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Overdrive Unit: Installation

WARNING: This page is about a different car, the 2003 Dodge Dakota. However, it is still accessible from the selected car via links, so may be relevant.
  1. Be sure overdrive unit Alignment Tool 6227-2 is fully seated before moving unit. If tool is not seated and gear splines rotate out of alignment, overdrive unit will have to be disassembled in order to realign splines.
  2. If overdrive piston retainer was not removed during service and original case gasket is no longer reusable, prepare new gasket by trimming it.
  3. Cut out old case gasket around piston retainer with razor knife (Fig 1).
    Fig 1: Installing Overdrive Case Gasket
    G02658132Courtesy of DAIMLERCHRYSLER CORP.
  4. Use old gasket as template and trim new gasket to fit.
  5. Position new gasket over piston retainer and on transmission case. Use petroleum jelly to hold gasket in place if necessary. Do not use any type of sealer to secure gasket. Use petroleum jelly only.
  6. Install selective spacer on intermediate shaft, if removed. Spacer goes in groove just rearward of shaft rear splines (Fig 2).
    Fig 2: Installing Intermediate Shaft Selective Spacer
    G02658133Courtesy of DAIMLERCHRYSLER CORP.
  7. Install thrust bearing in overdrive unit sliding hub. Use petroleum jelly to hold bearing in position.
    CAUTION: Be sure the shoulder on the inside diameter of the bearing is facing forward.
  8. Verify that splines in overdrive planetary gear and overrunning clutch hub are aligned with Alignment Tool 6227-2. Overdrive unit cannot be installed if splines are not aligned. If splines have rotated out of alignment, unit will have to be disassembled to realign splines.
  9. Carefully slide Alignment Tool 6227-2 out of overdrive planetary gear and overrunning clutch splines.
  10. Raise overdrive unit and carefully slide it straight onto intermediate shaft. Insert park rod into park lock reaction plug at same time. Avoid tilting overdrive during installation as this could cause planetary gear and overrunning clutch splines to rotate out of alignment. If this occurs, it will be necessary to remove and disassemble overdrive unit to realign splines.
  11. Work overdrive unit forward on intermediate shaft until seated against transmission case.
  12. Install bolts attaching overdrive unit to transmission unit. Tighten bolts in diagonal pattern to 34 N.m (25 ft-lbs).
  13. Connect the transmission speed sensor and overdrive wiring connectors.
  14. Install the transfer case, if equipped.
  15. Align and install propeller shaft(s), if necessary. (Refer to PROPELLER SHAFT )
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