Part 1
ASSEMBLY
Special Tools:
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 . AS68RC Transmission
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.
Figure 1 - AS68RC COMPONENTS
Figure 2 - 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.
Figure 3 - SNAP RING ORIENTATION
NOTE: Before final assembly of the transmission a B1 and B2 piston and clutch pack clearance check must be preformed.
Figure 4 - B2 PISTON
1. Lubricate the B2 brake piston seals with MOPAR(R) AS68RC ATF and install the B2 brake piston into the extension housing.
Figure 5 - B2 RETURN SPRING
2. Install the B2 brake piston return spring assembly.
Figure 6 - B2 PISTON COMPRESS
3. Install Bolt (1), Washer (3) and Compressor (2) onto the B2 brake piston assembly and compress the B2 brake piston assembly.
Figure 7 - B2 SNAP RING
4. Install the B2 brake piston snap ring (1).
5. Install the B2 wide snap ring (1).
Figure 9 - B2 CLUTCHES
NOTE: For the B2 brake, only the rear most plate (towards the piston) is selectable. However, the front most pressure plate (towards snap ring), always uses the plate marked "D".
6. Install the 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
Figure 10 - 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 90° Dial Indicator and mounts from the Dial Indicator Set and Extension Tip MLR- 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 compressor plate in order to contact the B2 brake piston.
Figure 11 - B2 AIR CHECK
10. Apply 400-500 kPa (58 - 72 psi) of air to check the B2 brake piston stroke Air Testing Transmission Clutch And Band Operation
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.
Figure 12 - B2 DIAL INDICATOR
11. Move the 90° Dial Indicator and mounts from Dial Indicator Set (1) and extension tip MLR- so that it makes contact with the compressor plate (2).
Figure 13 - B2 AIR CHECK
12. Apply 400 - 500 kPa( 58 - 72 psi) of air to check the B2 brake clutch clearance Air Testing Transmission Clutch And Band Operation
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 compressor plate.
Figure 14 - 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.
Figure 15 - B1 PISTON COMPRESS
19. Install the B1 piston return spring and a wide snap ring into the transmission case using tools and.
Figure 16 - 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.
Figure 17 - 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 and extension tip MLR- so the dial indicator tip contacts the B1 brake piston and check the B1 brake piston assembly stroke.
Figure 18 - B1 AIR CHECK
22. Apply 400-500 kPa (58 - 72 psi) of air to check the B1 brake piston stroke Air Testing Transmission Clutch And Band Operation
The B1 brake piston stroke clearance is 1.55 - 1.80 mm (0.061 - 0.071 in.)
Figure 19 - 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 (1) and extension tip MLR- so the tip makes contact with the B1 brake clutch pack apply 400 - 500 kPa( 58 - 72 psi) of air (2) to check the B1 brake clutch pack clearance Air Testing Transmission Clutch And Band Operation
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 and extension tip MLR-.
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.
Figure 20 - THRUST BEARING AND WASHER ORIENTATION BEHIND BULKHEAD
Figure 21 - 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.
Figure 22 - P2 PLANETARY ANNULUS GEAR
26. Install the B2 clutch pack and a wide snap ring.
27. Install the P2 planetary annulus gear.
Figure 23 - 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.
Figure 24 - 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.
Figure 25 - 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.
Figure 26 - P3 PLANETARY FRONT THRUST BEARING NO. 12
31. Lubricate with trans jell or petroleum jelly and install the number twelve thrust bearing.
Figure 27 - P3 PLANETARY CARRIER
32. Install the P3 planetary gear carrier the transmission case.
Figure 28 - NO. 13 THRUST BEARING AND WASHER
33. Lubricate with trans jell or petroleum jelly and install the number thirteen thrust bearing and washer.
Figure 29 - P3 ANNULUS GEAR
34. Install the P3 planetary annulus gear into the transmission case.
Figure 30 - 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.
Figure 31 - 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.
Figure 32 - F1 CLUTCH THRUST BEARING NO. 14
39. Lubricate with trans jell or petroleum jelly and install the number fourteen thrust bearing.
Figure 33 - PARK LOCK GEAR
40. Install the output shaft / park lock gear assembly into the transmission case.
Figure 34 - WASHER AND SPACER
