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Home >> Chrysler >> 2000 >> Intrepid Base >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Overhaul - 42LE Automatic Transmission >> Transaxle Reassembly >> Valve Body & Internal Components

Valve Body & Internal Components

  1. Using NEW gasket, install low-reverse clutch piston retainer in transaxle case. See Figure . Ensure 3 holes on gasket are aligned with 3 holes in transaxle case.
  2. Install and tighten low-reverse clutch piston retainer Torx screws to specification. See TORQUE SPECIFICATIONS  . Install low-reverse clutch piston inside transaxle case.
  3. Ensure components and spring on parking sprag assembly are properly installed. Perform STEP 4. See Figure . Install parking sprag assembly in transaxle case. Ensure guide bracket and sleeve on parking sprag assembly contacts rear of transaxle case.
  4. Install pivot pin and anchor shaft. Install and tighten parking sprag bolt to specification.
  5. Install clutch piston return spring for low-reverse clutch in transaxle case. Using spring compressor, compress clutch piston return spring for low-reverse clutch. See Figure . Install snap ring so ends of snap ring are properly positioned.
    CAUTION: Output shaft bearing preload must be checked and/or adjusted if any of the following components are replaced: rear planetary carrier and output shaft, output shaft bearings or transaxle case. See OUTPUT SHAFT BEARING PRELOAD  under COMPONENT DISASSEMBLY & REASSEMBLY.
  6. Install rear bearing for output shaft and Plate (6618-A) on rear of transaxle case. See Figure . Slightly tighten retaining bolts on plate until bolt heads are below surface of plate. DO NOT fully tighten bolts.
  7. Place transaxle case in press so plate is supported. Ensure clearance is present so output shaft can extend through plate when installed.
  8. Apply small amount of petroleum jelly to output shaft shim. Install output shaft shim on output shaft, just above bearing. Install output shaft in transaxle case. Press output shaft into rear bearing and transaxle case.
  9. Install NEW output shaft nut on output shaft. DO NOT reuse old output shaft nut. Install Holder (6497) on output shaft nut. Using torque wrench and Adapter (6498), tighten output shaft nut by turning counterclockwise. See Figure . Tighten output shaft nut to specification. See TORQUE SPECIFICATIONS  .
  10. Ensure no end play is present on output shaft. Use press and Staking Adapter (6589) to stake output shaft nut against output shaft. Ensure staked area on output shaft nut is fully bottomed in groove area on output shaft. Remove transaxle case from press. Remove plate from rear of transaxle case.
  11. Install transfer drive chain and sprockets. See TRANSFER DRIVE CHAIN & SPROCKETS  . Install 5 low-reverse clutch plates and 5 clutch discs, starting with a clutch plate and alternating with a clutch disc. See Figure . Ensure components are in correct sequence.
  12. Install flat snap ring and one low-reverse clutch plate. Ensure ends of snap ring are positioned between 2 and 3 o'clock position. See Fig 1 .
    Fig 1: Installing Snap Rings
    G94I36697Courtesy of CHRYSLER CORP.
  13. Install low-reverse clutch reaction plate. See Figure . Ensure flat side of low-reverse clutch reaction plate is facing upward, toward oil pump opening. Install tapered snap ring above low-reverse clutch reaction plate. Ensure ends of tapered snap ring are positioned between 9 and 10 o'clock position. See Fig 1 .
    14. CAUTION: Low-reverse clutch clearance must be checked after installing clutch assembly.
  14. To check low-reverse clutch clearance, assemble dial indicator and Dial Indicator Tip (6268) on transaxle case. See Fig 2 . Press low-reverse clutch pack downward and zero dial indicator. Using hook, pull one low-reverse clutch disc upward and note low-reverse clutch clearance on dial indicator. Remove dial indicator.
  15. Low-reverse clutch clearance should be .035-.060" (.89-1.52 mm). If clearance is not within specification, different thickness low-reverse clutch reaction plate can be installed. Low-reverse clutch reaction plates are available in the following thicknesses: .232" (5.89 mm), .242" (6.15 mm), .252" (6.40 mm), .262" (6.65 mm) and .273" (6.93 mm).
    Fig 2: Checking Low-Reverse Clutch Clearance
    G94J36698Courtesy of CHRYSLER CORP.
    Fig 3: Checking 2-4 Clutch Clearance
    G94A36699Courtesy of CHRYSLER CORP.
  16. Install 2-4 clutch discs and clutch plates, starting with a clutch disc and alternating with a clutch plate. See Figure . There should be 4 clutch discs and 4 clutch plates. Ensure components are in correct sequence.
  17. Install clutch piston return spring, 2-4 clutch piston and 2-4 clutch piston retainer. See Figure . Using 2-4 Clutch Compressor (5058), compress 2-4 clutch piston retainer. See Figure . Install snap ring. Ensure ends of snap ring are positioned in proper area. See Fig 1 . Release 2-4 clutch compressor.
    18. CAUTION: The 2-4 clutch clearance must be checked after installing clutch assembly.
  18. To check 2-4 clutch clearance, assemble dial indicator and Dial Indicator Tip (6268) on transaxle case. See Fig 3 . Press 2-4 clutch pack downward and zero dial indicator. Using hook, pull one 2-4 clutch disc upward and note 2-4 clutch clearance on dial indicator.
  19. The 2-4 clutch clearance should be .030-1.04" (.76-2.64 mm). If clearance is not within specification, check for improper installation of clutch components. There is no adjustment for 2-4 clutch clearance. Remove dial indicator.
  20. Apply small amount of petroleum jelly on thrust bearing and install on shaft side of sun gear. Ensure thrust bearing is flat against sun gear.
  21. Install sun gear in rear planetary. Install thrust bearing on front of sun gear. Install rear annulus gear. See Figure . It may be necessary to rotate rear annulus gear during installation. Install 2-4 clutch hub. Install thrust washer on front of 2-4 clutch hub.
    CAUTION: Correct thickness No. 4 thrust plate located on rear (shaft end) of overdrive clutch hub must be determined to maintain proper input shaft end play. See Figure .
  22. Apply petroleum jelly on overdrive clutch hub in 3 places. Install a .036" (.91 mm) thick No. 4 thrust plate on overdrive clutch hub. See Figure .
  23. Install input clutch assembly. See Figure . Ensure input clutch assembly is fully seated by looking through input speed sensor hole in transaxle case. If input clutch assembly is fully seated, input clutch hub will be fully visible. See Fig 4 . If input clutch assembly is not fully seated, remove and check for improper installation.
    Fig 4: Checking Input Clutch Assembly Installation
    G94D36700Courtesy of CHRYSLER CORP.
  24. Install gasket and oil pump. DO NOT install "O" ring on oil pump at this time. Install and tighten oil pump-to-transaxle case bolts to specification. See TORQUE SPECIFICATIONS  .
  25. Using dial indicator, check input shaft end play. See Figure . Input shaft end play should be .005-.025" (.13-.64 mm). If input shaft end play is not within specification, change No. 4 thrust plate thickness to obtain correct input shaft end play.
  26. For example, if input shaft end play is .055" (1.40 mm) with No. 4 thrust plate installed, select a No. 4 thrust plate with thickness of .071-.074" (1.80-1.88 mm). Install selected No. 4 thrust plate. This should change input shaft end play to .020" (.51 mm). The No. 4 thrust plate is available in thickness ranging from .036" (.91 mm) to .133" (3.38 mm).
    27. CAUTION: If a transaxle failure was present, do not attempt to clean or reuse oil cooler by-pass valve. Replace oil cooler by-pass valve.
  27. Once proper input shaft end play is obtained, remove oil pump and gasket. Install NEW "O" ring on oil pump. Install oil cooler by-pass valve in transaxle case with "O" ring end toward rear of transaxle case. See Figure .
  28. Install gasket and oil pump. Tighten oil pump-to-transaxle case bolts to specification. See TORQUE SPECIFICATIONS  . Ensure input shaft rotates smoothly.
  29. Using NEW seal rings, install overdrive and underdrive accumulator pistons and springs in transaxle case. See Figure . Using NEW seal rings, install low-reverse accumulator piston and springs.
  30. Install cover and snap ring above low-reverse accumulator piston. Install valve body. See VALVE BODY  under REMOVAL & INSTALLATION.
CAUTION: If a transaxle failure was present, flush oil cooler and check oil cooler flow. See OIL COOLER FLUSHING  and OIL COOLER FLOW CHECK  under ON-VEHICLE SERVICE.
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