Assembly

1. During assembly, lubricate components with transmission fluid or petroleum jelly as indicated.
2. If any of the transmission components are still assembled after overhaul checking procedures, disassemble as necessary in preparation for transmission assembly.





3. Verify thrust bearing and race installation during assembly. Refer to the Thrust Bearing Chart for bearing and race location and correct positioning.
4. Install rear planetary gear, second brake drum and output shaft as outlined in following steps:
5. Verify No. 10 thrust bearing and race. Bearing and race outer diameter is 57.7 mm (2.272 inch) and inside diameter is 39.2 mm (1.543 inch).





6. Coat thrust bearing and race assembly with petroleum jelly and install in case. Race faces down. Bearing rollers face up.





7. Align teeth of second brake drum and clutch pack.





8. Align rear planetary-output shaft assembly teeth with case slots and install assembly in case.





9. Install rear planetary snap ring with snap ring pliers. Chamfered side of snap ring faces up and toward case front.





10. Check first-reverse brake pack clearance with feeler gauge. Clearance should be 0.70 -1.20 mm (0.028 - 0.047 inch). If clearance is incorrect, planetary assembly, thrust bearing or snap ring is not properly seated in case. Remove and reinstall components if necessary.





11. Install second brake piston sleeve. Sleeve lip faces up and toward case front as shown.





12. Install second brake drum gasket with Installer Tool 7544, or equivalent. Gasket depth is 43.7 mm (1.720 inch).





13. Install park lock pawl, spring and pin.





14. Connect park lock rod to manual valve shift sector.





15. Position park lock rod bracket on case and tighten bracket attaching bolts to 10 Nm (84 inch lbs.) torque.





16. Verify park lock operation. Move shift sector to Park position. Park pawl should be firmly engaged (locked) in planetary ring gear.





17. Install No. 1 one-way clutch. Short flanged side of clutch faces up and toward case front.





18. Install second brake pack. Install disc then plate. Continue installation sequence until five discs and five plates are installed.
19. Install second brake pack retainer with rounded edge of retainer facing disc.
20. Install second brake pack snap ring.





21. Check brake pack clearance with feeler gauge. Clearance should be 0.062 - 1.98 mm (0.024 - 0.078 inch). If brake pack clearance is not correct, brake pack components are not seated. Reassemble brake pack if necessary.





22. Install planetary sun gear and input drum. Be sure drum thrust washer tabs are seated in drum. Use petroleum jelly to hold thrust washer in position if necessary.





23. Install front planetary gear on sun gear.





24. Support output shaft with wood blocks.





25. Install planetary snap ring on sun gear with snap ring plier tool 7541, or equivalent.





26. Install tabbed thrust race on front planetary gear. Washer tabs face down and toward gear. Race outer diameter is 47.8 mm (1.882 inch). Inside diameter is 34.3 mm (1.350 inch).





27. Install second coast brake band.





28. Install pin in second coast brake band. Then install retaining ring on pin.





29. Install thrust bearing and race in forward-direct clutch. Coat bearing/race with petroleum jelly to hold them in place.
30. Verify forward-direct clutch thrust bearing size.
^ Race outer diameter is 48.9 mm (1.925 inch) and inside diameter is 26.0 mm (1.024 inch).
^ Bearing outer diameter is 46.7 mm (1.839 inch) and inside diameter is 26.0 mm (1.024 inch).





31. Coat front planetary ring gear race with petroleum jelly and install it in ring gear.
32. Verify ring gear race size. Outer diameter is 47.0 mm (1.850 inch) and inside diameter is 26.5 mm (1.045 inch).





33. Align forward-direct clutch disc splines with screwdriver.





34. Align and install front planetary ring gear in forward-direct clutch.





35. Coat bearing and race with petroleum jelly and install them in ring gear. Verify bearing/race size.
^ Bearing outer diameter is 47.7 mm (1.878 inch) and inside diameter is 32.6 mm (1.283 inch).
^ Race outer diameter is 53.6 mm (2.110 inch) and inside diameter is 30.6 mm (1.205 inch).





36. Rotate front of transmission case downward and install assembled planetary gear/forward-direct clutch.





37. Check clearance between sun gear input drum and direct clutch drum. Clearance should be 9.8 - 11.8 mm (0.386 - 0.465 inch). If clearance is incorrect, planetary gear/forward-direct clutch assembly is not seated or is improperly assembled. Remove, and correct if necessary.





38. Coat thrust bearing and race assembly with petroleum jelly and install it on clutch shaft. Bearing faces up and toward case front as shown. Verify bearing/race size. Bearing and race outer diameter is 47.8 mm (1.882 inch) and inside diameter is 33.6 mm (1.301 inch).





39. Assemble second coast brake piston components.
40. Install assembled second coast brake piston in case.
41. Install replacement seals on second coast brake piston cover and install cover in case.





42. Install second coast brake piston snap ring with snap ring plier tool.
43. Check second coast brake piston stroke as follows:





a. Make reference mark on brake piston rod.
b. Apply 57 - 114 psi air pressure through feed hole. Alternately apply and release air pressure to operate piston.





c. Check stroke with gauge 7552, or equivalent.
d. If stroke length is incorrect, piston, cover or snap ring is not seated. Reassemble and check stroke again if necessary.





44. Coat thrust race and tabbed washer with petroleum jelly and install them on overdrive support. Verify race size. Race outer diameter is 50.9 mm (2.004 inch) and inside diameter is 36.2 mm (1.426 inch).





45. Install overdrive support in case. Use two long bolts to help align and guide support into position.





46. Install overdrive support snap ring with Snap Ring Plier Tool 7540, or equivalent. Chamfered side of snap ring faces up and toward case front. Snap ring ends must be aligned with case opening with ring ends approximately 24 mm (0.94 inch) from center line of case opening.





47. Install and tighten overdrive support bolts to 25 Nm (19 ft. lbs.) torque.





48. Check output shaft end play with dial indicator. End play should be 0.27 - 0.86 mm (0.0106 - 0.0339 inch).
49. If output shaft end play is incorrect, one or more of installed components is not seated. Reassemble as necessary and check end play again.





50. Install overdrive brake clutch pack. Install thickest clutch plate first. Rounded edge of plate faces up. Install first disc followed by another plate until four discs and three plates are installed.





51. Install stepped ring retainer plate with flat side facing disc. Then install brake pack snap ring.
52. Check overdrive brake piston stroke as follows:





a. Mount Gauge 7546, or equivalent in dial indicator and position gauge tool against overdrive brake piston.





b. Apply and release overdrive brake piston with compressed air and note piston stroke length on dial indicator. Apply air pressure through feed hole in case.
c. Piston stroke length should be 1.40 - 1.70 mm (0.55 - 0.66 inch).
d. If stroke is incorrect, brake pack or piston is installed incorrectly. Check and correct as necessary and measure piston stroke again.
53. Remove dial indicator and gauge tool.
54. Remove overdrive brake piston snap ring and remove overdrive clutch pack components.





55. Coat overdrive lower race, thrust bearing and upper race with petroleum jelly and install them in overdrive support. Be sure races and bearing are assembled and installed as shown.
56. Verify bearing/race sizes before proceeding. Bearing- race sizes are:
^ Outer diameter of lower race is 47.8 mm (1.882 inch) and inside diameter is 34.3 mm (1.350 inch).
^ Outer diameter of bearing is 47.7 mm (1.878 inch) and inside diameter is 32.7 mm (1.287 inch).
^ Outer diameter of upper race is 47.8 mm (1.882 inch) and inside diameter is 30.7 mm (1.209 inch).





57. Install overdrive planetary ring gear in support.





58. Coat ring gear thrust race and thrust bearing assembly with petroleum jelly and install them in gear.
59. Verify bearing/race size before proceeding.
^ Outer diameter of ring gear race-bearing is 47.8 mm (1.882 inch) and inside diameter is 24.2 mm (0.953 inch).
^ Outer diameter of bearing is 46.8 mm (1.844 inch) and inside diameter is 26.0 mm (1.024 inch).





60. Coat tabbed thrust race with petroleum jelly and install it on planetary gear. Race outer diameter is 41.8 mm (1.646 inch) and inside diameter is 27.1 mm (1.067 inch).





61. Install assembled overdrive planetary gear and clutch.





62. Coat thrust bearing and race assembly with petroleum jelly and install it on clutch input shaft. Bearing and race outer diameter is 50.2 mm (1.976 inch) and inside diameter is 28.9 mm (1.138 inch).
63. Install overdrive brake pack as follows:
a. Install 4.0 mm (0.157 inch) thick plate first. Rounded edge of plate must face upward.





b. Install a disc followed by a plate until the required number of discs and plates are installed. Be sure to install the stepped plate last with the flat side of the plate facing the disc.
c. Confirm that four discs and three plates have been installed.





64. Install clutch pack snap ring.





65. Coat thrust bearing race with petroleum jelly and install it in oil pump. Bearing race outer diameter is 47.2 mm (1.858 inch) and inside diameter is 28.1 mm (1.106 inch).
66. Lubricate and install replacement O-ring on oil pump body.





67. Install oil pump in case. Align pump and case bolt holes and carefully ease pump into place.

CAUTION: Do not use force to seat the pump. The seal rings on the stator shaft could be damaged if they bind or stick to the direct clutch drum.

68. Tighten oil pump bolts to 22 Nm (16 ft. lbs.) torque.
69. Verify input shaft rotation. Shaft should rotate smoothly and not bind.





70. Lubricate and install new O-ring on transmission throttle cable adapter and install cable in case.





71. Check clutch and brake operation. Operate clutches and brakes with compressed air applied through feed holes in case. Listen for clutch and brake application. If you do not hear a clutch or brake apply, disassemble transmission and repair fault before proceeding. It is necessary to block the overdrive clutch accumulator feed hole No. 8 in order to check direct clutch operation.





72. Lubricate and install new O-rings on accumulator pistons.
73. Assemble and install accumulator pistons and springs.





74. Install new check ball body and spring.





75. Position valve body on case.
76. Install detent spring.
77. Align manual valve, detent spring and shift sector.





78. Connect transmission throttle cable to throttle valve cam.
79. Install and tighten valve body-to-case bolts to 10 Nm (84 inch lbs.) torque.





80. Connect valve body solenoid wires to solenoids.
81. Install new O-ring on solenoid harness adapter and secure adapter to case.





82. Install valve body oil tubes. Tap tubes into place with a plastic mallet. Be sure the flanged tube ends and straight tube ends are installed as shown.
83. Install new gaskets on oil screen and install screen on valve body. Tighten screen bolts to 10 Nm (84 inch lbs.) torque.
84. Install magnet in oil pan. Be sure magnet does not interfere with valve body oil tubes.
85. Apply Mopar or Loctite 599, or equivalent to sealing surface of oil pan. Sealer bead should be at least 3 mm (1/8 inch) wide. Install pan on case and tighten pan bolts to 7 Nm (65 inch lbs.) torque.





86. Install transmission speed sensor rotor and key on output shaft.





87. Install spacer and speedometer drive gear on output shaft. Then install retaining snap ring.





88. Apply bead of Mopar or Loctite 599, or equivalent sealer to sealing surface at rear of case.
89. Install adapter housing on transmission. Tighten adapter bolts to 34 Nm (25 ft. lbs.) torque.





90. Install transmission speed sensor. Tighten sensor bolt to 7.4 Nm (65 inch lbs.) torque and connect sensor wire harness connector.





91. Install converter housing. Tighten 12 mm diameter housing bolts to 57 Nm (42 ft. lbs.) torque. Tighten 10 mm diameter housing bolts to 34 Nm (25 ft. lbs.) torque.
92. Install transmission shift lever on manual valve shaft. Do not install lever attaching nut at this time.
93. Move transmission shift lever fully rearward. Then move lever two detent positions forward.





94. Mount park/neutral position switch on manual valve shaft and tighten switch adjusting bolt just enough to keep switch from moving.
95. Install park/neutral position switch tabbed washer and retaining nut. Tighten nut to 6.9 Nm (61 inch lbs.) torque, but do not bend any of the washer tabs against the nut at this time.
96. Align park/neutral position switch standard line with groove or flat on manual shaft.
97. Tighten park/neutral position switch adjusting bolt to 13 Nm (108 inch lbs.) torque.
98. Install transmission shift lever on manual valve shaft. Tighten lever attaching nut to 16 Nm (12 ft. lbs.) torque.





99. Install retaining clamp for wire harness and throttle cable.
100. Install torque converter.





101. Verify that converter is seated by measuring distance between converter housing flange and one of the converter mounting pads. Use straightedge and vernier calipers to measure distance. Distance should be 16.5 mm (0.650 inch).
102. Secure converter in transmission with C-clamp or metal strapping. Do this before mounting transmission on jack or moving transmission under vehicle.
103. Install lower half of transmission fill tube (install upper half after transmission is in vehicle).

CAUTION: The transmission cooler and lines must be reverse flushed if overhaul corrected a malfunction that generated sludge, metal particles, or clutch friction material. The torque converter should also be replaced if contaminated by the same malfunction. Debris and residue not flushed from the cooler and lines will flow back into the transmission and converter. The result will be a repeat failure and shop comeback.