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41TE Transaxle

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Fig 1: Installing Both Output Bearing Cups
GC0000644Courtesy of CHRYSLER LLC
1 - OUTPUT BEARING CUPS
2 - WRENCHES
3 - INSTALLER - 5050
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 (1) using Installer 5050 (3). See Fig 1.
    Fig 2: Removing/Installing Piston Retainer Gasket
    GC0000636Courtesy of CHRYSLER LLC
    1 - GASKET HOLES MUST LINE UP
    2 - LOW/REVERSE CLUTCH PISTON RETAINER GASKET
  2. Install low/reverse piston retainer gasket (2). See Fig 2. Make sure gasket holes line up with case (1).
    Fig 3: Removing/Installing Piston Retainer
    GC0000635Courtesy of CHRYSLER LLC
    1 - LOW/REVERSE CLUTCH PISTON RETAINER
    2 - GASKET
  3. Install low/reverse piston retainer (1). See Fig 3.
    Fig 4: Removing/Installing Piston Retainer Attaching Screws
    GC0000634Courtesy of CHRYSLER LLC
    1 - LOW/REVERSE CLUTCH PISTON RETAINER
    2 - SCREWDRIVER
    3 - TORX-LOC SCREWS
  4. Install low/reverse piston retainer-to-case screws (3). See Fig 4and torque to 5 N.m (45 in. lbs.).
    Fig 5: Removing/Installing Low/Reverse Clutch Piston
    GC0000633Courtesy of CHRYSLER LLC
    1 - LOW/REVERSE CLUTCH PISTON
    2 - BONDED SEAL
    3 - BONDED SEAL
    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 (1). See Fig 5.
    Fig 6: Exploded View Of Guide Bracket
    GC0000632Courtesy of CHRYSLER LLC
    1 - ANTI-RATCHET SPRING
    2 - GUIDE BRACKET
    3 - SPLIT SLEEVE
    4 - SPACER
    5 - PAWL
    6 - STEPPED SPACER
  6. Use figure as a reference while assembling park guide bracket assembly. See Fig 6.
    Fig 7: Guide Bracket
    GC0000631Courtesy of CHRYSLER LLC
    1 - GUIDE BRACKET
    2 - ANTI-RATCHET SPRING (MUST BE ASSEMBLED AS SHOWN)
    3 - PAWL
  7. Assemble park guide bracket assembly. See Fig 7.
    Fig 8: View Of Pivot Shaft & Guide Bracket
    GC0000630Courtesy of CHRYSLER LLC
    1 - ANTIRACHET SPRING
    2 - GUIDE BRACKET
    3 - PIVOT SHAFT
    4 - PAWL
  8. Install guide bracket (2) into position and insert pivot shaft (3). See Fig 8.
    Fig 9: Removing/Installing Anchor Shaft & Plug
    GC0000628Courtesy of CHRYSLER LLC
    1 - GUIDE BRACKET ANCHOR SHAFT
    2 - PIVOT SHAFT
    3 - ANCHOR SHAFT PLUG
  9. Install anchor shaft (1) and plug (3). Make sure guide bracket and split sleeve are in contact with the rear of the transaxle case. See Fig 9.
    Fig 10: Identifying Low/Reverse Piston Return Spring
    GC0000627Courtesy of CHRYSLER LLC
    1 - LOW/REVERSE PISTON RETURN SPRING
    2 - PISTON
  10. Install low/reverse piston return spring (1). See Fig 10.
    Fig 11: View Of Compressor Tool In Use
    GC0000625Courtesy of CHRYSLER LLC
    1 - LOW/REVERSE CLUTCH RETURN SPRING
    2 - SNAP RING (INSTALL AS SHOWN)
    3 - DISC 6057
    4 - COMPRESSOR 5059
    5 - COMPRESSOR BAR 5058-3
  11. Install low/reverse spring compressor into position. See Fig 11.
    Fig 12: Removing/Installing Snap Ring
    GC0000626Courtesy of CHRYSLER LLC
    1 - SNAP RING OPENING MUST BE BETWEEN SPRING LEVERS (AS SHOWN)
    2 - SNAP RING PLIERS
    3 - DISC 6057
  12. Compress low/reverse piston and install snap ring (1). See Fig 12.
    Fig 13: Installing Rear Carrier Bearing Cone
    GC0000645Courtesy of CHRYSLER LLC
    1 - ARBOR PRESS RAM
    2 - INSTALLER 6053
    3 - NEW BEARING CONE
    4 - REAR CARRIER ASSEMBLY
  13. Install rear carrier bearing cone (3) using Installer 6053 (1). See Fig 13.
    Fig 14: Removing/Installing Rear Carrier Assembly
    GC0000622Courtesy of CHRYSLER LLC
    1 - REAR CARRIER ASSEMBLY
  14. Install rear carrier assembly (1) to transaxle case. See Fig 14.
    Fig 15: Installing Output Gear Bearing Cone
    GC0000646Courtesy of CHRYSLER LLC
    1 - ARBOR PRESS RAM
    2 - HANDLE C-4171
    3 - INSTALLER 5052
    4 - OUTPUT GEAR
  15. Install output gear bearing cone using Installer 5052 (3). See Fig 15.
    Fig 16: Checking Output Gear Bearings End Play
    GC0000647Courtesy of CHRYSLER LLC
    1 - GEAR CHECKING PLATE L-4432
    2 - DIAL INDICATOR
    3 - SPECIAL SCREWS 6260
    4 - OUTPUT GEAR
  16. 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.
    • Using Holder 6259, install output gear and bearing assembly. Torque to 271 N.m (200 ft. lbs.).
    • Measure bearing end play. Attach Gear Checking Plate L-4432 (1) 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.
    • Refer to OUTPUT GEAR BEARING SHIM CHART  for the required shim to obtain proper bearing setting.
    • Use Holder 6259 to remove the output gear retaining bolt and washer. To remove the output gear, use Gear Puller L4407A.
    • Remove the gauging shim and install the proper shim determined by the chart. Use grease to hold the shim in place.
    OUTPUT GEAR BEARING SHIM CHART

    End Play  Shim Needed  Part Number  - End Play  Shim Needed  Part Number 
    0.05mm (0.002 in.) 4.42mm (0.174 in.) 4412830AB - 0.53mm (0.021 in.) 3.94mm (0.155 in.) 4412818AB
    0.08mm (0.003 in.) 4.38mm (0.172 in.) 4412829AB - 0.56mm (0.022 in.) 3.90mm (0.154 in.) 4412817AB
    0.10mm (0.004 in.) 4.38mm (0.172 in.) 4412829AB - 0.58mm (0.023 in.) 3.90mm (0.154 in.) 4412817AB
    0.13mm (0.005 in.) 4.34mm (0.171 in.) 4412828AB - 0.61mm (0.024 in.) 3.86mm (0.152 in.) 4412816AB
    0.15mm (0.006 in.) 4.30mm (0.169 in.) 4412827AB - 0.64mm (0.025 in.) 3.82mm (0.150 in.) 4412815AB
    0.18mm (0.007 in.) 4.30mm (0.169 in.) 4412827AB - 0.66mm (0.026 in.) 3.82mm (0.150 in.) 4412815AB
    0.20mm (0.008 in.) 4.26mm (0.168 in.) 4412826AB - 0.69mm (0.027 in.) 3.78mm (0.149 in.) 4412814AB
    0.23mm (0.009 in.) 4.22mm (0.166 in.) 4412825AB - 0.71mm (0.028 in.) 3.74mm (0.147 in.) 4412813AB
    0.25mm (0.010 in.) 4.22mm (0.166 in.) 4412825AB - 0.74mm (0.029 in.) 3.74mm (0.147 in.) 4412813AB
    0.28mm (0.011 in.) 4.18mm (0.165 in.) 4412824AB - 0.76mm (0.030 in.) 3.70mm (0.146 in.) 4412812AB
    0.30mm (0.012 in.) 4.14mm (0.163 in.) 4412823AB - 0.79mm (0.031 in.) 3.66mm (0.144 in.) 4412811AB
    0.33mm (0.013 in.) 4.14mm (0.163 in.) 4412823AB - 0.81mm (0.032 in.) 3.66mm (0.144 in.) 4412811AB
    0.36mm (0.014 in.) 4.10mm (0.161 in.) 4412822AB - 0.84mm (0.033 in.) 3.62mm (0.143 in.) 4412810AB
    0.38mm (0.015 in.) 4.10mm (0.161 in.) 4412822AB - 0.86mm (0.034 in.) 3.62mm (0.143 in.) 4412810AB
    0.41mm (0.016 in.) 4.06mm (0.160 in.) 4412821AB - 0.89mm (0.035 in.) 3.58mm (0.141) 4412809AB
    0.43mm (0.017 in.) 4.02mm (0.158 in.) 4412820AB - 0.91mm (0.036 in.) 3.54mm (0.139 in.) 4412808AB
    0.46mm (0.018 in.) 4.02mm (0.158 in.) 4412820AB - 0.94mm (0.037 in.) 3.54mm (0.139 in.) 4412808AB
    0.48mm (0.019 in.) 3.98mm (0.157 in.) 4412819AB - 0.97mm (0.038 in.) 3.50mm (0.138 in.) 4412807AB
    0.51mm (0.020 in.) 3.94mm (0.155 in.) 4412818AB - - - -
    Fig 17: Installing Output Gear
    GC0000648Courtesy of CHRYSLER LLC
    1 - WRENCHES
    2 - INSTALLER 6261 WITH STUD
    3 - OUTPUT GEAR
  17. Install the output gear (3) and bearing assembly using Installer 6261 (2). See Fig 17.
    Fig 18: Removing/Installing Output Gear Bolt & Washer
    GC0000618Courtesy of CHRYSLER LLC
    1 - OUTPUT GEAR
    2 - BOLT
    3 - CONED LOCK WASHER
  18. Install NEW output gear retaining bolt (2) and washer (3). See Fig 18.
    Fig 19: Tightening Output Gear to 271 N.m (200 ft. lbs.)
    GC0000649Courtesy of CHRYSLER LLC
    1 - OUTPUT GEAR
    2 - TORQUE WRENCH
    3 - 200 FT. LBS.
    4 - HOLDER 6259
  19. Using Holder 6259 (4), torque output gear (1) retaining bolt to 271 N.m (200 ft. lbs.). See Fig 19.
    Fig 20: Checking Output Gear Bearings Turning Torque
    GC0000650Courtesy of CHRYSLER LLC
    1 - INCH-POUND TORQUE WRENCH
    2 - OUTPUT GEAR
  20. Using an inch pound torque wrench (1), check output shaft turning torque. See Fig 20.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: Installing Stirrup
    GC0000616Courtesy of CHRYSLER LLC
    1 - STIRRUP
    2 - OUTPUT GEAR RETAINING BOLT
  21. Install output gear stirrup (1) with serrated side out. See Fig 21.
    Fig 22: Removing/Installing Strap Bolts
    GC0000614Courtesy of CHRYSLER LLC
    1 - RETAINING STRAP
    2 - STIRRUP
    3 - RETAINING STRAP BOLTS
  22. Install retaining strap (1). See Fig 22.
  23. Install strap bolts (3) but do not tighten at this time.
    Fig 23: Turning Stirrup Clockwise Against Bolt Flats
    GC0000651Courtesy of CHRYSLER LLC
    1 - RETAINING STRAP
    2 - STIRRUP
  24. Rotate stirrup (2) clockwise against flats of retaining bolt. See Fig 23.
    Fig 24: Tightening Stirrup Strap Bolts to 23 N.m (200 in. lbs.)
    GC0000653Courtesy of CHRYSLER LLC
    1 - RETAINING STRAP
    2 - STIRRUP
  25. Torque stirrup strap bolts to 23 N.m (204 in. lbs.). See Fig 24.
    Fig 25: Bending Tabs On Strap Up Against Flats Of Bolts
    GC0000652Courtesy of CHRYSLER LLC
    1 - RETAINING STRAP TABS
    2 - RETAINING STRAP
    3 - STIRRUP
  26. Bend tabs (1) on strap up against flats of bolts. See Fig 25.
    Fig 26: Installing Transfer Shaft Bearing Cone
    GC0000654Courtesy of CHRYSLER LLC
    1 - INSTALLER 6052
    2 - NEW BEARING CONE
    3 - TRANSFER SHAFT
    4 - ARBOR PRESS RAM
  27. Install new transfer shaft bearing cone (2) using Installer 6052 (1). See Fig 26.
    Fig 27: Removing/Installing Transfer Shaft
    GC0000610Courtesy of CHRYSLER LLC
    1 - REMOVER/INSTALLER 5049-A
    2 - TRANSFER SHAFT
    3 - OUTPUT GEAR
  28. Using Remover/Installer 5049A (1), install transfer shaft (2). See Fig 27.
    Fig 28: Removing/Installing Transfer Shaft Bearing Snap Ring
    GC0000609Courtesy of CHRYSLER LLC
    1 - SNAP RING PLIERS 6051
    2 - TRANSFER SHAFT BEARING SNAP RING
    3 - TRANSFER SHAFT
  29. Using Snap Ring Pliers 6051 (1), install transfer shaft bearing snap ring (2). See Fig 28.
    Fig 29: Installing Transfer Shaft Bearing Cup Into Retainer
    GC0000655Courtesy of CHRYSLER LLC
    1 - ARBOR PRESS RAM
    2 - HANDLE C-4171
    3 - INSTALLER 6061
    4 - TRANSFER SHAFT BEARING CUP RETAINER
    5 - USE REMOVED BEARING CUP TO SUPPORT RETAINER
  30. Using an arbor press (1) install transfer shaft bearing cup into retainer using Installer 6061(3). Use removed bearing cup to support retainer (4). See Fig 29.
    Fig 30: Removing/Installing Bearing Cup Retainer
    GC0000606Courtesy of CHRYSLER LLC
    1 - ALIGN INDEXING TAB TO SLOT
    2 - BEARING CUP RETAINER
  31. Install bearing cup retainer (2) to transaxle. See Fig 30.
    Fig 31: Installing Transfer Gear Bearing Cone
    GC0000656Courtesy of CHRYSLER LLC
    1 - ARBOR PRESS RAM
    2 - HANDLE C-4171
    3 - NEW BEARING CONE
    4 - TRANSFER SHAFT GEAR
    5 - INSTALLER 5052
  32. Install new transfer gear bearing cone (3) to transfer gear (4) using Installer 5052 (5). See Fig 31.
    Fig 32: Removing/Installing Transfer Shaft Gear & (Select) Shim
    GC0000605Courtesy of CHRYSLER LLC
    1 - TRANSFER SHAFT GEAR
    2 - BEARING CUP RETAINER
    3 - SHIM (SELECT)
  33. TRANSFER GEAR BEARING ADJUSTMENT: 
    • Install a 4.66 mm (0.183 in.) gauging shim on the transfer shaft. See Fig 32.
    • Install transfer shaft gear using Installer 6261. Using Holder 6259, install transfer shaft gear retaining nut to 271 N.m (200 ft. lbs.).
    • Measure end play. Attach Gear Checking Plate 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 TRANSFER SHAFT BEARING SHIM CHART  for the required shim combination to obtain the proper bearing setting.
    • Use Holder 6259 to remove the retaining nut and washer. Remove the transfer shaft gear using Gear Puller L4407A.
    • Remove the gauging shim and install the proper shim indicated by the chart.
    TRANSFER SHAFT BEARING SHIM CHART

    End Play  Shim Needed  Part Number  - End Play  Shim Needed  Part Number 
    0.05mm (0.002 in.) 4.66mm (0.183 in.) 4505588AB - 0.76mm (0.030 in.) 3.94mm (0.155 in.) 4412818AB
    0.08mm (0.003 in.) 4.62mm (0.182 in.) 4412835AB - 0.79mm (0.031 in.) 3.90mm (0.154 in.) 4412817AB
    0.10mm (0.004 in.) 4.58mm (0.180 in.) 4412834AB - 0.81mm (0.032 in.) 3.90mm (0.154 in.) 4412817AB
    0.13mm (0.005 in.) 4.58mm (0.180 in.) 4412834AB - 0.84mm (0.033 in.) 3.86mm (0.152 in.) 4412816AB
    0.15mm (0.006 in.) 4.54mm (0.178 in.) 4412833AB - 0.86mm (0.034 in.) 3.82mm (0.150 in.) 4412815AB
    0.18mm (0.007 in.) 4.50mm (0.177 in.) 4412832AB - 0.89mm (0.035 in.) 3.82mm (0.150 in.) 4412815AB
    0.20mm (0.008 in.) 4.50mm (0.177 in.) 4412832AB - 0.91mm (0.036 in.) 3.78mm (0.149 in.) 4412814AB
    0.23mm (0.009 in.) 4.46mm (0.175 in.) 4412831AB - 0.94mm (0.037 in.) 3.74mm (0.147 in.) 4412813AB
    0.25mm (0.010 in.) 4.46mm (0.175 in.) 4412831AB - 0.97mm (0.038 in.) 3.74mm (0.147 in.) 4412813AB
    0.28mm (0.011 in.) 4.42mm (0.174 in.) 4412830AB - 0.99mm (0.039 in.) 3.70mm (0.146 in.) 4412812AB
    0.30mm (0.012 in.) 4.38mm (0.172 in.) 4412829AB - 1.02mm (0.040 in.) 3.66mm (0.144 in.) 4412811AB
    0.33mm (0.013 in.) 4.38mm (0.172 in.) 4412829AB - 1.04mm (0.041 in.) 3.66mm (0.144 in.) 4412811AB
    0.36mm (0.014 in.) 4.34mm (0.171 in.) 4412828AB - 1.07mm (0.042 in.) 3.62mm (0.143 in.) 4412810AB
    0.38mm (0.015 in.) 4.30mm (0.169 in.) 4412827AB - 1.08mm (0.043 in.) 3.62mm (0.143 in.) 4412810AB
    0.41mm (0.016 in.) 4.30mm (0.169 in.) 4412827AB - 1.12mm (0.044 in.) 3.58mm (0.141) 4412809AB
    0.43mm (0.017 in.) 4.26mm (0.168 in.) 4412826AB - 1.14mm (0.045 in.) 3.54mm (0.139 in.) 4412808AB
    0.46mm (0.018 in.) 4.22mm (0.166 in.) 4412825AB - 1.17mm (0.046 in.) 3.54mm (0.139 in.) 4412808AB
    0.48mm (0.019 in.) 4.22mm (0.166 in.) 4412825AB - 1.19mm (0.047 in.) 3.50mm (0.138 in.) 4412807AB
    0.50mm (0.020 in.) 4.18mm (0.165 in.) 4412824AB - 1.22mm (0.048 in.) 3.46mm (0.136 in.) 4412806AB
    0.53mm (0.021 in.) 4.18mm (0.165 in.) 4412824AB - 1.24mm (0.049 in.) 3.46mm (0.136 in.) 4412806AB
    0.56mm (0.022 in.) 4.14mm (0.163 in.) 4412823AB - 1.27mm (0.050 in.) 3.42mm (0.135 in.) 4412805AB
    0.58mm (0.023 in.) 4.10mm (0.161 in.) 4412822AB - 1.30mm (0.051 in.) 3.38mm (0.133 in.) 4412804AB
    0.61mm (0.024 in.) 4.10mm (0.161 in.) 4412822AB - 1.32mm (0.052 in.) 3.38mm (0.133 in.) 4412804AB
    0.64mm (0.025 in.) 4.06mm (0.160 in.) 4412821AB - 1.35mm (0.053 in.) 3.34mm (0.132 in.) 4412803AB
    0.66mm (0.026 in.) 4.02mm (0.158 in.) 4412820AB - 1.37mm (0.054 in.) 3.34mm (0.132 in.) 4412803AB
    0.69mm (0.027 in.) 4.02mm (0.158 in.) 4412820AB - 1.40mm (0.055 in.) 3.30mm (0.130 in.) 4412802AB
    0.71mm (0.028 in.) 3.98mm (0.157 in.) 4412819AB - 1.45mm (0.057 in 3.26mm (0.128 in.) 4412801AB
    0.74mm (0.029 in.) 3.94mm (0.155 in.) 4412818AB - 1.47mm (0.058 in.) 2.22mm (0.127 in.) 4505570AB
    Fig 33: Installing Transfer Shaft Gear
    GC0000657Courtesy of CHRYSLER LLC
    1 - WRENCHES
    2 - INSTALLER 6261
    3 - OUTPUT GEAR
    4 - TRANSFER SHAFT GEAR
  34. Install the transfer shaft gear (4) using Installer 6261 (2). See Fig 33.
    Fig 34: Tightening Transfer Gear Nut To 271 N.m (200 ft. lbs.)
    GC0000668Courtesy of CHRYSLER LLC
    1 - TRANSFER SHAFT GEAR
    2 - 200 FT. LBS.
    3 - TORQUE WRENCH
    4 - HOLDER 6259
    CAUTION: Install a NEW retaining nut, as the original nut MUST NOT be reused.
  35. Install the new retaining nut and washer.
  36. Using Holder 6259 (4), torque transfer gear retaining nut to 271 N.m (200 ft. lbs.). See Fig 34.
    Fig 35: Removing/Installing Rear Cover
    GC0000601Courtesy of CHRYSLER LLC
    1 - REAR COVER
    2 - 1/8 INCH BEAD OF MOPAR® ATF RTV (MS-GF41)
  37. 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.
  38. Install a bead of Mopar® ATF RTV (MS-GF41) (2) to transfer gear cover (1). See Fig 35.
    Fig 36: Removing/Installing Rear Cover Bolts
    GC0000600Courtesy of CHRYSLER LLC
    1 - REAR COVER BOLTS
    2 - REAR COVER
    3 - USE SEALANT ON BOLTS
  39. Use sealant on bolts (3), install transfer gear cover-to-case bolts (1) and torque to 20 N.m (175 in. lbs.) torque. See Fig 36.
    Fig 37: Identifying Low/Reverse Clutch Pack
    GC0000599Courtesy of CHRYSLER LLC
    1 - CLUTCH PLATES (5)
    2 - CLUTCH DISCS (5)
  40. Install low/reverse clutch pack (1,2). See Fig 37. Leave uppermost disc out until snap ring is installed.
    Fig 38: Removing/Installing Low/Reverse Reaction Plate Snap Ring
    GC0000598Courtesy of CHRYSLER LLC
    1 - SCREWDRIVER
    2 - LOW/REVERSE REACTION PLATE FLAT SNAP RING
    3 - DO NOT SCRATCH CLUTCH PLATE
  41. Install low/reverse reaction plate flat snap ring (2) insure you do not scratch clutch plate (3). See Fig 38.
    Fig 39: Removing/Installing One Disc
    GC0000597Courtesy of CHRYSLER LLC
    1 - ONE DISC FROM LOW/REVERSE CLUTCH
  42. Install remaining low/reverse clutch disc (1). See Fig 39.
    Fig 40: Removing/Installing Low/Reverse Reaction Plate
    GC0000596Courtesy of CHRYSLER LLC
    1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP)
  43. Install low/reverse reaction plate with flat side up (1). See Fig 40.
    Fig 41: View Of Tapered Snap Ring Instructions
    GC0000669Courtesy of CHRYSLER LLC
  44. Use as a reference while installing tapered snap ring. See Fig 41.
    Fig 42: Installing Snap Ring
    GC0000659Courtesy of CHRYSLER LLC
    1 - SCREWDRIVER
    2 - TAPERED SNAP RING (INSTALL AS SHOWN)
  45. Install tapered snap ring (with tapered side up) (2). See Fig 42.
    Fig 43: Checking Low/Reverse Clutch Clearance
    GC0000660Courtesy of CHRYSLER LLC
    1 - DIAL INDICATOR
    2 - DIAL INDICATOR TIP TOOL 6268
    3 - HOOK TOOL
  46. Set up dial indicator (1) 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 places. Take average of readings and select the proper low/reverse reaction plate to achieve specifications. See Fig 43.
    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.)
    Fig 44: Identifying 2/4 Clutch Pack
    GC0000594Courtesy of CHRYSLER LLC
    1 - CLUTCH PLATE (4)
    2 - CLUTCH DISC (4)
  47. Install 2/4 clutch pack (1, 2). See Fig 44.
    Fig 45: View Of Proper Orientation Of 2/4 Clutch Retainer & Spring
    GC0000663Courtesy of CHRYSLER LLC
    1 - NOTE POSITION
    2 - RETURN SPRING
    3 - 2/4 CLUTCH RETAINER
    NOTE: The 2/4 Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.
  48. Orient 2/4 clutch return spring to retainer (3). See Fig 45.
    Fig 46: Identifying 2/4 Clutch Retainer
    GC0000592Courtesy of CHRYSLER LLC
    1 - 2/4 CLUTCH RETAINER
    2 - 2/4 CLUTCH RETURN SPRING
  49. Install 2/4 clutch retainer to transaxle (1, 2). See Fig 46.
    Fig 47: Removing/Installing 2/4 Clutch Retainer Snap Ring
    GC0000549Courtesy of CHRYSLER LLC
    1 - COMPRESSING TOOL 5058-A
    2 - SCREWDRIVER
    3 - SNAP RING
    4 - 2/4 CLUTCH RETAINER
  50. Using Compressing Tool 5058-A (1), compress 2/4 clutch return spring just enough to install snap ring (3). See Fig 47.
  51. Install snap ring.
    Fig 48: Checking 2/4 Clutch Clearance
    GC0000667Courtesy of CHRYSLER LLC
    1 - DIAL INDICATOR
    2 - HOOK TOOL
    3 - DIAL INDICATOR TIP 6268
  52. Set up dial indicator (1) 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.  See Fig 48.
    Fig 49: Identifying Rear Sun Gear & No. 7 Needle Bearing
    GC0000640Courtesy of CHRYSLER LLC
    1 - #7 NEEDLE BEARING
    2 - REAR SUN GEAR
    NOTE: The number seven needle (1) 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. A small amount of petrolatum can be used to hold the bearing to the rear sun gear (2). See Fig 49.
    Fig 50: Identifying Rear Sun Gear & No. 7 Needle Bearing
    GC0000639Courtesy of CHRYSLER LLC
    1 - #7 NEEDLE BEARING
    2 - REAR SUN GEAR
  53. Install rear sun gear (2) and #7 needle bearing (1). See Fig 50.
    Fig 51: Removing/Installing Front Carrier & Rear Annulus Assembly
    GC0000589Courtesy of CHRYSLER LLC
    1 - #6 NEEDLE BEARING
    2 - FRONT CARRIER AND REAR ANNULUS ASSEMBLY (TWIST AND PULL OR PUSH TO REMOVE OR INSTALL).
  54. Install front carrier/rear annulus assembly (2) and #6 needle bearing (1). See Fig 51.
    Fig 52: View Of Front Sun Gear Assembly & #4 Thrust Washer
    GC0000588Courtesy of CHRYSLER LLC
    1 - FRONT SUN GEAR ASSEMBLY
    2 - #4 THRUST WASHER (FOUR TABS)
  55. Install front sun gear assembly (1) and #4 thrust washer (2). See Fig 52.
    Fig 53: Identifying No. 4 Thrust Plate
    GC0000587Courtesy of CHRYSLER LLC
    1 - OVERDRIVE SHAFT ASSEMBLY
    2 - #4 THRUST PLATE (SELECT)
    3 - 3 DABS OF PETROLATUM FOR RETENTION
  56. Select the thinnest #4 thrust plate thickness (2) and install to input clutch assembly. Use petrolatum to retain (3). See Fig 53.
    Fig 54: View Through Input Speed Sensor Hole
    GC0000664Courtesy of CHRYSLER LLC
    1 - INPUT CLUTCH RETAINER
    2 - INPUT SPEED SENSOR HOLE
    3 - OIL COOLER FITTINGS
  57. Install input clutch assembly into position and verify that it is completely seated by viewing through input speed sensor hole (2). If view through input speed sensor hole is not as shown in the below view, the input clutch assembly is not seated properly. See Fig 54.
    Fig 55: Removing/Installing Oil Pump O-Ring
    GC0000665Courtesy of CHRYSLER LLC
    1 - OIL PUMP ASSEMBLY
    2 - O-RING
  58. Remove oil pump o-ring (2). Be sure to reinstall oil pump o-ring after selecting the proper #4 thrust plate.  See Fig 55.
  59. Install pump and gasket to transmission. Install and torque bolts.
    Fig 56: Measuring Input Shaft End Play Using End Play Set 8266
    GC0000666Courtesy of CHRYSLER LLC
    1 - END PLAY SOCKET SET 8266
    2 - DIAL INDICATOR C-3339
    -
  60. Set up input shaft for measurement with Indicator Set C3339 (3) and End Play Set 8266 (1). See Fig 56.
  61. 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.
  62. Refer to the NO. 4 THRUST PLATE CHART  to select the proper No. 4 thrust plate.
    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.)
    Fig 57: Removing/Installing Input Clutch Assembly
    GC0000586Courtesy of CHRYSLER LLC
    1 - INPUT CLUTCH ASSEMBLY
    2 - #4 THRUST WASHER
  63. Install input clutch assembly (1). See Fig 57.
    Fig 58: Removing/Installing Caged Needle Bearing
    GC0000585Courtesy of CHRYSLER LLC
    1 - #1 CAGED NEEDLE BEARING
    2 - NOTE: TANGED SIDE OUT
  64. Install #1 caged needle bearing (1) note: tanged side out (2). See Fig 58.
    CAUTION: The cooler bypass valve must be replaced if transaxle failure has occurred. Do not attempt to reuse or clean old valve.
    Fig 59: Removing/Installing Bypass Valve
    GC0000584Courtesy of CHRYSLER LLC
    1 - COOLER BYPASS VALVE
  65. Install cooler bypass valve (1) with o-ring end towards rear of case. See Fig 59.
    Fig 60: Removing/Installing Oil Pump Gasket
    GC0000583Courtesy of CHRYSLER LLC
    1 - PUMP GASKET
  66. Install oil pump gasket (1). See Fig 60.
    Fig 61: Removing/Installing Oil Pump
    GC0000582Courtesy of CHRYSLER LLC
    1 - OIL PUMP
    2 - GASKET
  67. Install oil pump (1). See Fig 61.
    Fig 62: Removing/Installing Pump Bolts
    GC0000579Courtesy of CHRYSLER LLC
    1 - PUMP ATTACHING BOLTS
    2 - PUMP HOUSING
  68. Install oil pump-to-case bolts (1) and torque to 27 N.m (20 ft. lbs.). See Fig 62.
    Fig 63: Installing Low/Reverse Accumulator
    GC0000577Courtesy of CHRYSLER LLC
    1 - ACCUMULATOR PISTON
    2 - SEAL RINGS
    3 - RETURN SPRINGS
    4 - (NOTE NOTCH)
  69. Install low/reverse accumulator (1). See Fig 63.
    Fig 64: Removing Low/Reverse Accumulator Plug (Cover)
    GC0000575Courtesy of CHRYSLER LLC
    1 - ADJUSTABLE PLIERS
    2 - PLUG
  70. Install low/reverse accumulator plug (2). See Fig 64.
    Fig 65: Removing/Installing Low/Reverse Accumulator Snap Ring
    GC0000574Courtesy of CHRYSLER LLC
    1 - SNAP RING
    2 - PLUG
  71. Install low/reverse accumulator snap ring (1). See Fig 65.
    Fig 66: Identifying Underdrive & Overdrive Accumulators
    GC0000641Courtesy of CHRYSLER LLC
    1 - OVERDRIVE PISTON AND SPRING
    2 - UNDERDRIVE PISTON AND SPRING
    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.
  72. Install underdrive and overdrive accumulators (1, 2). See Fig 66.
    Fig 67: Removing/Installing Valve Body
    GC0000569Courtesy of CHRYSLER LLC
    1 - VALVE BODY
  73. Install valve body (1) to transaxle. Rotate manual valve shaft fully clockwise to ease installation. Make sure park rod rollers are positioned within park guide bracket. See Fig 67.
    Fig 68: Removing/Installing Valve Body Bolts
    GC0000567Courtesy of CHRYSLER LLC
    1 - VALVE BODY ATTACHING BOLTS (18)
    2 - VALVE BODY
  74. Install and torque valve body-to-case bolts (1) to 12 N.m (105 in. lbs.). See Fig 68.
    Fig 69: Removing/Installing Oil Filter
    GC0000566Courtesy of CHRYSLER LLC
    1 - OIL FILTER
    2 - O-RING
  75. Install oil filter (1) and new o-ring (2). See Fig 69.
    Fig 70: Removing/Installing Oil Pan
    GC0000565Courtesy of CHRYSLER LLC
    1 - OIL PAN
    2 - 1/8 INCH BEAD OF MOPAR® ATF RTV (MS-GF41)
    3 - OIL FILTER
  76. Apply an 1/8" bead of Mopar® ATF RTV (MS-GF41) (2) to oil pan (1) and immediately install to case. See Fig 70.
    Fig 71: Identifying Solenoid/Pressure Switch Assembly & Gasket
    GC0000563Courtesy of CHRYSLER LLC
    1 - SOLENOID/PRESSURE SWITCH ASSEMBLY
    2 - GASKET
  77. Install oil pan-to-case bolts and torque to 19 N.m (165 in. lbs.).
  78. Install solenoid/pressure switch assembly (1) and gasket (2) to case. See Fig 71.
    Fig 72: Identifying Solenoid Pack-To-Transaxle Bolts
    GC0000562Courtesy of CHRYSLER LLC
    1 - BOLTS
    2 - SOLENOID AND PRESSURE SWITCH ASSEMBLY
  79. Install and tighten solenoid/pressure switch assembly-to-transaxle case bolts (1) to 12 N.m (110 in. lbs.). See Fig 72.
  80. Install and torque input and output speed sensors to case to 27 N.m (20 ft. lbs.).
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