Disassembly and Assembly
DISASSEMBLY1. Drain fluid from transmission.
2. Clean exterior of transmission with suitable solvent or pressure washer.
3. Remove torque converter from front of transmission.
4. Remove throttle and shift levers from valve body manual shaft and throttle lever shaft.
5. Place transmission in vertical position.
6. Measure and record the input shaft end-play measurement.
Repair Stand:
7. Mount transmission in repair stand C-3750-13 or similar type stand.
8. Remove fluid pan and filter.
Park/Neutral Position Switch:
9. Remove [1][2]park/neutral position switch and seal.
10. Remove valve body and electronic governor.
Accumulator Components Removal:
11. Remove accumulator outer spring, piston and inner spring. Note position of piston and springs for assembly reference. Remove and discard piston seals if worn or cut.
12. Remove pump oil seal with suitable pry tool or slide-hammer mounted screw.
Front Band Lever Pin Access Plug:
13. Remove front band lever pin access plug. Use square end of 1/4 inch drive extension to remove plug as shown.
14. Remove oil pump and reaction shaft support assembly as follows:
Tightening Front Band To Hold Front Clutch In Place:
a. Tighten front band adjusting screw until band is tight around front clutch retainer. This will prevent retainer from coming out with pump and possibly damaging clutch or pump components.
b. Remove oil pump bolts.
Oil Pump Removal Tools:
c. Thread Slide Hammer Tools C-3752 into threaded holes in flange of oil pump housing.
Oil Pump Removal:
d. Remove oil pump and reaction shaft support by bumping slide hammers outward alternately to pull pump from case.
Oil Pump Gasket:
15. Remove oil pump gasket. Note gasket position in case for assembly reference.
16. Loosen front band adjusting screw until band is completely loose.
Front Band Linkage:
17. Remove front band strut and anchor.
Front Band:
18. Squeeze front band together slightly and slide band over front clutch retainer and out of case.
Removing Front/Rear Clutch Assemblies:
19. Remove front and rear clutch assemblies as a unit.
Front Band Lever And Pin:
20. Remove front band reaction pin and lever. Start pin through lever and out of case bore with drift or punch. Then use pencil magnet to withdraw pin completely.
Intermediate Shaft Thrust Washer:
21. Remove intermediate shaft thrust washer. Triangular shaped washer will either be on shaft pilot hub or in rear clutch retainer.
Intermediate Shaft Thrust Plate:
22. Remove thrust plate from intermediate shaft hub.
Intermediate Shaft And Planetary Geartrain:
23. Remove intermediate shaft-planetary geartrain assembly.
24. If overdrive unit is not to be serviced, install Alignment Shaft 6227-2 into the overdrive unit to prevent misalignment of the overdrive clutches during service of main transmission components.
25. Loosen rear band locknut and loosen adjusting screw 3-4 turns.
Low-Reverse Drum Snap Ring:
26. Remove snap ring that retains low-reverse drum on overdrive piston retainer hub.
Low-Reverse Drum And Thrust Washer:
27. Slide low-reverse drum and thrust washer off piston retainer hub and out of rear band.
Overrunning Clutch Race Position On Low-Reverse Drum:
28. Note that overrunning clutch race will remain on splines of low-reverse drum after removal. The race is a permanent press fit on the hub splines. Do not attempt to remove the race.
Overrunning Clutch:
29. Remove overrunning clutch assembly. Assembly can be removed without displacing rollers and springs if care is exercised. Note position of rollers and springs for assembly reference.
Rear Band Levers And Pins:
30. Remove rear band adjusting lever, reaction lever and pin.
31. Remove strut from rear band. Keep strut with levers and pin for cleaning, inspection and assembly reference.
Rear Band And Link:
32. Remove rear band and link.
Front Servo Retaining Snap Ring:
33. Compress front servo rod guide with large C-clamp and Tool C-4470, or Compressor Tool C-3422-B. Compress guide only enough to permit snap ring removal (about 1/8 inch).
34. Remove servo piston snap ring. Unseat one end of ring. Then carefully work removal tool around back of ring until free of ring groove. Exercise caution when removing snap ring. Servo bore can be scratched or nicked if care is not exercised.
Rear Servo Retaining Snap Ring:
35. Remove tools and remove servo piston and spring.
36. Compress rear servo piston with C-clamp and Tool C-4470, or Valve Spring Compressor C-3422-B. Compress servo spring retainer only enough to permit snap ring removal.
37. Remove servo piston snap ring. Start one end of ring out of bore. Then carefully work removal tool around back of snap ring until free of ring groove. Exercise caution when removing snap ring. Servo bore can be scratched or nicked if care is not exercised.
38. Remove tools and remove rear servo retainer, spring and piston assembly.
ASSEMBLY
Do not allow dirt, grease, or foreign material to enter the case or transmission components during assembly. Keep the transmission case and components clean. Also make sure the tools and workbench area used for reassembly operations are equally clean.
Shop towels used for wiping off tools and your hands must be made from lint free materials. Lint will stick to transmission parts and could interfere with valve operation or even restrict fluid passages.
Lubricate transmission clutch and gear components with MOPAR(r) ATF+4, type 9602, during reassembly. Soak clutch discs in transmission fluid before installation.
Use MOPAR(r) Door Ease, or Ru-Glyde on piston seals and O-rings to ease installation. Petroleum jelly can also be used to lubricate and hold thrust washers and plates in position during assembly.
Do not use chassis grease, bearing grease, white grease, or similar lubricants on any part. These types of lubricants can eventually block or restrict fluid passages and valve operation. Use petroleum jelly only.
Do not force parts into place. The transmission components and sub-assemblies are easily installed by hand when properly aligned. If a part seems difficult to install, it is either misaligned or incorrectly assembled. Verify that thrust washers, thrust plates and seal rings are correctly positioned.
The planetary geartrain, front/rear clutch assemblies and oil pump are all much easier to install when the transmission case is upright. Either tilt the case upward with wood blocks, or cut a hole in the bench large enough for the intermediate shaft and rear support. Then lower the shaft and support into the hole and support the rear of the case directly on the bench.
FRONT/REAR SERVO
1. Lubricate rear servo piston seal with MOPAR(r) Door Ease or ATF+4. Lubricate servo bore in case with ATF+4.
Rear Servo Piston:
2. Install rear servo piston in case. Position piston at slight angle to bore and insert piston with twisting motion.
Rear Servo Piston Spring And Retainer:
3. Install rear servo spring and retainer in case bore. Be sure spring is seated on piston.
Rear Servo Snap Ring:
4. Compress rear servo piston with C-clamp or Valve Spring Compressor C-3422-B and install servo piston snap ring.
5. Lubricate front servo piston components and servo bore in case with transmission fluid.
Front Servo Piston:
6. Install front servo piston in bore. Carefully "run" small, suitable tool around piston ring to press it back into groove and ease installation. Rotate piston into bore at same time. Rock piston slightly to ease piston ring past snap ring groove and into bore.
7. Bottom front servo piston in bore and install servo spring.
8. Install front servo piston rod guide as follows:
Front Servo Rod Guide And Snap Ring:
a. Place Tool SP-5560 (or similar size tool) on guide and position C-clamp on tool and case.
b. Slowly compress rod guide while simultaneously easing seal ring into bore with suitable tool.
9. Install rod guide snap ring.
OVERRUNNING CLUTCH, REAR BAND, AND LOW-REVERSE DRUM
1. Install overrunning clutch components if not yet installed.
Rear Band And Link:
2. Position rear band and link in case.
Low-Reverse Drum:
3. Install low-reverse drum. Slide drum through rear band, onto piston retainer hub and into engagement with overrunning clutch and race.
Low-Reverse Drum Snap Ring:
4. Install thrust washer in low-reverse drum spotface. Use petroleum jelly to hold washer in place.
5. Install snap ring that secures low-reverse drum to piston retainer hub.
Rear Band Levers And Strut:
6. Insert band reaction pin part way into case and band link.
Intermediate Shaft And Planetary Geartrain:
7. Install rear band adjusting lever, reaction lever, and strut. Be sure levers and strut are aligned and engaged before seating band reaction pin in case.
PLANETARY GEARTRAIN, FRONT/REAR CLUTCH, AND FRONT BAND
1. Remove Alignment Shaft 6227-2, if installed previously.
Intermediate Shaft And Planetary Geartrain:
2. Install assembled intermediate shaft and planetary geartrain. Support shaft carefully during installation. Do not allow shaft bearing/ bushing surfaces to become nicked or scratched.
Intermediate Shaft Thrust Plate:
3. Lubricate intermediate shaft thrust plate with petroleum jelly and install plate on shaft pilot hub.
Input Shaft Seal Ring And Thrust Washer:
4. Check input shaft front seal rings, fiber thrust washer and rear seal ring. Be ends of rear seal ring are hooked together and diagonal cut ends of front seal rings are firmly seated against each other as shown. Lubricate seal rings with petroleum jelly after checking them.
Assembling Front And Rear Clutches:
5. Assemble front and rear clutches. Align lugs on front clutch discs. Mount front clutch on rear clutch. Turn front clutch retainer back and forth until front clutch discs are fully seated on rear clutch splined hub.
Intermediate Shaft Thrust Washer:
6. Install intermediate shaft thrust washer in hub of rear clutch retainer. Use petroleum jelly to hold washer in place. Position washer so grooves are facing outward. Washer only fits one way in clutch retainer hub.
7. Place transmission case in upright position, or place blocks under front end of transmission repair stand to tilt case rearward. This makes it easier to install front/rear clutch assembly
Front/Rear Clutch Assemblies:
8. Align discs in rear clutch. Then install and engage assembly in front planetary and driving shell. Turn clutch retainers back and forth until both clutches are seated.
9. Position front band lever in case and over servo rod guide. Then install front band lever pin in case and slide it through lever.
10. Coat threads of front band pin access plug with sealer and install it in case. Tighten plug to 17 Nm (13 ft. lbs.) torque.
Front Band And Linkage:
11. Slide front band over front clutch retainer and install front band strut and anchor.
12. Tighten front band adjusting screw until band is tight on clutch retainer. This will hold clutches in place while oil pump is being installed. Verify that front/rear clutch assembly is still properly seated before tightening band.
OIL PUMP
Oil Pump Gasket And Pilot Studs:
1. Install oil pump Pilot Studs C-3288-B in case.
2. Install new oil pump gasket on pilot studs and seat it in case. Be sure gasket is properly aligned with fluid passages in case.
Front Clutch Thrust Washer:
3. Coat front clutch thrust washer with petroleum jelly to hold it in place. Then install washer over reaction shaft hub and seat it on pump.
CAUTION: The thrust washer bore (I.D.), is chamfered on one side. Make sure the chamfered side is installed so it faces the pump.
Reaction Shaft Seal Ring And Thrust Washer:
4. Check seal rings on reaction shaft support. Be sure rings are hooked together correctly. Also be sure fiber thrust washer is in position. Use extra petroleum jelly to hold washer in place if necessary.
5. Lubricate oil pump seals with petroleum MOPAR(r) ATF+4, type 9602.
Oil Pump:
6. Mount oil pump on pilot studs and slide pump into case opening. Work pump into case by hand. Do not use a mallet or similar tools to seat pump.
7. Remove pilot studs and install oil pump bolts. Tighten pump bolts alternately and evenly to fully seat pump in case. Then final-tighten pump bolts to 20 Nm (15 ft. lbs.) torque.
8. Verify correct installation. Rotate input and intermediate shafts and check for bind. If bind exists, components are either misassembled, or not seated. Disassemble and correct as necessary before proceeding.
INPUT SHAFT END PLAY CHECK
NOTE: Overdrive unit must be installed in order to correctly measure the input shaft end-play.
1. Check input shaft end play as follows.
Checking Input Shaft End Play:
2. Attach dial indicator to converter housing. Position indicator plunger against input shaft and zero indicator.
3. Move input shaft in and out and record reading.
4. End play should be 0.86 - 2.13 mm (0.034-0.084 inch).
5. If end play is incorrect, change intermediate shaft thrust washer. The thrust washer controls end play and is available in three thicknesses for adjustment purposes.
ACCUMULATOR, VALVE BODY, OIL PAN, AND TORQUE CONVERTER
Accumulator Piston And Springs:
1. Install accumulator inner spring, piston and outer spring.
2. Verify that [1][2]park/neutral position switch has not been installed in case. Valve body can not be installed if switch is in position.
Manual Lever Shaft Seal:
3. Install new valve body manual shaft seal in case. Lubricate seal lip and manual shaft with petroleum jelly. Start seal over shaft and into case. Seat seal with 15/16 inch, deep well socket.
4. Install valve body as follows:
a. Start park rod into park pawl. If rod will not slide past park pawl, pawl is engaged in park gear. Rotate overdrive output shaft with suitable size 12 point socket; this will free pawl and allow rod to engage.
b. Align and seat valve body on case. Be sure manual lever shaft and overdrive connector are fully seated in case.
c. Install and start all valve body attaching bolts by hand. Then tighten bolts evenly, in a diagonal pattern to 12 Nm (105 inch lbs.) torque. Do not overtighten valve body bolts. This could result in distortion and cross leakage after installation.
5. Install new filter on valve body. Tighten filter screws to 4 Nm (35 inch lbs.).
6. Install seal on [1][2]park/neutral position switch. Then install and tighten switch to 34 Nm (25 ft. lbs.).
CAUTION: If the condition of the transmission before the overhaul procedure caused excessive metallic or fiber contamination in the fluid, replace the torque converter and reverse flush the cooler(s) and cooler lines. Fluid contamination and transmission failure can result if not done.
7. Install torque converter. Use C-clamp or metal strap to hold converter in place for installation.
BAND ADJUSTMENT AND FINAL
1. Adjust front and rear bands as follows:
a. Loosen locknut on each band adjusting screw 4-5 turns.
b. Tighten both adjusting screws to 8 Nm (72 inch lbs.).
c. Back off front band adjusting screw 2-7/8 turns.
d. Back off rear band adjusting screw 2 turns.
e. Hold each adjusting screw in position and tighten locknut to 34 Nm (25 ft. lbs.) torque.
2. Install magnet in oil pan. Magnet seats on small protrusion at corner of pan.
3. Position new oil pan gasket on case and install oil pan. Tighten pan bolts to 17 Nm (13 ft. lbs.).
4. Install throttle valve and shift selector levers on valve body manual lever shaft.
5. Apply small quantity of dielectric grease to terminal pins of solenoid case connector and neutral switch.
6. Fill transmission with recommended fluid. Refer to Service Procedures section.
7. Road test vehicle to verify repair.