Part 2
ASSEMBLY
36. Install the #7 needle bearing (1) to the rear sun gear (2). The number 7 needle bearing has three antireversal tabs and is common with the number 5 and number 2 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.
37. Install rear sun gear (2) and #7 needle bearing (1).
38. Install front carrier/rear annulus assembly (2) and #6 needle bearing (1).
39. Install front sun gear assembly (1) and #4 thrust washer (2).
40. Determine proper #4 thrust plate thickness. Select the thinnest available #4 thrust plate.
41. Install #4 thrust plate (2) using petrolatum to hold into position.
42. Install input clutch assembly. Ensure the input clutch assembly is completely seated by viewing position through input speed sensor hole. If the speed sensor tone wheel is not centered in the opening, the input clutches assembly is not seated properly.
43. Remove the oil pump o-ring (2) and install oil pump and gasket to transmission. Use screw-in dowels or phillips-head screwdrivers to align pump to case. Be sure to reinstall O-ring on oil pump after selecting the proper No. 4 thrust plate.
44. Measure the input shaft end play with the transmission in the vertical position. This will ensure that the measurement will be accurate.
45. Set up and measure endplay using End Play Set 8266A (1, 2) and Dial Indicator Set C-3339A (3) as shown.
46. Measure input shaft end play. Input shaft end play must be 0.127 to 0.635 mm (0.005 to 0.025 inch). For example, if end play reading is 0.055 inch, select No. 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.
47. Remove oil pump, gasket, and input clutch assembly to gain access to and install proper #4 thrust plate.
48. Install input clutch assembly (1) with proper thrust plate.
49. Install #1 caged needle bearing (1).
CAUTION: By-pass valve MUST be replaced if transmission failure occurs.
50. Replace cooler by-pass valve (1) if transmission failure has occurred.
NOTE: To align oil pump, gasket, and case during installation, use threaded dowels or Phillips screwdrivers.
51. Install oil pump gasket (2).
52. Install oil pump (2) and torque oil pump-to-case bolts (1) to 30 Nm (265 in. lbs.). Do not reuse original oil pump bolts.
53. Install low/reverse accumulator (1) as shown.
54. Install low/reverse accumulator plug (2).
55. Install low/reverse accumulator snap ring (1).
56. Install underdrive (2) and overdrive (1) accumulators and springs.
CAUTION: Do not handle the valve body by the manual shaft. Damage could result.
57. Install valve body (1) into place as shown.
58. Install seven (7) valve body-to-case bolts (1) and torque to 12 Nm (105 in. lbs.).
59. Install transmission oil filter (1) and o-ring. Tighten the bolts to 5 Nm (45 in. lbs.).
60. If necessary, install a new transmission fill tube grommet into the transmission case with Installer 8254.
61. Install transmission oil pan (1) with a bead of Mopar(R) ATF RTV.
NOTE: Before installing the oil pan bolt in the bolt hole located between the torque converter clutch on and U/D clutch pressure tap circuits , it will be necessary to replenish the sealing patch on the bolt using Mopar(R) Lock & Seal Adhesive.
62. Install and torque the oil pan-to-case bolts to 20 Nm (14.5 ft. lbs.).
NOTE: Before installing either speed sensor bolt, it will be necessary to replenish the sealing patch on the bolt using Mopar(R) Lock & Seal Adhesive.
63. Install both speed sensors (1, 2) into the transmission case. Torque the speed sensor bolts to 9 Nm (80 in. lbs.).
64. As a final check of the transmission, measure the input shaft end play. This will indicate when a #4 thrust plate change is required. The #4 thrust plate is located behind the overdrive clutch hub. Attach a dial indicator to transmission bell housing with its plunger seated against end of input shaft. Move input shaft in and out to obtain end play reading. Input shaft end play must be 0.127 to 0.635 mm (0.005 to 0.025 inch). If not within specifications, make the necessary thrust plate adjustment.
65. Inspect the lube tube grommet (2) for damage. If the grommet lip is damaged, it will need to be replaced.
66. Install output shaft bearing in the rear transmission housing. Using Bearing Installer 9287 (1), install the output shaft bearing (2) into the transmission housing. The closed side of the plastic cage must point towards the transmission.
67. Install the snap-ring into the groove in the output shaft.
68. Install the output shaft into the output shaft bearing.
69. Install the retaining ring (1). Ensure that the retaining ring is seated correctly in the groove.
70. Install the output shaft washer onto the output shaft.
71. Install a new transmission rear seal into the transmission case with Seal Installer 8902A (1).
72. Install the propeller shaft flange onto the output shaft and install an new flange nut finger tight.
73. Install the extension housing (2) onto the transmission case.
NOTE: Before installing the lowermost four extension housing bolts, it will be necessary to replenish the sealing patch on the bolts using Mopar(R) Lock & Seal Adhesive.
74. Install the bolts that hold the extension housing onto the transmission case. Be sure to install any stud bolts to their original locations. Tighten the bolts to 54 Nm (40 ft.lbs.).
75. Verify that the transmission is in PARK in order to prepare for the installation of the output shaft nut. Tighten the flange nut to 200 Nm (147 ft.lbs.).
76. Stake the output shaft nut to the output shaft as follows. Place the Staking Tool 9078 (2) and Driver Handle C-4171 onto the output shaft.
77. Rotate the Staking Tool 9078 (2) until the alignment pin (3) engages the output shaft notch (4).
78. Press downward on the staking tool (1) until the staking pin (3) contacts the output shaft nut flange (2).
79. Strike the Driver handle C-4171 with a suitable hammer until the output shaft nut is securely staked to the output shaft.