AW60T Automatic Transaxle - Assembly
ASSEMBLY
Special Tools:
1. Install the bell housing side transfer shaft bearing race using (D-146) and (C-4171)
2. Install the bell housing side differential side bearing race using (9617)and (C-4171)
3. Install the case side differential bearing and shim using (8255) and a press.
4. Install the case side transfer shaft bearing race using Race Installer (10312) and (C-4171).
5. Install new O-rings to the 1st gear and reverse brake piston.
6. Install new oil seal rings.
7. Install the needle bearing to the case using an appropriately sized socket.
8. Install the 1st gear and reverse brake piston.
9. Install the C2 clutch thrust washer (1).
10. Install the 1st gear and reverse brake return spring (1).
11. Install the snap ring (1)
12. Install the C2 clutch assembly (1).
13. Install the snap ring.
14. Install the B2 disc pack (1).
15. Install the snap ring (1).
16. Install the thrust washers and thrust bearing.
17. Install the rear planetary carrier and one way clutch as a unit (1 and 2).
18. Install the large and small rear planetary gears (1).
19. Install the snap ring (1)
.
20. Install the output speed sensor (2) and the speed sensor bolt (1). Tighten to Tighten to 6 Nm (53 in.lbs.).
21. Install the counter drive gear assembly (1).
22. Install the counter drive gear assembly bolts. Tighten to 62 Nm (46 ft.lbs.).
23. Install the fluid transfer pipe (2) and install the transfer pipe bolts (1), tighten to 6 Nm (53 in.lbs.).
24. Install the left side counter gear bearing using (C-3717)
.
25. Install the right side counter gear bearing using (C-4040)
.
26. Install the counter gear shaft (2) and the differential (1).
27. Install the new manual lever seal using (10141-5).
28. Install the manual lever (1).
29. Install the plunger to the case.
30. Install the actuator rod (1).
31. Rotate the actuator rod (1) and turn the manual shift lever (2) so the rod key slot and tabs line up, connect.
32. Install the parking pawl (2) and the spring and pivot assembly (1).
33. Install the manual shift shaft the detent (2) and detent bolt (1). Tighten to 10 Nm (89 in.lbs.).
34. Connect the actuator rod (2) to the bracket (3). Install the parking pawl actuator bracket bolts (1). Tighten to 10 Nm (89 in.lbs.).
35. Install the thrust washers (1) and bearings (2).
36. Install the sun gear input drum (1)
.
37. Install the C1 clutch assembly (1).
38. Install the front planetary carrier and input shaft annulus gear assembly (1).
39. Install the B1 brake / C3 clutch assembly (1).
40. Install the nylon thrust washer (1).
41. Install the B1 band (1).
42. Install the B1 band bolt (1). Tighten to 167 Nm (123 ft.lbs.)
43. Install the B1 band servo assembly (1-3), install new O-rings.
44. Install the the oil strainer (2) and bolts (1). Tighten the bolts to 6 Nm (53 in.lbs.)
45. Install the oil pump.
46. Install the oil pump bolts (1). Tighten to 25 Nm (18 ft.lbs.).
47. Check that the input shaft turns smoothly, if not then remove the pump and reinstall.
48. Using a dial indicator, measure the vertical input shaft end play. The end play should be within 0.399-1.131mm (0.016-0.045 in.).
49. Install the tube (3), bolt (1) and retention tab (2). Tighten the bolt to 6 Nm (53 in.lbs.).
50. Install the magnets (1) to the oil reservoir lock plate.
51. Install the oil reservoir lock plate and bolts (1 and 2). Tighten the bolts to 6 Nm (53 in.lbs.).
52. Install the new transmission gasket after coating them with ATF.
53. Apply a uniform bead of MOPAR 3 Bond to the case halves
54. Assemble the case halves.
55. Install the transaxle case bolts. Note that the longer bolts are in positions (1).
56. Install the transaxle case bolts. Tighten to 30 Nm (22 ft.lbs.) following the sequence shown.
57. Install the input speed sensor (2) to the case. Install the input speed sensor bolt (1), Tighten to 6 Nm (53 in.lbs.).
58. Install the external oil cooler Installation.
59. Install the valve body assembly Valve Body - Installation.
60. Install the transmission control module Transmission Control Module - Installation.