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Section 2 (C635 DDCT Automatic Transmission - (Service Information) - 500L): Disassembly: Disassembly

WARNING: This page is about a different variant/trim than selected.
NOTE:

When replacing a housing component or internal gear shaft, all tapered bearings and races must be replaced to establish proper bearing shim selection. Refer to Turning Torque procedures to determine proper shim selection. Refer to BEARING PRELOAD ADJUSTMENT .

Fig 1: Electrical Connector
GC0156378Courtesy of CHRYSLER GROUP, LLC
  1. Drain the transmission. Refer to FLUID, STANDARD PROCEDURE .
  2. Remove the dual clutch assembly.
  3. Disconnect the electrical connection (1) for the odd gear slave cylinder.
    Fig 2: Valve Body Electrical Connectors
    GC0155664Courtesy of CHRYSLER GROUP, LLC
  4. Disconnect the valve body electrical connectors (1).
    Fig 3: Even Gear Pressure Transducer & Gear Selector Position Sensor Connectors
    GC0155545Courtesy of CHRYSLER GROUP, LLC
  5. Disconnect the electrical connection (1) for the even gear pressure transducer.
  6. Disconnect the electrical connection (2) for the gear selector position sensor.
    Fig 4: Hydraulic Power Unit Pressure Transducer & Sensor Module Connectors
    GC0155803Courtesy of CHRYSLER GROUP, LLC
  7. Disconnect the electrical connection (1) for the hydraulic power unit pressure transducer.
  8. Disconnect the electrical connection (2) for the sensor module.
    Fig 5: Park Position Sensor Connector & Fasteners
    GC0156281Courtesy of CHRYSLER GROUP, LLC
  9. Disconnect the electrical connection (1) for the park position sensor.
  10. Disconnect the wiring harness from the transaxle.
    Fig 6: Slave Cylinder Hydraulic Line
    GC0155884Courtesy of CHRYSLER GROUP, LLC
  11. Remove the odd gear slave cylinder hydraulic line (1) from the valve body.
    Fig 7: Retention Clip & Fastening Clip
    GC0155839Courtesy of CHRYSLER GROUP, LLC
  12. Remove the odd gear slave cylinder hydraulic line fastening clip (2) and discard.
  13. Remove the odd gear slave cylinder hydraulic line from the retention clip (1).
  14. Remove the odd gear slave cylinder hydraulic line.
    Fig 8: Slave Cylinder Bolts
    GC0156158Courtesy of CHRYSLER GROUP, LLC
  15. Remove the odd gear slave cylinder bolts (1).
    Fig 9: Slave Cylinder
    GC0155743Courtesy of CHRYSLER GROUP, LLC
  16. Remove the odd gear slave cylinder (1).
    Fig 10: Special Tool #10331-1 & Special Tool #10331-2
    GC0155637Courtesy of CHRYSLER GROUP, LLC
  17. Install (special tool #10331-1, Remover, Seal) into (special tool #10331-2, Sleeve).
    Fig 11: Special Tool #10331-1
    GC0157166Courtesy of CHRYSLER GROUP, LLC
    Fig 12: Special Tool #10331-2
    GC0157255Courtesy of CHRYSLER GROUP, LLC
    Fig 13: Special Tool #10331-2 Installed
    GC0155980Courtesy of CHRYSLER GROUP, LLC
  18. Thread (special tool #10331-2, Sleeve) to the seal and tighten the bolt to extract the inner even gear oil seal.
    Fig 14: Special Tool #10331-2
    GC0157255Courtesy of CHRYSLER GROUP, LLC
    Fig 15: Park Position Sensor Connector & Fasteners
    GC0156281Courtesy of CHRYSLER GROUP, LLC
  19. Remove the park position sensor screws (2).
    Fig 16: Park Position Sensor
    GC0156324Courtesy of CHRYSLER GROUP, LLC
  20. Remove the park position sensor (1).
    Fig 17: Park System Shaft Seal And Bushing Assembly
    GC0155748Courtesy of CHRYSLER GROUP, LLC
  21. Remove the park system shaft seal and bushing assembly (1).
    Fig 18: Park System Access Pan Bolts
    GC0155866Courtesy of CHRYSLER GROUP, LLC
  22. Remove the park system access pan bolts (1) and remove the pan.
    Fig 19: Park System Attachment Bolts
    GC0155573Courtesy of CHRYSLER GROUP, LLC
  23. Remove the park system attachment bolts (1).
    Fig 20: Park System Shaft Assembly
    GC0155529Courtesy of CHRYSLER GROUP, LLC
  24. Remove the park system shaft assembly (1).
    Fig 21: Hydraulic Fluid Reservoir
    GC0156230Courtesy of CHRYSLER GROUP, LLC
  25. Drain the hydraulic fluid reservoir (1).
  26. Remove the two reservoir retaining bolts.
  27. Remove the hydraulic fluid reservoir (1) and remove and discard reservoir the O-ring.
    Fig 22: Even Gear Slave Cylinder Hydraulic Line
    GC0155784Courtesy of CHRYSLER GROUP, LLC
  28. Disconnect and remove the even gear slave cylinder hydraulic line.
    Fig 23: Valve Body And Hydraulic Power Unit Pipes
    GC0155949Courtesy of CHRYSLER GROUP, LLC
  29. Remove and disconnect the pipes (1, 2 and 3) from the valve body and the hydraulic power unit.
    Fig 24: Hydraulic Power Unit Bolt
    GC0155850Courtesy of CHRYSLER GROUP, LLC
  30. Remove the hydraulic power unit bolt (1).
    Fig 25: Accumulator Strap & Hydraulic Power Unit Screws
    GC0155721Courtesy of CHRYSLER GROUP, LLC
  31. Remove the mounting screws for the accumulator strap (1) and the hydraulic power unit (2, 3).
    Fig 26: Hydraulic Power Unit
    GC0155568Courtesy of CHRYSLER GROUP, LLC
  32. Remove the hydraulic power unit (1).
    Fig 27: Valve Body Bolts
    GC0156081Courtesy of CHRYSLER GROUP, LLC
  33. Remove the remaining seven valve body bolts (1) and remove the valve body.
    Fig 28: Slave Cylinder Bolts & Plastic Retainer
    GC0155763Courtesy of CHRYSLER GROUP, LLC
  34. Disconnect the hydraulic fitting from the plastic retainer (2) from outside the case by releasing the tabs and pushing the fitting into the case.
  35. Remove the even gear slave cylinder bolts (1) and remove the slave cylinder with the line attached.
    Fig 29: Input Shaft Oil Seal
    GC0155531Courtesy of CHRYSLER GROUP, LLC
  36. Remove the input shaft oil seal (1) using a screw or hook style puller.
    Fig 30: Reverse Gear Idler Retaining Bolt
    GC0155875Courtesy of CHRYSLER GROUP, LLC
  37. Remove the reverse gear idler retaining bolt (1).
    Fig 31: Long & Short Case Bolts
    GC0155730Courtesy of CHRYSLER GROUP, LLC
  38. Remove the long case bolts (1) and the short case bolts (2).
    Fig 32: Gear Side Half & Bell Housing Side Half
    GC0155646Courtesy of CHRYSLER GROUP, LLC
  39. Separate the case halves carefully prying on the gear side half (1) and the bell housing side half.
    Fig 33: Reverse Idler Gear Assembly
    GC0147610Courtesy of CHRYSLER GROUP, LLC
  40. Remover the reverse idler gear assembly (1).
    Fig 34: Shifter Fork Pivot Pin & Shifter Fork Assembly
    GC0147609Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The shifter fork and pin can be removed as an assembly.

  41. Remove the 2-4-5-R shifter fork pivot pin (1).
  42. Remove the 2-4-5-R shifter fork assembly (2).
    Fig 35: 1-3-6 Shifter Fork Pivot Pin & Shifter Fork Assembly
    GC0155666Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The shifter fork and pin can be removed as an assembly.

  43. Remove the 1-3-6 shifter fork pivot pin (2).
  44. Remove the 1-3-6 shifter fork assembly (1).
    Fig 36: Output And Main Shafts
    GC0147625Courtesy of CHRYSLER GROUP, LLC
  45. Remove the shafts (1) as a group.
    Fig 37: Bearing Race Plate Bolts
    GC0147817Courtesy of CHRYSLER GROUP, LLC
  46. Remove the bearing race plate bolts (1) and remove the bearing race plate.
    Fig 38: Differential Assembly
    GC0147819Courtesy of CHRYSLER GROUP, LLC
  47. Remove the differential assembly.
    Fig 39: Removing Bell Housing Side Differential Bearing Race
    GC0147642Courtesy of CHRYSLER GROUP, LLC
  48. Remove the bellhousing side differential bearing race (2) using (special tool #C-637, Slide Hammer, Universal) and (special tool #9664, Remover, Bearing Cup) (1).
    Fig 40: Special Tool #C-637
    GC0140368Courtesy of CHRYSLER GROUP, LLC
    Fig 41: Special Tool #9664
    GC0143076Courtesy of CHRYSLER GROUP, LLC
    Fig 42: Input Shaft Bearing Cup
    GC0147627Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Tool (special tool #D-111, Installer, Bearing Cup) is shown, all other tools are similar in function.

  49. Remove the bearing cups from the race mounting plate using a suitable press and tools as follows:
    • (special tool #D-111, Installer, Bearing Cup) (3)
    • (special tool #10302, Installer, Bearing Cup) (1)
    • (special tool #9948-4, Installer, Bushing) (2)
    Fig 43: Removing Differential Bearing Race Cups & Shims
    GC0147629Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Do not discard the shim as it will be utilized as the starting point for the bearing preload adjustment process.

    NOTE:

    Case side shown, bell housing side similar.

  50. Remove the case side differential bearing race cup (1) and shim using (special tool #C-637, Slide Hammer, Universal), (special tool #9664, Remover, Bearing Cup) (3).
    Fig 44: Special Tool #C-637
    GC0140368Courtesy of CHRYSLER GROUP, LLC
    Fig 45: Special Tool #9664
    GC0143076Courtesy of CHRYSLER GROUP, LLC
    Fig 46: Removing Case Side Gear Shaft Bearing Race Cups & Shims
    GC0147630Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Document the location of each shim and bearing race as they will be utilized as the starting point for the bearing preload adjustment process.

  51. Remove the case side gear bearing race cups (2) and shims using (special tool #C-637, Slide Hammer, Universal) (special tool #9664, Remover, Bearing Cup) (1).
    Fig 47: Special Tool #C-637
    GC0140368Courtesy of CHRYSLER GROUP, LLC
    Fig 48: Special Tool #9664
    GC0143076Courtesy of CHRYSLER GROUP, LLC
    Fig 49: Lubricating Duct
    GC0147626Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The lower end of the lubricating duct (1) fits underneath the metal oil duct (2).

  52. Remove the lubricating duct (1) by pulling upward.
    Fig 50: Shaft Oil Ducts
    GC0147628Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The oil ducts are staked to the case and may require some grinding prior to removal.

  53. Remove the output shaft oil ducts (1) from the case using an appropriate screwdriver or equivalent.
    Fig 51: Removing Axle Seal
    GC0147863Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Left side is shown, right side is similar.

  54. Remove the axle seal(s) (3) using (special tool #6341A, Remover, Seal) (2) and (special tool #C-637, Slide Hammer, Universal) (1).
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