9. Assemble regulator valve line pressure plug, sleeve, throttle plug and spring. Insert assembly in valve body and install end plate. Tighten end plate screws to 4 Nm (35 inch lbs.) torque.
10. Install 1-2 and 2-3 shift valves and springs.
11. Install 1-2 shift control valve and spring.

Valve Body Components:

12. Assemble 3-2 downshift housing. Install throttle plug, limit valve and spring and secure in housing with retainer.
13. Position shift valve end plate on 3-2 downshift housing. Then align housing and end plate on valve body. Carefully compress shift valve springs and install screws that secure housing and end plate to valve body. Tighten screws to 4 Nm (35 inch lbs.) torque.
14. Install shuttle valve as follows.
a. Insert shuttle valve in bore.
b. Insert plastic guides in shuttle valve secondary spring.
c. Install secondary spring on end of valve.
d. Hold shuttle valve in place.
e. Compress secondary spring and install E-clip in groove at end of shuttle valve. Verify that spring and E-clip are properly seated before proceeding.

Control Valve Locations:

15. Install shuttle valve cover and cover screws to 4 Nm (35 inch lbs.) torque.
16. Install 1-2 and 2-3 valve governor plugs. Then install shuttle valve primary spring and throttle plug.
17. Align and install governor plug end plate on valve body and install end plate screws. Tighten screws to 4 Nm (35 inch lbs.) torque.
18. Install manual valve.
19. Install throttle valve and spring. Then install kickdown valve and detent.
20. Install pressure regulator valve and switch valve.





21. Install manual lever detent spring in housing. Place detent ball on end of spring and push ball and spring into housing. Secure ball and spring with Retainer Tool 6583, or equivalent.





22. Insert line pressure adjusting screw in adjusting screw bracket.
23. Place valve spring on end of line pressure regulator valve.





24. Install switch valve spring on tang at end of adjusting screw bracket.
25. Install adjusting screw bracket on valve body. Align springs, press bracket toward valve body and install long bottom bracket attaching screw first. Do not tighten screw fully at this time.
26. Carefully align bracket on valve body and transfer plate and install remaining (two) bracket screws. Verify that valve springs and bracket are properly aligned. Then tighten all three bracket screws to 4 Nm (35 inch lbs.) torque.
27. Install throttle lever in valve body. Then install manual lever over throttle lever and start manual lever into valve body.
28. Align manual lever detent with detent ball and align lever arm with manual valve. Hold throttle lever upward. Then press down on manual lever until lever is fully seated.
29. Install manual lever seal, washer and retaining E-clip.
30. Lubricate shaft of manual lever with light coat of petroleum jelly. This will help protect seal lip when manual shaft seal is installed.
31. Verify that throttle lever is aligned with end of kickdown valve stem and that manual lever arm is engaged in manual valve.
32. If line pressure and/or throttle pressure adjustment screw settings were not disturbed, continue with overhaul or reassembly. However, if adjustment screw settings were moved or changed, readjust as described in Valve Body Control Pressure