Planetary GEARTRAIN/ Output Shaft: Assembly

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.

Lubricate sun gear and planetary gears with transmission fluid during assembly. Use petroleum jelly to lubricate intermediate shaft bushing surfaces, thrust washers and thrust plates and to hold these parts in place during assembly.
Install front snap-ring on sun gear and install gear in driving shell. Then install thrust plate over sun gear and against rear side of driving shell (Fig 1). Install rear snap-ring to secure sun gear and thrust plate in driving shell.

Fig 1: Installing Sun Gear
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Install rear annulus gear on intermediate shaft (Fig 2).

Fig 2: Installing Rear Annulus Gear On Intermediate Shaft
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Install thrust plate in annulus gear (Fig 3). Be sure plate is seated on shaft splines and against gear.

Fig 3: Installing Rear Annulus Thrust Plate
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Install rear planetary gear in rear annulus gear (Fig 4). Be sure planetary carrier is seated against annulus gear.

Fig 4: Installing Rear Planetary Gear
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Install tabbed thrust washer on front face of rear planetary gear (Fig 5). Seat washer tabs in matching slots in face of gear carrier. Use extra petroleum jelly to hold washer in place if desired.

Fig 5: Installing Rear Planetary Thrust Washer
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Lubricate sun gear bushings with petroleum jelly or transmission fluid.
Install sun gear and driving shell on intermediate shaft (Fig 6). Seat shell against rear planetary gear. Verify that thrust washer on planetary gear was not displaced during installation.

Fig 6: Installing Sun Gear And Driving Shell
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Install tabbed thrust washer in driving shell (Fig 7), be sure washer tabs are seated in tab slots of driving shell. Use extra petroleum jelly to hold washer in place if desired.

Fig 7: Installing Driving Shell Thrust Washer
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Install tabbed thrust washer on front planetary gear (Fig 8). Seat washer tabs in matching slots in face of gear carrier. Use extra petroleum jelly to hold washer in place if desired.

Fig 8: Installing Thrust Washer On Front Planetary Gear
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Install front annulus gear over and onto front planetary gear (Fig 9). Be sure gears are fully meshed and seated.

Fig 9: Assembling Front Planetary And Annulus Gears
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Install front planetary and annulus gear assembly (Fig 10). Hold gears together and slide them onto shaft. Be sure planetary pinions are seated on sun gear and that planetary carrier is seated on intermediate shaft.

Fig 10: Installing Front Planetary And Annulus Gear Assembly
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Place geartrain in upright position. Rotate gears to be sure all components are seated and properly assembled. Snap-ring groove at forward end of intermediate shaft will be completely exposed when components are assembled correctly.
Install new planetary snap-ring in groove at end of intermediate shaft (Fig 11).

Fig 11: Installing Planetary Snap-Ring
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Turn planetary geartrain over. Position wood block under front end of intermediate shaft and support geartrain on shaft. Be sure all geartrain parts have moved forward against planetary snap-ring. This is important for accurate end play check.
Check planetary geartrain end play with feeler gauge (Fig 12). Insert gauge between rear annulus gear and shoulder on intermediate shaft as shown. End play should be 0.15 to 1.22 mm (0.006 to 0.048 in.).

Fig 12: Checking Planetary Geartrain End Play
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If end play is incorrect, install thinner/thicker planetary snap-ring as needed.