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 during reassembly. Soak clutch discs in transmission fluid before installation.


Use petroleum jelly 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 ATF +4. Lubricate servo bore in case with ATF +4.
2. Install rear servo piston (1) in case. Position piston at slight angle to bore and insert piston with twisting motion.




3. Install rear servo spring (1) and retainer (3) in case bore. Be sure spring (1) is seated on piston (2).




4. Compress rear servo piston with C-clamp (2) or Valve Spring Compressor C-3422-B and install servo piston snap-ring (4).




5. Lubricate front servo piston (2) components and servo bore in case with transmission fluid.
6. Install front servo piston (2) in bore. Carefully "run" small, suitable tool (1) 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 (2) guide as follows:
a. Place Tool SP-5560 (or similar size tool) (5) 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 (4).

OVERRUNNING CLUTCH, REAR BAND, AND LOW-REVERSE DRUM





1. Install overrunning clutch components if not yet installed.
2. Position rear band reaction pin and band in case. Be sure that the twin lugs on the band are seated against the reaction pin.
3. Install low-reverse drum. Slide drum through rear band, onto piston retainer hub and into engagement with overrunning clutch and race.
4. Install thrust washer in low-reverse drum spotface (2). Use petroleum jelly to hold washer in place.
5. Install snap-ring (3) that secures low-reverse drum to piston retainer hub.
6. Insert the rear band pivot pin part way into the case.
7. Install rear band adjusting lever and pivot pin. Be sure lever and the single lug on the band are aligned and engaged before seating band pivot pin in case.

PLANETARY GEARTRAIN, FRONT/REAR CLUTCH, AND FRONT BAND





1. Remove Alignment Shaft 6227-2, if installed previously.
2. Install assembled intermediate shaft and planetary geartrain (1) Support shaft carefully during installation. Do not allow shaft bearing/bushing surfaces to become nicked or scratched.




3. Lubricate intermediate shaft thrust plate (1) with petroleum jelly and install plate on shaft pilot hub (2).




4. Check input shaft front seal rings (1), fiber thrust washer (4), and rear seal ring (3). Be sure the 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.




5. Assemble front (1) and rear (2) 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.




6. Install intermediate shaft thrust washer (3) in hub of rear clutch retainer (2). 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 (1).
8. Align discs in rear clutch. Then install and engage assembly (1) in front planetary and driving shell. Turn clutch retainers back and forth until both clutches are seated.




9. Position front band lever (1) 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.
11. Slide front band over front clutch retainer and install front band strut (2) and anchor (3).
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





1. Install oil pump Pilot Studs C-3288-B (2) in case.
2. Install new oil pump gasket (1) on pilot studs and seat it in case. Be sure gasket is properly aligned with fluid passages in case.




3. Coat the reaction shaft thrust washer (1) 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 (2) on one side. Make sure the chamfered side is installed so it faces the pump.




4. Check seal rings (1) on reaction shaft support. Be sure rings are hooked together correctly. Also be sure fiber thrust washer (3) is in position. Use extra petroleum jelly to hold washer in place if necessary.




5. Check the torque converter hub seal ring on the reaction shaft for damage. Also check that the seal ring rotates freely in the reaction shaft groove. Replace the seal if necessary.
6. Lubricate oil pump seals with petroleum Mopar(R) ATF +4.
7. Mount oil pump on pilot studs and slide pump into case opening (1). Work pump into case by hand. Do not use a mallet or similar tools to seat pump.
8. Remove pilot studs (2) 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.
9. Verify correct installation. Rotate input and intermediate shafts and check for bind. If bind exists, components are either mis-assembled, 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. Measure input shaft end play.

NOTE: If end play is incorrect, transmission is incorrectly assembled, or reaction shaft thrust washer is incorrect. The reaction shaft thrust washer is selective.
a. Attach Adapter 8266-5 (2) to Handle 8266-8 (1).
b. Attach Dial Indicator C-3339 (3) to Handle 8266-8 (1).
c. Install the assembled tool onto the input shaft of the transmission and tighten the retaining screw on Adapter 8266-5 to secure it to the input shaft.
d. Position the dial indicator plunger against a flat spot on the oil pump and zero the dial indicator.
e. Move input shaft in and out and record reading. End play should be 0.86 - 2.13 mm (0.034 - 0.084 in.). Adjust as necessary.

ACCUMULATOR, VALVE BODY, OIL PAN, AND TORQUE CONVERTER





1. Install accumulator inner spring (3) (V-10 engine only), piston (1), and outer spring (2) (diesel engine only).




2. Verify that the transmission range sensor has not been installed in case. Valve body can not be installed if sensor is in position.
3. Install new valve body manual shaft seal (2) 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 (1).




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 in. 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 in. 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. Fluid contamination and transmission failure can result if not done.

6. Move the transmission manual shaft lever to the manual LOW position.
7. Install the TRS mounting bracket into the transmission case. Using TRS Mounting Bracket Socket 8581 (3), tighten the mounting bracket (2) to 34 Nm (300 in.lbs.).




8. Install the TRS into the mounting bracket with the wiring connector facing the front of the transmission.
9. Install the two screws to hold the TRS to the mounting bracket. Tighten the screws to 5 Nm (45 in.lbs.).








10. Verify proper sensor operation.
11. Move the transmission manual shaft lever to the PARK position.
12. 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 in. lbs.).
c. Back off front band adjusting screw 1-3/4 turns, for diesel vehicles, or 1-1/2 turns for V-10 vehicles.
d. Back off rear band adjusting screw 3 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 13.6 Nm (125 in. 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.