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Section 132 (62TE 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: Installing Both Output Bearing Cups Using Installer 5050
GC0122553Courtesy of CHRYSLER GROUP, LLC
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 (Refer to QUICK LEARN PROCEDURE ).

  1. Install both output bearing cups (2) using Installer (special tool #5050A, Installer, Bearing Cup) (1).
    Fig 2: Removing/Installing Low/Reverse Piston Retainer Gasket
    GC0115927Courtesy 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: Remove/Install Piston Retainer
    GC0115926Courtesy of CHRYSLER GROUP, LLC
    1 - LOW/REVERSE CLUTCH PISTON RETAINER
    2 - GASKET
  3. Install low/reverse piston retainer (1).
    Fig 4: Installing Low/Reverse Piston Retainer-To-Case Screws
    GC0115925Courtesy 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: Remove/Install Low/Reverse Clutch Piston
    GC0115924Courtesy 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: Removing/Installing Low/Reverse Piston Belleville Spring Into Position
    GC0115920Courtesy of CHRYSLER GROUP, LLC
    1 - LOW/REVERSE PISTON RETURN SPRING
    2 - PISTON
  6. Install low/reverse piston return spring (1).
    Fig 7: Low/Reverse Spring Compressor Tool
    GC0115917Courtesy of CHRYSLER GROUP, LLC
    1 - DISC 6057
    2 - COMPRESSOR 5059-A
    3 - COMPRESSOR BAR 5058A-3
  7. Install Disk (special tool #6057, Disc, Spring Compressor) (1), Compressor (special tool #5059-A, Compressor, Spring) (2) and Compressor Bar (special tool #5058A-3, Screw, Forcing) (3).
    Fig 8: Compressing Low/Reverse Spring
    GC0115918Courtesy of CHRYSLER GROUP, LLC
    1 - LOW/REVERSE CLUTCH RETURN SPRING
    2 - SNAP RING (INSTALL AS SHOWN IN ILLUSTRATION)
    3 - DISC 6057
    4 - COMPRESSOR 5059
    5 - COMPRESSOR BAR 5058-3
  8. Install low/reverse spring compressor into position.
    Fig 9: Installing Snap Ring
    GC0115919Courtesy of CHRYSLER GROUP, LLC
    1 - SNAP RING OPENING MUST BE BETWEEN SPRING LEVERS (AS SHOWN IN ILLUSTRATION)
    2 - SNAP RING PLIERS
    3 - DISC 6057
  9. Compress low/reverse piston and install snap ring (1).
    Fig 10: Install Rear Carrier Bearing Cone
    GC0115932Courtesy of CHRYSLER GROUP, LLC
    1 - ARBOR PRESS RAM
    2 - INSTALLER 6053
    3 - NEW BEARING CONE
    4 - REAR CARRIER ASSEMBLY
  10. Install rear carrier bearing cone (3) using Installer (special tool #6053, Installer, Bearing) (1).
    Fig 11: View Of Rear Carrier Assembly
    GC0122529Courtesy of CHRYSLER GROUP, LLC
  11. Install rear carrier assembly (1) to transaxle case.
    Fig 12: Install Output Gear Bearing Cone
    GC0115933Courtesy of CHRYSLER GROUP, LLC
    1 - ARBOR PRESS RAM
    2 - HANDLE C-4171
    3 - INSTALLER 5052
    4 - OUTPUT GEAR
  12. Install output gear bearing cone using Installer (special tool #6758, Installer, Ball Joint) (3).
    Fig 13: Checking Output Gear Bearings End Play
    GC0115934Courtesy of CHRYSLER GROUP, LLC
    1 - GEAR CHECKING PLATE L-4432
    2 - DIAL INDICATOR
    3 - SPECIAL SCREWS 6260
    4 - OUTPUT GEAR
  13. OUTPUT GEAR BEARING ADJUSTMENT: 
    1. With output gear removed, install a 4.50 mm (0.177 in.) gauging shim on the rear carrier assembly hub, using grease to hold the shim in place.
    2. Using Holder (special tool #6259, Holder), install output gear, bearing assembly and bolt. Tighten to 271 N.m (200 ft. lbs.).
    3. Measure bearing end play. Attach Gear Checking Plate (special tool #L-4432, Fixture) (1) to the gear.
    4. Push and pull the gear while rotating back and forth to ensure seating of bearing rollers.
    5. Using a dial indicator mounted to the transaxle case, measure output gear end play.
    6. Refer to the OUTPUT GEAR BEARING SHIM CHART  for the required shim to obtain proper bearing setting.
    7. Use Holder (special tool #6259, Holder) to remove the output gear retaining bolt and washer. To remove the output gear, use Gear Puller (special tool #L-4407A, Puller, Gear).
    8. 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
    0.05mm (0.002 in.) 4.42mm (0.174 in.) 4412830AB
    0.08mm (0.003 in.) 4.38mm (0.172 in.) 4412829AB
    0.10mm (0.004 in.) 4.38mm (0.172 in.) 4412829AB
    0.13mm (0.005 in.) 4.34mm (0.171 in.) 4412828AB
    0.15mm (0.006 in.) 4.30mm (0.169 in.) 4412827AB
    0.18mm (0.007 in.) 4.30mm (0.169 in.) 4412827AB
    0.20mm (0.008 in.) 4.26mm (0.168 in.) 4412826AB
    0.23mm (0.009 in.) 4.22mm (0.166 in.) 4412825AB
    0.25mm (0.010 in.) 4.22mm (0.166 in.) 4412825AB
    0.28mm (0.011 in.) 4.18mm (0.165 in.) 4412824AB
    0.30mm (0.012 in.) 4.14mm (0.163 in.) 4412823AB
    0.33mm (0.013 in.) 4.14mm (0.163 in.) 4412823AB
    0.36mm (0.014 in.) 4.10mm (0.161 in.) 4412822AB
    0.38mm (0.015 in.) 4.10mm (0.161 in.) 4412822AB
    0.41mm (0.016 in.) 4.06mm (0.160 in.) 4412821AB
    0.43mm (0.017 in.) 4.02mm (0.158 in.) 4412820AB
    0.46mm (0.018 in.) 4.02mm (0.158 in.) 4412820AB
    0.48mm (0.019 in.) 3.98mm (0.157 in.) 4412819AB
    0.51mm (0.020 in.) 3.94mm (0.155 in.) 4412818AB
    0.53mm (0.021 in.) 3.94mm (0.155 in.) 4412818AB
    0.56mm (0.022 in.) 3.90mm (0.154 in.) 4412817AB
    0.58mm (0.023 in.) 3.90mm (0.154 in.) 4412817AB
    0.61mm (0.024 in.) 3.86mm (0.152 in.) 4412816AB
    0.64mm (0.025 in.) 3.82mm (0.150 in.) 4412815AB
    0.66mm (0.026 in.) 3.82mm (0.150 in.) 4412815AB
    0.69mm (0.027 in.) 3.78mm (0.149 in.) 4412814AB
    0.71mm (0.028 in.) 3.74mm (0.147 in.) 4412813AB
    0.74mm (0.029 in.) 3.74mm (0.147 in.) 4412813AB
    0.76mm (0.030 in.) 3.70mm (0.146 in.) 4412812AB
    0.79mm (0.031 in.) 3.66mm (0.144 in.) 4412811AB
    0.81mm (0.032 in.) 3.66mm (0.144 in.) 4412811AB
    0.84mm (0.033 in.) 3.62mm (0.143 in.) 4412810AB
    0.86mm (0.034 in.) 3.62mm (0.143 in.) 4412810AB
    0.89mm (0.035 in.) 3.58mm (0.141) 4412809AB
    0.91mm (0.036in.) 3.54mm (0.139 in.) 4412808AB
    0.94mm (0.037 in.) 3.54mm (0.139 in.) 4412808AB
    0.97mm (0.038 in.) 3.50mm (0.138 in.) 4412807AB
    Fig 14: Install Output Gear
    GC0147209Courtesy of CHRYSLER GROUP, LLC
    1 - WRENCHES
    2 - INSTALLER 6261 WITH STUD
    3 - OUTPUT GEAR
  14. Install the output transfer gear (3) and bearing assembly using Installer (special tool #6261, Installer, Gear) (2).
    Fig 15: Identifying Holder 9739 On Output Transfer Gear
    GC0122554Courtesy of CHRYSLER GROUP, LLC
  15. Install NEW output transfer gear retaining bolt and washer.
  16. Install Holder (special tool #9739, Holder, Gear) (1) onto the output transfer gear (2).
  17. Tighten output transfer gear retaining bolt to 271 N.m (200 ft. lbs.).
    Fig 16: Checking Output Shaft Turning Torque
    GC0122555Courtesy of CHRYSLER GROUP, LLC
  18. Using an inch pound torque wrench, check output shaft turning torque. Output shaft turning torque should be within 0.4-1.0 N.m (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 0.4-1.0 N.m (3-8 in. lbs). is obtained.
    Fig 17: Removing/Installing Low/Reverse Clutch Pack
    GC0115894Courtesy of CHRYSLER GROUP, LLC
    1 - CLUTCH PLATES (5)
    2 - CLUTCH DISCS (5)
  19. Install low/reverse clutch pack (1, 2). Leave uppermost disc out until snap ring is installed.
    Fig 18: Removing/Installing Low/Reverse Reaction Plate Snap Ring
    GC0115893Courtesy of CHRYSLER GROUP, LLC
    1 - SCREWDRIVER
    2 - LOW/REVERSE REACTION PLATE FLAT SNAP RING
    3 - DO NOT SCRATCH CLUTCH PLATE
  20. Install low/reverse reaction plate flat snap ring (2), insure you do not scratch clutch plate (3).
    Fig 19: Remove/Install One Low/Reverse Clutch Disc
    GC0115892Courtesy of CHRYSLER GROUP, LLC
    1 - ONE DISC FROM LOW/REVERSE CLUTCH
  21. Install remaining low/reverse clutch disc (1).
    Fig 20: Removing/Installing Low/Reverse Reaction Plate
    GC0115891Courtesy of CHRYSLER GROUP, LLC
    1 - LOW/REVERSE REACTION PLATE (BEVEL SIDE UP)
  22. Install low/reverse reaction plate (1).
    Fig 21: Bevel/Lug Side Up
    GC0147172Courtesy of CHRYSLER GROUP, LLC
  23. Ensure that the plate is installed with the bevel / lug side up.
    Fig 22: Tapered Snap Ring Instructions
    GC0122556Courtesy of CHRYSLER GROUP, LLC
  24. Use as a reference while installing tapered snap ring.
    Fig 23: Snap Ring Installed
    GC0115946Courtesy of CHRYSLER GROUP, LLC
    1 - SCREWDRIVER
    2 - TAPERED SNAP RING (INSTALL AS SHOWN IN ILLUSTRATION)
  25. Install tapered snap ring (with tapered side up) (2).
    Fig 24: Check Low/Reverse Clutch Clearance
    GC0115947Courtesy of CHRYSLER GROUP, LLC
    1 - DIAL INDICATOR
    2 - DIAL INDICATOR TIP TOOL 6268
    3 - HOOK TOOL
  26. Set up dial indicator (1) 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 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
    05078829AA 5.88 mm (0.232 in.)
    05078830AA 6.14 mm (0.242 in.)
    05078831AA 6.40 mm (0.252 in.)
    05078832AA 6.66 mm (0.262 in.)
    05078833AA 6.92 mm (0.273 in.)
    Fig 25: Removing/Installing 2/4 Clutch Pack
    GC0115889Courtesy of CHRYSLER GROUP, LLC
    1 - CLUTCH PLATE (4)
    2 - CLUTCH DISC (4)
  27. Install 2/4 clutch pack (1, 2).
    Fig 26: Identifying Return Spring
    GC0115948Courtesy of CHRYSLER GROUP, LLC
    1 - NOTE POSITION
    2 - RETURN SPRING
    3 - 2/4 CLUTCH RETAINER
    NOTE:

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

  28. Orient 2/4 clutch return spring to retainer (3).
    Fig 27: 2/4 Clutch Retainer
    GC0115887Courtesy of CHRYSLER GROUP, LLC
    1 - 2/4 CLUTCH RETAINER
    2 - 2/4 CLUTCH RETURN SPRING
  29. Install 2/4 clutch retainer to transaxle (1, 2).
    Fig 28: Remove/Install 2/4 Clutch Retainer Snap Ring
    GC0115886Courtesy of CHRYSLER GROUP, LLC
    1 - COMPRESSING TOOL 5058A
    2 - SCREWDRIVER
    3 - SNAP RING
    4 - 2/4 CLUTCH RETAINER
  30. Using Compressing Tool (special tool #5058A, Compressor, Spring) (1), compress 2/4 clutch return spring just enough to install snap ring (3).
  31. Install snap ring.
    Fig 29: Check 2/4 Clutch Clearance
    GC0115949Courtesy of CHRYSLER GROUP, LLC
    1 - DIAL INDICATOR
    2 - HOOK TOOL
    3 - DIAL INDICATOR TIP 6268
  32. Set up dial indicator (1) and 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 30: Identifying Rear Sun Gear
    GC0081352Courtesy of CHRYSLER GROUP, LLC
    1 - #7 NEEDLE BEARING
    2 - REAR SUN GEAR
    NOTE:

    The number seven needle (1) bearing has three anti-reversal tabs and is common with the number five 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 (2).

    Fig 31: Remove/Install Rear Sun Gear and #7 Needle Bearing
    GC0115885Courtesy of CHRYSLER GROUP, LLC
    1 - #7 NEEDLE BEARING
    2 - REAR SUN GEAR
  33. Install rear sun gear (2) and number seven needle bearing (1).
    Fig 32: Removing/Installing Front Carrier/Rear Annulus Assembly
    GC0115884Courtesy of CHRYSLER GROUP, LLC
    1 - #6 NEEDLE BEARING
    2 - FRONT CARRIER AND REAR ANNULUS ASSEMBLY (TWIST AND PULL OR PUSH TO REMOVE OR INSTALL).
  34. Install front carrier/rear annulus assembly (2) and number six needle bearing (1).
    Fig 33: Removing/Installing Front Sun Gear Assembly And #4 Thrust Washer
    GC0081351Courtesy of CHRYSLER GROUP, LLC
    1 - FRONT SUN GEAR ASSEMBLY
    2 - #4 THRUST WASHER (FOUR TABS)
  35. Install front sun gear assembly (1) and #4 thrust washer (2).
    Fig 34: No. 4 Thrust Plate
    GC0115883Courtesy of CHRYSLER GROUP, LLC
    1 - OVERDRIVE SHAFT ASSEMBLY
    2 - #4 THRUST PLATE (SELECT)
    3 - 3 DABS OF PETROLATUM FOR RETENTION
  36. Select the thinnest #4 thrust plate thickness (2) and install to input clutch assembly. Use petrolatum to retain (3).
    Fig 35: Locating Input Speed Sensor Hole & Input Clutch Assembly
    GC0122557Courtesy of CHRYSLER GROUP, LLC
  37. Install input clutch assembly into position and verify that it is completely seated by viewing through input speed sensor hole (3). If view through input speed sensor hole is not as shown in the illustration, the input clutch assembly (2) is not seated properly.
    Fig 36: Removing/Installing Oil Pump O-Ring
    GC0081353Courtesy of CHRYSLER GROUP, LLC
    1 - OIL PUMP ASSEMBLY
    2 - O-RING
  38. Remove oil pump O-ring (2). Be sure to reinstall oil pump O-ring after selecting the proper #4 thrust plate. 
  39. Install pump and gasket to transmission. Install and torque bolts.
    Fig 37: Measuring Input Shaft End Play
    GC0081354Courtesy of CHRYSLER GROUP, LLC
    1 - END PLAY SOCKET SET 8266A
    2 - DIAL INDICATOR C-3339A
     
  40. Set up input shaft for measurement with Indicator Set (special tool #C-3339A, Set, Dial Indicator) (3) and End Play Set (special tool #8266B, End Play Socket Set) (1, 2).
  41. Measure the input shaft end play with the transaxle in the vertical position. Input shaft end play must be within 0.13-0.64 mm (0.005 to 0.025 in.)  For example, if end play reading is 0.055 in. select NO. 4 Thrust Plate which is 0.071-0.074 in. thick. This should provide an input shaft end play reading of 0.020 in. which is within specifications.
  42. Refer to the NO. 4 THRUST PLATE CHART  to select the proper No. 4 thrust plate. Refer to NO. 4 THRUST PLATE CHART .
    NO. 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 38: Removing/Installing Input Clutch Assembly
    GC0115882Courtesy of CHRYSLER GROUP, LLC
    1 - INPUT CLUTCH ASSEMBLY
    2 - #4 THRUST WASHER
  43. Install input clutch assembly (1).
    Fig 39: Removing/Installing Caged Needle Bearing
    GC0115881Courtesy of CHRYSLER GROUP, LLC
    1 - #1 CAGED NEEDLE BEARING
    2 - NOTE: TANGED SIDE OUT
  44. Install number one caged needle bearing (1) note: tanged side out (2).
    CAUTION:

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

    Fig 40: Identifying Cooler Bypass Valve
    GC0122520Courtesy of CHRYSLER GROUP, LLC
  45. Install cooler bypass valve (1) with O-ring end towards rear of case.
    Fig 41: Identifying Oil Pump Gasket
    GC0122519Courtesy of CHRYSLER GROUP, LLC
  46. Install oil pump gasket (1).
    Fig 42: Locating Front Pump Bolts
    GC0122516Courtesy of CHRYSLER GROUP, LLC
  47. Install oil pump (2).
  48. Install oil pump-to-case bolts (1) and tighten 30 N.m (265 in. lbs.).
    Fig 43: Install Stirrup
    GC0115937Courtesy of CHRYSLER GROUP, LLC
    1 - STIRRUP
    2 - OUTPUT GEAR RETAINING BOLT
  49. Install output gear stirrup (1) with serrated side out.
    Fig 44: Install Strap Bolts
    GC0115908Courtesy of CHRYSLER GROUP, LLC
    1 - RETAINING STRAP
    2 - STIRRUP
    3 - RETAINING STRAP BOLTS
  50. Install retaining strap (1).
  51. Install strap bolts (3) but do not tighten at this time.
    Fig 45: Turn Stirrup Clockwise Against Bolt Flats
    GC0115938Courtesy of CHRYSLER GROUP, LLC
    1 - RETAINING STRAP
    2 - STIRRUP
  52. Rotate stirrup (2) clockwise against flats of retaining bolt.
    Fig 46: Torque Stirrup Strap Bolts
    GC0115939Courtesy of CHRYSLER GROUP, LLC
    1 - RETAINING STRAP
    2 - STIRRUP
  53. Tighten stirrup strap bolts to 23 N.m (200 in. lbs.).
    Fig 47: Bend Tabs On Strap Up Against Flats Of Bolts
    GC0115940Courtesy of CHRYSLER GROUP, LLC
    1 - RETAINING STRAP TABS
    2 - RETAINING STRAP
    3 - STIRRUP
  54. Bend tabs (1) on strap up against flats of bolts.
    Fig 48: Identifying Differential, Bearing Cups, Shim, Seals & Oil Slinger
    GC0122545Courtesy of CHRYSLER GROUP, LLC
  55. Install the differential, bearing cups, shim, seals and oil slinger into case.
    Fig 49: Identifying Differential Cover, Seal, Oil Singer & Small Bearing Cup
    GC0122544Courtesy of CHRYSLER GROUP, LLC
  56. Install the differential cover.
    Fig 50: Identifying Differential Cover Bolts
    GC0122543Courtesy of CHRYSLER GROUP, LLC
  57. Install the differential cover bolts (1) and tighten to 61 N.m (45 ft. lbs.).
    Fig 51: Identifying Differential Output Bearing Cover & Bolts
    GC0122542Courtesy of CHRYSLER GROUP, LLC
  58. Install the differential output bearing cover (2).
  59. Install the differential output bearing cover bolts (1) and tighten to 12 N.m (105 in. lbs.).
    Fig 52: Checking Differential Turning Torque
    GC0122558Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Remote pinion gear must NOT  be installed while checking turning torque.

  60. Using the Turning Torque Tool (special tool #9735, Fixture, Torque Turning) (1) and an inch pound torque wrench (2) check the differential turning torque, it should be 1.0-2.5 N.m (10 to 22 in-lbs drag). If turning torque is more than 2.5 N.m (22 in-lbs drag) decrease shim size behind the end cover and recheck. If turning torque is less than 1.0 N.m (10 in-lbs drag) increase shim size.
  61. After proper turning torque is achieved for the differential remove the differential from the case and set aside keeping the correct shim with the differential.
    Fig 53: Removing/Installing Remote Pinion Cover
    GC0122539Courtesy of CHRYSLER GROUP, LLC
  62. Install the remote pinion bearing cup in the case (small cup) using Installer (special tool #9730, Installer, Bearing Cup) and Handle (special tool #C-4171, Driver Handle, Universal).
  63. Install the remote pinion bearing cup in the cover using Installer (special tool #9729, Installer, Bearing Cup) and Handle (special tool #C-4171, Driver Handle, Universal).
  64. Install the remote pinion (2) into the transaxle case.
    Fig 54: Identifying Remote Pinion & Cover
    GC0122538Courtesy of CHRYSLER GROUP, LLC
  65. Install the remote pinion cover (2) into transaxle case.
    Fig 55: Identifying Remote Pinion Cover & Bolts
    GC0122537Courtesy of CHRYSLER GROUP, LLC
  66. Install the bolts (1) at the remote pinion cover (2) and tighten to 16 N.m (140 in. lbs.).
    Fig 56: Checking Turning Torque Using Inch Pound Torque Wrench
    GC0122559Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Differential assembly must not be installed when checking for pinion drag torque.

  67. Check turning torque using Differential Bearing Torque Tool (special tool #C-4995A, Tool, Differential Bearing Torque) (2) and an inch pound torque wrench (1). Turning torque for the remote pinion gear should be 0.2-1.0 N.m (2 to 8 in-lbs drag). If more than 1.0 N.m (8 in-lbs drag) decrease shim size under the remote pinion bearing cover cup. If turning torque is less than 0.2 N.m (2 in-lbs drag) increase the shim size under the remote pinion bearing cover cup.
    Fig 57: Installing Holder 9908 To Compounder Bearing Retainer
    GC0122534Courtesy of CHRYSLER GROUP, LLC
  68. Install Holder (special tool #9908, Adapter, Puller) (2) onto the compounder bearing retainer to help in installation.
  69. Install the compounder bearing retainer into the transaxle case.
    Fig 58: Identifying Compounder Bearing Retainer Bolts
    GC0122533Courtesy of CHRYSLER GROUP, LLC
  70. Remove Holder (special tool #9908, Adapter, Puller) from the compounder bearing retainer.
  71. Install all the bolts at the compounder bearing retainer and tighten to 12 N.m (105 in. lbs.).
    Fig 59: Removing/Installing Snap Ring At Underdrive Compounder Assembly
    GC0122532Courtesy of CHRYSLER GROUP, LLC
  72. Install snap ring (1) at top of the compounder bearing retainer.
    Fig 60: Identifying Dial Indicator C-3339, Compounder End Play Tool 9951 & Plug At Case
    GC0122560Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Insure End Play Tool (special tool #9951, Tool, Compounder Shim) is not binding in support plate that is bolted to the case.

    NOTE:

    Always use original shim to determine end play.

  73. Remove plug at case (3).
  74. Install compounder End Play Tool (special tool #9951, Tool, Compounder Shim) (2) through the hole in the front case.
  75. Install Dial Indicator (special tool #C-3339A, Set, Dial Indicator) (1) onto End Play Tool (special tool #9951, Tool, Compounder Shim).
  76. Use moderate downward pressure on End Play Tool (special tool #9951, Tool, Compounder Shim) and zero Dial Indicator (special tool #C-3339A, Set, Dial Indicator).
  77. Use moderate upward pressure on End Play Tool (special tool #9951, Tool, Compounder Shim) and take reading from Dial Indicator (special tool #C-3339A, Set, Dial Indicator).
  78. Remove End Play Tool (special tool #9951, Tool, Compounder Shim) and zero Dial Indicator (special tool #C-3339A, Set, Dial Indicator).
  79. Adjust shim thickness in the underdrive unit to 0.010 to 0.020".
  80. Install the correct (select) helical shim and assemble the underdrive compounder and retest. Refer to ASSEMBLY, UNDERDRIVE COMPOUNDER, ASSEMBLY .
  81. Using Mopar® lock AND seal adhesive install plug back into case and tighten to 24 N.m (18 ft. lbs.).
    Fig 61: Install Output Gear Bearing Cone
    GC0115933Courtesy of CHRYSLER GROUP, LLC
    1 - ARBOR PRESS RAM
    2 - HANDLE C-4171
    3 - INSTALLER 5052
    4 - OUTPUT GEAR
  82. Install the transfer gear (underdrive compounder side) cone using Installer (special tool #6756, Receiver, Ball Joint) (3).
    Fig 62: Tightening Transfer Gear Nut
    GC0122561Courtesy of CHRYSLER GROUP, LLC
  83. Install Holder (special tool #9739, Holder, Gear) (1) onto the transfer gear (underdrive compounder side) (2).
  84. Install a new  transfer gear (underdrive compounder side) nut and tighten to 271 N.m (200 ft. lbs.).
  85. Use Staking Tool (special tool #9721, Staking Tool) and stake the new nut.
    Fig 63: Identifying Differential, Bearing Cups, Shim, Seals & Oil Slinger
    GC0122545Courtesy of CHRYSLER GROUP, LLC
  86. Install the differential, bearing cups, shim and oil slinger into case.
    Fig 64: Identifying Differential Cover, Seal, Oil Singer & Small Bearing Cup
    GC0122544Courtesy of CHRYSLER GROUP, LLC
  87. Use a bead of Mopar® ATF RTV (MS-GF41).
  88. Install the differential cover.
    Fig 65: Identifying Differential Cover Bolts
    GC0122543Courtesy of CHRYSLER GROUP, LLC
  89. Install the differential cover bolts (1) and tighten to 61 N.m (45 ft. lbs.).
    Fig 66: Identifying Differential Output Bearing Cover & Bolts
    GC0122542Courtesy of CHRYSLER GROUP, LLC
  90. Use a bead of Mopar® ATF RTV (MS-GF41).
  91. Install the differential output bearing cover (2) and tighten bolts to 12 N.m (105 in. lbs.).
  92. Install differential oil seals into the case using installer MD998334-01.
    Fig 67: Identifying Transfer Gears & Oil Scavenger
    GC0122523Courtesy of CHRYSLER GROUP, LLC
  93. Install the oil scavenger (2).
    Fig 68: Identifying Transfer Gear Cover-To-Case Bolts
    GC0122522Courtesy of CHRYSLER GROUP, LLC
  94. Install the transfer gear cover (1), use a bead of Mopar® ATF RTV (MS-GF41).
  95. Install transfer gear cover-to-case bolts (2) and tighten to 12 N.m (105 in. lbs.).
    Fig 69: Removing/Installing Park Guide Assembly
    GC0122548Courtesy of CHRYSLER GROUP, LLC
  96. Install the park pawl tube (1) into case (2) making sure guide pin aligns with hole in case.
    Fig 70: Removing/Installing Snap Ring For Park Guide Assembly
    GC0122547Courtesy of CHRYSLER GROUP, LLC
  97. Install the snap ring (1) for the park pawl tube.
    Fig 71: Identifying Park Pawl & Park Pawl Spring
    GC0122552Courtesy of CHRYSLER GROUP, LLC
  98. Install the park pawl (1) and the park pawl spring (2).
    Fig 72: Identifying Park Pawl Shaft
    GC0122551Courtesy of CHRYSLER GROUP, LLC
  99. Install the park pawl shaft (1).
    Fig 73: Removing/Installing Park Pawl Shaft Plug
    GC0122549Courtesy of CHRYSLER GROUP, LLC
  100. Install the park pawl shaft and park pawl pipe plug tighten to 27 N.m (20 ft. lbs.).
    Fig 74: Removing/Installing Park Pawl Shaft & Screw
    GC0122546Courtesy of CHRYSLER GROUP, LLC
  101. Install the set screw (1) for the park pawl shaft and tighten to 1 N.m (10 in. lbs.).
  102. Install the manual lever, TRS and seal. Refer to SENSOR, TRANSMISSION RANGE, INSTALLATION .
    Fig 75: Identifying Accumulators & 2/4 Clutch Oil Supply Seal
    GC0122515Courtesy of CHRYSLER GROUP, LLC
    1 - UD ACCUMULATOR
    2 - 2/4 ACCUMULATOR
    3 - LR ACCUMULATOR
    4 - 2/4 CLUTCH OIL SUPPLY SEAL
    5 - LC ACCUMULATOR
    6 - DC ACCUMULATOR
    7 - OD ACCUMULATOR
  103. Install all six accumulators (1, 2, 3, 5, 6 and 7) into case along with the accumulator return springs.
  104. Install a new  2/4 clutch oil supply seal (4) into the case.
    Fig 76: Removing/Installing Oil Transfer Tubes
    GC0122514Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Install transmission oil on the oil transfer tubes O-rings.

  105. Install the oil transfer tubes (2) into the case/compounder.
    Fig 77: Identifying Oil Transfer Tubes, Manual Valve & Valve Body
    GC0122513Courtesy of CHRYSLER GROUP, LLC
  106. Install valve body (1) onto the oil transfer tubes and manual valve (3) at the rooster comb.
    Fig 78: Identifying Valve Body Bolts
    GC0122512Courtesy of CHRYSLER GROUP, LLC
  107. Install the valve body bolts (1) and tighten to 7 N.m (50 in. lbs.).
    Fig 79: Identifying Range Sensor, Detent Spring, Bolts & Electrical Connector
    GC0122511Courtesy of CHRYSLER GROUP, LLC
  108. Install the detent spring (2).
  109. Install the bolt (3) holding the detent spring and tighten to 7 N.m (50 in. lbs.).
  110. Install the electrical connector (1) at the range sensor (4).
    Fig 80: Identifying Valve Body Oil Pan & Bolts
    GC0122509Courtesy of CHRYSLER GROUP, LLC
  111. Install the valve body oil pan, use a bead of Mopar® ATF RTV (MS-GF41).
  112. Install the valve body oil pan bolts and tighten to 12 N.m (105 in. lbs.).
    Fig 81: Identifying Oil Filter Seal & Case
    GC0122506Courtesy of CHRYSLER GROUP, LLC
  113. Install the fluid filter seal (1) at the case.
    Fig 82: Identifying Fluid Filter & Bolts
    GC0122505Courtesy of CHRYSLER GROUP, LLC
  114. Install the fluid filter (2).
  115. Install the fluid filter mounting nuts and tighten to 5 N.m (40 in. lbs.).
    Fig 83: Identifying Oil Filter, Pan & Bolts
    GC0122504Courtesy of CHRYSLER GROUP, LLC
  116. Install the fluid filter oil pan, use a bead of Mopar® ATF RTV (MS-GF41).
  117. Install the fluid filter oil pan bolts and tighten to 12 N.m (105 in. lbs.).
    Fig 84: Front Sound Dampener Cover & Fasteners
    GC0122507Courtesy of CHRYSLER GROUP, LLC
  118. If equipped install the Front Sound Dampener Cover (2) and the fasteners (1).
    Fig 85: Identifying Speed Sensors
    GC0122503Courtesy of CHRYSLER GROUP, LLC
  119. Install the speed sensors (1, 2 and 3) and tighten bolts to 12 N.m (105 in. lbs.).
    Fig 86: Top Sound Dampener Cover
    GC0122508Courtesy of CHRYSLER GROUP, LLC
  120. If equipped install the Top Sound Dampener Cover (1).
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