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Overdrive Unit Gear Train: Reassembly

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  1. Lubricate components with Mopar ATF Plus Type 7176 fluid. Soak clutch discs in ATF at least 20 minutes before installing. Install NEW pilot bushing and NEW inner bushing in output shaft (if necessary). Lubricate pilot bushing and inner bushing with petroleum jelly.
    CAUTION: Ensure front bearing is installed on output shaft with groove in front bearing for retaining ring facing toward splined end of output shaft.
  2. Install front bearing on output shaft so groove in front bearing for front bearing retaining ring faces toward splined end of output shaft. Install front bearing snap ring on output shaft. Install annulus gear on output shaft, ensuring reference marks are aligned. Install annulus gear snap ring.
  3. Install direct clutch drum on annulus gear ensuring reference marks are aligned. Ensure lugs on direct clutch drum fully engage lugs on annulus gear. Install outer retaining ring.
  4. Slide the direct clutch drum forward. Install inner retaining ring. Install overrunning clutch on overrunning clutch hub. See Fig 1 . Shoulder on overrunning clutch should seat in small recess at edge of overrunning clutch hub.
    Fig 1: Installing Overrunning Clutch
    G92I13407Courtesy of CHRYSLER CORP.
  5. Coat thrust bearing with petroleum jelly and install on overrunning clutch hub. Ensure thrust bearing is fully seated on overrunning clutch hub.
  6. Insert expanding-type snap ring pliers into splines on overrunning clutch hub. Expand snap ring pliers against splines. Rotate overrunning clutch hub counterclockwise and install overrunning clutch assembly in direct clutch drum.
  7. Install planetary gear in annulus gear. Ensure planetary gear is fully seated. Install spring plate on sun gear with shoulder on spring plate toward front of sun gear (if removed). See Fig 2 . Install snap ring.
    Fig 2: Installing Spring Plate & Thrust Bearing On Sun Gear
    G92J13408Courtesy of CHRYSLER CORP.
  8. Coat thrust bearing with petroleum jelly and install on sun gear. Ensure thrust bearing fully seats against spring plate.
  9. Install sun gear, spring plate and thrust bearing in direct clutch drum. Install Alignment Shaft (6227-2) through sun gear to align splines of planetary gear and overrunning clutch hub. See Fig 3 . Ensure alignment shaft is fully seated.
    CAUTION: Ensure direct clutch components are installed in original location and original number of components are installed.
  10. Install direct clutch spring on spring plate in direct clutch hub. Ensure spring is properly seated. Assemble direct clutch pack. See Fig 4 and Fig 5 .
    Fig 3: Aligning Planetary Gear & Overrunning Clutch Hub Splines
    G94C38549Courtesy of CHRYSLER CORP.
    Fig 4: Assembling Direct Clutch Pack (46RE & 46RH)
    G94J38736Courtesy of CHRYSLER CORP.
    Fig 5: Assembling Direct Clutch Pack (47RE & 47RH)
    G94A38737Courtesy of CHRYSLER CORP.
  11. Install reaction plate on direct clutch hub. One side of reaction plate contains a counter bore area. See Fig 4 and Fig 5 . Counter bore area should be installed so it fits over raised splines at rear of direct clutch hub. See Fig 6 .
    CAUTION: With reaction plate installed, surface of reaction plate should be even with surface of direct clutch hub. Counter bore area on reaction plate should be against raised splines on direct clutch hub. See Fig 6 .
    Fig 6: Installing Reaction Plate & Pressure Plate
    G92E13411Courtesy of CHRYSLER CORP.
  12. Alternately install clutch discs and clutch plates on reaction plate starting with clutch disc. See Fig 4 and Fig 5 . Install pressure plate with raise area away from clutch pack. See Fig 6 .
  13. Install direct clutch pack and direct clutch hub on direct clutch spring. Ensure direct clutch hub is started on the splines on the sun gear. Place overdrive unit gear train assembly in press.
  14. Install spring compressor and spacer on top of direct clutch hub. See Figure . Slide direct clutch pack upward and set it on edge of spring compressor.
  15. Compress direct clutch spring so direct clutch hub snap ring and retaining ring for direct clutch pack are visible. Install direct clutch pack in direct clutch drum. Install retaining ring for direct clutch pack ring and direct clutch hub snap ring.
    CAUTION: Ensure retaining ring for direct clutch pack and direct clutch hub snap ring are fully seated.
  16. Release press. Remove spring compressor. Ensure alignment shaft is fully seated. If alignment shaft becomes unseated, it may be necessary to disassemble overdrive unit gear train and realign splines. Remove overdrive unit gear train assembly from press.
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