Step 31 - 40

ASSEMBLY

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

NOTE: If transaxle is being overhauled (clutch and/or seal replacement), the TCM/PCM Quick Learn procedure must be performed Testing and Inspection.





31. Install bearing cup retainer (2) to transaxle.




32. Install new transfer gear bearing cone (3) to transfer gear (4) using Installer 5052 (5).




33. TRANSFER GEAR BEARING ADJUSTMENT:
a. Install a 4.66 mm (0.183 in.) gauging shim 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.









34. Install the transfer shaft gear (4) using Installer 6261 (2).




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

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




37. 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.
38. Install a bead of Mopar(R) ATF RTV (MS-GF41) (2) to transfer gear cover (1).




39. Use sealant on bolts (3), install transfer gear cover-to-case bolts (1) and torque to 20 Nm (175 in. lbs.) torque.




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