Part 3
ASSEMBLY - Continued
46. Remove oil pump, gasket, and input clutch assembly to gain access to and install proper #4 thrust plate.
47. Install input clutch assembly (1) with proper thrust plate(Figure 40).
48. Install #1 caged needle bearing (1)(Figure 41).
CAUTION: By-pass valve MUST be replaced if transmission failure occurs.
49. Replace cooler by-pass valve (1) (Figure 42) if transmission failure has occurred.
NOTE: To align oil pump, gasket, and case during installation, use threaded dowels or Phillips screwdrivers.
50. Install oil pump gasket (2)(Figure 43).
51. Install oil pump (2) (Figure 44) and torque oil pump-to-case bolts (1) to 30 Nm (265 in. lbs.). Do not reuse original oil pump bolts.
52. Install low/reverse accumulator (1) (Figure 45) as shown.
53. Install low/reverse accumulator plug (2)(Figure 46).
54. Install low/reverse accumulator snap ring (1)(Figure 47).
55. Install underdrive (2) and overdrive (1) accumulators and springs(Figure 48).
CAUTION: Do not handle the valve body by the manual shaft. Damage could result.
56. Install valve body (1) (Figure 49) into place as shown.
57. Install seven (7) valve body-to-case bolts (1)(Figure 50) and torque to 12 Nm (105 in. lbs.).
58. Install transmission oil filter (1)(Figure 51). Tighten the bolts to 5 Nm (45 in. lbs.).
59. Install transmission oil pan (1) (Figure 52) with a bead of Mopar(R) ATF RTV.
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 (Figure 53), it will be necessary to replenish the sealing patch on the bolt using Mopar(R) Lock AND Seal Adhesive.
60. Install and torque the 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.
61. Install both speed sensors (1, 2) (Figure 54) into the transmission case. Torque the speed sensor bolts to 9 Nm (80 in. lbs.).
62. 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 (Figure 55). Install tool (2), (1) and 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.
63. On 4X2 transmissions, perform the following, if necessary:
a.
Install the extension shaft bearing (2)(Figure 56) onto the extension shaft.
b.
Install the extension shaft bearing retaining ring (3) (Figure 57) onto the extension shaft (1).
c.
Install the extension shaft (2) and bearing assembly (3) (Figure 58) into the extension housing (1).
d.
Install the extension shaft bearing snap ring (3) (Figure 59) into the extension housing.
e.
Verify that the extension shaft snap ring (3) (Figure 60) is fully engaged in the snap ring groove.
64. Inspect the lube tube grommet (2) (Figure 61) for damage. If the grommet lip is damaged, it will need to be replaced.
65. Install the 4X4 stub shaft onto the transmission output shaft.
66. Place a bead of Mopar(R) ATF RTV on the rear surface of the transmission case for the adapter/extension housing.
67. Install the adapter (Figure 62) housing (2) onto the transmission case, 4X4 vehicles only.
68. Install the extension (Figure 63) housing (2) onto the transmission case, 4X2 vehicles only.
NOTE: Before installing the lowermost four adapter/extension housing bolts, it will be necessary to replenish the sealing patch on the bolts using Mopar(R) Lock AND Seal Adhesive.
69. Install the bolts (Figure 65) that hold the adapter or extension 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.).