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Valve Body & Internal Components

NOTE: Input shaft end play should be measured before transaxle disassembly. Measurement indicates if No. 4 thrust plate may need replacement. No. 4 thrust plate is located on rear (shaft end) of overdrive clutch hub. See Figure .
  1. Remove torque converter. Attach dial indicator to transaxle case with dial indicator stem seated against end of input shaft. See Fig 1 .
  2. Move input shaft inward and zero dial indicator. Pull input shaft outward and note reading. Input shaft end play should be .005-.025" (.13-.64 mm). Record input shaft end play for reassembly reference.
    Fig 1: Measuring Input Shaft End Play
    G94J36656Courtesy of CHRYSLER CORP.
  3. Disconnect harness connector from input and output speed sensors located on left side of transaxle. See Figure . Ensure weather seals remain on harness connectors.
  4. Unscrew both input and output speed sensors from transaxle case. Disconnect TR sensor harness connector. See Figure .
  5. Rotate shift lever on transaxle fully clockwise. Remove shift lever from manual valve lever on transaxle. Remove bolts and oil pan. Remove bolts, oil filter retainers, oil filter and "O" ring. See Figure . Remove bolts and valve body assembly.
    6. CAUTION: Note location of all accumulators and springs for reassembly reference. Components must be installed in correct locations.
    Fig 2: Identifying Accumulator Locations
    G94A36657Courtesy of CHRYSLER CORP.
  6. Remove overdrive and underdrive accumulator pistons and springs from transaxle case. See Fig 2 . Remove snap ring and cover located above low-reverse accumulator piston. Remove low-reverse accumulator piston and springs. Note location of notch on side of low-reverse accumulator piston in relation to location on transaxle case.
  7. Remove snap ring retaining long stub shaft in transaxle case. Long stub shaft is left stub shaft when viewed from rear of transaxle. Install Adapter (6669) on end of long stub shaft. Attach slide hammer on adapter. Using slide hammer, pull long stub shaft from transaxle case.
    8. CAUTION: Oil cooler by-pass valve must be replaced if a transaxle failure is present. Do not attempt to clean oil cooler by-pass valve.
  8. Remove oil pump bolts. Install 2 slide hammer pullers on opposite sides of oil pump. Push inward on input shaft while using slide hammer pullers to pull oil pump from transaxle case. Remove oil pump and gasket. Remove oil cooler by-pass valve. See Fig 3 .
  9. Remove thrust bearing from front of input shaft. Remove input clutch assembly. See Fig 4 . Remove thrust washer, 2-4 clutch hub, rear annulus gear and thrust bearing. See Fig 5 . Remove sun gear and thrust bearing.
    Fig 3: Removing & Installing Oil Cooler By-Pass Valve
    G94B36658Courtesy of CHRYSLER CORP.
    Fig 4: Removing Input Clutch Assembly
    G94C36659Courtesy of CHRYSLER CORP.
    Fig 5: Exploded View Of Gear Train, Low-Reverse Clutch & 2-4 Clutch Components
    G94F36660Courtesy of CHRYSLER CORP.
  10. Using 2-4 Clutch Compressor (5058), compress 2-4 clutch piston retainer enough to remove snap ring. See Fig 6 . Remove snap ring. Remove 2-4 clutch compressor.
  11. Remove 2-4 clutch piston retainer, 2-4 clutch piston and clutch piston return spring. See Fig 5 . Remove 2-4 clutch discs and clutch plates. Note position of clutch plates and discs (4 each) for reassembly reference.
  12. Remove snap ring and low-reverse clutch reaction plate. Note direction of snap ring installation. Snap ring is tapered and must be installed with tapered side toward oil pump area.
  13. Remove one low-reverse clutch disc and flat snap ring. Remove low-reverse clutch plates and clutch discs. See Fig 5 . Note position of clutch plates discs (5 each) for reassembly reference.
    Fig 6: Compressing 2-4 Clutch Piston Retainer
    G94G36661Courtesy of CHRYSLER CORP.
  14. Remove drive chain, output shaft sprocket and transfer shaft sprocket. See DIFFERENTIAL ASSEMBLY, TRANSFER SHAFT & COMPONENTS  .
    15. CAUTION: Failure to release staked areas on output shaft nut before removing will result in thread damage on output shaft.
  15. Using die grinder, grind 2 staked areas on shoulder of output shaft nut so staked area is thinner. Using a hammer and chisel, release 2 staked areas away from output shaft. Use care not to damage output shaft.
  16. Install Holder (6497) on output shaft nut. Using breaker bar and Adapter (6498), remove output shaft nut by rotating breaker bar and output shaft clockwise. See Fig 7 .
  17. Using press, press rear planetary carrier and output shaft from transaxle case. Use care not to lose output shaft shim located on output shaft. See Fig 5 . Remove bearing races for output shaft from transaxle case, if necessary.
  18. Using Spring Compressor (5059A), compress clutch piston return spring for low-reverse clutch piston. See Fig 8 . Remove snap ring. Remove spring compressor. Remove clutch piston return spring for low-reverse clutch piston.
  19. Remove parking sprag bolt. Perform STEP 1. See Fig 9 . Using punch, remove anchor shaft for parking sprag assembly. Perform STEP 2. Remove pivot pin from parking sprag assembly. Perform STEP 3. Remove parking sprag assembly. Perform STEP 4.
  20. Remove low-reverse clutch piston from inside transaxle case. See Fig 5 . Remove Torx screws from low-reverse clutch piston retainer. Remove low-reverse clutch piston retainer and gasket. See Fig 5 . If removing differential assembly, transfer shaft and components, see DIFFERENTIAL ASSEMBLY, TRANSFER SHAFT & COMPONENTS  .
Fig 7: Removing Or Installing Output Shaft Nut (Transfer Shaft Nut Is Similar)
G94H36662Courtesy of CHRYSLER CORP.
Fig 8: Compressing Clutch Piston Return Spring
G94I36663Courtesy of CHRYSLER CORP.
Fig 9: Removing & Installing Parking Sprag Assembly
G94J36664Courtesy of CHRYSLER CORP.
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