Part 1

CAUTION:

Do not reuse gaskets, oil seals and rubber parts. Replace them with new ones at every reassembly. O-ring of oil dipstick need not be replaced.
Do not use grease other than petrolatum or industrial Vaseline.
Apply automatic transaxle fluid to friction element, rotating parts, and sliding parts before installation. Use the specified automatic transaxle fluid. New clutch disc should be immersed In automatic transaxle fluid for more than two hours before installation.
Do not apply sealer or adhesive to gaskets..
When bushing must be replaced, replace assembly which includes it.
Do not use shop towels during disassembly and reassembly operation.
The oil in the cooler should also be replaced.

1. Before assembly of the transaxle, measure the end play of the low-reverse brake, and select a pressure plate to be used so that the end play will be the standard value.

1. Install the brake reaction plate, brake plate and brake disc to the transaxle case.

CAUTION: If new brake discs are used, be sure to immerse them in ATF for two hours or longer.

2. Install the appropriate pressure plate and then install the return spring.

CAUTION: Be sure that the return spring Is installed so that it faces in the correct direction.

3. Apply a coating of petrolatum to the wave spring and attach it to the center support.




4. Install the special tool to the center support.




5. Install the snap ring.







6. Install the special tool and a dial gauge at the rear side of the transaxle case.

CAUTION: Install the dial gauge so that it contacts the brake reaction plate at a right angle from the transfer idler shaft hole.




7. Using a manual pump, pump air in from the position shown in the illustration; then read the indication of the dial gauge, and select the pressure plate that will provide the standard value.

Standard value: 1.0 - 1.2 mm (0.0394 - 0.0472 in.)







2. Using the special tool, tap in the bearing outer race.




3. Install the parking sprag rod to the manual control shaft. Then press into the transaxle case as shown in the illustration.

At this time, do not install O-ring (larger one of two O-rings) on manual control shaft.

NOTE: If installed before inserting shaft, the O-ring will interface with shaft set screw hole.




4. After installing new O-ring on manual control shaft, draw shaft back into case, then install set screw and gasket. Also install detent steel ball, seat and spring at the same time.




5. Install sprag rod support and tighten two bolts.

Sprag rod support bolts: 24 Nm (17 ft.lbs.)




6. Using the special tool, press the bearing into the transfer driven gear.




7. Using the special tool, press the bearing into the transfer shaft.




8. Attach the transfer shaft to the transaxle case.




9. Install the special tool to the transaxle case to support the transfer shaft.




10. Insert the thickest 1.80 mm (0.0709 in.) spacer.




11. Using the special tools, install the transfer driven gear.




12. After removing the special tool, affix the converter housing side of the transfer shaft.




13. Tighten the lock nut to the specified torque.

Transfer lock nut: 215 Nm (156 ft.lbs.)




14. After installing the special tool, measure the end play of the transfer shaft; then select the spacer(s) needed to obtain the standard value, and refit.

Transfer shaft end play: 0 - 0.025 mm (0 - 0.00098 in.)




15. Using a punch, lock the lock nut to prevent rotation. Attach the transfer cover.




16. Insert an assembly of the annular gear, output flange, transfer drive gear and bearing into the case.




17. Install snap ring on output flange rear bearing.




18. Coat petroleum jelly on the spacer and attach it to the transaxle case.




19. Install two taper roller bearings and spacer to transfer idler gear.




20. Place the transfer idler gear into the case, and then insert the idler shaft from the outer side of the case and screw it in.




21. In this condition, attach the special tool to the output shaft flange and check to be sure that the output flange turns easily.




22. Tighten the idler shaft by using special tool.




23. Insert special tool into output flange and measure preload using a low reading torque wrench.

Adjust preload by tightening or loosening transfer idler shaft.

Preload: 0.8 Nm (.59 ft.lbs.) F4A22
1.5 Nm (1.08 ft.lbs.) F4A23




24. After the preload adjustment is completed, eliminate the backlash between the idler shaft and the lock plate by moving the idler shaft in the loosening direction. Attach the lock plate and tighten the lock plate bolt.

Lock plate bolt: 54 Nm (39 ft.lbs.)







25. Install bearing retainer, and tighten screws to specified torque. Sealant should not stick out of screw head.

Screw: 20 Nm (14 ft.lbs.)

Specified sealant: MOPAR PART No.4318031 or MOPAR Part No.4318032 or equivalent.




26. Using a punch, lock the flush head screw to prevent rotation.




Identification Of Thrust Bearings, Thrust Races And Thrust Washers




27. Apply a coating of petrolatum to thrust bearing # 12 and attach to the planetary carrier.




28. Install the planetary carrier to the case.




29. Assemble the reverse sun gear and the forward sun gear in the following order:

1. Attach the seal ring and the snap ring to the reverse sun gear. When attaching, squeeze the seal ring as shown in the figure.

2. Attach the thrust race # 9 to the forward sun gear.

3. Attach the thrust race # 10 to the forward sun gear.




4. Assemble the reverse sun gear and the forward sun gear.




30. Install both of the previously assembled sun gears inside the planetary carrier.




31. Install the brake disc and brake plate.




32. Install the selected brake pressure plate.




33. Install the return spring.