Section 1288 (As69RC Automatic Transmission (Service Information) 3500 Hd): Assembly: Assembly: Notes

WARNING: This page is about a different car, the 2016 RAM 3500 HD. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

If the transmission is being reconditioned (clutch/seal replacement) or replaced, it is necessary to perform the Quick Learn Procedure using the scan tool. Refer to MODULE, TRANSMISSION CONTROL, MODULE PROGRAMMING .

NOTE:

Apply trans jell or petroleum jelly to all slide portions, rolling contacts surfaces, thrust surfaces etc. to prevent burnout during initial operation. Lubricate O-rings and O-ring seals with MOPAR® ASRC ATF. Soak all friction discs in MOPAR® ASRC ATF for at least two hours before assembly of clutch packs.

Fig 1: Transmission Component Locations

Courtesy of CHRYSLER GROUP, LLC

Fig 2: Thrust Bearing Orientation

Courtesy of CHRYSLER GROUP, LLC

1 - CORRECT INSTALLATION

2 - INCORRECT INSTALLATION

CAUTION:

A thrust bearing must be installed correctly or transmission failure may occur.

When installing a thrust bearing be certain the rolled surface (outer race) of the thrust bearing contacts the rolled surface of the component.

NOTE:

Before final assembly of the transmission a B1 and B2 piston and clutch pack clearance check must be preformed.

Fig 3: Installing NEW Roll Pin

Courtesy of CHRYSLER GROUP, LLC

If removed, prepare the manual shaft for installation by placing a NEW roll pin retaining sleeve on the rooster comb.
While holding the rooster comb in position, slide the manual shaft through the transmission case and rooster comb.
Rotate the roll pin locking sleeve (1) with the blind hole in the rooster comb (3) and make a mark (2) on the rooster comb to identify the location of the blind hole in the rooster comb.

Fig 4: Rotating Roll Pin Locking Sleeve
Courtesy of CHRYSLER GROUP, LLC
Rotate the roll pin locking sleeve (1) so that so that a roll pin can be inserted through the bore (2) of the rooster comb (3) and manual shaft.
Install a NEW roll pin so that it is flush with rooster comb and the roll pin locking sleeve can rotate freely.

Fig 5: Turning Roll Pin Locking Sleeve
Courtesy of CHRYSLER GROUP, LLC
Turn the roll pin locking sleeve (3) that both ends of the roll pin are covered.
Using a suitable punch (1), stake the roll pin locking sleeve (3) to the rooster comb blind hole so that it cannot rotate. The blind hole location on the rooster comb is indicated by the previously made mark (2).
Install the park rod to the rooster comb.

Fig 6: B2 Piston
Courtesy of CHRYSLER GROUP, LLC
Lubricate the B2 brake piston seals with MOPAR® ASRC ATF and install the B2 brake piston (2) into the extension housing, making sure the alignment mark on the piston lines up with the alignment mark on the case (1).

Fig 7: B2 Return Spring
Courtesy of CHRYSLER GROUP, LLC
Install the B2 brake piston return spring assembly.

Fig 8: B2 Piston Compress
Courtesy of CHRYSLER GROUP, LLC
Install bolt (special tool #8622, Screw, Clutch Spring Compressor) (1), (special tool #9982-2, Plate, Back Up) (3) and compressor (special tool #MB991790, Compressor, Spring) onto the B2 brake piston assembly and compress the B2 brake piston spring.

Fig 9: B2 Snap Ring
Courtesy of CHRYSLER GROUP, LLC
Install the B2 brake piston snap ring.

Fig 10: B2 Clutch Snap Ring
Courtesy of CHRYSLER GROUP, LLC

1 - SNAP RING
Install the B2 wide snap ring (1).

Fig 11: B2 Clutches
Courtesy of CHRYSLER GROUP, LLC

NOTE:
For the B2 brake, only the rear most plate (towards the piston) is selectable. However, the front most pressure plate (towards snap ring), always uses the plate marked "D".
Install the (special tool #9982-1, Compressor) compressor plate into the transmission case in order to check the clutch pack clearance.

Install the B2 brake clutch pack into the transmission case.

CLUTCH CLEARANCE AND PISTON TRAVEL COMBINATIONS

	MEASUREMENT ITEM	CONDITION	SUSPECTED CAUSE	ACTION
	Clutch Clearance	Normal	Discs/Plates are worn thin and warped, snap ring and groove height, piston wear.	Replace the discs and plates and recheck clearances. If not OK- Check the piston, snap ring and snap ring groove
	Piston Travel	High
LOW PROBABILITY	Clutch Clearance	Normal	Piston travel issue (interference, obstruction from broken part) or Discs/Plates are too thick (above specs.) and snap ring grove at wrong height (high).	Replace the discs and plates and recheck clearances. If not OK- Check the piston, snap ring and snap ring groove
	Piston Travel	Low
LOW PROBABILITY	Clutch Clearance	High	Low possibility, piston height, snap-ring groove, snap-ring thickness, disk and plates thickness and flatness.	Replace the discs and plates and recheck clearances. If not OK- Check the piston, snap ring and snap ring groove.
	Piston Travel	Normal
	Clutch Clearance	High	Discs/Plates are worn (thin) or snap ring thickness groove height, piston height.	Replace the discs and plates and recheck clearances. If not OK- Check the piston, snap ring and snap ring groove.
	Piston Travel	High
LOW PROBABILITY	Clutch Clearance	High	Piston travel issue (interference, obstruction from broken part combined with improper piston height, snap ring groove wear or height, or snap ring thickness) or piston does not fully return.	Replace the discs and plates and recheck clearances. If not OK- Check the piston, snap ring and snap ring groove.
	Piston Travel	Low
	Clutch Clearance	Low	Discs/Plates are not flat or combination of high piston height and low snap ring groove height.	Replace the discs and plates and recheck clearances. If not OK- Check the piston, snap ring and snap ring groove.
	Piston Travel	Normal
	Clutch Clearance	Low	Discs/Plates are worn (thin) and warped.	Replace the discs and plates and recheck clearances. If not OK- Check the piston, snap ring and snap ring groove
	Piston Travel	High
	Clutch Clearance	Low	Discs/Plates are too thick/extra discs or snap ring height too low or piston too tall.	Replace the discs and plates and recheck clearances. If not OK- Check the piston, snap ring and snap ring groove
	Piston Travel	Low

Fig 12: Dial Indicator & Clutch Compressor Plate

Courtesy of CHRYSLER GROUP, LLC

1 - 9524 90° DIAL INDICATOR

2 - 9982-1 CLUTCH COMPRESSOR PLATE

NOTE:

If the B2 brake piston assembly stroke is not within tolerance, check the B2 brake piston seals and the hydraulic fluid circuit path.

Using two bolts, temporarily install the extension housing onto the transmission case.

Install the (special tool #9524, Indicator, Dial) 90° Dial Indicator and mounts from the Dial Indicator Set (special tool #C-3339A, Set, Dial Indicator) and Extension Tip MLR- (special tool #6268, Tip, Dial Indicator) so that the extension tip passes through one of the two smaller holes in the transmission case bulk head and through a void in the (special tool #9982-1, Compressor) compressor plate in order to contact the B2 brake piston.

Fig 13: Transmission Brake & Clutch Pistons

Courtesy of CHRYSLER GROUP, LLC

1 - B2 BRAKE

2 - K3 CLUTCH

3 - K2 CLUTCH

4 - K1 CLUTCH

5 - B1 BRAKE

Apply 400-500 kPa (58 - 72 psi) of air to check the B2 (1) piston stroke. Refer to DIAGNOSIS AND TESTING .
The B2 brake piston stroke clearance is 1.84 - 2.28 mm (0.072 - 0.090 in.).

NOTE:
The selectable clutch pack reaction plates are identified by an alpha numeric numeral stamped into the face of the plate.

Fig 14: Dial Indicator & Clutch Compressor Plate
Courtesy of CHRYSLER GROUP, LLC

1 - 9524 90° DIAL INDICATOR

2 -9982 CLUTCH COMPRESSOR PLATE

Move the 90° Dial Indicator (special tool #9524, Indicator, Dial) and mounts from Dial Indicator Set (special tool #C-3339A, Set, Dial Indicator) (1) and extension tip MLR- (special tool #6268, Tip, Dial Indicator) so that it makes contact with the (special tool #9982-1, Compressor) compressor plate (2).

Fig 15: Transmission Brake & Clutch Pistons

Courtesy of CHRYSLER GROUP, LLC

1 - B2 BRAKE

2 - K3 CLUTCH

3 - K2 CLUTCH

4 - K1 CLUTCH

5 - B1 BRAKE

Apply 400 - 500 kPa(58 - 72 psi) of air to check the B2 brake clutch clearance. Refer to DIAGNOSIS AND TESTING .
The B2 brake clutch pack clearance is 1.60 - 2.04 mm (0.063 - 0.080 in.). If the clearance is not within tolerance choose the correct selectable reaction plate.
- A = 5.40 mm (0.212 in.)
- B = 5.60 mm (0.220 in.)
- C = 5.80 mm (0.228 in.)
- D = 6.00 mm (0.236 in.)
Assemble and disassemble as necessary to achieve the correct B2 brake clearance.
Remove the dial indicator set.
Remove the extension housing and set aside.
Remove the B2 clutch pack and snap ring.
Remove the (special tool #9982-1, Compressor) compressor plate.

Fig 16: B1 Piston Groove
Courtesy of CHRYSLER GROUP, LLC

NOTE:
The orientation of the groove on the B1 piston is at the 12:00 o'clock position to the transmission case.
Apply MOPAR® ASRC ATF to the seals of the B1 piston and install the piston into the transmission case.

Fig 17: B1 Piston Compress
Courtesy of CHRYSLER GROUP, LLC
Install the B1 piston return spring and a wide snap ring into the transmission case using tools (special tool #8622, Screw, Clutch Spring Compressor), (special tool #9982-1, Compressor) and (special tool #9982-2, Plate, Back Up).
NOTE:
Place special tool 9982-1 onto the piston return spring.

Fig 18: B1 Clutches
Courtesy of CHRYSLER GROUP, LLC
Install the B1 clutch assembly, into the deeper grooves of the transmission case with the thickest pressure plate to the inside and install a wide snap ring.

Fig 19: B1 Piston Travel
Courtesy of CHRYSLER GROUP, LLC

NOTE:
If the B1 brake piston assembly stroke is not within tolerance, check the B1 brake piston seals and the hydraulic fluid circuit path.

Install the Dial Indicator set (special tool #C-3339A, Set, Dial Indicator) and extension tip MLR- (special tool #6268, Tip, Dial Indicator) so the dial indicator tip contacts the B1 brake piston and check the B1 brake piston assembly stroke.

Fig 20: Transmission Brake & Clutch Pistons

Courtesy of CHRYSLER GROUP, LLC

1 - B2 BRAKE

2 - K3 CLUTCH

3 - K2 CLUTCH

4 - K1 CLUTCH

5 - B1 BRAKE

Apply 400-500 kPa (58 - 72 psi) of air to check the B1 (5) piston stroke. Refer to DIAGNOSIS AND TESTING .
The B1 brake piston stroke clearance is 1.55 - 1.80 mm (0.061 - 0.071 in.)

NOTE:
The selectable clutch pack reaction plates are identified by an alpha numeric numeral stamped into the face of the plate.
Move the Dial Indicator Set (special tool #C-3339A, Set, Dial Indicator) (1) and extension tip MLR- (special tool #6268, Tip, Dial Indicator) so the tip makes contact with the B1 brake clutch pack apply 400 - 500 kPa(58 - 72 psi) of air (2) to check the B1 brake clutch pack clearance
Refer to DIAGNOSIS AND TESTING .

The B1 brake clutch pack clearance is 1.25 - 1.50 mm (0.049 - 0.059 in.). If the clearance is not within tolerance, choose the correct selectable reaction plate.
- A = 5.40 mm (0.212 in.)
- B = 5.55 mm (0.218 in.)
- C = 5.70 mm (0.224 in.)
- D = 5.85 mm (0.230 in.)
- E = 6.0 mm (0.236 in.)

Remove the dial indicator set (special tool #C-3339A, Set, Dial Indicator) and extension tip MLR- (special tool #6268, Tip, Dial Indicator).

CAUTION:

While installing the trust washers and bearings be certain they are orientated correctly to the transmission component. A thrust bearing must be installed correctly or transmission failure may occur.

Fig 21: Thrust Bearing And Washer Orientation Behind Bulkhead

Courtesy of CHRYSLER GROUP, LLC

1- TRANSMISSION BULK HEAD

2 - THRUST BEARING NO. 9

3 - THRUST BEARING NO. 10

4 - THRUST BEARING RACE / WASHER

5 - THRUST BEARING NO. 11

6 - THRUST BEARING NO. 12

7 - THRUST WASHER

8 - THRUST BEARING NO. 13

9 - THRUST BEARING NO. 14

10 - SELECTABLE END PLAY WASHER

11 - SELECTABLE END PLAY WASHER (4WD)

12 - OIL PAN

Fig 22: Installing P2 Carrier Thrust Bearing No. 9

Courtesy of CHRYSLER GROUP, LLC

1 - P2 CARRIER THRUST BEARING NO. 9

Lubricate with trans jell or petroleum jelly and install the number nine thrust bearing into the transmission case.

Fig 23: P2 Planetary Annulus Gear
Courtesy of CHRYSLER GROUP, LLC
Install the B2 clutch pack and a wide snap ring.
Install the P2 planetary annulus gear.

Fig 24: P2 Planetary Gear Thrust Bearing No. 10
Courtesy of CHRYSLER GROUP, LLC
Lubricate with trans jell or petroleum jelly and install the number ten thrust bearing into the transmission case.

Fig 25: P2 Planetary Carrier
Courtesy of CHRYSLER GROUP, LLC

Install P2 planetary gear carrier into the transmission case.

NOTE:

Be certain the sun gear shaft seal rings are in position. Lubricate the front sun gear shaft seal ring with MOPAR® ASRC ATF.

Fig 26: Sun Gear Shaft

Courtesy of CHRYSLER GROUP, LLC

1 - SUN GEAR SHAFT

2 - THRUST BEARING NO. 11

3 - THRUST BEARING RACE / WASHER

Lubricate with trans jell or petroleum jelly and install the number eleven thrust bearing (2) and thrust bearing race/washer (3) and the sun gear shaft (1) into the transmission case.

Fig 27: P3 Planetary Front Thrust Bearing No. 12
Courtesy of CHRYSLER GROUP, LLC
Lubricate with trans jell or petroleum jelly and install the number twelve thrust bearing.

Fig 28: P3 Planetary Carrier
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Install the P3 planetary gear carrier the transmission case.

Fig 29: Thrust Bearing & Washer No. 13
Courtesy of CHRYSLER GROUP, LLC
Lubricate with trans jell or petroleum jelly and install the number thirteen thrust bearing and washer.

Fig 30: P3 Annulus Gear
Courtesy of CHRYSLER GROUP, LLC

Install the P3 annulus gear.

Fig 31: Park Pawl 1

Courtesy of CHRYSLER GROUP, LLC

1 - PARK PAWL

2 - PARK PAWL WASHER

3 - PARK PAWL SPRING

NOTE:

Install the park brake pawl with spring to pull pawl away from the park brake gear.

Install the park brake pawl assembly.

Fig 32: F1 Clutch Thrust Bearing No. 14
Courtesy of CHRYSLER GROUP, LLC

1 - B2 CLUTCH THRUST BEARING NO. 14
Lubricate with trans jell or petroleum jelly and install the number fourteen thrust bearing.

Fig 33: Output Shaft & Shim
Courtesy of CHRYSLER GROUP, LLC
Install the output shaft (1) and shim (2) into the transmission case.

Fig 34: Removing Park Gear
Courtesy of CHRYSLER GROUP, LLC
Install the park lock gear onto the output shaft.

Fig 35: Removing/Installing Output Shaft End Play Selectable Washer And Spacer
Courtesy of CHRYSLER GROUP, LLC

1 - OUTPUT SHAFT END PLAY SELECTABLE WASHER

2 - SPACER
Install the selectable end play washer (1) onto the output shaft and park lock gear assembly.

Fig 36: Removing/Installing Park Pawl Pivot Thrust Washer
Courtesy of CHRYSLER GROUP, LLC
Install the park pawl pivot thrust washer between the extension housing and trans case.
NOTE:
Trans gel or petroleum jelly can be applied to the park pawl thrust washer to aid in the extension housing installation.

Fig 37: Extension Housing
Courtesy of CHRYSLER GROUP, LLC
Install the extension housing with a new gasket, while aligning park brake shaft and the transmission range selector shaft, onto the transmission case.

Install and tighten the extension housing bolts. Tighten bolts to 37 N.m (27 ft. lbs.).

NOTE:

End- play readings that are below specification (smaller gap) may indicate that a bearing is out of position or that the transmission might have been set-up incorrectly.

NOTE:

The selectable output shaft end-play washers are identified by an alpha numeric numeral stamped onto the face of the washer.

Fig 38: 2WD End-Play Check

Courtesy of CHRYSLER GROUP, LLC

1 - C-3339A DIAL INDICATOR

2 - 8266-8 HANDLE

3 - 8266-22 SOCKET

Install (special tool #8266-22, Socket, End Play) and snug the set screw. Install (special tool #8266-8, Handle) onto the socket and tighten screw.
Install (special tool #C-3339A, Set, Dial Indicator).
With the transmission in a vertical position, measure and record the output shaft end-play. The output shaft end-play clearance is 0.50-0.90 mm (0.019-0.035 in.). Assemble and disassemble as necessary to achieve the correct output shaft end-play clearance.
2WD and 4WD EXTENSION HOUSING INTERNAL SELECTABLE END-PLAY WASHERS
- I = 1.00mm (0.039 in.)
- J = 1.20 mm (0.047 in.)
- K = 1.40 mm (0.055 in.)
- L = 1.60 mm (0.063 in.)
- M = 1.80 mm (0.071 in.)
- N = 2.00 mm (0.079 in.)
Remove the Dial Indicator (2) set up.

Fig 39: Output Shaft Flange
Courtesy of CHRYSLER GROUP, LLC

1 - OUTPUT SHAFT FLANGE

2 - O-RING SEAL
Install a new output shaft seal into the 2WD extension housing using (special tool #10476, Installer, Seal).
Install the output shaft flange (1) and O-ring seal (2).

Fig 40: Installing Flange Holder Tool C-3281 To Assist In Removing Output Flange Nut
Courtesy of CHRYSLER GROUP, LLC

1 - FLANGE HOLDER TOOL C-3281

NOTE:
Do not exceed the specified torque value on the output shaft nut.
Install the NEW output shaft flange nut and tighten to 210 N.m (155 ft.lbs.).

Using a small chisel, stake the output shaft flange nut into the void on the output shaft.

CAUTION:

While installing the trust washers and bearings be certain they are orientated correctly to the transmission component. A thrust bearing must be installed correctly or transmission failure may occur.

Fig 41: Thrust Washer And Bearing Orientation Before Bulkhead

Courtesy of CHRYSLER GROUP, LLC

1 - NYLON WASHER

2 - THRUST WASHER

3 - THRUST BEARING NO. 1 (WITH SELECTABLE RACE)

4 - THRUST BEARING NO. 2

5 - THRUST BEARING NO. 3

6 - THRUST BEARING NO. 4

7 - THRUST BEARING NO. 5

8 - THRUST BEARING NO. 6

9 - THRUST BEARING NO. 7

10 - THRUST BEARING NO. 8

11 - TRANSMISSION BULK HEAD

12 - OIL PAN

Fig 42: K3 Support Seal Rings

Courtesy of CHRYSLER GROUP, LLC

1 - K3 SUPPORT SEAL RINGS

Apply trans jell or petroleum jelly onto the seal rings. Install the K3 support seal rings.

Fig 43: K3 Hub Rear Thrust Bearing No. 8
Courtesy of CHRYSLER GROUP, LLC
Lubricate with trans jell or petroleum jelly and install the number eight thrust bearing.

Fig 44: K3 Clutch
Courtesy of CHRYSLER GROUP, LLC
Install the K3 clutch into the transmission case.

Fig 45: P1 Annulus Thrust Washer No. 7
Courtesy of CHRYSLER GROUP, LLC

1 - P1 ANNULUS THRUST BEARING NO. 7
Lubricate with trans jell or petroleum jelly and install the number seven thrust bearing.

Fig 46: P1 Annulus Gear
Courtesy of CHRYSLER GROUP, LLC
Install the P1 annulus gear into the transmission case.

Fig 47: P1 Thrust Bearing No. 6
Courtesy of CHRYSLER GROUP, LLC

1 - THRUST BEARING NO. 6
Lubricate with trans jell or petroleum jelly and install the number six thrust bearing.

Fig 48: Installing P1 Planetary Carrier Into Transmission Case
Courtesy of CHRYSLER GROUP, LLC
Install the P1 planetary carrier into the transmission case.
NOTE:
The front sun gear/PTO rear thrust bearing is captured in the P1 planetary.

Fig 49: P1 Carrier Bolts
Courtesy of CHRYSLER GROUP, LLC

1 - BOLTS
Install the P1 planetary carrier and the bolts (1) into the transmission case and hand tighten.

Fig 50: Carrier Snap Ring
Courtesy of CHRYSLER GROUP, LLC

NOTE:
The tapered edge of the snap ring faces outward. The "hooked" ends of the snap ring should be to the window side of the enabled side of PTO.
Install the P1 planetary carrier snap ring into the transmission case. Tighten the P1 carrier in this sequence, torque left bolt to bolt to 28 N.m (21 ft.lbs.), torque right bolt to 28 N.m (21 ft. lbs.) and finally torque left bolt again to 28 N.m (21 ft. lbs.).

Fig 51: Front Sun / PTO Drive Gear
Courtesy of CHRYSLER GROUP, LLC
Install the front sun / PTO drive gear into the transmission case.
NOTE:
The front sun gear/PTO rear thrust bearing is captured in the P1 planetary.

Fig 52: Front Sun/Pto Front Thrust Bearing No. 4
Courtesy of CHRYSLER GROUP, LLC
Lubricate with trans jell or petroleum jelly and install thrust bearing number four.

Fig 53: K2 Hub Thrust Bearing No. 3
Courtesy of CHRYSLER GROUP, LLC

1 - K2 THRUST BEARING No. 3
Lubricate with trans jell or petroleum jelly and install thrust bearing number three.

Fig 54: K2 Hub
Courtesy of CHRYSLER GROUP, LLC
Install the K2 clutch hub into the transmission case.

Fig 55: K1 Thrust Bearing No. 2
Courtesy of CHRYSLER GROUP, LLC

1 - K1 THRUST BEARING NO. 2
Lubricate with trans jell or petroleum jelly and install thrust bearing number two.

Fig 56: K1 Hub
Courtesy of CHRYSLER GROUP, LLC

Install the K1 clutch hub and thrust bearing into the transmission case.

Fig 57: K1 And K2 Clutches

Courtesy of CHRYSLER GROUP, LLC

1 - K1 CLUTCH ASSEMBLIES

2 - NO. 1 BEARING RACE (SELECT)

3 - THRUST WASHER

4 - K2 CLUTCH ASSEMBLIES

Apply trans jell or petroleum jelly onto the input shaft seal rings and install the K2 clutch assembly (3) onto the K1 clutch / input shaft assembly (1) with selectable input shaft end-play thrust bearing number one (2) and thrust washer (3) in place.

Fig 58: K2 Retainer
Courtesy of CHRYSLER GROUP, LLC
Install the K2 clutch assembly and the K1 clutch / input shaft assembly into the transmission case.

Fig 59: Removing Oil Pump Seal Ring
Courtesy of CHRYSLER GROUP, LLC

NOTE:
Be certain the input shaft seal rings are in place as well as the seal ring on the oil pump hub (2).

Fig 60: Removing Oil Pump Nylon Thrust Washer
Courtesy of CHRYSLER GROUP, LLC
Lubricate with trans jell or petroleum jelly and install the nylon thrust washer (3) onto the oil pump (1).
NOTE:
The nylon thrust washer is keyed the oil pump (2).

NOTE:
Two pin punches inserted through the oil pump mounting holes will aid in the installation of the oil pump.

Fig 61: Installing Oil Pump Onto Transmission Case
Courtesy of CHRYSLER GROUP, LLC
Install a new torque converter hub seal into the oil pump using (special tool #10478, Installer, Oil Pump Seal).
Lubricate the oil pump o-ring with MOPAR® ASRC ATF.
NOTE:
Be sure that sealant is cleaned from the threads of the oil pump.
Install the oil pump with a NEW gasket onto the transmission case.

Apply a light coating of MOPAR® thread sealant onto the oil pump bolts and install the bolts. Tighten bolts in a crisscross pattern to 21 N.m (15.5 ft.lbs.).

Fig 62: Input Shaft End Play

Courtesy of CHRYSLER GROUP, LLC

1 - Socket 8266-22

2 - Dial Indicator C-3339A

3 - Handle 8266-A

Fig 63: K1 And K2 Clutches

Courtesy of CHRYSLER GROUP, LLC

1 - K1 CLUTCH ASSEMBLIES

2 - NO. 1 BEARING RACE (SELECT)

3 - THRUST WASHER

4 - K2 CLUTCH ASSEMBLIES

NOTE:

The input shaft end-play clearance may be checked with or without the torque converter housing in place.

NOTE:

The input shaft end-play clearance is adjusted by means of the selectable NO. 1 thrust bearing race (2). The Thrust Washer (3) is non selectable.

Install the Dial Indicator Set (special tool #C-3339A, Set, Dial Indicator) and Input Shaft Spline Socket (special tool #8266-22, Socket, End Play), (special tool #8266-8, Handle) to check the input shaft end-play clearance.
The input shaft end-play clearance for both 2WD and 4WD is 0.50-0.90 mm (0.019-0.035 in.). If the clearance is not within tolerance choose the correct selectable thrust bearing race.
- Bearing race number one = 0.81 mm (0.031 in.)
- Bearing race number two = 1.10 mm (0.043 in.)
- Bearing race number three = 1.60 mm (0.063 in.)
Assemble and disassemble as necessary to achieve the input shaft end-play clearance.
Remove the Dial Indicator (2) set up.
NOTE:
These dimensions are at time of production.

Fig 64: Removing/Installing Input Speed Sensor
Courtesy of CHRYSLER GROUP, LLC
Install the input speed sensor (1) into the trans case (2).
Tighten the input speed sensor bolt to 8 N.m (70 in. lbs.).
Install the valve body. Refer to VALVE BODY, INSTALLATION .

Fig 65: Torque Converter Housing
Courtesy of CHRYSLER GROUP, LLC
Install the torque converter housing to the transmission case.
Install the torque converter housing bolts and tighten to 64 N.m (47 ft.lbs.).

Fig 66: Removing Cooler Line Fittings
Courtesy of CHRYSLER GROUP, LLC
Apply trans jell or petroleum jelly onto the cooler line seals and install the cooler line fittings (1) into the transmission case.
Tighten the cooler line fittings (1) to 44 N.m (32 ft.lbs.).

Fig 67: Removing Fitting Caps
Courtesy of CHRYSLER GROUP, LLC
Install the cooler line fitting caps (1) that were removed during disassembly.

Fig 68: Removing Jiffy Tite Fittings From Cooler Line Fittings
Courtesy of CHRYSLER GROUP, LLC
Apply trans jell or petroleum jelly onto the Jiffy Tite fitting seals and install the Jiffy Tite fittings (1) onto the cooler line fittings (2).
Tighten Jiffy Tite fittings (1) to 25 N.m (18 ft.lbs.).

Fig 69: Temperature Sensor & ATF Output Cooler Line Fitting
Courtesy of CHRYSLER GROUP, LLC
Install the ATF output temperature sensor (1) onto the output cooler line fitting (2).
Tighten the ATF output temperature sensor (1) to 34 N.m (25 ft. lbs.).

Fig 70: PTO Dust Cover
Courtesy of CHRYSLER GROUP, LLC

NOTE:
Transmission could have two PTO covers. If Transmission has two PTO covers, it is equipped with a left side PTO. The warning label will go on the right side cover with an enabled left side PTO.
Install a new gasket onto the PTO cover and apply a light coating of MOPAR® thread sealant onto the PTO cover bolts, install the bolts. Tighten the PTO cover bolts to 15 N.m (11 ft.lbs.).

Fig 71: Breather Fitting
Courtesy of CHRYSLER GROUP, LLC
Lubricate the O-ring with ASRC ATF and install a new breather hose fitting into the transmission case.

Fig 72: Manual Shift Lever Seal Installation
Courtesy of CHRYSLER GROUP, LLC
Lubricate the manual shift lever seals (one on each side of the transmission) with trans jell or petroleum jelly and install the seal into the transmission case.

Fig 73: Transmission Fill Tube
Courtesy of CHRYSLER GROUP, LLC
Lubricate the transmission fill tube O-ring with trans jell or petroleum jelly and install the fill tube (1) into the transmission.
Install the transmission fill tube bolt and tighten bolt to 12.5 N.m (110 in. lbs.).
Install the transmission range sensor. Refer to VALVE BODY, INSTALLATION .
Install the manual shift lever onto the transmission manual shift lever shaft. Tighten the inside nut to 12.5 N.m (110 in. lbs.). While holding the inside nut tighten the outside nut to 12.5 N.m (9 ft.lbs.).

Fig 74: Output Speed Sensor
Courtesy of CHRYSLER GROUP, LLC
Apply trans jell or petroleum jelly onto the output speed sensor seal and install the output speed sensor into the transmission case.
Install the output speed sensor bolt. Tighten the output speed sensor bolt to 8 N.m (70 in. lbs.).
WARNING:
Be certain the transmission is secure when installing the torque converter, the torque converter is very heavy. Failure to follow these instructions may result in personal injury or may be fatal.

Fig 75: Removing/Installing Torque Converter From Transmission
Courtesy of CHRYSLER GROUP, LLC
Apply trans jell or petroleum jelly onto the input shaft ring seals and torque converter hub seal.
Install the torque converter onto the input shaft while applying inward pressure and rotating back and forth at the same time in order to align the input shaft splines and the two teeth on the oil pump drive gear.
Install a C-clamp or similar devise to secure the torque converter into the torque converter housing.