Part 3

ASSEMBLY




Figure 52 Install Rear Sun Gear and #7 Needle Bearing







NOTE: The number seven needle bearing (1) (Figure 52) has three anti-reversal tabs and is common with the number five and number two 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.




Figure 53 Install Front Carrier/Rear Annulus Assembly






56. Install front carrier/rear annulus assembly (2) (Figure 53) and #6 needle bearing (1).




Figure 54 Install Front Sun Gear Assembly






57. Install front sun gear assembly (1) (Figure 54) and #4 thrust washer (2).




Figure 55 Select Thinnest No. 4 Thrust Plate






58. Select the thinnest #4 thrust plate thickness and install to input clutch assembly (1) (Figure 55). Use petrolatum to retain.




Figure 56 View Through Input Speed Sensor Hole






59. Install input clutch assembly into position and verify that it is completely seated by viewing through input speed sensor hole. View through input speed sensor hole (2) (Figure 56), if not as shown in picture, the input clutch assembly is not seated properly.




Figure 57 Remove Oil Pump O-Ring






60. Remove oil pump O-ring (2) (Figure 57). Be sure to reinstall oil pump O-ring after selecting the proper #4 thrust plate.




Figure 58 Measure Input Shaft End Play Using Tool 8266-Typical






61. Install pump and gasket to transmission. Install and torque bolts.
62. Set up input shaft for measurement with Indicator Set C-3339 (2) and End Play Socket Set 8266 (1) (Figure 58).
63. Measure the input shaft end play with the transaxle in the vertical position. Input shaft end play must be within 0.005 to 0.025 inch. For example, if end play reading is 0.055 inch, select No. 4 Thrust Plate which is 0.071 to 0.074 thick. This should provide an input shaft end play reading of 0.020 inch which is within specifications.
64. Refer to the No. 4 thrust plate chart to select the proper No. 4 thrust plate.

No. 4 Thrust Plate Chart:

Figure 59 Install Input Clutch Assembly






65. Install input clutch assembly (1) (Figure 59).




Figure 60 Install No.1 Caged Needle Bearing






66. Install #1 caged needle bearing (1) (Figure 60).




Figure 61 Install Cooler Bypass Valve

1 - COOLER BYPASS VALVE

CAUTION: The cooler bypass valve must be replaced if transaxle failure has occurred. Do not attempt to reuse or clean old valve.

67. Install cooler bypass valve (1) (Figure 61) with O-ring end towards rear of case.




Figure 62 Install Oil Pump Gasket

1 - PUMP GASKET

68. Install oil pump gasket (1) (Figure 62).




Figure 63 Install Oil Pump






69. Install oil pump assembly (1) (Figure 63).




Figure 64 Install Pump-to-Case Bolts






70. Install oil pump-to-case bolts (1) (Figure 64) and torque to 27 Nm (20 ft. lbs.).




Figure 65 Low/Reverse Accumulator






71. Install low/reverse accumulator (1) (Figure 65)




Figure 66 Install Low/Reverse Accumulator Plug






72. Install low/reverse accumulator plug (2) (Figure 66).




Figure 67 Install Low/Reverse Accumulator Snap Ring






73. Install low/reverse accumulator snap ring (1) (Figure 67).




Figure 68 Underdrive and Overdrive Accumulators







NOTE: Depending on engine application, some accumulators will have two springs, and others will have one spring. The springs are color-coded for application and year.

74. Install underdrive (2) (Figure 68) and overdrive (4) accumulators and springs.




Figure 69 Valve Body Removal/Installation

1 - VALVE BODY

75. Install valve body (1) (Figure 69) to transaxle. Rotate manual valve shaft fully clockwise to ease installation. Make sure park rod rollers are positioned within park guide bracket.




Figure 70 Install Valve Body-to-Case Bolts






76. Install and torque valve body-to-case bolts (1) (Figure 70) to 12 Nm (105 in. lbs.).




Figure 71 Install Oil Filter and O-Ring






77. Install oil filter and new O-ring (1, 2) (Figure 71).




Figure 72 Install Oil Pan






78. Apply an 1/8" bead of Mopar(R) ATF RTV (MS-GF41) (2) (Figure 72) to oil pan (1) and immediately install to case.




Figure 73 Solenoid/Pressure Switch Assembly and Gasket






79. Install oil pan-to-case bolts and torque to 19 Nm (165 in. lbs.).
80. Install solenoid/pressure switch assembly (1) (Figure 73) and gasket to case (2).




Figure 74 Attaching Bolts






81. Install and tighten solenoid/pressure switch assembly-to-transaxle case bolts (1) (Figure 74) to 12 Nm (110 in. lbs.).
82. Install and torque input and output speed sensors to case to 27 Nm (20 ft. lbs.).