Part 2

ASSEMBLY











25. Install the #7 needle bearing to the rear sun gear. The number 7 needle bearing has three antireversal tabs and is common with the number 5 and number 2 position. The orientation should allow the bearing to seat flat against the rear sun gear. A small amount of petrolatum can be used to hold the bearing to the rear sun gear.










26. Install rear sun gear and #7 needle bearing
.









27. Install front carrier/rear annulus assembly and #6 needle bearing.










28. Install front sun gear assembly and #4 thrust washer.










29. Determine proper #4 thrust plate thickness.
a. Select the thinnest #4 thrust plate thickness.
b. Install #4 thrust plate using petrolatum to hold into position.
c. Install input clutch assembly. Ensure the input clutch assembly is completely seated by viewing position through input speed sensor hole. If the speed sensor tone wheel is not centered in the opening, the input clutch assembly is not seated properly.
d. Remove the oil pump o-ring and install oil pump and gasket to transmission. Tighten the oil pump bolts to 30 Nm (265 in. lbs.). Use screw-in dowels or phillips-head screwdrivers to align pump to case. Be sure to reinstall O-ring on oil pump after selecting the proper No. 4 thrust plate.
e. Measure the input shaft end play with the transmission in the vertical position. This will ensure that the measurement will be accurate.
f. Set up and measure endplay using End Play Set 8266A and Dial Indicator Set C-3339A.
g. Measure input shaft end play. Input shaft end play must be 0.127 to 0.635 mm (0.005 to 0.025 inch). For example, if end play reading is 0.055 inch, select No. 4 Thrust Plate which is 0.071 to 0.074 thick. This should provide an input shaft end play reading of 0.020 inch, which is within specifications.

h. Remove oil pump, gasket, and input clutch assembly to gain access to and install proper #4 thrust plate.









30. Install #1 caged needle bearing.










31. Install input clutch assembly with proper thrust plate.










CAUTION: By-pass valve MUST be replaced if transmission failure occurs.

32. Replace cooler by-pass valve if transmission failure has occurred.










NOTE: To align oil pump, gasket, and case during installation, use threaded dowels or phillips screwdrivers.

33. Install oil pump gasket.










NOTE: Do not reuse original oil pump bolts.

34. Install oil pump and torque the new oil pump-to-case bolts to 30 Nm (265 in. lbs.).










35. Install low/reverse accumulator.










36. Install low/reverse accumulator plug.










37. Install low/reverse accumulator snap ring.










38. Install underdrive and overdrive accumulators and springs.










CAUTION: Do not handle the valve body by the manual shaft. Damage could result.

39. Install valve body into place.



















40. Install seven (7) valve body-to-case bolts and torque to 12 Nm (105 in. lbs.).










NOTE: Before installing the oil pan bolt in the bolt hole located between the torque converter clutch on and U/D clutch pressure tap circuits , it will be necessary to replentish the sealing patch on the bolt using Mopar(R) Lock AND Seal Adhesive.

41. Install transmission oil filter. Tighten the bolts to 5 Nm (45 in. lbs.)










42. Install transmission oil pan with a bead of Mopar(R) ATF RTV. Torque oil pan-to-case bolts to 20 Nm (14.5 ft. lbs.).










NOTE: Before installing either speed sensor bolt,it will be necessary to replenish the sealing patch on the bolt using Mopar(R) Lock AND Seal Adhesive.

43. Install both speed sensors into transmission case. Torque the speed sensor bolts to 9 Nm (80 in. lbs.).










44. As a final check of the transmission, measure the input shaft end play. This will indicate when a #4 thrust plate change is required. The #4 thrust plate is located behind the overdrive clutch hub. Attach a dial indicator to transmission bell housing with its plunger seated against end of input shaft. Move input shaft in and out to obtain end play reading. Input shaft end play must be 0.127 to 0.635 mm (0.005 to 0.025 inch). If not within specifications, make the necessary thrust plate adjustment.










45. Inspect the lube tube grommet for damage. If the grommet lip is damaged, it will need to be replaced.










46. Install the 4X4 stub shaft onto the transmission output shaft.
47. Place a bead of Mopar(R) ATF RTV on the rear surface of the transmission case for the adapter housing.
48. Install the adapter housing onto the transmission case.










NOTE: Before installing the lowermost four adapter housing bolts,it will be necessary to replenish the sealing patch on the bolts using Mopar(R) Lock AND Seal Adhesive.











49. Install the bolts that hold the adapter housing onto the transmission case. Be sure to install any stud bolts to their original locations. Tighten the bolts to 54 Nm (40 ft.lbs.).