Repair Procedure

NOTE:
Be sure there are no speed sensor(s) related DTCs present before proceeding further with this service bulletin.

1. Raise the vehicle on a suitable hoist.





2. Remove transfer gear cover-to-case bolts and catch any transmission fluid which may drain in a suitable container (Fig. 1).





3. Remove transfer gear cover (Fig. 2).








4. Remove the differential cover and bolts (Fig. 3) and (Fig. 4).

5. Count the number of teeth on both the ring gear and the transfer gear.

6. Does the ring gear have 63 teeth and the transfer gear have 46 teeth?

a. Yes >> further diagnosis is required. This service bulletin does not apply

b. No >> go to Step # 7.

7. Does the ring gear have 59 teeth and the transfer gear have 49 teeth?

a. Yes >> further diagnosis is required. This service bulletin does not apply

b. No >> go to Step # 8.

NOTE:
If the ring gear has 63 teeth and the transfer gear has 49 teeth then you must replace the transfer gear set with part 04713443AC.

NOTE:
If the ring gear has 59 teeth and the transfer gear has 46 teeth then you must replace the transfer gear set with part 04713444AD.








8. Using Tool 6259, remove transfer shaft gear-to-shaft nut and coned washer (Fig. 5) and (Fig. 6).





9. Using tool L-4407A, remove transfer shaft gear (Fig. 7).





10. Remove transfer gear and shim (select) (Fig. 8).





11. Draw or scribe a line from the indexing slot on the bearing cup retainer to the transfer cover bolt flange. (THIS WILL ALLOW THE BEARING RETAINER TO BE INSTALLED IN THE ORIGINAL POSITION SHOULD IT COME OUT.(Fig. 9).

12. Remove stirrup and strap and bolts.

13. Using tools L-4407 and 6259 remove the output gear bolt, washer and shim.

14. Install gauging shim .177" (4.50 mm), PN 4412832, and new output gear (lubricate bearing with ATF+4 before installing on output shaft) using old bolt & washer. Torque to 200 ft.lbs. (271 N-m).

NOTE:
Shim thickness should be verified with a micrometer.

15. Attach tool L-4432 to the output gear, push and pull on the gear while turning it back and forth to assure the bearing rollers are seated.

16. Measure the end play of the output gear bearing using a dial indicator attached to the transaxle case and record end play.

17. Using an inch-pound torque wrench, check and record the output gear turning torque.

18. With output bearing turning torque determined, refer to the Output Gear Bearing Shim Chart








OUTPUT GEAR BEARING SHIM CHART

19. Using tools L4407 & 6259, remove output gear, bolt and washer.

20. Remove gauging shim and install the proper shim selected in Step # 18. Verify the shim thickness with a micrometer before installing. Using the old retaining bolt and washer, torque to 200 ft.lbs. (271 N-m).

21. Using a dial indicator measure output gear end play. If end play is zero, go to Step # 22. If end play exists, repeat Step # 13 to Step # 21.

22. Using an inch-pound torque wrench, check and record the output gear turning torque.

23. Subtract the torque value recorded in Step # 17 from the torque value recorded in Step # 22. The difference must be 3 to 8 inch pounds.

NOTE:
This is the output bearing turning torque.

24. If the turning torque is too high, install a 0.04 mm (.0016 in.) thicker shim. If the turning torques is too low, install a 0.04 mm (.0016 in.) thinner shim. Repeat until the difference Step # 23 is 3-8 inch pounds.

25. Remove the old retaining bolt & washer and discard. Install the new retaining bolt & washer and tighten to 271 N.m (200 ft. lbs.).

26. Install stirrup and strap and bolts.

27. Install a 4.66 mm (0.183 in.) gauging shim, p/n 4505588, onto the transfer shaft.

NOTE:
Before install the gear make sure the bearing cup retainer index slot lines up with the mark made in Step # 11.

28. Lubricate the bearing on the new transfer gear with ATF, and install the gear using the old retainer nut and washer. Tighten the retaining nut to 271 N.m (200 ft.lbs.).

29. Measure the transfer shaft end play as follows:

a. Install Miller special tool L-4432 to the transfer gear.

b. Install a greased steel ball in the end of the transfer shaft. (To aid in measuring transfer shaft end play).

c. Push and pull the gear while rotating back and forth to insure the bearing rollers are seated.

d. Using a dial indicator, measure the transfer shaft end play.

30. Refer to the Transfer Shaft Bearing Shim Chart for the required shim combination to obtain the proper bearing setting.











TRANSFER SHAFT BEARING SHIM CHART

31. Remove the transfer gear using Miller Special Tools L-4407 & 6259.

32. Remove the gauging shim and install the selected shim combination from Step # 30.

33. Install the transfer gear making sure the bearing cup retainer is properly indexed, torque the retainer bolt to 271 N-m (200 ft.lbs.).

NOTE:
The retainer index tab can be viewed through the large hole in the gear.

34. Measure the transfer shaft end play as follows:

a. Install Miller special tool L-4432 to the transfer gear.

b. Install a greased steel ball in the end of the transfer shaft. (To aid in measuring transfer shaft end play).

c. Push and pull the gear while rotating back and forth to insure the bearing rollers are seated.

d. Using a dial indicator, measure the transfer shaft end play.

35. End play should be 0.05 to 0.10 mm (0.002 to 0.004 in.). Is the end play too high?

a. Yes >> install a 0.04 mm (0.0016 in) thinner shim. Repeat until 0.05 to 0.10 mm (0.002 to 0.004 in.) is obtained.

b. No >> go to Step # 36.

36. Is the end play too low?

a. Yes� install a 0.04 mm (0.0016 in) thicker shim. Repeat until 0.05 to 0.10 mm (0.002 to 0.004 in.) is obtained.

b. No >> go to Step # 37.

37. Remove the steel ball installed in Step # 34b.

38. Remove the old retaining nut & washer and discard. Install the new retaining nut & washer supplied and tighten to 271 N-m (200 ft.lbs.).

39. Install a bead of Mopar(R) ATF RTV (MS-GF41) to transfer gear cover and install the cover (Fig. 2).

40. Install transfer gear cover-to-case bolts and torque to 20 N-m (175 in. lbs.) torque (Fig. 1).

41. Lower the vehicle.

42. Fill transaxle with suitable amount of ATF+4 (Automatic Transmission Fluid - Type 9602). Refer to the detailed service information available in TechCONNECT, under: Service Info, 21 - Transmission/Transaxle/Automatic - 41 TE/Fluid - Standard Procedure

43. Using the DRBIII(R) erase any diagnostic trouble codes (DTC) and reset the pinion factor.