Part 3

ASSEMBLY




Figure 49 Number 7 Bearing







NOTE: The number seven needle (1) (Figure 49) bearing 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 (2).




Figure 50 Install Rear Sun Gear and #7 Needle Bearing






53. Install rear sun gear (2) (Figure 50) and #7 needle bearing (1).




Figure 51 Install Front Carrier and Rear Annulus Assembly






54. Install front carrier/rear annulus assembly (2) (Figure 51) and #6 needle bearing (1).




Figure 52 Install Front Sun Gear Assembly






55. Install front sun gear assembly (1) (Figure 52) and #4 thrust washer (2).




Figure 53 Select Thinnest No. 4 Thrust Plate






56. Select the thinnest #4 thrust plate thickness (2) (Figure 53) and install to input clutch assembly. Use petrolatum to retain (3).




Figure 54 View Through Input Speed Sensor Hole






57. Install input clutch assembly into position and verify that it is completely seated by viewing through input speed sensor hole (2) (Figure 54). If view through input speed sensor hole is not as shown in the below view, the input clutch assembly is not seated properly.




Figure 55 Remove Oil Pump O-Ring






58. Remove oil pump O-ring (2) (Figure 55). Be sure to reinstall oil pump O-ring after selecting the proper #4 thrust plate.
59. Install pump and gasket to transmission. Install and torque bolts.




Figure 56 Measure Input Shaft End Play Using End Play Set 8266






60. Set up input shaft for measurement with Indicator Set C3339 (3) and End Play Set 8266 (1) (Figure 56).
61. 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.
62. Refer to the No. 4 thrust plate chart NO. 4 THRUST PLATE CHART to select the proper No. 4 thrust plate.

No. 4 Thrust Plate Chart:

Figure 57 Install Input Clutch Assembly






63. Install input clutch assembly (1) (Figure 57).




Figure 58 Install Caged Needle Bearing






64. Install #1 caged needle bearing (1) (Figure 58)

Note: tanged side out (2).

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




Figure 59 Install Cooler Bypass Valve

1 - COOLER BYPASS VALVE

65. Install cooler bypass valve (1) (Figure 59) with O-ring end towards rear of case.




Figure 60 Install Oil Pump Gasket

1 - PUMP GASKET

66. Install oil pump gasket (1) (Figure 60).




Figure 61 Install Oil Pump






67. Install oil pump (1) (Figure 61).




Figure 62 Install Pump-to-Case Bolts






68. Install oil pump-to-case bolts (1) (Figure 62) and torque to 27 Nm (20 ft. lbs.).




Figure 63 Install Low/Reverse Accumulator






69. Install low/reverse accumulator (1) (Figure 63).




Figure 64 Install Low/Reverse Accumulator Plug (Cover)






70. Install low/reverse accumulator plug (2) (Figure 64).




Figure 65 Install Low/Reverse Accumulator Snap Ring






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




Figure 66 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.

72. Install underdrive and overdrive accumulators (1, 2) (Figure 66).




Figure 67 Install Valve Body

1 - VALVE BODY

73. Install valve body (1) (Figure 67) to transaxle. Rotate manual valve shaft fully clockwise to ease installation. Make sure park rod rollers are positioned within park guide bracket.




Figure 68 Install Valve Body-to-Case Bolts






74. Install and torque valve body-to-case bolts (1) (Figure 68) to 12 Nm (105 in. lbs.).



Figure 69 Install Oil Filter






75. Install oil filter (1) (Figure 69) and new O-ring (2).




Figure 70 Install Oil Pan






76. Apply an 1/8" bead of Mopar(R) ATF RTV (MS-GF41) (2) (Figure 70) to oil pan (1) and immediately install to case.




Figure 71 Solenoid/Pressure Switch Assembly and Gasket






77. Install oil pan-to-case bolts and torque to 19 Nm (165 in. lbs.).
78. Install solenoid/pressure switch assembly (1) (Figure 71) and gasket (2) to case.




Figure 72 Solenoid Pack-to-Transaxle Bolts






79. Install and tighten solenoid/pressure switch assembly-to-transaxle case bolts (1) to 12 Nm (110 in. lbs.)(Figure 72).
80. Install and torque input and output speed sensors to case to 27 Nm (20 ft. lbs.).