41TE 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 )

Install both output bearing cups using Tool 5050. See Fig 1.

Fig 1: Install Both Output Bearing Cups

Courtesy of DAIMLERCHRYSLER CORP.

1 - OUTPUT BEARING CUPS

2 - WRENCHES

3 - TOOL 5050

Install low/reverse piston retainer gasket. See Fig 2. Make sure gasket holes line up with case.

Fig 2: Removing/Installing Piston Retainer Gasket
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1 - GASKET HOLES MUST LINE UP

2 - LOW/REVERSE CLUTCH PISTON RETAINER GASKET
Install low/reverse piston retainer. See Fig 3.

Fig 3: Removing/Installing Piston Retainer
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1 - LOW/REVERSE CLUTCH PISTON RETAINER

2 - GASKET

Install low/reverse piston retainer-to-case bolts and torque to 5 N.m (45 in. lbs.). See Fig 4.

Fig 4: Removing/Installing Piston Retainer Attaching Screws

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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.

Install low/reverse clutch piston. See Fig 5.

Fig 5: Removing/Installing Low/Reverse Clutch Piston

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1 - LOW/REVERSE CLUTCH PISTON

2 - BONDED SEAL

3 - BONDED SEAL

Assemble park guide bracket assembly. See Fig 7. See Fig 6.

Fig 6: Guide Bracket Disassembled

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1 - ANTIRATCHET SPRING

2 - GUIDE BRACKET

3 - SPLIT SLEEVE

4 - SPACER

5 - PAWL

6 - STEPPED SPACER

Fig 7: Guide Bracket

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1 - GUIDE BRACKET

2 - ANTIRATCHET SPRING (MUST BE ASSEMBLED AS SHOWN)

3 - PAWL

Install guide bracket into position and insert pivot shaft. See Fig 8.

Fig 8: Pivot Shaft and Guide Bracket

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1 - ANTIRACHET SPRING

2 - GUIDE BRACKET

3 - PIVOT SHAFT

4 - PAWL

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: Removing/Installing Anchor Shaft and Plug

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1 - GUIDE BRACKET ANCHOR SHAFT

2 - PIVOT SHAFT

3 - ANCHOR SHAFT PLUG

Install low/reverse piston return spring. See Fig 10.

Fig 10: Low/Reverse Piston Return Spring
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1 - LOW/REVERSE PISTON RETURN SPRING

2 - PISTON

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

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1 - LOW/REVERSE CLUTCH RETURN SPRING

2 - SNAP RING (INSTALL AS SHOWN)

3 - TOOL 6057

4 - TOOL 5059

5 - TOOL 5058-3

Fig 12: Removing/Installing Snap Ring

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1 - SNAP RING OPENING MUST BE BETWEEN SPRING LEVERS (AS SHOWN)

2 - SNAP RING PLIERS

3 - TOOL 6057

Install rear carrier bearing cone using Tool 6053. See Fig 13.

Fig 13: Install Rear Carrier Bearing Cone

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1 - ARBOR PRESS RAM

2 - TOOL 6053

3 - NEW BEARING CONE

4 - REAR CARRIER ASSEMBLY

Install rear carrier assembly to transaxle case. See Fig 14.

Fig 14: Removing/Installing Rear Carrier Assembly
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1 - REAR CARRIER ASSEMBLY

Install output gear bearing cone using Tool 5052. See Fig 15.

Fig 15: Install Output Gear Bearing Cone

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1 - ARBOR PRESS RAM

2 - HANDLE C-4171

3 - TOOL 5052

4 - OUTPUT GEAR

OUTPUT GEAR BEARING ADJUSTMENT:

With output gear removed, 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

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1 - TOOL L-4432

2 - DIAL INDICATOR

3 - SPECIAL SCREWS TOOL 6260

4 - OUTPUT GEAR

Fig 17: Output Gear and (Select) Shim

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1 - REAR CARRIER ASSEMBLY

2 - SHIM (SELECT)

3 - OUTPUT GEAR

OUTPUT GEAR BEARING SHIM CHART

End Play	Shim Needed	Part Number
0.05 mm (0.002 in.)	4.42 mm (0.174 in.)	4412830AB
0.08 mm (0.003 in.)	4.38 mm (0.172 in.)	4412829AB
0.10 mm (0.004 in.)	4.38 mm (0.172 in.)	4412829AB
0.13 mm (0.005 in.)	4.34 mm (0.171 in.)	4412828AB
0.15 mm (0.006 in.)	4.30 mm (0.169 in.)	4412827AB
0.18 mm (0.007 in.)	4.30 mm (0.169 in.)	4412827AB
0.20 mm (0.008 in.)	4.26 mm (0.168 in.)	4412826AB
0.23 mm (0.009 in.)	4.22 mm (0.166 in.)	4412825AB
0.25 mm (0.010 in.)	4.22 mm (0.166 in.)	4412825AB
0.28 mm (0.011 in.)	4.18 mm (0.165 in.)	4412824AB
0.30 mm (0.012 in.)	4.14 mm (0.163 in.)	4412823AB
0.33 mm (0.013 in.)	4.14 mm (0.163 in.)	4412823AB
0.36 mm (0.014 in.)	4.10 mm (0.161 in.)	4412822AB
0.38 mm (0.015 in.)	4.10 mm (0.161 in.)	4412822AB
0.41 mm (0.016 in.)	4.06 mm (0.160 in.)	4412821AB
0.43 mm (0.017 in.)	4.02 mm (0.158 in.)	4412820AB
0.46 mm (0.018 in.)	4.02 mm (0.158 in.)	4412820AB
0.48 mm (0.019 in.)	3.98 mm (0.157 in.)	4412819AB
0.51 mm (0.020 in.)	3.94 mm (0.155 in.)	4412818AB
0.53 mm (0.021 in.)	3.94 mm (0.155 in.)	4412818AB
0.56 mm (0.022 in.)	3.90 mm (0.154 in.)	4412817AB
0.58 mm (0.023 in.)	3.90 mm (0.154 in.)	4412817AB
0.61 mm (0.024 in.)	3.86 mm (0.152 in.)	4412816AB
0.64 mm (0.025 in.)	3.82 mm (0.150 in.)	4412815AB
0.66 mm (0.026 in.)	3.82 mm (0.150 in.)	4412815AB
0.69 mm (0.027 in.)	3.78 mm (0.149 in.)	4412814AB
0.71 mm (0.028 in.)	3.74 mm (0.147 in.)	4412813AB
0.74 mm (0.029 in.)	3.74 mm (0.147 in.)	4412813AB
0.76 mm (0.030 in.)	3.70 mm (0.146 in.)	4412812AB
0.79 mm (0.031 in.)	3.66 mm (0.144 in.)	4412811AB
0.81 mm (0.032 in.)	3.66 mm (0.144 in.)	4412811AB
0.84 mm (0.033 in.)	3.62 mm (0.143 in.)	4412810AB
0.86 mm (0.034 in.)	3.62 mm (0.143 in.)	4412810AB
0.89 mm (0.035 in.)	3.58 mm (0.141)	4412809AB
0.91 mm (0.036 in.)	3.54 mm (0.139 in.)	4412808AB
0.94 mm (0.037 in.)	3.54 mm (0.139 in.)	4412808AB
0.97 mm (0.038 in.)	3.50 mm (0.138 in.)	4412807AB

Install the output gear and bearing assembly using Tool 6261. See Fig 18.

Fig 18: Install Output Gear

Courtesy of DAIMLERCHRYSLER CORP.

1 - WRENCHES

2 - TOOL 6261 WITH STUD

3 - OUTPUT GEAR

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

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1 - OUTPUT GEAR

2 - BOLT

3 - CONED LOCK WASHER

Fig 20: Tighten Output Gear to 271 N.m (200 ft. lbs.)

Courtesy of DAIMLERCHRYSLER CORP.

1 - OUTPUT GEAR

2 - TORQUE WRENCH

3 - 200 FT. LBS.

4 - TOOL 6259

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
Courtesy of DAIMLERCHRYSLER CORP.

1 - INCH-POUND TORQUE WRENCH

2 - OUTPUT GEAR
Install output gear stirrup with serrated side out. See Fig 22.

Fig 22: Install Stirrup
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1 - STIRRUP

2 - OUTPUT GEAR RETAINING BOLT
Install retaining strap.

Install strap bolts but do not tighten at this time. See Fig 23.

Fig 23: Removing/Installing Strap Bolts

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1 - RETAINING STRAP

2 - STIRRUP

3 - RETAINING STRAP BOLTS

Rotate stirrup clockwise against flats of retaining bolt. See Fig 24.

Fig 24: Turn Stirrup Clockwise Against Bolt Flats
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1 - RETAINING STRAP

2 - STIRRUP
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.)
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1 - RETAINING STRAP

2 - STIRRUP

Bend tabs on strap up against flats of bolts. See Fig 26.

Fig 26: Bend Tabs on Strap up Against Flats of Bolts

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1 - RETAINING STRAP TABS

2 - RETAINING STRAP

3 - STIRRUP

Install transfer shaft bearing cone using Tool 6052. See Fig 27.

Fig 27: Install Transfer Shaft Bearing Cone

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1 - TOOL 6052

2 - NEW BEARING CONE

3 - TRANSFER SHAFT

4 - ARBOR PRESS RAM

Install bearing cup and oil baffle to transfer shaft. See Fig 28.

Fig 28: Identifying Shaft Components

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1 - BEARING CUP

2 - BEARING CONE

3 - TRANSFER SHAFT

4 - OIL BAFFLE

5 - O-RING

Using Tool 5049A, install transfer shaft. See Fig 29.

Fig 29: Removing/Installing Transfer Shaft

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1 - SPECIAL TOOL 5049-A

2 - TRANSFER SHAFT

3 - OUTPUT GEAR

Using Tool 6051, install transfer shaft bearing snap ring. See Fig 30.

Fig 30: Removing/Installing Transfer Shaft Bearing Snap Ring

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1 - SNAP RING PLIERS TOOL 6051

2 - TRANSFER SHAFT BEARING SNAP RING

3 - TRANSFER SHAFT

Install transfer shaft bearing cup into retainer using Tool 6061. See Fig 31.

Fig 31: Install Transfer Shaft Bearing Cup Into Retainer

Courtesy 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

Install bearing cup retainer to transaxle. See Fig 32.

Fig 32: Remove Bearing Cup Retainer
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1 - ALIGN INDEXING TAB TO SLOT

2 - BEARING CUP RETAINER

Install transfer gear bearing cone to transfer gear using Tool 5052. See Fig 33.

Fig 33: Install Transfer Gear Bearing Cone

Courtesy of DAIMLERCHRYSLER CORP.

1 - ARBOR PRESS RAM

2 - HANDLE C-4171

3 - NEW BEARING CONE

4 - TRANSFER SHAFT GEAR

5 - TOOL 5052

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: Removing/Installing Transfer Shaft Gear and (Select) Shim

Courtesy 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
0.05 mm (0.002 in.)	4.66 mm (0.183 in.)	4505588AB
0.08 mm (0.003 in.)	4.62 mm (0.182 in.)	4412835AB
0.10 mm (0.004 in.)	4.58 mm (0.180 in.)	4412834AB
0.13 mm (0.005 in.)	4.58 mm (0.180 in.)	4412834AB
0.15 mm (0.006 in.)	4.54 mm (0.178 in.)	4412833AB
0.18 mm (0.007 in.)	4.50 mm (0.177 in.)	4412832AB
0.20 mm (0.008 in.)	4.50 mm (0.177 in.)	4412832AB
0.23 mm (0.009 in.)	4.46 mm (0.175 in.)	4412831AB
0.25 mm (0.010 in.)	4.46 mm (0.175 in.)	4412831AB
0.28 mm (0.011 in.)	4.42 mm (0.174 in.)	4412830AB
0.30 mm (0.012 in.)	4.38 mm (0.172 in.)	4412829AB
0.33 mm (0.013 in.)	4.38 mm (0.172 in.)	4412829AB
0.36 mm (0.014 in.)	4.34 mm (0.171 in.)	4412828AB
0.38 mm (0.015 in.)	4.30 mm (0.169 in.)	4412827AB
0.41 mm (0.016 in.)	4.30 mm (0.169 in.)	4412827AB
0.43 mm (0.017 in.)	4.26 mm (0.168 in.)	4412826AB
0.46 mm (0.018 in.)	4.22 mm (0.166 in.)	4412825AB
0.48 mm (0.019 in.)	4.22 mm (0.166 in.)	4412825AB
0.50 mm (0.020 in.)	4.18 mm (0.165 in.)	4412824AB
0.53 mm (0.021 in.)	4.18 mm (0.165 in.)	4412824AB
0.56 mm (0.022 in.)	4.14 mm (0.163 in.)	4412823AB
0.58 mm (0.023 in.)	4.10 mm (0.161 in.)	4412822AB
0.61 mm (0.024 in.)	4.10 mm (0.161 in.)	4412822AB
0.64 mm (0.025 in.)	4.06 mm (0.160 in.)	4412821AB
0.66 mm (0.026 in.)	4.02 mm (0.158 in.)	4412820AB
0.69 mm (0.027 in.)	4.02 mm (0.158 in.)	4412820AB
0.71 mm (0.028 in.)	3.98 mm (0.157 in.)	4412819AB
0.74 mm (0.029 in.)	3.94 mm (0.155 in.)	4412818AB
0.76 mm (0.030 in.)	3.94 mm (0.155 in.)	4412818AB
0.79 mm (0.031 in.)	3.90 mm (0.154 in.)	4412817AB
0.81 mm (0.032 in.)	3.90 m (0.154 in.)	4412817AB
0.84 m (0.033 in.)	3.86 mm (0.152 in.)	4412816AB
0.86 mm (0.034 in.)	3.82 mm (0.150 in.)	4412815AB
0.89 mm (0.035 in.)	3.82 mm (0.150 in.)	4412815AB
0.91 mm (0.036 in.)	3.78 mm (0.149 in.)	4412814AB
0.94 mm (0.037 in.)	3.74 mm (0.147 in.)	4412813AB
0.97 mm (0.038 in.)	3.74 mm (0.147 in.)	4412813AB
0.99 mm (0.039 in.)	3.70 mm (0.146 in.)	4412812AB
1.02 mm (0.040 in.)	3.66 mm (0.144 in.)	4412811AB
1.04 mm (0.041 in.)	3.66 mm (0.144 in.)	4412811AB
1.07 mm (0.042 in.)	3.62 mm (0.143 in.)	4412810AB
1.08 mm (0.043 in.)	3.62 mm (0.143 in.)	4412810AB
1.12 mm (0.044 in.)	3.58 mm (0.141)	4412809AB
1.14 mm (0.045 in.)	3.54 mm (0.139 in.)	4412808AB
1.17 mm (0.046 in.)	3.54 mm (0.139 in.)	4412808AB
1.19 mm (0.047 in.)	3.50 mm (0.138 in.)	4412807AB
1.22 mm (0.048 in.)	3.46 mm (0.136 in.)	4412806AB
1.24 mm (0.049 in.)	3.46 mm (0.136 in.)	4412806AB
1.27 mm (0.050 in.)	3.42 mm (0.135 in.)	4412805AB
1.30 mm (0.051 in.)	3.38 mm (0.133 in.)	4412804AB
1.32 mm (0.052 in.)	3.38 mm (0.133 in.)	4412804AB
1.35 mm (0.053 in.)	3.34 mm (0.132 in.)	4412803AB
1.37 mm (0.054 in.)	3.34 mm (0.132 in.)	4412803AB
1.40 mm (0.055 in.)	3.30 mm (0.130 in.)	4412802AB
1.45 mm (0.057 in.)	3.26 mm (0.128 in.)	4412801AB
1.47 mm (0.058 in.)	2.22 mm (0.127 in.)	4505570AB

Install the transfer shaft gear using Tool 6261. See Fig 35.

Fig 35: Install Transfer Shaft Gear

Courtesy 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.

Install the new retaining nut and washer.

Using Tool 6259, torque transfer gear retaining nut to 271 N.m (200 ft. lbs.). See Fig 36.

Fig 36: Tighten Transfer Gear Nut to 271 N.m (200 ft. lbs.)

Courtesy of DAIMLERCHRYSLER CORP.

1 - TRANSFER SHAFT GEAR

2 - 200 FT. LBS.

3 - TORQUE WRENCH

4 - SPECIAL TOOL 6259

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.
Install a bead of Mopar(R) ATF RTV (MS-GF41) to transfer gear cover. See Fig 37.

Fig 37: Removing/Installing Rear Cover
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1 - REAR COVER

2 - 1/8 INCH BEAD OF MOPAR(R) ATF RTV (MS-GF41) AS SHOWN

Install transfer gear cover-to-case bolts and torque to 20 N.m (175 in. lbs.) torque. See Fig 38.

Fig 38: Removing/Installing Rear Cover Bolts

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1 - REAR COVER BOLTS

2 - REAR COVER

3 - USE SEALANT ON BOLTS

Install low/reverse clutch pack. See Fig 39. Leave uppermost disc out until snap ring is installed.

Fig 39: Removing/Installing Low/Reverse Clutch Pack
Courtesy of DAIMLERCHRYSLER CORP.

1 - CLUTCH PLATES (5)

2 - CLUTCH DISCS (5)

Install low/reverse reaction plate flat snap ring. See Fig 40.

Fig 40: Removing/Installing Low/Reverse Reaction Plate Snap Ring

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1 - SCREWDRIVER

2 - LOW/REVERSE REACTION PLATE FLAT SNAP RING

3 - DO NOT SCRATCH CLUTCH PLATE

Install remaining low/reverse clutch disc. See Fig 41.

Fig 41: Removing/Installing One Disc
Courtesy of DAIMLERCHRYSLER CORP.

1 - ONE DISC FROM LOW/REVERSE CLUTCH
Install low/reverse reaction plate with flat side up. See Fig 42.

Fig 42: Removing/Installing Low/Reverse Reaction Plate
Courtesy of DAIMLERCHRYSLER CORP.

1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP)
Install tapered snap ring (with tapered side up) as shown in Fig 43. See Fig 44.

Fig 43: Tapered Snap Ring Instructions
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Fig 44: Snap Ring Installed
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1 - SCREWDRIVER

2 - TAPERED SNAP RING (INSTALL AS SHOWN)

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

Courtesy 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.)

Install 2/4 clutch pack. See Fig 46.

Fig 46: Removing/Installing 2/4 Clutch Pack
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1 - CLUTCH PLATE (4)

2 - CLUTCH DISC (4)

NOTE: The 2/4 Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.

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

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1 - NOTE POSITION

2 - RETURN SPRING

3 - 2/4 CLUTCH RETAINER

Fig 48: 2/4 Clutch Retainer

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1 - 2/4 CLUTCH RETAINER

2 - 2/4 CLUTCH RETURN SPRING

Using tool 5058, compress 2/4 clutch return spring just enough to install snap ring. See Fig 49.

Fig 49: Removing/Installing 2/4 Clutch Retainer Snap Ring

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1 - TOOL 5058

2 - SCREWDRIVER

3 - SNAP RING

4 - 2/4 CLUTCH RETAINER

Install snap ring.

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

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1 - DIAL INDICATOR

2 - HOOK TOOL

3 - DIAL INDICATOR TIP TOOL 6268

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: Locating Rear Sun Gear & No. 7 Needle Bearing
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1 - #7 NEEDLE BEARING

2 - REAR SUN GEAR

Fig 52: Removing/Installing Rear Sun Gear and No. 7 Needle Bearing
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1 - #7 NEEDLE BEARING

2 - REAR SUN GEAR

Install front carrier/rear annulus assembly and #6 needle bearing. See Fig 53.

Fig 53: Removing/Installing Front Carrier and Rear Annulus Assembly

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1 - #6 NEEDLE BEARING

2 - FRONT CARRIER AND REAR ANNULUS ASSEMBLY (TWIST AND PULL OR PUSH TO REMOVE OR INSTALL).

Install front sun gear assembly and #4 thrust washer. See Fig 54.

Fig 54: Removing/Installing Front Sun Gear Assembly
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1 - FRONT SUN GEAR ASSEMBLY

2 - #4 THRUST WASHER (FOUR TABS)

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: Identifying No. 4 Thrust Plate

Courtesy 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

Courtesy of DAIMLERCHRYSLER CORP.

1 - INPUT CLUTCH RETAINER

2 - INPUT SPEED SENSOR HOLE

3 - OIL COOLER FITTINGS

Fig 57: Remove Oil Pump O-Ring

Courtesy of DAIMLERCHRYSLER CORP.

1 - OIL PUMP ASSEMBLY

2 - O-RING

Fig 58: Measuring Input Shaft End Play Using End Play Set 8266

Courtesy of DAIMLERCHRYSLER CORP.

1 - TOOL 8266-8

2 - TOOL 8266-2

3 - TOOL C-3339

NO. 4 THRUST PLATE CHART

PART NUMBER	THICKNESS
4431665AB	1.60 mm (0.063 in.)
3836237AB	1.73 mm (0.068 in.)
4431666AB	1.80 mm (0.071 in.)
3836238AB	1.96 mm (0.077 in.)
4431667AB	2.03 mm (0.080 in.)
3836239AB	2.16 mm (0.085 in.)
4431668AB	2.24 mm (0.088 in.)
3836240AB	2.39 mm (0.094 in.)
4431669AB	2.46 mm (0.097 in.)
3836241AB	2.62 mm (0.103 in.)
4446670AB	2.67 mm (0.105 in.)
4446671AB	2.90 mm (0.114 in.)

Install input clutch assembly. See Fig 59.

Fig 59: Removing/Installing Input Clutch Assembly
Courtesy of DAIMLERCHRYSLER CORP.

1 - INPUT CLUTCH ASSEMBLY

2 - #4 THRUST WASHER
Install #1 caged needle bearing. See Fig 60.

Fig 60: Removing/Installing Caged Needle Bearing
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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.
Install cooler bypass valve with o-ring end towards rear of case. See Fig 61.

Fig 61: Removing/Installing Bypass Valve
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1 - COOLER BYPASS VALVE
Install oil pump gasket. See Fig 62.

Fig 62: Removing/Installing Oil Pump Gasket
Courtesy of DAIMLERCHRYSLER CORP.

1 - PUMP GASKET
Install oil pump assembly. See Fig 63.

Fig 63: Removing/Installing Oil Pump
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1 - OIL PUMP

2 - GASKET
Install oil pump-to-case bolts and torque to 27 N.m (20 ft. lbs.). See Fig 64.

Fig 64: Removing/Installing Pump Bolts
Courtesy of DAIMLERCHRYSLER CORP.

1 - PUMP ATTACHING BOLTS

2 - PUMP HOUSING
Install low/reverse accumulator. See Fig 65.

Fig 65: Low/Reverse Accumulator
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1 - PISTON

2 - RETURN SPRINGS
Install low/reverse accumulator plug. See Fig 66.

Fig 66: Removing/Installing Low/Reverse Accumulator Plug (Cover)
Courtesy of DAIMLERCHRYSLER CORP.

1 - ADJUSTABLE PLIERS

2 - PLUG
Install low/reverse accumulator snap ring. See Fig 67.

Fig 67: Removing/Installing Low/Reverse Accumulator Snap Ring
Courtesy 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.
Install underdrive and overdrive accumulators. See Fig 68.

Fig 68: Underdrive and Overdrive Accumulators
Courtesy of DAIMLERCHRYSLER CORP.

1 - OVERDRIVE PISTON AND SPRING

2 - UNDERDRIVE PISTON AND SPRING
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: Removing/Installing Valve Body
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1 - VALVE BODY
Install and torque valve body-to-case bolts to 12 N.m (105 in. lbs.). See Fig 70.

Fig 70: Removing/Installing Valve Body Bolts
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1 - VALVE BODY ATTACHING BOLTS (18)

2 - VALVE BODY
Install oil filter and new o-ring. See Fig 71.

Fig 71: Removing/Installing Oil Filter
Courtesy of DAIMLERCHRYSLER CORP.

1 - OIL FILTER

2 - O-RING

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: Removing/Installing Oil Pan

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1 - OIL PAN

2 - 1/8 INCH BEAD OF MOPAR(R) ATF RTV (MS-GF41)

3 - OIL FILTER

Install oil pan-to-case bolts and torque to 19 N.m (165 in. lbs.).
Install solenoid/pressure switch assembly and gasket to case. See Fig 73.

Fig 73: Solenoid/Pressure Switch Assembly and Gasket
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1 - SOLENOID/PRESSURE SWITCH ASSEMBLY

2 - GASKET
Install and tighten solenoid/pressure switch assembly-to-transaxle case bolts to 12 N.m (110 in. lbs.). See Fig 74.

Fig 74: Solenoid Pack-to-Transaxle Bolts
Courtesy of DAIMLERCHRYSLER CORP.

1 - BOLTS

2 - SOLENOID AND PRESSURE SWITCH ASSEMBLY
Install and torque input and output speed sensors to case to 27 N.m (20 ft. lbs.).