Part 2

ASSEMBLY




Figure 28 Install Bearing Cup to Shaft






29. Install bearing cup (1) (Figure 28) and oil baffle (4) to transfer shaft (3).




Figure 29 Install Transfer Shaft






30. Using Remover/Installer 5049A (1) (Figure 29), install transfer shaft (2).




Figure 30 Install Transfer Shaft Bearing Snap Ring






31. Using Snap Ring Pliers 6051 (1) (Figure 30), install transfer shaft bearing snap ring (2).




Figure 31 Install Transfer Shaft Bearing Cup Into Retainer






32. Install transfer shaft bearing cup into retainer (4) (Figure 31) using Installer 6061 (3).




Figure 32 Install Bearing Cup Retainer






33. Install bearing cup retainer (2) (Figure 32) to transaxle.




Figure 33 Install Transfer Gear Bearing Cone






34. Install transfer gear bearing cone to transfer gear (4) (Figure 33) using Installer 5052, (5) Handle C-4171 and an arbor press.




Figure 34 Install Transfer Shaft Gear and (Select) Shim






35. TRANSFER GEAR BEARING ADJUSTMENT:

a. Install a 4.66 mm (0.184 in.) gauging shim (3) (Figure 34) on the transfer shaft.
b. Install transfer shaft gear using Installer 6261. Using Holder 6259, install transfer shaft gear retaining nut to 271 Nm (200 ft. lbs.).
c. Measure end play. Attach Gear Checking Plate L4432 to the transfer gear.
d. Mount a steel ball with grease into the end of the transfer shaft.
e. Push and pull the gear while rotating back and forth to ensure seating of the bearing rollers.
f. Using a dial indicator, measure transfer shaft end play.
g. Refer to the transfer shaft bearing shim chart for the required shim combination to obtain the proper bearing setting.
h. Use Holder 6259 to remove the retaining nut and washer. Remove the transfer shaft gear using Gear Puller L4407A.
i. Remove the gauging shim and install the proper shim indicated by the chart.

Transfer Shaft Bearing Shim Chart (Part 1):

Transfer Shaft Bearing Shim Chart (Part 2):

Figure 35 Install Transfer Shaft Gear






36. Install the transfer shaft gear (4) (Figure 35) using Installer 6261 (2).




Figure 36 Tighten Nut to 271 Nm (200 ft. lbs.)







CAUTION: Install a NEW retaining nut, as the original nut MUST NOT be reused.

37. Install the new retaining nut and washer.
38. Using Holder 6259 (4) (Figure 36), torque (3) transfer gear retaining nut to 271 Nm (200 ft. lbs.).




Figure 37 Install Rear Cover






39. Measure transfer shaft end play. Transfer shaft end play should be within 0.05-0.10 mm (0.002-0.004 in.). If the end play is too high, install a 0.04 mm (0.0016 in.) thicker shim. If the end play is too low, install a 0.04 mm (0.0016 in.) thinner shim. Repeat until 0.05-0.10 mm (0.002-0.004 in.) end play is obtained.
40. Install a bead of Mopar(R) ATF RTV (MS-GF41) (2) (Figure 37) to transfer gear cover.




Figure 38 Install Rear Cover Bolts






41. Install transfer gear cover-to-case bolts (1) (Figure 38) and torque to 20 Nm (175 in. lbs.) torque.




Figure 39 Install Low/Reverse Clutch






42. Install low/reverse clutch pack (1, 2) (Figure 39). Leave uppermost disc out until snap ring is installed.




Figure 40 Install Low/Reverse Reaction Plate Snap Ring






43. Install low/reverse reaction plate flat snap ring (2) (Figure 40).




Figure 41 Install One Disc

1 - ONE DISC FROM LOW/REVERSE CLUTCH

44. Install remaining low/reverse clutch disc (1) (Figure 41).




Figure 42 Install Low/Reverse Reaction Plate

1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP)

45. Install low/reverse reaction plate with flat side up (1) (Figure 42).




Figure 43 Tapered Snap Ring Instructions

46. Proper Installation of snap ring (with tapered side up) (Figure 43).




Figure 44 Snap Ring Installed






47. Install tapered snap ring (with tapered side up) (Figure 44).




Figure 45 Check Low/Reverse Clutch Clearance






48. Set up dial indicator (1) (Figure 45) and indicator tool 6268 (2) to measure low/reverse clutch clearance. Press down on clutch pack with finger and zero dial indicator. Low/Reverse clutch pack clearance is 0.89-1.47 mm (0.035-0.058 in.). Set up indicator (1) and record measurement in four places. Take average of readings and select the proper low/reverse reaction plate to achieve specifications.

Low/Reverse Reaction Plate Chart:

Figure 46 Install 2/4 Clutch






49. Install 2/4 clutch pack (1, 2) (Figure 46).

NOTE: The 2/4 Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.




Figure 47 Proper Orientation of 2/4 Clutch Retainer and Spring






50. Orient 2/4 clutch return spring (2) (Figure 47) to retainer (1).




Figure 48 2/4 Clutch Retainer






51. Install 2/4 clutch return spring (2) (Figure 48) into transaxle.




Figure 49 Install 2/4 Clutch Retainer Snap Ring






52. Using Compressor 5058 (1) (Figure 49), compress 2/4 clutch return spring just enough to install snap ring.
53. Install snap ring (3).




Figure 50 Check 2/4 Clutch Clearance






54. Set up dial indicator (1), (Figure 50) indicator tip 6268 (3) and hook tool (2), measure 2/4 clutch clearance. Press down on clutch pack with finger and zero dial indicator. 2/4 clutch pack clearance is 0.76-2.64 mm (0.030-0.104 in.). Set up indicator and record measurement in four (4) places. Take average of readings. If clearance is outside this range, the clutch is assembled improperly. There is no adjustment for 2/4 clutch clearance.




Figure 51 Number 7 Bearing






55. Install rear sun gear and #7 needle bearing (1) (Figure 51).