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Section 131 (40TE/41TE Automatic Transmission (Service Information)): Assembly: Assembly

WARNING: This page is about a different car, the 2016 Dodge Journey and 2015 Dodge Journey. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Install Both Output Bearing Cups
GC0115638Courtesy of CHRYSLER GROUP, LLC
1 - OUTPUT BEARING CUPS
2 - WRENCHES
3 - INSTALLER 5050A
CAUTION:

The cooler bypass valve must be replaced if transaxle failure has occurred. Do not attempt to reuse or clean old valve.

NOTE:

If transaxle is being overhauled (clutch and/or seal replacement), the TCM/PCM Quick Learn procedure must be performed ( MODULE, POWERTRAIN CONTROL, STANDARD PROCEDURE ).

  1. Install both output bearing cups using (special tool #5050A, Installer, Bearing Cup) (3).
    Fig 2: Removing/Installing Low/Reverse Piston Retainer Gasket
    GC0115639Courtesy of CHRYSLER GROUP, LLC
    1 - GASKET HOLES MUST LINE UP
    2 - LOW/REVERSE CLUTCH PISTON RETAINER GASKET
  2. Install low/reverse piston retainer gasket (2). Make sure gasket holes line up with case (1).
    Fig 3: Install Piston Retainer
    GC0115640Courtesy of CHRYSLER GROUP, LLC
    1 - LOW/REVERSE CLUTCH PISTON RETAINER
    2 - GASKET
  3. Install low/reverse piston retainer (1).
    Fig 4: Install Piston Retainer-To-Case Screws
    GC0115641Courtesy of CHRYSLER GROUP, LLC
    1 - LOW/REVERSE CLUTCH PISTON RETAINER
    2 - SCREWDRIVER
    3 - TORX-LOC SCREWS
  4. Install low/reverse piston retainer-to-case screws (3) and tighten to 5 N.m (45 in. lbs.).
    Fig 5: Install Low/Reverse Clutch Piston
    GC0115642Courtesy of CHRYSLER GROUP, LLC
    1 - LOW/REVERSE CLUTCH PISTON
    2 - BONDED SEAL
    3 - BONDED SEAL
    NOTE:

    The Low/Reverse Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.

  5. Install low/reverse clutch piston (1).
    Fig 6: Exploded View Of Guide Bracket
    GC0115643Courtesy of CHRYSLER GROUP, LLC
    1 - ANTIRATCHET SPRING
    2 - GUIDE BRACKET
    3 - SPLIT SLEEVE
    4 - SPACER
    5 - PAWL
    6 - STEPPED SPACER
  6. Park guide bracket assembly - anti-ratchet spring (1), guide bracket (2), split sleeve (3), spacer (4), pawl (5), and stepped spacer (6).
    Fig 7: Assembling Guide Bracket Assembly
    GC0115644Courtesy of CHRYSLER GROUP, LLC
    1 - GUIDE BRACKET
    2 - ANTI-RATCHET SPRING (MUST BE ASSEMBLED AS SHOWN IN ILLUSTRATION)
    3 - PAWL
  7. Assemble park guide bracket assembly.
    Fig 8: Pivot Shaft And Guide Bracket
    GC0115645Courtesy of CHRYSLER GROUP, LLC
    1 - ANTIRACHET SPRING
    2 - GUIDE BRACKET
    3 - PIVOT SHAFT
    4 - PAWL
  8. Install guide bracket (2) into position and insert pivot shaft (3).
    Fig 9: Install Anchor Shaft And Plug
    GC0115646Courtesy of CHRYSLER GROUP, LLC
    1 - GUIDE BRACKET ANCHOR SHAFT
    2 - PIVOT SHAFT
    3 - ANCHOR SHAFT PLUG
  9. Install anchor shaft and plug (3). Make sure guide bracket and split sleeve are in contact with the rear of the transaxle case.
    Fig 10: Removing/Installing Low/Reverse Piston Belleville Spring Into Position
    GC0115647Courtesy of CHRYSLER GROUP, LLC
    1 - LOW/REVERSE PISTON RETURN SPRING
    2 - PISTON
  10. Install low/reverse piston return spring (1).
    Fig 11: Compressor Tool In Use
    GC0115648Courtesy of CHRYSLER GROUP, LLC
    1 - LOW/REVERSE CLUTCH RETURN SPRING
    2 - SNAP RING (INSTALL AS SHOWN IN ILLUSTRATION)
    3 - DISC 6057
    4 - COMPRESSOR 5059-A
    5 - BAR 5058A-3
  11. Install low/reverse (special tool #6057, Disc, Spring Compressor) (3), (special tool #5059-A, Compressor, Spring) (4) and (special tool #5058A-3, Screw, Forcing) (5) into position.
    Fig 12: Installing Snap Ring
    GC0115649Courtesy of CHRYSLER GROUP, LLC
    1 - SNAP RING OPENING MUST BE BETWEEN SPRING LEVERS (AS SHOWN IN ILLUSTRATION)
    2 - SNAP RING PLIERS
    3 - DISC 6057
  12. Compress low/reverse piston and install snap ring. Snap ring opening must be between spring levers (1).
    Fig 13: Install Rear Carrier Bearing Cone
    GC0115650Courtesy of CHRYSLER GROUP, LLC
    1 - ARBOR PRESS RAM
    2 - INSTALLER 6053
    3 - NEW BEARING CONE
    4 - REAR CARRIER ASSEMBLY
  13. Install rear carrier bearing cone using (special tool #6053, Installer, Bearing) (2) using an Arbor Press (1).
    Fig 14: Install Rear Carrier Assembly
    GC0115651Courtesy of CHRYSLER GROUP, LLC
    1 - REAR CARRIER ASSEMBLY
  14. Install rear carrier assembly (1) to transaxle case.
    Fig 15: Install Output Gear Bearing Cone
    GC0115652Courtesy of CHRYSLER GROUP, LLC
    1 - ARBOR PRESS RAM
    2 - HANDLE C-4171
    3 - INSTALLER 5052
    4 - OUTPUT GEAR
  15. Install output gear bearing cone using (special tool #5052, Installer, Bearing) (3) (special tool #C-4171, Driver Handle, Universal) (2) and an Arbor Press (1).
    Fig 16: Output Gear And (Select) Shim
    GC0115653Courtesy of CHRYSLER GROUP, LLC
    1 - REAR CARRIER ASSEMBLY
    2 - SHIM (SELECT)
    3 - OUTPUT GEAR
  16. OUTPUT GEAR BEARING ADJUSTMENT: 
    1. With output gear (3) installed, install a 4.50 mm (0.177 in.) gauging shim (2) on the rear carrier assembly hub (1), using grease to hold the shim in place.
    2. Using (special tool #6259, Holder), install output gear and bearing assembly. Tighten to 271 N.m (200 ft. lbs.).
    Fig 17: Checking Output Gear Bearings End Play
    GC0115654Courtesy of CHRYSLER GROUP, LLC
    1 - GEAR CHECKING PLATE L-4432
    2 - DIAL INDICATOR
    3 - SPECIAL SCREWS 6260
    4 - OUTPUT GEAR
  17. OUTPUT GEAR BEARING ADJUSTMENT: cont. 
    1. Measure bearing end play. Attach (special tool #L-4432, Fixture) (1) to the gear (4).
    2. Push and pull the gear while rotating back and forth to ensure seating of bearing rollers.
    3. Using a Dial Indicator (2) mounted to the transaxle case, measure output gear (4) end play.
    4. Refer to the OUTPUT GEAR BEARING SHIM CHART below for the required shim to obtain proper bearing setting.
    5. Use (special tool #6259, Holder) to remove the output gear retaining bolt and washer. To remove the output gear, use (special tool #L-4407A, Puller, Gear).
    6. Remove the gauging shim and install the proper shim determined by the chart. Use grease to hold the shim in place.
    OUTPUT GEAR BEARING SHIM CHART

    End Play Shim Needed Part Number   End Play Shim Needed Part Number
    0.05mm (0.002 in.) 4.42mm (0.174 in.) 4412830AB   0.53mm (0.021 in.) 3.94mm (0.155 in.) 4412818AB
    0.08mm (0.003 in.) 4.38mm (0.172 in.) 4412829AB   0.56mm (0.022 in.) 3.90mm (0.154 in.) 4412817AB
    0.10mm (0.004 in.) 4.38mm (0.172 in.) 4412829AB   0.58mm (0.023 in.) 3.90mm (0.154 in.) 4412817AB
    0.13mm (0.005 in.) 4.34mm (0.171 in.) 4412828AB   0.61mm (0.024 in.) 3.86mm (0.152 in.) 4412816AB
    0.15mm (0.006 in.) 4.30mm (0.169 in.) 4412827AB   0.64mm (0.025 in.) 3.82mm (0.150 in.) 4412815AB
    0.18mm (0.007 in.) 4.30mm (0.169 in.) 4412827AB   0.66mm (0.026 in.) 3.82mm (0.150 in.) 4412815AB
    0.20mm (0.008 in.) 4.26mm (0.168 in.) 4412826AB   0.69mm (0.027 in.) 3.78mm (0.149 in.) 4412814AB
    0.23mm (0.009 in.) 4.22mm (0.166 in.) 4412825AB   0.71mm (0.028 in.) 3.74mm (0.147 in.) 4412813AB
    0.25mm (0.010 in.) 4.22mm (0.166 in.) 4412825AB   0.74mm (0.029 in.) 3.74mm (0.147 in.) 4412813AB
    0.28mm (0.011 in.) 4.18mm (0.165 in.) 4412824AB   0.76mm (0.030 in.) 3.70mm (0.146 in.) 4412812AB
    0.30mm (0.012 in.) 4.14mm (0.163 in.) 4412823AB   0.79mm (0.031 in.) 3.66mm (0.144 in.) 4412811AB
    0.33mm (0.013 in.) 4.14mm (0.163 in.) 4412823AB   0.81mm (0.032 in.) 3.66mm (0.144 in.) 4412811AB
    0.36mm (0.014 in.) 4.10mm (0.161 in.) 4412822AB   0.84mm (0.033 in.) 3.62mm (0.143 in.) 4412810AB
    0.38mm (0.015 in.) 4.10mm (0.161 in.) 4412822AB   0.86mm (0.034 in.) 3.62mm (0.143 in.) 4412810AB
    0.41mm (0.016 in.) 4.06mm (0.160 in.) 4412821AB   0.89mm (0.035 in.) 3.58mm (0.141 in.) 4412809AB
    0.43mm (0.017 in.) 4.02mm (0.158 in.) 4412820AB   0.91mm (0.036 in.) 3.54mm (0.139 in.) 4412808AB
    0.46mm (0.018 in.) 4.02mm (0.158 in.) 4412820AB   0.94mm (0.037 in.) 3.54mm (0.139 in.) 4412808AB
    0.48mm (0.019 in.) 3.98mm (0.157 in.) 4412819AB   0.97mm (0.038 in.) 3.50mm (0.138 in.) 4412807AB
    0.51mm (0.020 in.) 3.94mm (0.155 in.) 4412818AB        
    Fig 18: Install Output Gear
    GC0147187Courtesy of CHRYSLER GROUP, LLC
    1 - WRENCHES
    2 - INSTALLER 6261 WITH STUD
    3 - OUTPUT GEAR
  18. Install the output gear and bearing assembly using (special tool #6261, Installer, Gear) (2).
    Fig 19: Output Gear Bolt And Washer
    GC0115655Courtesy of CHRYSLER GROUP, LLC
    1 - OUTPUT GEAR
    2 - BOLT
    3 - CONED LOCK WASHER
  19. Install NEW output gear retaining bolt (2) and washer (3).
    Fig 20: Tighten Output Gear To 271 N.m (200 Ft. Lbs.)
    GC0115656Courtesy of CHRYSLER GROUP, LLC
    1 - OUTPUT GEAR
    2 - TORQUE WRENCH
    3 - 200 FT. LBS.
    4 - HOLDER 6259
  20. Using (special tool #6259, Holder) (4), tighten output gear retaining bolt to 271 N.m (200 ft. lbs.).
    Fig 21: Check Output Gear Bearings Turning Torque
    GC0115657Courtesy of CHRYSLER GROUP, LLC
    1 - INCH-POUND TORQUE WRENCH
    2 - OUTPUT GEAR
  21. Using an Inch Pound Torque Wrench (1), check output shaft turning torque. Output shaft turning torque should be within 3-8 in. lbs.  If the turning torque is too high, install a 0.04 mm (0.0016 in.) thicker shim. If the turning torque is too low, install a 0.04 mm (0.0016 in.) thinner shim. Repeat until the proper turning torque of 3-8 in. lbs. is obtained.
    Fig 22: Install Stirrup
    GC0115658Courtesy of CHRYSLER GROUP, LLC
    1 - STIRRUP
    2 - OUTPUT GEAR RETAINING BOLT
  22. Install output gear stirrup (1) with serrated side out.
    Fig 23: Install Strap Bolts
    GC0115659Courtesy of CHRYSLER GROUP, LLC
    1 - RETAINING STRAP
    2 - STIRRUP
    3 - RETAINING STRAP BOLTS
  23. Install retaining strap (1).
  24. Install strap bolts (3) but do not tighten at this time.
    Fig 24: Turn Stirrup Clockwise Against Flats Of Output Gear Retaining Bolt
    GC0115660Courtesy of CHRYSLER GROUP, LLC
    1 - RETAINING STRAP
    2 - STIRRUP
  25. Rotate stirrup (2) clockwise against flats of retaining bolt.
    Fig 25: Torque Stirrup Strap Bolts
    GC0115661Courtesy of CHRYSLER GROUP, LLC
    1 - RETAINING STRAP
    2 - STIRRUP
  26. Tighten stirrup strap bolts to 23 N.m (200 in. lbs.).
    Fig 26: Bend Tabs On Strap Up Against Flats Of Bolts
    GC0115662Courtesy of CHRYSLER GROUP, LLC
    1 - RETAINING STRAP TABS
    2 - RETAINING STRAP
    3 - STIRRUP
  27. Bend tabs (1) on strap up against flats of bolts.
    Fig 27: Install Transfer Shaft Bearing Cone
    GC0115663Courtesy of CHRYSLER GROUP, LLC
    1 - INSTALLER 6052
    2 - NEW BEARING CONE
    3 - TRANSFER SHAFT
    4 - ARBOR PRESS RAM
  28. Install transfer shaft bearing cone using (special tool #6052, Installer, Bearing/Seal) (1).
    Fig 28: Install Bearing Cup To Shaft
    GC0115664Courtesy of CHRYSLER GROUP, LLC
    1 - BEARING CUP
    2 - BEARING CONE
    3 - TRANSFER SHAFT
    4 - OIL BAFFLE
    5 - O-RING
    NOTE:

    Insure O-ring is installed on the bearing cup before the cup is installed.

  29. Install bearing cup (1) and oil baffle (4) to transfer shaft (3).
    Fig 29: Install Transfer Shaft
    GC0115665Courtesy of CHRYSLER GROUP, LLC
    1 - REMOVER/INSTALLER 5049-A
    2 - TRANSFER SHAFT
    3 - OUTPUT GEAR
  30. Using (special tool #5049-A, Remover/Installer) (1), install transfer shaft (2).
    Fig 30: Install Transfer Shaft Bearing Snap Ring
    GC0115666Courtesy of CHRYSLER GROUP, LLC
    1 - SNAP RING PLIERS 6051A
    2 - TRANSFER SHAFT BEARING SNAP RING
    3 - TRANSFER SHAFT
  31. Using (special tool #6051A, Plier, Snap Ring) (1), install transfer shaft bearing snap ring (2).
    Fig 31: Install Transfer Shaft Bearing Cup Into Retainer
    GC0115667Courtesy of CHRYSLER GROUP, LLC
    1 - ARBOR PRESS RAM
    2 - HANDLE C-4171
    3 - INSTALLER 6061
    4 - TRANSFER SHAFT BEARING CUP RETAINER
    5 - USE REMOVED BEARING CUP TO SUPPORT RETAINER
  32. Install transfer shaft bearing cup into retainer (4) using (special tool #6061, Installer, Cup) (3).
    Fig 32: Install Bearing Cup Retainer
    GC0115668Courtesy of CHRYSLER GROUP, LLC
    1 - ALIGN INDEXING TAB TO SLOT
    2 - BEARING CUP RETAINER
  33. Install bearing cup retainer (2) to transaxle.
    Fig 33: Install Transfer Gear Bearing Cone
    GC0115669Courtesy of CHRYSLER GROUP, LLC
    1 - ARBOR PRESS RAM
    2 - HANDLE C-4171
    3 - NEW BEARING CONE
    4 - TRANSFER SHAFT GEAR
    5 - INSTALLER 5052
  34. Install transfer gear bearing cone to transfer gear (4) using (special tool #5052, Installer, Bearing), (5) (special tool #C-4171, Driver Handle, Universal) and an Arbor Press.
    Fig 34: Install Transfer Shaft Gear And (Select) Shim
    GC0115670Courtesy of CHRYSLER GROUP, LLC
    1 - TRANSFER SHAFT GEAR
    2 - BEARING CUP RETAINER
    3 - SHIM (SELECT)
  35. TRANSFER GEAR BEARING ADJUSTMENT: 
    1. Install a 4.66 mm (0.184 in.) gauging shim (3) on the transfer shaft.
    2. Install transfer shaft gear using (special tool #6261, Installer, Gear). Using (special tool #6259, Holder), install transfer shaft gear retaining nut to 271 N.m (200 ft. lbs.).
    3. Measure end play. Attach Gear Checking Plate L4432 to the transfer gear.
    4. Mount a steel ball with grease into the end of the transfer shaft.
    5. Push and pull the gear while rotating back and forth to ensure seating of the bearing rollers.
    6. Using a Dial Indicator, measure transfer shaft end play.
    7. Refer to the TRANSFER SHAFT BEARING SHIM CHART below for the required shim combination to obtain the proper bearing setting.
    8. Use to remove the retaining nut and washer. Remove the transfer shaft gear using (special tool #L-4407A, Puller, Gear).
    9. Remove the gauging shim and install the proper shim indicated by the chart.
    TRANSFER SHAFT BEARING SHIM CHART

    End Play Shim Needed Part Number   End Play Shim Needed Part Number
    0.05mm (0.002 in.) 4.66mm (0.183 in.) 4505588AB   0.76mm (0.030 in.) 3.94mm (0.155 in.) 4412818AB
    0.08mm (0.003 in.) 4.62mm (0.182 in.) 4412835AB   0.79mm (0.031 in.) 3.90mm (0.154 in.) 4412817AB
    0.10mm (0.004 in.) 4.58mm (0.180 in.) 4412834AB   0.81mm (0.032 in.) 3.90mm (0.154 in.) 4412817AB
    0.13mm (0.005 in.) 4.58mm (0.180 in.) 4412834AB   0.84mm (0.033 in.) 3.86mm (0.152 in.) 4412816AB
    0.15mm (0.006 in.) 4.54mm (0.178 in.) 4412833AB   0.86mm (0.034 in.) 3.82mm (0.150 in.) 4412815AB
    0.18mm (0.007 in.) 4.50mm (0.177 in.) 4412832AB   0.89mm (0.035 in.) 3.82mm (0.150 in.) 4412815AB
    0.20mm (0.008 in.) 4.50mm (0.177 in.) 4412832AB   0.91mm (0.036 in.) 3.78mm (0.149 in.) 4412814AB
    0.23mm (0.009 in.) 4.46mm (0.175 in.) 4412831AB   0.94mm (0.037 in.) 3.74mm (0.147 in.) 4412813AB
    0.25mm (0.010 in.) 4.46mm (0.175 in.) 4412831AB   0.97mm (0.038 in.) 3.74mm (0.147 in.) 4412813AB
    0.28mm (0.011 in.) 4.42mm (0.174 in.) 4412830AB   0.99mm (0.039 in.) 3.70mm (0.146 in.) 4412812AB
    0.30mm (0.012 in.) 4.38mm (0.172 in.) 4412829AB   1.02mm (0.040 in.) 3.66mm (0.144 in.) 4412811AB
    0.33mm (0.013 in.) 4.38mm (0.172 in.) 4412829AB   1.04mm (0.041 in.) 3.66mm (0.144 in.) 4412811AB
    0.36mm (0.014 in.) 4.34mm (0.171 in.) 4412828AB   1.07mm (0.042 in.) 3.62mm (0.143 in.) 4412810AB
    0.38mm (0.015 in.) 4.30mm (0.169 in.) 4412827AB   1.08mm (0.043 in.) 3.62mm (0.143 in.) 4412810AB
    0.41mm (0.016 in.) 4.30mm (0.169 in.) 4412827AB   1.12mm (0.044 in.) 3.58mm (0.141 in.) 4412809AB
    0.43mm (0.017 in.) 4.26mm (0.168 in.) 4412826AB   1.14mm (0.045 in.) 3.54mm (0.139 in.) 4412808AB
    0.46mm (0.018 in.) 4.22mm (0.166 in.) 4412825AB   1.17mm (0.046 in.) 3.54mm (0.139 in.) 4412808AB
    0.48mm (0.019 in.) 4.22mm (0.166 in.) 4412825AB   1.19mm (0.047 in.) 3.50mm (0.138 in.) 4412807AB
    0.50mm (0.020 in.) 4.18mm (0.165 in.) 4412824AB   1.22mm (0.048 in.) 3.46mm (0.136 in.) 4412806AB
    0.53mm (0.021 in.) 4.18mm (0.165 in.) 4412824AB   1.24mm (0.049 in.) 3.46mm (0.136 in.) 4412806AB
    0.56mm (0.022 in.) 4.14mm (0.163 in.) 4412823AB   1.27mm (0.050 in.) 3.42mm (0.135 in.) 4412805AB
    0.58mm (0.023 in.) 4.10mm (0.161 in.) 4412822AB   1.30mm (0.051 in.) 3.38mm (0.133 in.) 4412804AB
    0.61mm (0.024 in.) 4.10mm (0.161 in.) 4412822AB   1.32mm (0.052 in.) 3.38mm (0.133 in.) 4412804AB
    0.64mm (0.025 in.) 4.06mm (0.160 in.) 4412821AB   1.35mm (0.053 in.) 3.34mm (0.132 in.) 4412803AB
    0.66mm (0.026 in.) 4.02mm (0.158 in.) 4412820AB   1.37mm (0.054 in.) 3.34mm (0.132 in.) 4412803AB
    0.69mm (0.027 in.) 4.02mm (0.158 in.) 4412820AB   1.40mm (0.055 in.) 3.30mm (0.130 in.) 4412802AB
    0.71mm (0.028 in.) 3.98mm (0.157 in.) 4412819AB   1.45mm (0.057 in 3.26mm (0.128 in.) 4412801AB
    0.74mm (0.029 in.) 3.94mm (0.155 in.) 4412818AB   1.47mm (0.058 in.) 2.22mm (0.127 in.) 4505570AB
    Fig 35: Install Transfer Shaft Gear
    GC0147188Courtesy of CHRYSLER GROUP, LLC
    1 - WRENCHES
    2 - INSTALLER 6261
    3 - OUTPUT GEAR
    4 - TRANSFER SHAFT GEAR
  36. Install the transfer shaft gear (4) using (special tool #6261, Installer, Gear) (2).
    Fig 36: Tighten Nut To 271 N.m (200 Ft. Lbs.)
    GC0115671Courtesy of CHRYSLER GROUP, LLC
    1 - TRANSFER SHAFT GEAR
    2 - 200 FT. LBS.
    3 - TORQUE WRENCH
    4 - HOLDER 6259
    CAUTION:

    Install a NEW retaining nut, as the original nut MUST NOT be reused.

  37. Install the new retaining nut and washer.
  38. Using (special tool #6259, Holder) (4), tighten transfer gear retaining nut to 271 N.m (200 ft. lbs.).
    Fig 37: Install Rear Cover
    GC0115672Courtesy of CHRYSLER GROUP, LLC
    1 - REAR COVER
    2 - 1/8 INCH BEAD OF MOPAR® ATF RTV (MS-GF41)
  39. Measure transfer shaft end play. Transfer shaft end play should be within 0.05-0.10 mm (0.002-0.004 in.).  If the end play is too high, install a 0.04 mm (0.0016 in.) thicker shim. If the end play is too low, install a 0.04 mm (0.0016 in.) thinner shim. Repeat until 0.05-0.10 mm (0.002-0.004 in.) end play is obtained.
  40. Install a bead of Mopar® ATF RTV (MS-GF41) (2) to transfer gear cover.
    Fig 38: Install Rear Cover Bolts
    GC0115673Courtesy of CHRYSLER GROUP, LLC
    1 - REAR COVER BOLTS
    2 - REAR COVER
    3 - USE SEALANT ON BOLTS
  41. Install transfer gear cover-to-case bolts (1) and torque to 20 N.m (175 in. lbs.) torque.
    Fig 39: Removing/Installing Low/Reverse Clutch
    GC0115602Courtesy of CHRYSLER GROUP, LLC
    1 - CLUTCH PLATE
    2 - CLUTCH DISC
  42. Install low/reverse clutch pack (1, 2). Leave uppermost disc out until snap ring is installed.
    Fig 40: Install Low/Reverse Reaction Plate Snap Ring
    GC0115674Courtesy of CHRYSLER GROUP, LLC
    1 - SCREWDRIVER
    2 - LOW/REVERSE REACTION PLATE FLAT SNAP RING
    3 - DO NOT SCRATCH CLUTCH PLATE
  43. Install low/reverse reaction plate flat snap ring (2).
    Fig 41: Install One Disc
    GC0115675Courtesy of CHRYSLER GROUP, LLC
    1 - ONE DISC FROM LOW/REVERSE CLUTCH
  44. Install remaining low/reverse clutch disc (1).
    Fig 42: Install Low/Reverse Reaction Plate
    GC0115676Courtesy of CHRYSLER GROUP, LLC
    1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP)
  45. Install low/reverse reaction plate with flat side up (1).
    Fig 43: Identifying Proper Snap Ring Orientation
    GC0115677Courtesy of CHRYSLER GROUP, LLC
  46. Proper installation of snap ring (with tapered side up).
    Fig 44: Snap Ring Installed
    GC0115678Courtesy of CHRYSLER GROUP, LLC
    1 - SCREWDRIVER
    2 - TAPERED SNAP RING (INSTALL AS SHOWN IN ILLUSTRATION)
  47. Install tapered snap ring (with tapered side up).
    Fig 45: Check Low/Reverse Clutch Clearance
    GC0115679Courtesy of CHRYSLER GROUP, LLC
    1 - DIAL INDICATOR
    2 - DIAL INDICATOR TIP TOOL 6268
    3 - HOOK TOOL
  48. Set up Dial Indicator (1) and (special tool #6268, Tip, Dial Indicator) (2) to measure low/reverse clutch clearance. Press down on clutch pack with finger and zero dial indicator. Low/Reverse clutch pack clearance is 0.89-1.47 mm (0.035-0.058 in.)  . Set up Indicator (1) and record measurement in four places. Take average of readings and select the proper low/reverse reaction plate to achieve specifications.
    LOW/REVERSE REACTION PLATE CHART

    PART NUMBER THICKNESS
    4799846AA 5.88 mm (0.232 in.)
    4799847AA 6.14 mm (0.242 in.)
    4799848AA 6.40 mm (0.252 in.)
    4799849AA 6.66 mm (0.262 in.)
    4799855AA 6.92 mm (0.273 in.)
    Fig 46: Removing/Installing 2/4 Clutch
    GC0115597Courtesy of CHRYSLER GROUP, LLC
    1 - CLUTCH DISC
    2 - CLUTCH PLATE
  49. Install 2/4 clutch pack (1, 2).
    NOTE:

    The 2/4 Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.

    Fig 47: Identifying Return Spring
    GC0115680Courtesy of CHRYSLER GROUP, LLC
    1 - NOTE POSITION
    2 - RETURN SPRING
    3 - 2/4 CLUTCH RETAINER
  50. Orient 2/4 clutch return spring (2) to retainer (1).
    Fig 48: 2/4 Clutch Retainer
    GC0115681Courtesy of CHRYSLER GROUP, LLC
    1 - 2/4 CLUTCH RETAINER
    2 - 2/4 CLUTCH RETURN SPRING
  51. Install 2/4 clutch return spring (2) into transaxle.
    Fig 49: Install 2/4 Clutch Retainer Snap Ring
    GC0115682Courtesy of CHRYSLER GROUP, LLC
    1 - COMPRESSOR 5058A
    2 - SCREWDRIVER
    3 - SNAP RING
    4 - 2/4 CLUTCH RETAINER
  52. Using (special tool #5058A, Compressor, Spring) (1), compress 2/4 clutch return spring just enough to install snap ring.
  53. Install snap ring (3).
    Fig 50: Check 2/4 Clutch Clearance
    GC0115683Courtesy of CHRYSLER GROUP, LLC
    1 - DIAL INDICATOR
    2 - HOOK TOOL
    3 - DIAL INDICATOR TIP 6268
  54. Set up Dial Indicator (1), (special tool #6268, Tip, Dial Indicator) (3) and Hook tool (2), measure 2/4 clutch clearance. Press down on clutch pack with finger and zero dial indicator. 2/4 clutch pack clearance is 0.76-2.64 mm (0.030-0.104 in.).  Set up indicator and record measurement in four places. Take average of readings. If clearance is outside this range, the clutch is assembled improperly. There is no adjustment for 2/4 clutch clearance. 
    Fig 51: Identifying Rear Sun Gear & No. 7 Bearing
    GC0115684Courtesy of CHRYSLER GROUP, LLC
    1 - #7 NEEDLE BEARING
    2 - REAR SUN GEAR
  55. Install rear sun gear and #7 needle bearing (1).
    Fig 52: Install Rear Sun Gear And #7 Needle Bearing
    GC0115685Courtesy of CHRYSLER GROUP, LLC
    1 - #7 NEEDLE BEARING
    2 - REAR SUN GEAR
    NOTE:

    The number seven needle bearing (1) has three anti-reversal tabs and is common with the number five and number two position. The orientation should allow the bearing to seat flat against the rear sun gear. A small amount of petrolatum can be used to hold the bearing to the rear sun gear.

    Fig 53: Install Front Carrier/Rear Annulus Assembly
    GC0115686Courtesy of CHRYSLER GROUP, LLC
    1 - #6 NEEDLE BEARING
    2 - FRONT CARRIER AND REAR ANNULUS ASSEMBLY (TWIST AND PULL OR PUSH TO REMOVE OR INSTALL).
  56. Install front carrier/rear annulus assembly (2) and #6 needle bearing (1).
    Fig 54: Identifying Front Sun Gear Assembly And #4 Thrust Washer
    GC0115687Courtesy of CHRYSLER GROUP, LLC
    1 - FRONT SUN GEAR ASSEMBLY
    2 - #4 THRUST WASHER (FOUR TABS)
  57. Install front sun gear assembly (1) and #4 thrust washer (2).
    Fig 55: Select Thinnest No. 4 Thrust Plate
    GC0115688Courtesy of CHRYSLER GROUP, LLC
    1 - OVERDRIVE SHAFT ASSEMBLY
    2 - #4 THRUST PLATE (SELECT)
    3 - 3 DABS OF PETROLATUM FOR RETENTION
  58. Select the thinnest #4 thrust plate thickness and install to input clutch assembly (1). Use petrolatum to retain.
    Fig 56: View Through Input Speed Sensor Hole
    GC0115689Courtesy of CHRYSLER GROUP, LLC
    1 - INPUT CLUTCH RETAINER
    2 - INPUT SPEED SENSOR HOLE
    3 - OIL COOLER FITTINGS
  59. Install input clutch assembly into position and verify that it is completely seated by viewing through input speed sensor hole. View through input speed sensor hole (2), if not as shown in illustration , the input clutch assembly is not seated properly.
    Fig 57: Removing Oil Pump O-Ring
    GC0115690Courtesy of CHRYSLER GROUP, LLC
    1 - OIL PUMP ASSEMBLY
    2 - O-RING
  60. Remove oil pump O-ring (2). Be sure to reinstall oil pump O-ring after selecting the proper #4 thrust plate. 
    Fig 58: Measuring Input Shaft End Play
    GC0115691Courtesy of CHRYSLER GROUP, LLC
    1 - HANDLE
    2 - END PLAY SOCKET SET 8266
    3 - TOOL C-3339A
  61. Install pump and gasket to transmission. Install oil pump-to-case bolts and tighten to 27 N.m (20 ft. lbs.).
  62. Set up input shaft for measurement with (special tool #C-3339A, Set, Dial Indicator) (2) and (special tool #8266B, End Play Socket Set) (1).
  63. Measure the input shaft end play with the transaxle in the vertical position. Input shaft end play must be within 0.005 to 0.025 inch.  For example, if end play reading is 0.055 inch, select # 4 Thrust Plate which is 0.071 to 0.074 thick. This should provide an input shaft end play reading of 0.020 inch which is within specifications.
  64. Refer to the # 4 THRUST PLATE CHART below to select the proper # 4 thrust plate.
    # 4 THRUST PLATE CHART

    PART NUMBER THICKNESS
    4431665AB 1.60mm (0.063 in.)
    3836237AB 1.73mm (0.068 in.)
    4431666AB 1.80mm (0.071 in.)
    3836238AB 1.96mm (0.077 in.)
    4431667AB 2.03mm (0.080 in.)
    3836239AB 2.16mm (0.085 in.)
    4431668AB 2.24mm (0.088 in.)
    3836240AB 2.39mm (0.094 in.)
    4431669AB 2.46mm (0.097 in.)
    3836241AB 2.62mm (0.103 in.)
    4446670AB 2.67mm (0.105 in.)
    4446671AB 2.90mm (0.114 in.)
    Fig 59: Install Input Clutch Assembly
    GC0147189Courtesy of CHRYSLER GROUP, LLC
    1 - INPUT CLUTCH ASSEMBLY
    2 - #4 THRUST WASHER
  65. Install input clutch assembly (1).
    Fig 60: Removing/Installing Caged Needle Bearing
    GC0115692Courtesy of CHRYSLER GROUP, LLC
    1 - #1 CAGED NEEDLE BEARING
    2 - NOTE: TANGED SIDE OUT
  66. Install #1 caged needle bearing (1).
    Fig 61: Install Cooler Bypass Valve
    GC0115693Courtesy of CHRYSLER GROUP, LLC
    1 - COOLER BYPASS VALVE
    CAUTION:

    The cooler bypass valve must be replaced if transaxle failure has occurred. Do not attempt to reuse or clean old valve.

  67. Install cooler bypass valve (1) with O-ring end towards rear of case.
    Fig 62: Install Oil Pump Gasket
    GC0115694Courtesy of CHRYSLER GROUP, LLC
    1 - PUMP GASKET
  68. Install oil pump gasket (1).
    Fig 63: Install Oil Pump
    GC0115695Courtesy of CHRYSLER GROUP, LLC
    1 - OIL PUMP
    2 - GASKET
  69. Install oil pump assembly (1).
    Fig 64: Install Pump-To-Case Bolts
    GC0115696Courtesy of CHRYSLER GROUP, LLC
    1 - PUMP ATTACHING BOLTS
    2 - PUMP HOUSING
  70. Install oil pump-to-case bolts (1) and tighten to 27 N.m (20 ft. lbs.).
    Fig 65: Low/Reverse Accumulator
    GC0115579Courtesy of CHRYSLER GROUP, LLC
    1 - ACCUMULATOR PISTON
    2 - SEAL RINGS
    3 - RETURN SPRINGS
    4 - (NOTE NOTCH)
  71. Install low/reverse accumulator (1).
    Fig 66: Removing/Installing Low/Reverse Accumulator Plug
    GC0115697Courtesy of CHRYSLER GROUP, LLC
    1 - ADJUSTABLE PLIERS
    2 - PLUG
  72. Install low/reverse accumulator plug (2).
    Fig 67: Install Low/Reverse Accumulator Snap Ring
    GC0115698Courtesy of CHRYSLER GROUP, LLC
    1 - SNAP RING
    2 - PLUG
  73. Install low/reverse accumulator snap ring (1).
    Fig 68: Underdrive And Overdrive Accumulators
    GC0115576Courtesy of CHRYSLER GROUP, LLC
    1 - RETURN SPRING
    2 - UNDERDRIVE CLUTCH ACCUMULATOR
    3 - SEAL RING (2)
    4 - OVERDRIVE CLUTCH ACCUMULATOR
    NOTE:

    Depending on engine application, some accumulators will have two springs, and others will have one spring. The springs are color-coded for application and year.

  74. Install underdrive (2) and overdrive (4) accumulators and springs.
    Fig 69: Valve Body Removal/Installation
    GC0115699Courtesy of CHRYSLER GROUP, LLC
    1 - VALVE BODY
  75. Install valve body (1) to transaxle. Rotate manual valve shaft fully clockwise to ease installation. Make sure park rod rollers are positioned within park guide bracket.
    Fig 70: Install Valve Body-To-Case Bolts
    GC0115700Courtesy of CHRYSLER GROUP, LLC
    1 - VALVE BODY ATTACHING BOLTS (18)
    2 - VALVE BODY
  76. Install and tighten valve body-to-case bolts (1) to 12 N.m (105 in. lbs.).
    Fig 71: Install Oil Filter And O-Ring
    GC0115701Courtesy of CHRYSLER GROUP, LLC
    1 - OIL FILTER
    2 - O-RING
  77. Install oil filter (1) and new O-ring (2).
    Fig 72: Install Oil Pan
    GC0115702Courtesy of CHRYSLER GROUP, LLC
    1 - OIL PAN
    2 - 1/8 INCH BEAD OF MOPAR® ATF RTV (MS-GF41)
    3 - OIL FILTER
  78. Apply a 1/8" bead of Mopar® ATF RTV (MS-GF41) (2) to oil pan (1) and immediately install to case.
    Fig 73: Solenoid/Pressure Switch Assembly And Gasket
    GC0115703Courtesy of CHRYSLER GROUP, LLC
    1 - SOLENOID/PRESSURE SWITCH ASSEMBLY
    2 - GASKET
  79. Install oil pan-to-case bolts and tighten to 19 N.m (165 in. lbs.).
  80. Install solenoid/pressure switch assembly (1) and gasket (2) to case.
    Fig 74: Attaching Bolts
    GC0115704Courtesy of CHRYSLER GROUP, LLC
    1 - BOLTS
    2 - SOLENOID AND PRESSURE SWITCH ASSEMBLY
  81. Install and tighten solenoid/pressure switch assembly-to-transaxle case bolts (1) to 12 N.m (106 in. lbs.).
  82. Install and tighten input and output speed sensors to case to 27 N.m (20 ft. lbs.).
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