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Home >> Dodge and Ram >> 2007 >> RAM 3500 HD Truck 4WD V8-5.7L VIN D >> Repair and Diagnosis >> Transmission and Drivetrain >> Automatic Transmission/Transaxle >> Service and Repair >> Overhaul >> AS68RC Automatic Transmission >> Assembly >> Part 1

Part 1






ASSEMBLY

NOTE: If the transmission is being reconditioned (clutch/seal replacement) or replaced, it is necessary to perform the Quick Learn Procedure using the scan tool.

NOTE: Apply trans jell or petroleum jelly to all slide portions, rolling contacts surfaces, thrust surfaces etc. to prevent burnout during initial operation. Lubricate O-rings and O-ring seals with Mopar(R) AS68RC ATF. Soak all friction discs in Mopar(R) AS68RC ATF for at least two hours before assembly of clutch packs.




AS68RC COMPONENTS










THRUST BEARING ORIENTATION







CAUTION: A thrust bearing must be installed correctly or transmission failure may occur.

When installing a thrust bearing be certain the rolled surface (outer race) of the thrust bearing contacts the rolled surface of the component.


NOTE: There five snap ring in the back half of the transmission case, three wide and two narrow snap rings.




SNAP RING ORIENTATION







NOTE: Before final assembly of the transmission a B1 and B2 piston and clutch pack clearance check must be preformed.




B2 PISTON

1. Lubricate the B2 brake piston seals with Mopar(R) AS68RC ATF and install the B2 brake piston into the extension housing.




B2 RETURN SPRING

2. Install the B2 brake piston return spring assembly.




B2 PISTON COMPRESS






3. Install tools Bolt 8622 (1), Washer 9922-2 (3) and Compressor MB991790 (2) onto the B2 brake piston assembly and compress the B2 brake piston assembly.




B2 SNAP RING

1 - SNAP RING

4. Install the B2 brake piston snap ring (1).




5. Install the B2 wide snap ring (1).




B2 CLUTCHES


NOTE: For the B2 brake, only the front most plate is selectable. However, the rear most pressure plate, towards the piston, always uses the plate marked "D".

6. Install the 9982 compressor plate into the transmission case in order to check the clutch pack clearance.
7. Install the B2 brake clutch pack into the transmission case.

Clutch Clearance And Piston Travel Combinations:












B2 PISTON STROKE







NOTE: If the B2 brake piston assembly stroke is not within tolerance, check the B2 brake piston seals and the hydraulic fluid circuit path.

8. Using two bolts, temporarily install the extension housing onto the transmission case.
9. Install the 9524 90� Dial Indicator and mounts from the Dial Indicator Set C-3339-A and Extension Tip MLR- 6268 so that the extension tip passes through one of the two smaller holes in the transmission case bulk head and through a void in the 9982 compressor plate in order to contact the B2 brake piston.




B2 AIR CHECK

10. Apply 400-500 kPa (52 - 78 psi) of air to check the B2 brake piston stroke.

The B2 brake piston stroke clearance is 1.84 - 2.28 mm (0.072 - 0.090 in.).


NOTE: The selectable clutch pack reaction plates are identified by an alpha numeric numeral stamped into the face of the plate.




B2 DIAL INDICATOR






11. Move the 90� Dial Indicator 9524 and mounts from Dial Indicator Set C-3339-A (1) and extension tip MLR- 6268 so that it makes contact with the 9982 compressor plate (2).




B2 AIR CHECK

12. Apply 400 - 500 kPa( 52 - 78 psi) of air to check the B2 brake clutch clearance.

The B2 brake clutch pack clearance is 1.60 - 2.04 mm (0.063 - 0.080 in.). If the clearance is not within tolerance choose the correct selectable reaction plate.

- A = 5.40 mm (0.212 in.)
- B = 5.60 mm (0.220 in.)
- C = 5.80 mm (0.228 in.)
- D = 6.00 mm (0.236 in.)

13. Assemble and disassemble as necessary to achieve the correct B2 brake clearance.
14. Remove the dial indicator set.
15. Remove the extension housing and set aside.
16. Remove the B2 clutch pack and snap ring.
17. Remove the measuring plate MB991632-1.




B1 PISTON GROOVE


NOTE: The orientation of the groove on the B1 piston is at the 12:00 o'clock position to the transmission case.

18. Apply Mopar(R) AS68RC ATF to the seals of the B1 piston and install the piston into the transmission case.




B1 PISTON COMPRESS

19. Install the B1 piston return spring and a wide snap ring into the transmission case using tools 8622, 9982-2 and MB 991790.




B1 CLUTCHES

20. Install the B1 clutch assembly, into the deeper grooves of the transmission case with the thickest pressure plate to the inside and install a wide snap ring.




B1 PISTON TRAVEL


NOTE: If the B1 brake piston assembly stroke is not within tolerance, check the B1 brake piston seals and the hydraulic fluid circuit path.

21. Install the Dial Indicator set C-3339-A and extension tip MLR- 6268 so the dial indicator tip contacts the B1 brake piston and check the B1 brake piston assembly stroke.




B1 AIR CHECK






22. Apply 400-500 kPa (52 - 78 psi) of air to check the B1 brake piston stroke.

The B1 brake piston stroke clearance is 1.55 - 1.80 mm (0.061 - 0.071 in.)





B1 AIR CHECK







NOTE: The selectable clutch pack reaction plates are identified by an alpha numeric numeral stamped into the face of the plate.

23. Move the Dial Indicator Set C-3339-A (1) and extension tip MLR- 6268 so the tip makes contact with the B1 brake clutch pack apply 400 - 500 kPa( 52 - 78 psi) of air (2) to check the B1 brake clutch pack clearance.

The B1 brake clutch pack clearance is 1.25 - 1.50 mm (0.049 - 0.059 in.). If the clearance is not within tolerance, choose the correct selectable reaction plate.

- A = 5.40 mm (0.212 in.)
- B = 5.55 mm (0.218 in.)
- C = 5.70 mm (0.224 in.)
- D = 5.85 mm (0.230 in.)
- E = 6.0 mm (0.236 in.)

24. Remove the dial indicator set C-3339-A and extension tip MLR- 6268.

CAUTION: While installing the trust washers and bearings be certain they are orientated correctly to the transmission component. A thrust bearing must be installed correctly or transmission failure may occur.




THRUST BEARING AND WASHER ORIENTATION BEHIND BULKHEAD










P2 CARRIER THRUST BEARING NO. 9

25. Lubricate with trans jell or petroleum jelly and install the number nine thrust bearing into the transmission case.




P2 PLANETARY ANNULUS GEAR

26. Install the B2 clutch pack and a wide snap ring.
27. Install the P2 planetary annulus gear.




P2 PLANETARY GEAR THRUST BEARING NO. 10

28. Lubricate with trans jell or petroleum jelly and install the number ten thrust bearing into the transmission case.




P2 PLANETARY CARRIER

29. Install P2 planetary gear carrier into the transmission case.

NOTE: Be certain the sun gear shaft seal rings are in position. Lubricate the front sun gear shaft seal ring with Mopar(R) AS68RC ATF.




SUN GEAR SHAFT






30. Lubricate with trans jell or petroleum jelly and install the number eleven thrust bearing (2) and thrust bearing race / washer (3) and the sun gear shaft (1) into the transmission case.




P3 PLANETARY FRONT THRUST BEARING NO. 12

31. Lubricate with trans jell or petroleum jelly and install the number twelve thrust bearing.




P3 PLANETARY CARRIER

32. Install the P3 planetary gear carrier the transmission case.




NO. 13 THRUST BEARING AND WASHER

33. Lubricate with trans jell or petroleum jelly and install the number thirteen thrust bearing and washer.




P3 ANNULUS GEAR

34. Install the P3 planetary annulus gear into the transmission case.




ONE WAY CLUTCH

35. Install a narrow inner F1 one way clutch snap ring into the transmission case.
36. Align the F1 one way clutch to the scribe marks and install the F1 one way clutch into the transmission case.
37. Install a narrow F1 one way clutch outer snap ring into the transmission case.




PARK PAWL 1







NOTE: Install the park brake pawl with spring to pull pawl away from the park brake gear.

38. Install the park brake pawl assembly.




F1 CLUTCH THRUST BEARING NO. 14

39. Lubricate with trans jell or petroleum jelly and install the number fourteen thrust bearing.




PARK LOCK GEAR

40. Install the output shaft / park lock gear assembly into the transmission case.

NOTE: The 4WD extension housing has two selectable end-play washers located fore and aft of the output shaft bearing. The external selectable end-play washer is located between the output shaft bearing and the snap ring.




WASHER AND SPACER






41. Install the spacer (2), so that the spacer covers the lower splines of the output shaft, and install the selectable end play washer (1) onto the output shaft and park lock gear assembly.




4WD EXTENSION HOUSING

42. Install a new output shaft seal into the 2WD extension housing using Installer tool 9985 or Installer tool 9984 for the 4WD extension housing.
43. Install the extension housing with a new gasket, while aligning park brake shaft and the transmission range selector shaft, onto the transmission case.
44. Install and hand tighten the extension housing bolts. On the 4WD extension housing install the outer selectable end play washer and the snap ring.
45. Temporarily install the output shaft flange, O-ring and output shaft nut.

NOTE: End- play readings that are below specification (smaller gap) may indicate that a bearing is out of position or that the transmission might have been set-up incorrectly.

NOTE: The selectable output shaft end-play washers are identified by an alpha numeric numeral stamped onto the face of the washer.




OUTPUT SHAFT END PLAY

46. While the transmission is in a vertical position install the Dial Indicator Set C-3339, using a pry tool measure the output shaft end-play.

The output shaft end-play clearance for both 2WD and 4WD, with the external end-play washer and snap ring removed, is 0.50-0.90 mm (0.019-0.035 in.). On the 4WD extension housing, the output shaft end-play clearance must be performed twice using the dial Indicator set C-3339-A and the 4WD output shaft end-play socket 8266-20, once with the external selectable end-play washer and snap ring removed and a second time with the external selectable end-play washer and snap ring washer in place to achieve a clearance of 0.00 mm - 0.24 mm (0.000-0.009 in.). If the clearance is not within tolerance, choose the correct selectable washer.


2WD and 4WD INTERNAL SELECTABLE END-PLAY WASHERS
- I = 1.00mm (0.039 in.)
- J = 1.20 mm (0.047 in.)
- K = 1.40 mm (0.055 in.)
- L = 1.60 mm (0.063 in.)
- M = 1.80 mm (0.071 in.)
- N = 2.00 mm (0.079 in.)





4WD OUTPUT SHAFT END PLAY







4WD EXTERNAL SELECTABLE END PLAY WASHERS
- I = 1.0 mm (0.039 in.)
- J = 1.20 mm (0.047 in.)
- K = 1.40 mm (0.055 in.)
- L = 1.60 mm (0.063 in.)
- M = 1.80 mm (0.071 in.)
- N = 2.0. mm (0.079 in.)
- O = 2.20 mm (0.087 in.)
- P = 2.40 mm (0.094 in.)

47. Assemble and disassemble as necessary to achieve the correct output shaft end-play clearance.
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