Removal and Installation
REMOVALCAUTION: The transmission and torque converter must be removed as an assembly to avoid component damage. The converter driveplate, converter hub O-ring, or oil seal can be damaged if the converter is left attached to the driveplate during removal. Be sure to remove the transmission and converter as an assembly.
1. Disconnect the negative battery cable.
2. Raise and support the vehicle
3. Mark propeller shaft and axle yokes for assembly alignment.
4. Remove the rear propeller shaft
5. Remove the front propeller shaft.
6. Remove the engine to transmission collar (Fig. 8).
7. Remove the exhaust support bracket from the rear of the transmission.
8. Disconnect and lower or remove any necessary exhaust components.
9. Remove the starter motor.
10. Rotate crankshaft in clockwise direction until converter bolts are accessible. Then remove bolts one at a time. Rotate crankshaft with socket wrench on dampener bolt.
11. Disconnect wires from solenoid and pressure switch assembly, input and output speed sensors, and line pressure sensor.
12. Disconnect gearshift cable from transmission manual valve lever (Fig. 9).
13. Disconnect transfer case shift cable from the transfer case shift lever (Fig. 10).
14. Remove the clip securing the transfer case shift cable into the cable support bracket.
15. Disconnect transmission fluid cooler lines at transmission fittings and clips.
16. Disconnect the transmission vent hose from the transmission.
17. Support rear of engine with safety stand or jack.
18. Raise transmission slightly with service jack to relieve load on crossmember and supports.
19. Remove bolts securing rear support and cushion to transmission and crossmember (Fig. 11).
20. Remove bolts attaching crossmember to frame and remove crossmember.
21. Remove transfer case (Fig. 12) and (Fig. 13).
22. Remove all remaining converter housing bolts.
23. Carefully work transmission and torque converter assembly rearward off engine block dowels.
24. Hold torque converter in place during transmission removal.
25. Lower transmission and remove assembly from under the vehicle.
26. To remove torque converter, carefully slide torque converter out of the transmission.
DISASSEMBLY
1. Drain fluid from transmission.
2. Clean exterior of transmission with suitable solvent or pressure washer.
3. Remove the torque converter from the transmission.
4. Remove the manual shift lever from the transmission.
5. Remove the input, output, and line pressure sensors from the transmission case (Fig. 14).
6. Inspect the ends of the sensors for debris, which may indicate the nature of the transmission failure.
7. Install Support Stand 8257 onto the transmission case (Fig. 15).
8. Using Adapter 8266-1 from End-Play Tool Set 8266 and Dial Indicator C-3339, measure and record the input shaft end-play (Fig. 16).
NOTE: When measuring the input shaft end-play, two "stops" will be felt. When the input shaft is pushed inward and the dial indicator zeroed, the first "stop" felt when the input shaft is pulled outward is the movement of the input shaft in the input clutch housing hub. This value should not be included in the end-play measured value and therefore must be recorded and subtracted from the dial indicator reading.
9. Remove the bolts holding the transmission extension/adapter housing to the transmission case.
10. Remove the extension/adapter housing from the transmission case.
11. Using Alignment Plate 8261, Adapter 8266-17 from End-Play Tool Set 8266 and Dial Indicator C-3339, measure and record the output shaft endplay (Fig. 17).
12. Remove the bolts holding the transmission oil pan to the transmission case.
13. Remove the transmission oil pan from the transmission case.
14. Remove the primary oil filter and the oil cooler return filter (Fig. 18).
15. Remove the cooler return filter bypass valve.
16. Remove the bolts holding the valve body to the transmission case (Fig. 19).
17. Remove the valve body from the transmission case.
18. Remove the outer snap-ring securing the transmission front cover into the transmission case (Fig. 20).
19. Remove the inner snap-ring securing the transmission front cover to the oil pump (Fig. 20).
20. Reaching through a case opening in the valve body area with a long blunted tool, remove the transmission front cover from the transmission case.
21. Remove the bolts holding the oil pump into the transmission case (Fig. 21).
22. Remove the oil pump. Hold inward on the input shaft to prevent pulling the input clutch assembly with the oil pump (Fig. 21).
23. Remove the number 1 bearing from the input clutch assembly (Fig. 22).
24. Remove the input clutch assembly from the transmission case (Fig. 22).
25. Remove the number 5 bearing and selective thrust plate from the input clutch assembly (Fig. 22), or the 4C clutch retainer/bulkhead.
26. Remove the 4C clutch retainer/bulkhead tapered snap-ring from the transmission case (Fig. 23).
27. Remove the 4C clutch retainer/bulkhead from the transmission case (Fig. 23).
28. Remove the front 2C clutch pack snap-ring from the transmission case (Fig. 24).
29. Remove the 2C clutch pack from the transmission case (Fig. 24).
30. Remove the rear selective plate and number 6 bearing from the reaction annulus (Fig. 25).
31. Remove the reaction annulus from the reaction planetary carrier (Fig. 25).
32. Remove the number 7 bearing (Fig. 25).
33. Remove the reaction sun gear (Fig. 25).
34. Remove the number 8 bearing from the reaction planetary carrier (Fig. 25).
35. Remove the reaction planetary carrier (Fig. 25). Note that this planetary gear set has three pinion gears.
36. Remove the number 9 bearing from the reverse planetary gear set (Fig. 25).
37. Remove the snap-ring holding the park spray gear onto the output shaft (Fig. 26).
38. Remove the park spray gear from the output shaft (Fig. 27).
39. Remove the input/reverse planetary assembly (Fig. 28).
40. Remove the number 12 bearing from the input/reverse planetary assembly (Fig. 28).
41. Remove the snap-ring holding the low/reverse clutch retainer into the transmission case (Fig. 29).
42. Remove the low/reverse clutch retainer from the transmission case (Fig. 29).
43. Remove the park pawl rod and e-clip (Fig. 30).
44. Remove the park pawl rod guide snap-ring (Fig. 30).
45. Remove the park pawl rod guide (Fig. 30).
46. Remove the park pawl pivot shaft, park pawl, and spring (Fig. 30).
47. Remove the manual selector shaft (Fig. 30).
48. Remove the manual selector shaft seal.
49. Remove the dipstick tube seal.
CLEANING
The use of crocus cloth is permissible where necessary, providing it is used carefully. When used on shafts, or valves, use extreme care to avoid rounding off sharp edges. Sharp edges are vital as they prevent foreign matter from getting between the valve and valve bore.
Do not reuse oil seals, gaskets, seal rings, or O-rings during overhaul. Replace these parts as a matter of course. Also do not reuse snap rings or E-clips that are bent or distorted. Replace these parts as well.
Lubricate transmission parts with Mopar ATF +4, Type 9602, transmission fluid during overhaul and assembly. Use petroleum jelly, Mopar Door Ease, or Ru-Glyde to prelubricate seals, O-rings, and thrust washers. Petroleum jelly can also be used to hold parts in place during reassembly.
Clean the case in a solvent tank. Flush the case bores and fluid passages thoroughly with solvent. Dry the case and all fluid passages with compressed air. Be sure all solvent is removed from the case and that all fluid passages are clear.
NOTE: Do not use shop towels or rags to dry the case (or any other transmission component) unless they are made from lint-free materials. Lint will stick to case surfaces and transmission components and circulate throughout the transmission after assembly. A sufficient quantity of lint can block fluid passages and interfere with valve body operation.
INSPECTION
Inspect the case for cracks, porous spots, worn bores, or damaged threads. Damaged threads can be repaired with Helicoil thread inserts. However, the case will have to be replaced if it exhibits any type of damage or wear.
ASSEMBLY
1. Clean and inspect all components. Replace any components, which show evidence of excessive wear or scoring.
2. Install the cooler filter bypass valve.
3. Torque the bypass valve to specification. The valve uses a tapered pipe thread and excessive torque can damage the transmission case. Tighten the cooler filter bypass valve to 4.5 Nm (40 in. lbs.).
4. Install a new selector shaft seal using Seal Installer 8253 (Fig. 31).
5. Install the manual selector shaft and retaining screw. Tighten the manual selector shaft retaining screw to 28 Nm (250 in. lbs.).
6. Install the park pawl, spring, and shaft (Fig. 32).
7. Install the park rod and e-clip (Fig. 32).
8. Install the park rod guide and snap-ring (Fig. 32).
9. Install a new dipstick tube seal using Seal Installer 8254 (Fig. 33).
NOTE: Before final assembly of transmission centerline, the 2C/4C clutch components should be installed into position and measured as follows:
10. Install the 2C reaction plate into the transmission case (Fig. 34). The reaction plate is directional. The plate must be installed with the flat side toward the front of the transmission.
11. Install the 2C clutch pack into the transmission case (Fig. 34).
12. Install the flat 2C clutch snap-ring into the transmission case (Fig. 34).
13. Install the 4C retainer/bulkhead into the transmission case. Make sure that the oil feed holes are pointing toward the valve body area.
14. Install the 4C retainer/bulkhead tapered snap-ring into the transmission case. Make sure that the open ends of the snap-ring are located in the case opening toward the valve body area.
15. Using a feeler gauge through the opening in the rear of the transmission case, measure the 2C clutch pack clearance between the 2C reaction plate and the transmission case at four different points. The average of these measurements is the 2C clutch pack clearance. The correct clutch clearance is 0.455 - 1.335 mm (0.018 - 0.053 in.). The reaction plate is not selective. If the clutch pack clearance is not within specification, the reaction plate, all the friction discs, and steels must be replaced.
16. Remove the 4C retainer/bulkhead and all of the 2C clutch components from the transmission case.
17. Install the low/reverse clutch assembly (Fig. 35). Make sure that the oil feed hole points toward the valve body area and that the bleed orifice is aligned with the notch in the rear of the transmission case.
18. Install the snap-ring to hold the low/reverse clutch retainer into the transmission case (Fig. 35). The snap-ring is tapered and must be installed with the tapered side forward. Once installed, verify that the snap-ring is fully seated in the snap-ring groove.
19. Air check the low/reverse clutch and verify correct overrunning clutch operation.
20. Install the number 12 bearing over the output shaft and against the rear planetary gear set. The flat side of the bearing goes toward the planetary gearset and the raised tabs on the inner race should face the rear of the transmission.
21. Install the reverse/input planetary assembly through the low/reverse clutch assembly (Fig. 36).
22. Install the park spray onto the output shaft (Fig. 37).
23. Install the snap-ring to hold the park spray onto the output shaft (Fig. 38).
24. Install the 2C reaction plate into the transmission case (Fig. 39). The reaction plate is directional. The plate must be installed with the flat side toward the front of the transmission.
25. Install the 2C clutch pack into the transmission case (Fig. 39).
26. Install the number 8 bearing inside the reaction carrier with the outer race against the reaction planetary carrier.
27. Install the reaction planetary gear set and the number 9 bearing, with the inner race against the reaction planetary carrier, into the transmission case (Fig. 40).
28. Install the flat 2C clutch snap-ring into the transmission case (Fig. 39).
29. Install the reaction sun gear into the reaction planetary gear set. Make sure the small shoulder is facing the front of the transmission (Fig. 40).
30. Install the number 7 bearing onto the reaction sun gear with the inner race against the sun gear (Fig. 40).
31. Install the output shaft selective thrust plate onto the reaction annulus with the oil grooves facing the annulus gear and the tabs and notches aligned as shown in (Fig. 41).
32. Install the number 6 bearing against the output shaft selective thrust plate with the flat side against the thrust plate (Fig. 40) and the raised tabs on the inner race facing the front of the transmission.
33. Install the reaction annulus into the reaction planetary gear set (Fig. 40).
34. Install the 4C retainer/bulkhead into the transmission case. Make sure that the oil feed holes are pointing toward the valve body area. Rotate the reaction annulus during the installation of the 4C retainer/bulkhead to ease installation.
35. Install the 4C retainer/bulkhead tapered snap-ring into the transmission case (Fig. 42) with the taper toward the front of the case. Make sure that the open ends of the snap-ring are located in the case opening toward the valve body area.
36. Air check the 2C and 4C clutch operation.
37. Using Alignment Plate 8261, Adapter 8266-17 from End-Play Tool Set 8266 and Dial Indicator C-3339, measure and record the output shaft endplay (Fig. 43). The correct output shaft end-play is 0.22 - 0.55 mm (0.009 - 0.021 in.). Adjust as necessary. Install the chosen output shaft selective thrust plate and re-measure end-play to verify selection.
38. Apply a bead of RTV silicone and install the extension/adapter housing onto the transmission case.
39. Install and torque the bolts to hold the extension/adapter housing onto the transmission case. The correct torque is 54 Nm (40 ft. lbs.).
40. Install the number 5 bearing and selective thrust plate onto the 4C retainer/bulkhead (Fig. 44). Be sure that the outer race of the bearing is against the thrust plate.
41. Install the input clutch assembly into the transmission case (Fig. 44). Make sure that the input clutch assembly is fully installed by performing a visual inspection through the input speed sensor hole. If the tone wheel teeth on the input clutch assembly are centered in the hole, the assembly is fully installed.
42. Install the number 1 bearing with the outer race up in the pocket of the input clutch assembly (Fig. 44).
43. Install the oil pump into the transmission case (Fig. 45).
44. Install the bolts to hold the oil pump into the transmission case. Tighten the oil pump bolts to 28 Nm (250 in. lbs.).
45. Using Adapter 8266-1 from End-Play Tool Set 8266 and Dial Indicator C-3339, measure and record the input shaft end-play (Fig. 46). The correct endplay is 0.46 - 0.89 mm (0.018 - 0.035 in.). Adjust as necessary. Install the chosen thrust plate on the number 5 bearing and re-measure end-play to verify selection.
NOTE: When measuring the input shaft end-play, two "stops" will be felt. When the input shaft is pushed inward and the dial indicator zeroed, the first "stop" felt when the input shaft is pulled outward is the movement of the input shaft in the input clutch housing hub. This value should not be included in the end-play measured value and therefore must be recorded and subtracted from the dial indicator reading.
46. Install the transmission front cover into the transmission case (Fig. 47).
47. Install the outer snap-ring to hold the transmission front cover into the transmission case (Fig. 47).
48. Partially install the inner transmission front cover snap-ring onto the oil pump (Fig. 47).
49. Using Installer 8255, install the inner transmission front cover snap-ring the remainder of the way onto the oil pump (Fig. 48).
50. Install the valve body (Fig. 49). Verify that the pin on the manual lever has properly engaged the TRS selector plate. Tighten the valve body to transmission case bolts to 12 Nm (105 in. lbs.).
51. Install a new primary oil filter seal in the oil pump inlet bore. Seat the seal in the bore with the butt end of a hammer, or other suitable tool.
CAUTION: The primary oil filter seal MUST be fully installed flush against the oil pump body. DO NOT install the seal onto the filter neck and attempt to install the filter and seal as an assembly. Damage to the transmission will result.
52. Install the primary oil filter and the oil cooler return filter (Fig. 50). Tighten the screw to hold the primary oil filter to the valve body to 4.5 Nm (40 in. lbs.). Using Oil Filter Wrench 8321, tighten the cooler return oil filter to the transmission case to 14 Nm (125 in. lbs.).
53. Apply RTV silicone to the oil pan and install the transmission oil pan. Tighten the bolts to 12 Nm (105 in. lbs.).
54. Install the input, output, and line pressure sensors (Fig. 51). Tighten the bolts to 12 Nm (105 in. lbs.).
55. Install the manual shift lever from the transmission. Torque the retaining cross-bolt to 16 Nm (140 in. lbs.).
INSTALLATION
1. Check torque converter hub and hub drive flats for sharp edges burrs, scratches, or nicks. Polish the hub and flats with 320/400 grit paper and crocus cloth if necessary. Verify that the converter hub O-ring is properly installed and is free of any debris. The hub must be smooth to avoid damaging pump seal at installation.
2. If a replacement transmission is being installed, transfer any components necessary, such as the manual shift lever and shift cable bracket, from the original transmission onto the replacement transmission.
3. Lubricate oil pump seal lip with transmission fluid.
4. Align converter and oil pump.
5. Carefully insert converter in oil pump. Then rotate converter back and forth until fully seated in pump gears.
6. Check converter seating with steel scale and straightedge (Fig. 52). Surface of converter lugs should be at least 13 mm (1/2 in.) to rear of straightedge when converter is fully seated.
7. Temporarily secure converter with C-clamp.
8. Position transmission on jack and secure it with chains.
9. Check condition of converter driveplate. Replace the plate if cracked, distorted or damaged. Also be sure transmission dowel pins are seated in engine block and protrude far enough to hold transmission in alignment.
10. Apply a light coating of Mopar High Temp Grease to the torque converter hub pocket in the rear pocket of the engine's crankshaft.
11. Raise transmission and align the torque converter with the drive plate and the transmission converter housing with the engine block.
12. Move transmission forward. Then raise, lower, or tilt transmission to align the converter housing with the engine block dowels.
13. Carefully work transmission forward and over engine block dowels until converter hub is seated in crankshaft. Verify that no wires, or the transmission vent hose, have become trapped between the engine block and the transmission.
14. Install two bolts to attach the transmission to the engine.
15. Install remaining torque converter housing to engine bolts. Tighten to 68 Nm (50 ft. lbs.).
16. Install rear transmission crossmember. Tighten crossmember to frame bolts to 68 Nm (50 ft. lbs.).
17. Install rear support to transmission. Tighten bolts to 47 Nm (35 ft. lbs.).
18. Lower transmission onto crossmember and install bolts attaching transmission mount to crossmember. Tighten clevis bracket to crossmember bolts to 47 Nm (35 ft. lbs.). Tighten the clevis bracket to rear support bolt to 68 Nm (50 ft. lbs.).
19. Remove engine support fixture.
20. Install new plastic retainer grommet on any shift cable that was disconnected. Grommets should not be reused. Use pry tool to remove rod from grommet and cut away old grommet. Use pliers to snap new grommet into cable and to snap grommet onto lever.
21. Connect gearshift cable to transmission.
22. Connect wires to solenoid and pressure switch assembly connector, input and output speed sensors, and line pressure sensor. Be sure transmission harnesses are properly routed.
CAUTION: It is essential that correct length bolts be used to attach the converter to the driveplate. Bolts that are too long will damage the clutch surface inside the converter.
23. Install all torque converter-to-driveplate bolts by hand.
24. Verify that the torque converter is pulled flush to the driveplate. Tighten bolts to 31 Nm (270 in. lbs.).
25. Install starter motor and cooler line bracket.
26. Connect cooler lines to transmission.
27. Install transmission fill tube.
28. Install exhaust components.
29. Install transfer case. Tighten transfer case nuts to 35 Nm (26 ft. lbs.).
30. Install the transfer case shift cable to the cable support bracket and the transfer case shift lever.
31. Install the transmission collar onto the transmission and the engine. Tighten the bolts to 54 Nm (40 ft. lbs.).
32. Align and connect propeller shaft(s).
33. Adjust gearshift cable if necessary.
34. Lower vehicle.
35. Fill transmission with Mopar ATF +4, type 9602, Automatic Transmission fluid.