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40TE Automatic Transaxle: Assembly

WARNING: This page is about a different car, the 2005 Dodge Stratus and 2005 Chrysler Sebring. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: The cooler bypass valve must be replaced if transaxle failure has occurred. Do not attempt to reuse or clean old valve.
NOTE: If transaxle is being overhauled (clutch and/or seal replacement), the TCM/PCM Quick Learn procedure must be performed. (Refer to STANDARD PROCEDURE )
  1. Install both output bearing cups using Tool 5050. See Fig 1.
    Fig 1: Install Both Output Bearing Cups
    GC0020477Courtesy of DAIMLERCHRYSLER CORP.
    1 - OUTPUT BEARING CUPS
    2 - WRENCHES
    3 - TOOL 5050
  2. Install low/reverse piston retainer gasket. See Fig 2. Make sure gasket holes line up with case.
    Fig 2: Install Piston Retainer Gasket
    GC0020478Courtesy of DAIMLERCHRYSLER CORP.
    1 - GASKET HOLES MUST LINE UP
    2 - LOW/REVERSE CLUTCH PISTON RETAINER GASKET
  3. Install low/reverse piston retainer. See Fig 3.
    Fig 3: Install Piston Retainer
    GC0020479Courtesy of DAIMLERCHRYSLER CORP.
    1 - LOW/REVERSE CLUTCH PISTON RETAINER
    2 - GASKET
  4. Install low/reverse piston retainer-to-case bolts and torque to 5 N.m (45 in. lbs.). See Fig 4.
    Fig 4: Install Piston Retainer-to-Case Screws
    GC0020480Courtesy of DAIMLERCHRYSLER CORP.
    1 - LOW/REVERSE CLUTCH PISTON RETAINER
    2 - SCREWDRIVER
    3 - TORX-LOC SCREWS
    NOTE: The Low/Reverse Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.
  5. Install low/reverse clutch piston. See Fig 5.
    Fig 5: Install Low/Reverse Clutch Piston
    GC0020481Courtesy of DAIMLERCHRYSLER CORP.
    1 - LOW/REVERSE CLUTCH PISTON
    2 - BONDED SEAL
    3 - BONDED SEAL
  6. Assemble park guide bracket assembly. See Fig 7. See Fig 6.
    Fig 6: Guide Bracket Disassembled
    GC0020482Courtesy of DAIMLERCHRYSLER CORP.
    1 - ANTIRATCHET SPRING
    2 - GUIDE BRACKET
    3 - SPLIT SLEEVE
    4 - SPACER
    5 - PAWL
    6 - STEPPED SPACER
    Fig 7: Guide Bracket
    GC0020483Courtesy of DAIMLERCHRYSLER CORP.
    1 - GUIDE BRACKET
    2 - ANTIRATCHET SPRING (MUST BE ASSEMBLED AS SHOWN)
    3 - PAWL
  7. Install guide bracket into position and insert pivot shaft. See Fig 8.
    Fig 8: Pivot Shaft and Guide Bracket
    GC0020484Courtesy of DAIMLERCHRYSLER CORP.
    1 - ANTIRACHET SPRING
    2 - GUIDE BRACKET
    3 - PIVOT SHAFT
    4 - PAWL
  8. Install anchor shaft and plug. See Fig 9. Make sure guide bracket and split sleeve are in contact with the rear of the transaxle case.
    Fig 9: Install Anchor Shaft and Plug
    GC0020486Courtesy of DAIMLERCHRYSLER CORP.
    1 - GUIDE BRACKET ANCHOR SHAFT
    2 - PIVOT SHAFT
    3 - ANCHOR SHAFT PLUG
  9. Install low/reverse piston return spring. See Fig 10.
    Fig 10: Low/Reverse Piston Return Spring
    GC0020487Courtesy of DAIMLERCHRYSLER CORP.
    1 - LOW/REVERSE PISTON RETURN SPRING
    2 - PISTON
  10. Install low/reverse spring compressor into position. See Fig 11. Compress low/reverse piston and install snap ring as shown in Fig 12.
    Fig 11: Compressor Tool in Use
    GC0020489Courtesy of DAIMLERCHRYSLER CORP.
    1 - LOW/REVERSE CLUTCH RETURN SPRING
    2 - SNAP RING (INSTALL AS SHOWN)
    3 - TOOL 6057
    4 - TOOL 5059
    5 - TOOL 5058-3
    Fig 12: Install Snap Ring
    GC0020490Courtesy of DAIMLERCHRYSLER CORP.
    1 - SNAP RING OPENING MUST BE BETWEEN SPRING LEVERS (AS SHOWN)
    2 - SNAP RING PLIERS
    3 - TOOL 6057
  11. Install rear carrier bearing cone using Tool 6053. See Fig 13.
    Fig 13: Install Rear Carrier Bearing Cone
    GC0020491Courtesy of DAIMLERCHRYSLER CORP.
    1 - ARBOR PRESS RAM
    2 - TOOL 6053
    3 - NEW BEARING CONE
    4 - REAR CARRIER ASSEMBLY
  12. Install rear carrier assembly to transaxle case. See Fig 14.
    Fig 14: Install Rear Carrier Assembly
    GC0020492Courtesy of DAIMLERCHRYSLER CORP.
    1 - REAR CARRIER ASSEMBLY
  13. Install output gear bearing cone using Tool 5052. See Fig 15.
    Fig 15: Install Output Gear Bearing Cone
    GC0020493Courtesy of DAIMLERCHRYSLER CORP.
    1 - ARBOR PRESS RAM
    2 - HANDLE C-4171
    3 - TOOL 5052
    4 - OUTPUT GEAR
  14. OUTPUT GEAR BEARING ADJUSTMENT: 
    • With output gear Installed, install a 4.50 mm (0.177 in.) gauging shim on the rear carrier assembly hub, using grease to hold the shim in place. See Fig 17.
    • Using Tool 6259, install output gear and bearing assembly. Torque to 271 N.m (200 ft. lbs.).
    • Measure bearing end play. Attach Tool L-4432 to the gear. See Fig 16.
    • Push and pull the gear while rotating back and forth to ensure seating of bearing rollers.
    • Using a dial indicator mounted to the transaxle case, measure output gear end play as shown in Fig 16.
    • Refer to the output gear bearing shim chart for the required shim to obtain proper bearing setting.
    • Use Tool 6259 to remove the output gear retaining bolt and washer. To remove the output gear, use Tool L4407A.
    • Remove the gauging shim and install the proper shim determined by the chart. Use grease to hold the shim in place.
    Fig 16: Checking Output Gear Bearings End Play
    GC0020494Courtesy of DAIMLERCHRYSLER CORP.
    1 - TOOL L-4432
    2 - DIAL INDICATOR
    3 - SPECIAL SCREWS TOOL 6260
    4 - OUTPUT GEAR
    Fig 17: Output Gear and (Select) Shim
    GC0020495Courtesy of DAIMLERCHRYSLER CORP.
    1 - REAR CARRIER ASSEMBLY
    2 - SHIM (SELECT)
    3 - OUTPUT GEAR
    OUTPUT GEAR BEARING SHIM CHART

    End Play Shim Needed Part Number
    0.05mm (0.002 in.) 4.42mm (0.174 in.) 4412830AB
    0.08mm (0.003 in.) 4.38mm (0.172 in.) 4412829AB
    0.10mm (0.004 in.) 4.38mm (0.172 in.) 4412829AB
    0.13mm (0.005 in.) 4.34mm (0.171 in.) 4412828AB
    0.15mm (0.006 in.) 4.30mm (0.169 in.) 4412827AB
    0.18mm (0.007 in.) 4.30mm (0.169 in.) 4412827AB
    0.20mm (0.008 in.) 4.26mm (0.168 in.) 4412826AB
    0.23mm (0.009 in.) 4.22mm (0.166 in.) 4412825AB
    0.25mm (0.010 in.) 4.22mm (0.166 in.) 4412825AB
    0.28mm (0.011 in.) 4.18mm (0.165 in.) 4412824AB
    0.30mm (0.012 in.) 4.14mm (0.163 in.) 4412823AB
    0.33mm (0.013 in.) 4.14mm (0.163 in.) 4412823AB
    0.36mm (0.014 in.) 4.10mm (0.161 in.) 4412822AB
    0.38mm (0.015 in.) 4.10mm (0.161 in.) 4412822AB
    0.41mm (0.016 in.) 4.06mm (0.160 in.) 4412821AB
    0.43mm (0.017 in.) 4.02mm (0.158 in.) 4412820AB
    0.46mm (0.018 in.) 4.02mm (0.158 in.) 4412820AB
    0.48mm (0.019 in.) 3.98mm (0.157 in.) 4412819AB
    0.51mm (0.020 in.) 3.94mm (0.155 in.) 4412818AB
    0.53mm (0.021 in.) 3.94mm (0.155 in.) 4412818AB
    0.56mm (0.022 in.) 3.90mm (0.154 in.) 4412817AB
    0.58mm (0.023 in.) 3.90mm (0.154 in.) 4412817AB
    0.61mm (0.024 in.) 3.86mm (0.152 in.) 4412816AB
    0.64mm (0.025 in.) 3.82mm (0.150 in.) 4412815AB
    0.66mm (0.026 in.) 3.82mm (0.150 in.) 4412815AB
    0.69mm (0.027 in.) 3.78mm (0.149 in.) 4412814AB
    0.71mm (0.028 in.) 3.74mm (0.147 in.) 4412813AB
    0.74mm (0.029 in.) 3.74mm (0.147 in.) 4412813AB
    0.76mm (0.030 in.) 3.70mm (0.146 in.) 4412812AB
    0.79mm (0.031 in.) 3.66mm (0.144 in.) 4412811AB
    0.81mm (0.032 in.) 3.66mm (0.144 in.) 4412811AB
    0.84mm (0.033 in.) 3.62mm (0.143 in.) 4412810AB
    0.86mm (0.034 in.) 3.62mm (0.143 in.) 4412810AB
    0.89mm (0.035 in.) 3.58mm (0.141) 4412809AB
    0.91mm (0.036 in.) 3.54mm (0.139 in.) 4412808AB
    0.94mm (0.037 in.) 3.54mm (0.139 in.) 4412808AB
    0.97mm (0.038 in.) 3.50mm (0.138 in.) 4412807AB
  15. Install the output gear and bearing assembly using Tool 6261. See Fig 18.
    Fig 18: Install Output Gear
    GC0020496Courtesy of DAIMLERCHRYSLER CORP.
    1 - WRENCHES
    2 - TOOL 6261 WITH STUD
    3 - OUTPUT GEAR
  16. Install NEW output gear retaining bolt and washer. See Fig 19. Using Tool 6259, torque output gear retaining bolt to 271 N.m (200 ft. lbs.). See Fig 20.
    Fig 19: Output Gear Bolt and Washer
    GC0020497Courtesy of DAIMLERCHRYSLER CORP.
    1 - OUTPUT GEAR
    2 - BOLT
    3 - CONED LOCK WASHER
    Fig 20: Tighten Output Gear to 271 N*m (200 ft. lbs.)
    GC0020498Courtesy of DAIMLERCHRYSLER CORP.
    1 - OUTPUT GEAR
    2 - TORQUE WRENCH
    3 - 200 FT. LBS.
    4 - TOOL 6259
  17. Using an inch pound torque wrench, check output shaft turning torque. See Fig 21.Output shaft turning torque should be within 3-8 in. lbs.  If the turning torque is too high, install a 0.04 mm (0.0016 in.) thicker shim. If the turning torque is too low, install a 0.04 mm (0.0016 in.) thinner shim. Repeat until the proper turning torque of 3-8 in. lbs. is obtained.
    Fig 21: Check Output Gear Bearings Turning Torque
    GC0020499Courtesy of DAIMLERCHRYSLER CORP.
    1 - INCH-POUND TORQUE WRENCH
    2 - OUTPUT GEAR
  18. Install output gear stirrup with serrated side out. See Fig 22.
    Fig 22: Install Stirrup
    GC0020500Courtesy of DAIMLERCHRYSLER CORP.
    1 - STIRRUP
    2 - OUTPUT GEAR RETAINING BOLT
  19. Install retaining strap. See Fig 23.
  20. Install strap bolts but do not tighten at this time. See Fig 23.
    Fig 23: Install Strap Bolts
    GC0020501Courtesy of DAIMLERCHRYSLER CORP.
    1 - RETAINING STRAP
    2 - STIRRUP
    3 - RETAINING STRAP BOLTS
  21. Rotate stirrup clockwise against flats of retaining bolt. See Fig 24.
    Fig 24: Turn Stirrup Clockwise Against Flats Of Output Gear Retaining Bolt
    GC0020502Courtesy of DAIMLERCHRYSLER CORP.
    1 - RETAINING STRAP
    2 - STIRRUP
  22. Torque stirrup strap bolts to 23 N.m (200 in. lbs.). See Fig 25.
    Fig 25: Tighten Stirrup Strap Bolts to 23 N.m (200 in. lbs.)
    GC0020505Courtesy of DAIMLERCHRYSLER CORP.
    1 - RETAINING STRAP
    2 - STIRRUP
  23. Bend tabs on strap up against flats of bolts. See Fig 26.
    Fig 26: Bend Tabs On Strap Up Against Flats Of Bolts
    GC0020504Courtesy of DAIMLERCHRYSLER CORP.
    1 - RETAINING STRAP TABS
    2 - RETAINING STRAP
    3 - STIRRUP
  24. Install transfer shaft bearing cone using Tool 6052. See Fig 27.
    Fig 27: Install Transfer Shaft Bearing Cone
    GC0020506Courtesy of DAIMLERCHRYSLER CORP.
    1 - TOOL 6052
    2 - NEW BEARING CONE
    3 - TRANSFER SHAFT
    4 - ARBOR PRESS RAM
  25. Install bearing cup and oil baffle to transfer shaft. See Fig 28.
    Fig 28: Install Bearing Cup to Shaft
    GC0020507Courtesy of DAIMLERCHRYSLER CORP.
    1 - BEARING CUP
    2 - BEARING CONE
    3 - TRANSFER SHAFT
    4 - OIL BAFFLE
    5 - O-RING
  26. Using Tool 5049A, install transfer shaft. See Fig 29.
    Fig 29: Install Transfer Shaft
    GC0020508Courtesy of DAIMLERCHRYSLER CORP.
    1 - SPECIAL TOOL 5049-A
    2 - TRANSFER SHAFT
    3 - OUTPUT GEAR
  27. Using Tool 6051, install transfer shaft bearing snap ring. See Fig 30.
    Fig 30: Install Transfer Shaft Bearing Snap Ring
    GC0020509Courtesy of DAIMLERCHRYSLER CORP.
    1 - SNAP RING PLIERS TOOL 6051
    2 - TRANSFER SHAFT BEARING SNAP RING
    3 - TRANSFER SHAFT
  28. Install transfer shaft bearing cup into retainer using Tool 6061. See Fig 31.
    Fig 31: Install Transfer Shaft Bearing Cup Into Retainer
    GC0020510Courtesy of DAIMLERCHRYSLER CORP.
    1 - ARBOR PRESS RAM
    2 - HANDLE C-4171
    3 - TOOL 6061
    4 - TRANSFER SHAFT BEARING CUP RETAINER
    5 - USE REMOVED BEARING CUP TO SUPPORT RETAINER
  29. Install bearing cup retainer to transaxle. See Fig 32.
    Fig 32: Install Bearing Cup Retainer
    GC0020511Courtesy of DAIMLERCHRYSLER CORP.
    1 - ALIGN INDEXING TAB TO SLOT
    2 - BEARING CUP RETAINER
  30. Install transfer gear bearing cone to transfer gear using Tool 5052. See Fig 33.
    Fig 33: Install Transfer Gear Bearing Cone
    GC0020512Courtesy of DAIMLERCHRYSLER CORP.
    1 - ARBOR PRESS RAM
    2 - HANDLE C-4171
    3 - NEW BEARING CONE
    4 - TRANSFER SHAFT GEAR
    5 - TOOL 5052
  31. TRANSFER GEAR BEARING ADJUSTMENT: 
    • Install a 4.66 mm (0.184 in.) gauging shim on the transfer shaft. See Fig 34.
    • Install transfer shaft gear using Tool 6261. Using Tool 6259, install transfer shaft gear retaining nut to 271 N.m (200 ft. lbs.).
    • Measure end play. Attach Tool L4432 to the transfer gear.
    • Mount a steel ball with grease into the end of the transfer shaft.
    • Push and pull the gear while rotating back and forth to ensure seating of the bearing rollers.
    • Using a dial indicator, measure transfer shaft end play.
    • Refer to the transfer shaft bearing shim chart for the required shim combination to obtain the proper bearing setting.
    • Use Tool 6259 to remove the retaining nut and washer. Remove the transfer shaft gear using Tool L4407A.
    • Remove the gauging shim and install the proper shim indicated by the chart. See Fig 34.
    Fig 34: Install Transfer Shaft Gear and (Select) Shim
    GC0020513Courtesy of DAIMLERCHRYSLER CORP.
    1 - TRANSFER SHAFT GEAR
    2 - BEARING CUP RETAINER
    3 - SHIM (SELECT)
    TRANSFER SHAFT BEARING SHIM CHART

    End Play Shim Needed Part Number
    0.05mm (0.002 in.) 4.66mm (0.183 in.) 4505588AB
    0.08mm (0.003 in.) 4.62mm (0.182 in.) 4412835AB
    0.10mm (0.004 in.) 4.58mm (0.180 in.) 4412834AB
    0.13mm (0.005 in.) 4.58mm (0.180 in.) 4412834AB
    0.15mm (0.006 in.) 4.54mm (0.178 in.) 4412833AB
    0.18mm (0.007 in.) 4.50mm (0.177 in.) 4412832AB
    0.20mm (0.008 in.) 4.50mm (0.177 in.) 4412832AB
    0.23mm (0.009 in.) 4.46mm (0.175 in.) 4412831AB
    0.25mm (0.010 in.) 4.46mm (0.175 in.) 4412831AB
    0.28mm (0.011 in.) 4.42mm (0.174 in.) 4412830AB
    0.30mm (0.012 in.) 4.38mm (0.172 in.) 4412829AB
    0.33mm (0.013 in.) 4.38mm (0.172 in.) 4412829AB
    0.36mm (0.014 in.) 4.34mm (0.171 in.) 4412828AB
    0.38mm (0.015 in.) 4.30mm (0.169 in.) 4412827AB
    0.41mm (0.016 in.) 4.30mm (0.169 in.) 4412827AB
    0.43mm (0.017 in.) 4.26mm (0.168 in.) 4412826AB
    0.46mm (0.018 in.) 4.22mm (0.166 in.) 4412825AB
    0.48mm (0.019 in.) 4.22mm (0.166 in.) 4412825AB
    0.50mm (0.020 in.) 4.18mm (0.165 in.) 4412824AB
    0.53mm (0.021 in.) 4.18mm (0.165 in.) 4412824AB
    0.56mm (0.022 in.) 4.14mm (0.163 in.) 4412823AB
    0.58mm (0.023 in.) 4.10mm (0.161 in.) 4412822AB
    0.61mm (0.024 in.) 4.10mm (0.161 in.) 4412822AB
    0.64mm (0.025 in.) 4.06mm (0.160 in.) 4412821AB
    0.66mm (0.026 in.) 4.02mm (0.158 in.) 4412820AB
    0.69mm (0.027 in.) 4.02mm (0.158 in.) 4412820AB
    0.71mm (0.028 in.) 3.98mm (0.157 in.) 4412819AB
    0.74mm (0.029 in.) 3.94mm (0.155 in.) 4412818AB
    0.76mm (0.030 in.) 3.94mm (0.155 in.) 4412818AB
    0.79mm (0.031 in.) 3.90mm (0.154 in.) 4412817AB
    0.81mm (0.032 in.) 3.90mm (0.154 in.) 4412817AB
    0.84mm (0.033 in.) 3.86mm (0.152 in.) 4412816AB
    0.86mm (0.034 in.) 3.82mm (0.150 in.) 4412815AB
    0.89mm (0.035 in.) 3.82mm (0.150 in.) 4412815AB
    0.91mm (0.036 in.) 3.78mm (0.149 in.) 4412814AB
    0.94mm (0.037 in.) 3.74mm (0.147 in.) 4412813AB
    0.97mm (0.038 in.) 3.74mm (0.147 in.) 4412813AB
    0.99mm (0.039 in.) 3.70mm (0.146 in.) 4412812AB
    1.02mm (0.040 in.) 3.66mm (0.144 in.) 4412811AB
    1.04mm (0.041 in.) 3.66mm (0.144 in.) 4412811AB
    1.07mm (0.042 in.) 3.62mm (0.143 in.) 4412810AB
    1.08mm (0.043 in.) 3.62mm (0.143 in.) 4412810AB
    1.12mm (0.044 in.) 3.58mm (0.141) 4412809AB
    1.14mm (0.045 in.) 3.54mm (0.139 in.) 4412808AB
    1.17mm (0.046 in.) 3.54mm (0.139 in.) 4412808AB
    1.19mm (0.047 in.) 3.50mm (0.138 in.) 4412807AB
    1.22mm (0.048 in.) 3.46mm (0.136 in.) 4412806AB
    1.24mm (0.049 in.) 3.46mm (0.136 in.) 4412806AB
    1.27mm (0.050 in.) 3.42mm (0.135 in.) 4412805AB
    1.30mm (0.051 in.) 3.38mm (0.133 in.) 4412804AB
    1.32mm (0.052 in.) 3.38mm (0.133 in.) 4412804AB
    1.35mm (0.053 in.) 3.34mm (0.132 in.) 4412803AB
    1.37mm (0.054 in.) 3.34mm (0.132 in.) 4412803AB
    1.40mm (0.055 in.) 3.30mm (0.130 in.) 4412802AB
    1.45mm (0.057 in.) 3.26mm (0.128 in.) 4412801AB
    1.47mm (0.058 in.) 2.22mm (0.127 in.) 4505570AB
  32. Install the transfer shaft gear using Tool 6261. See Fig 35.
    Fig 35: Install Transfer Shaft Gear
    GC0020514Courtesy of DAIMLERCHRYSLER CORP.
    1 - WRENCHES
    2 - SPECIAL TOOL 6261
    3 - OUTPUT GEAR
    4 - TRANSFER SHAFT GEAR
    CAUTION: Install a NEW retaining nut, as the original nut MUST NOT be reused.
  33. Install the new retaining nut and washer.
  34. Using Tool 6259, torque transfer gear retaining nut to 271 N.m (200 ft. lbs.). See Fig 36.
    Fig 36: Tighten Nut to 271 N*m (200 ft. lbs.)
    GC0020553Courtesy of DAIMLERCHRYSLER CORP.
    1 - TRANSFER SHAFT GEAR
    2 - 200 FT. LBS.
    3 - TORQUE WRENCH
    4 - SPECIAL TOOL 6259
  35. Measure transfer shaft end play. Transfer shaft end play should be within 0.05-0.10 mm (0.002-0.004 in.).  If the end play is too high, install a 0.04 mm (0.0016 in.) thicker shim. If the end play is too low, install a 0.04 mm (0.0016 in.) thinner shim. Repeat until 0.05-0.10 mm (0.002-0.004 in.) end play is obtained.
  36. Install a bead of Mopar(R) ATF RTV (MS-GF41) to transfer gear cover. See Fig 37.
    Fig 37: Install Rear Cover
    GC0020515Courtesy of DAIMLERCHRYSLER CORP.
    1 - REAR COVER
    2 - 1/8 INCH BEAD OF MOPAR(R) ATF RTV (MS-GF41) AS SHOWN
  37. Install transfer gear cover-to-case bolts and torque to 20 N.m (175 in. lbs.) torque. See Fig 38.
    Fig 38: Install Rear Cover Bolts
    GC0020516Courtesy of DAIMLERCHRYSLER CORP.
    1 - REAR COVER BOLTS
    2 - REAR COVER
    3 - USE SEALANT ON BOLTS
  38. Install low/reverse clutch pack. See Fig 39. Leave uppermost disc out until snap ring is installed.
    Fig 39: Removing/Installing Low/Reverse Clutch
    GC0020475Courtesy of DAIMLERCHRYSLER CORP.
    1 - CLUTCH PLATE
    2 - CLUTCH DISC
  39. Install low/reverse reaction plate flat snap ring. See Fig 40.
    Fig 40: Install Low/Reverse Reaction Plate Snap Ring
    GC0020517Courtesy of DAIMLERCHRYSLER CORP.
    1 - SCREWDRIVER
    2 - LOW/REVERSE REACTION PLATE FLAT SNAP RING
    3 - DO NOT SCRATCH CLUTCH PLATE
  40. Install remaining low/reverse clutch disc. See Fig 41.
    Fig 41: Install One Disc
    GC0020518Courtesy of DAIMLERCHRYSLER CORP.
    1 - ONE DISC FROM LOW/REVERSE CLUTCH
  41. Install low/reverse reaction plate with flat side up. See Fig 42.
    Fig 42: Install Low/Reverse Reaction Plate
    GC0020519Courtesy of DAIMLERCHRYSLER CORP.
    1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP)
  42. Install tapered snap ring (with tapered side up) as shown in Fig 43. See Fig 44.
    Fig 43: Tapered Snap Ring Instructions
    GC0020556Courtesy of DAIMLERCHRYSLER CORP.
    Fig 44: Snap Ring Installed
    GC0020521Courtesy of DAIMLERCHRYSLER CORP.
    1 - SCREWDRIVER
    2 - TAPERED SNAP RING (INSTALL AS SHOWN)
  43. Set up dial indicator as shown in Fig 45 to measure low/reverse clutch clearance. Press down on clutch pack with finger and zero dial indicator. Low/Reverse clutch pack clearance is 0.89-1.47 mm (0.035-0.058 in.)  . Set up indicator and record measurement in four (4) places. Take average of readings and select the proper low/reverse reaction plate to achieve specifications.
    Fig 45: Check Low/Reverse Clutch Clearance
    GC0020522Courtesy of DAIMLERCHRYSLER CORP.
    1 - DIAL INDICATOR
    2 - DIAL INDICATOR TIP TOOL 6268
    3 - HOOK TOOL
    LOW/REVERSE REACTION PLATE CHART

    PART NUMBER THICKNESS
    4799846AA 5.88 mm (0.232 in.)
    4799847AA 6.14 mm (0.242 in.)
    4799848AA 6.40 mm (0.252 in.)
    4799849AA 6.66 mm (0.262 in.)
    4799855AA 6.92 mm (0.273 in.)
  44. Install 2/4 clutch pack. See Fig 46.
    Fig 46: Removing/Installing 2/4 Clutch
    GC0020476Courtesy of DAIMLERCHRYSLER CORP.
    1 - CLUTCH DISC
    2 - CLUTCH PLATE
    NOTE: The 2/4 Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.
  45. Orient 2/4 clutch return spring to retainer as shown in Fig 47, and install to transaxle. See Fig 48.
    Fig 47: Proper Orientation of 2/4 Clutch Retainer and Spring
    GC0020525Courtesy of DAIMLERCHRYSLER CORP.
    1 - NOTE POSITION
    2 - RETURN SPRING
    3 - 2/4 CLUTCH RETAINER
    Fig 48: 2/4 Clutch Retainer
    GC0020526Courtesy of DAIMLERCHRYSLER CORP.
    1 - 2/4 CLUTCH RETAINER
    2 - 2/4 CLUTCH RETURN SPRING
  46. Using tool 5058, compress 2/4 clutch return spring just enough to install snap ring. See Fig 49.
    Fig 49: Install 2/4 Clutch Retainer Snap Ring
    GC0020527Courtesy of DAIMLERCHRYSLER CORP.
    1 - TOOL 5058
    2 - SCREWDRIVER
    3 - SNAP RING
    4 - 2/4 CLUTCH RETAINER
  47. Install snap ring.
  48. Set up dial indicator as shown in Fig 50 and measure 2/4 clutch clearance. Press down on clutch pack with finger and zero dial indicator. 2/4 clutch pack clearance is 0.76-2.64 mm (0.030-0.104 in.).  Set up indicator and record measurement in four (4) places. Take average of readings. If clearance is outside this range, the clutch is assembled improperly. There is no adjustment for 2/4 clutch clearance. 
    Fig 50: Check 2/4 Clutch Clearance
    GC0020550Courtesy of DAIMLERCHRYSLER CORP.
    1 - DIAL INDICATOR
    2 - HOOK TOOL
    3 - DIAL INDICATOR TIP TOOL 6268
  49. Install rear sun gear and #7 needle bearing. See Fig 52.
    NOTE: The number seven needle bearing has three anti-reversal tabs and is common with the number five and number two position. The orientation should allow the bearing to seat flat against the rear sun gear. See Fig 51. A small amount of petrolatum can be used to hold the bearing to the rear sun gear.
    Fig 51: Number 7 Bearing
    GC0020555Courtesy of DAIMLERCHRYSLER CORP.
    1 - #7 NEEDLE BEARING
    2 - REAR SUN GEAR
    Fig 52: Install Rear Sun Gear and #7 Needle Bearing
    GC0020554Courtesy of DAIMLERCHRYSLER CORP.
    1 - #7 NEEDLE BEARING
    2 - REAR SUN GEAR
  50. Install front carrier/rear annulus assembly and #6 needle bearing. See Fig 53.
    Fig 53: Install Front Carrier/Rear Annulus Assembly
    GC0020530Courtesy of DAIMLERCHRYSLER CORP.
    1 - #6 NEEDLE BEARING
    2 - FRONT CARRIER AND REAR ANNULUS ASSEMBLY (TWIST AND PULL OR PUSH TO REMOVE OR INSTALL).
  51. Install front sun gear assembly and #4 thrust washer. See Fig 54.
    Fig 54: Install Front Sun Gear Assembly
    GC0020531Courtesy of DAIMLERCHRYSLER CORP.
    1 - FRONT SUN GEAR ASSEMBLY
    2 - #4 THRUST WASHER (FOUR TABS)
  52. DETERMINING #4 THRUST PLATE THICKNESS/INPUT SHAFT END PLAY: 
    • Select the thinnest #4 thrust plate thickness and install to input clutch assembly. See Fig 55. Use petrolatum to retain.
    • Install input clutch assembly into position and verify that it is completely seated by viewing through input speed sensor hole. If view through input speed sensor hole is not as shown in Fig 56, the input clutch assembly is not seated properly.
    • Remove oil pump o-ring. See Fig 57. Be sure to reinstall oil pump o-ring after selecting the proper #4 thrust plate. 
    • Install pump and gasket to transmission. Install and torque bolts.
    • Set up input shaft for measurement with Indicator Set C3339 and End Play Set 8266 as shown in Fig 58.
    • Measure the input shaft end play with the transaxle in the vertical position. Input shaft end play must be within 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.
    • Refer to the No. 4 thrust plate chart to select the proper No. 4 thrust plate:
    Fig 55: Select Thinnest No. 4 Thrust Plate
    GC0020532Courtesy of DAIMLERCHRYSLER CORP.
    1 - OVERDRIVE SHAFT ASSEMBLY
    2 - #4 THRUST PLATE (SELECT)
    3 - 3 DABS OF PETROLATUM FOR RETENTION
    Fig 56: View Through Input Speed Sensor Hole
    GC0020533Courtesy of DAIMLERCHRYSLER CORP.
    1 - INPUT CLUTCH RETAINER
    2 - INPUT SPEED SENSOR HOLE
    3 - OIL COOLER FITTINGS
    Fig 57: Remove Oil Pump O-Ring
    GC0020534Courtesy of DAIMLERCHRYSLER CORP.
    1 - OIL PUMP ASSEMBLY
    2 - O-RING
    Fig 58: Measure Input Shaft End Play Using Tool 8266 - Typical
    GC0020535Courtesy of DAIMLERCHRYSLER CORP.
    1 - TOOL 8266-8
    2 - TOOL 8266-2
    3 - TOOL C-3339
    NO. 4 THRUST PLATE CHART

    PART NUMBER THICKNESS
    4431665AB 1.60mm (0.063 in.)
    3836237AB 1.73mm (0.068 in.)
    4431666AB 1.80mm (0.071 in.)
    3836238AB 1.96mm (0.077 in.)
    4431667AB 2.03mm (0.080 in.)
    3836239AB 2.16mm (0.085 in.)
    4431668AB 2.24mm (0.088 in.)
    3836240AB 2.39mm (0.094 in.)
    4431669AB 2.46mm (0.097 in.)
    3836241AB 2.62mm (0.103 in.)
    4446670AB 2.67mm (0.105 in.)
    4446671AB 2.90mm (0.114 in.)
  53. Install input clutch assembly. See Fig 59.
    Fig 59: Install Input Clutch Assembly
    GC0020536Courtesy of DAIMLERCHRYSLER CORP.
    1 - INPUT CLUTCH ASSEMBLY
    2 - #4 THRUST WASHER
  54. Install #1 caged needle bearing. See Fig 60.
    Fig 60: Install No. 1 Caged Needle Bearing
    GC0020551Courtesy of DAIMLERCHRYSLER CORP.
    1 - #1 CAGED NEEDLE BEARING
    2 - NOTE: TANGED SIDE OUT
    CAUTION: The cooler bypass valve must be replaced if transaxle failure has occurred. Do not attempt to reuse or clean old valve.
  55. Install cooler bypass valve with o-ring end towards rear of case. See Fig 61.
    Fig 61: Install Cooler Bypass Valve
    GC0020537Courtesy of DAIMLERCHRYSLER CORP.
    1 - COOLER BYPASS VALVE
  56. Install oil pump gasket. See Fig 62.
    Fig 62: Install Oil Pump Gasket
    GC0020538Courtesy of DAIMLERCHRYSLER CORP.
    1 - PUMP GASKET
  57. Install oil pump assembly. See Fig 63.
    Fig 63: Install Oil Pump
    GC0020539Courtesy of DAIMLERCHRYSLER CORP.
    1 - OIL PUMP
    2 - GASKET
  58. Install oil pump-to-case bolts and torque to 27 N.m (20 ft. lbs.). See Fig 64.
    Fig 64: Install Pump-to-Case Bolts
    GC0020540Courtesy of DAIMLERCHRYSLER CORP.
    1 - PUMP ATTACHING BOLTS
    2 - PUMP HOUSING
  59. Install low/reverse accumulator. See Fig 65.
    Fig 65: Low/Reverse Accumulator
    GC0000643Courtesy of DAIMLERCHRYSLER CORP.
    1 - PISTON
    2 - RETURN SPRINGS
  60. Install low/reverse accumulator plug. See Fig 66.
    Fig 66: Install Low/Reverse Accumulator Plug
    GC0020552Courtesy of DAIMLERCHRYSLER CORP.
    1 - ADJUSTABLE PLIERS
    2 - PLUG
  61. Install low/reverse accumulator snap ring. See Fig 67.
    Fig 67: Install Low/Reverse Accumulator Snap Ring
    GC0020542Courtesy of DAIMLERCHRYSLER CORP.
    1 - SNAP RING
    2 - PLUG
    NOTE: Depending on engine application, some accumulators will have two springs, and others will have one spring. The springs are color-coded for application and year.
  62. Install underdrive and overdrive accumulators and springs. See Fig 68.
    Fig 68: Underdrive and Overdrive Accumulators
    GC0000641Courtesy of DAIMLERCHRYSLER CORP.
    1 - OVERDRIVE PISTON AND SPRING
    2 - UNDERDRIVE PISTON AND SPRING
  63. Install valve body to transaxle. See Fig 69. Rotate manual valve shaft fully clockwise to ease installation. Make sure park rod rollers are positioned within park guide bracket.
    Fig 69: Valve Body Removal/Installation
    GC0020543Courtesy of DAIMLERCHRYSLER CORP.
    1 - VALVE BODY
  64. Install and torque valve body-to-case bolts to 12 N.m (105 in. lbs.). See Fig 70.
    Fig 70: Install Valve Body-to-Case Bolts
    GC0020544Courtesy of DAIMLERCHRYSLER CORP.
    1 - VALVE BODY ATTACHING BOLTS (18)
    2 - VALVE BODY
  65. Install oil filter and new o-ring. See Fig 71.
    Fig 71: Install Oil Filter and O-Ring
    GC0020545Courtesy of DAIMLERCHRYSLER CORP.
    1 - OIL FILTER
    2 - O-RING
  66. Apply an 1/8" bead of Mopar(R) ATF RTV (MS-GF41) to oil pan and immediately install to case. See Fig 72.
    Fig 72: Install Oil Pan
    GC0020546Courtesy of DAIMLERCHRYSLER CORP.
    1 - OIL PAN
    2 - 1/8 INCH BEAD OF MOPAR(R) ATF RTV (MS-GF41)
    3 - OIL FILTER
  67. Install oil pan-to-case bolts and torque to 19 N.m (165 in. lbs.).
  68. Install solenoid/pressure switch assembly and gasket to case. See Fig 73.
    Fig 73: Solenoid/Pressure Switch Assembly and Gasket
    GC0020548Courtesy of DAIMLERCHRYSLER CORP.
    1 - SOLENOID/PRESSURE SWITCH ASSEMBLY
    2 - GASKET
  69. Install and tighten solenoid/pressure switch assembly-to-transaxle case bolts to 12 N.m (110 in. lbs.). See Fig 74.
    Fig 74: Attaching Bolts
    GC0020549Courtesy of DAIMLERCHRYSLER CORP.
    1 - BOLTS
    2 - SOLENOID AND PRESSURE SWITCH ASSEMBLY
  70. Install and torque input and output speed sensors to case to 27 N.m (20 ft. lbs.).
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