Planetary GEARTRAIN/Output Shaft: Assembly

WARNING: This page is about a different car, the 2004 Dodge Dakota. However, it is still accessible from the selected car via links, so may be relevant.

Lubricate output shaft and planetary components with transmission fluid. Use petroleum jelly to lubricate and hold thrust washers and plates in position.
Assemble rear annulus gear and support if disassembled. Be sure support snap-ring is seated and that shoulder-side of support faces rearward (Fig 1).

Fig 1: Assembling Rear Annulus And Planetary Gear
Courtesy of DAIMLERCHRYSLER CORP.
Install rear thrust washer on rear planetary gear. Use enough petroleum jelly to hold washer in place. Also be sure all four washer tabs are properly engaged in gear slots.
Install rear annulus over and onto rear planetary gear (Fig 1).
Install assembled rear planetary and annulus gear on output shaft (Fig 2). Verify that assembly is fully seated on shaft.

Fig 2: Installing Rear Annulus And Planetary On Output Shaft
Courtesy of DAIMLERCHRYSLER CORP.
Install front thrust washer on rear planetary gear (Fig 3). Use enough petroleum jelly to hold washer on gear. Be sure all four washer tabs are seated in slots.

Fig 3: Installing Rear Planetary Front Thrust Washer
Courtesy of DAIMLERCHRYSLER CORP.
Install spacer on sun gear (Fig 4).

Fig 4: Installing Spacer On Sun Gear
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Install thrust plate on sun gear (Fig 5). Note that driving shell thrust plates are interchangeable. Use either plate on sun gear and at front/rear of shell.

Fig 5: Installing Driving Shell Front Thrust Plate On Sun Gear
Courtesy of DAIMLERCHRYSLER CORP.
Hold sun gear in place and install thrust plate over sun gear at rear of driving shell (Fig 6).

Fig 6: Installing Driving Shell Rear Thrust Plate
Courtesy of DAIMLERCHRYSLER CORP.
Position wood block on bench and support sun gear on block (Fig 7). This makes it easier to align and install sun gear lock ring. Keep wood block handy as it will also be used for geartrain end play check.

Fig 7: Supporting Sun Gear On Wood Block
Courtesy of DAIMLERCHRYSLER CORP.
Align rear thrust plate on driving shell and install sun gear lock ring. Be sure ring is fully seated in sun gear ring groove (Fig 8).

Fig 8: Installing Sun Gear Lock Ring
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Install assembled driving shell and sun gear on output shaft (Fig 9).

Fig 9: Installing Assembled Sun Gear And Driving Shell On Output Shaft
Courtesy of DAIMLERCHRYSLER CORP.
Install rear thrust washer on front planetary gear (Fig 10). Use enough petroleum jelly to hold washer in place and be sure all four washer tabs are seated.

Fig 10: Installing Rear Thrust Washer On Front Planetary Gear
Courtesy of DAIMLERCHRYSLER CORP.
Install front planetary gear on output shaft and in driving shell (Fig 11).

Fig 11: Installing Front Planetary And Annulus Gears
Courtesy of DAIMLERCHRYSLER CORP.
Install front thrust washer on front planetary gear. Use enough petroleum jelly to hold washer in place and be sure all four washer tabs are seated.
Assemble front annulus gear and support, if necessary. Be sure support snap-ring is seated.
Install front annulus on front planetary (Fig 11).
Position thrust plate on front annulus gear support (Fig 12). Note that plate has two tabs on it. These tabs fit in notches of annulus hub.

Fig 12: Positioning Thrust Plate On Front Annulus Support
Courtesy of DAIMLERCHRYSLER CORP.
Install thrust washer in front annulus (Fig 13). Align flat on washer with flat on planetary hub. Also be sure washer tab is facing up.

Fig 13: Installing Front Annulus Thrust Washer
Courtesy of DAIMLERCHRYSLER CORP.
Install front annulus snap-ring (Fig 14). Use snap-ring pliers to avoid distorting ring during installation. Also be sure ring is fully seated.

Fig 14: Installing Front Annulus Snap-Ring
Courtesy of DAIMLERCHRYSLER CORP.
Install planetary selective snap-ring with snap-ring pliers (Fig 15). Be sure ring is fully seated.

Fig 15: Installing Planetary Selective Snap-Ring
Courtesy of DAIMLERCHRYSLER CORP.
Turn planetary geartrain assembly over so driving shell is facing workbench. Then support geartrain on wood block positioned under forward end of output shaft. This allows geartrain components to move forward for accurate end play check.
Check planetary geartrain end play with feeler gauge (Fig 16). Gauge goes between shoulder on output shaft and end of rear annulus support.

Fig 16: Checking Planetary Geartrain End Play
Courtesy of DAIMLERCHRYSLER CORP.
Geartrain end play should be 0.12 to 1.22 mm (0.005 to 0.048 in.). If end play is incorrect, snap-ring (or thrust washers) may have to be replaced. Snap-rings are available in three different thicknesses for adjustment purposes.