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Determining Intermediate Shaft Selective Spacer & Overdrive Piston Thrust Plate

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  1. To determine intermediate shaft selective spacer, output shaft end play is checked. Place overdrive unit in vertical position. Install Adapter (6312) through sun gear, planetary gear and into pilot bushing in output shaft. See Fig 1 . Ensure adapter bottoms against shoulder on planetary gear.
  2. Install Bar (6311) across surface of overdrive unit case. Position Caliper (C-4962) on bar. Extend caliper downward through bar until it contacts adapter. Note reading on caliper. This is the output shaft end play.
  3. Using the output shaft end play reading, determine the proper intermediate shaft selective spacer thickness. Refer to the INTERMEDIATE SHAFT SELECTIVE SPACER SELECTION TABLE  . Remove adapter. Retain intermediate shaft selective spacer for overdrive unit installation.
    INTERMEDIATE SHAFT SELECTIVE SPACER SELECTION

    Output Shaft End Play: In. (mm) (1) Shaft Spacer Thickness: In. (mm)
    .7336-.7505 (18.633-19.063) .158-.159 (4.01-4.04)
    .7506-.7675 (19.065-19.494) .175-.176 (4.44-4.47)
    .7676-.7855 (19.497-19.951) .193-.194 (4.90-4.93)
    .7856-.8011 (19.954-20.348) .211-.212 (5.35-5.38)
    (1) Measurement taken with Adapter (6312) installed through sun gear, planetary gear and into pilot bushing in output shaft.
    Fig 1: Measuring Output Shaft End Play
    G92F13412Courtesy of CHRYSLER CORP.
  4. To determine overdrive piston thrust plate thickness, install Bar (6311) across surface of overdrive unit case. Position Caliper (C-4962) on bar.
  5. Extend caliper through the bar and measure distance to surface of direct clutch hub thrust bearing seat in 4 places 90 degrees apart. See Fig 2 .
  6. Determine the average distance by adding the 4 measurements together and dividing by 4. Using the average distance, determine the proper overdrive piston thrust plate thickness. See the OVERDRIVE PISTON THRUST PLATE SELECTION  . Remove caliper and bar. Retain overdrive piston thrust plate for overdrive unit installation.
CAUTION: Ensure intermediate shaft selective spacer and overdrive piston thrust plate and overdrive piston thrust bearing are installed before installing overdrive unit on transmission.
OVERDRIVE PISTON THRUST PLATE SELECTION

Hub Thrust Bearing Seat Average Distance: In. (mm) Overdrive Piston Thrust Plate Thickness: In. (mm)
1.7500-1.7649 (44.450-44.828) .108-.110 (2.74-2.79)
1.7650-1.7799 (44.831-45.209) .123-.125 (3.12-3.18)
1.7800-1.7949 (45.212-45.590) .138-.140 (3.50-3.56)
1.7950-1.8099 (45.593-45.971) .153-.155 (3.89-3.94)
1.8100-1.8249 (45.974-46.352) .168-.170 (4.27-4.31)
1.8250-1.8399 (46.355-46.733) .183-.185 (4.65-4.70)
1.8400-1.8549 (46.736-47.114) .198-.200 (5.03-5.08)
1.8550-1.8699 (47.117-47.495) .213-.215 (5.41-5.46)
1.8700-1.8849 (47.498-47.876) .228-.230 (5.79-5.84)
1.8850-1.8999 (47.879-48.257) .243-.245 (6.17-6.22)
Fig 2: Measuring Distance To Direct Clutch Hub Thrust Bearing Seat
G92G13413Courtesy of CHRYSLER CORP.
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