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41TE Automatic Transaxle: Assembly

CAUTION: The cooler bypass valve must be replaced if transaxle failure has occurred. Do not attempt to reuse or clean old valve.
NOTE: If transaxle is being overhauled (clutch and/or seal replacement), the TCM/PCM Quick Learn procedure must be performed. (Refer to STANDARD PROCEDURE )
  1. Install both output bearing cups using Tool 5050 (Fig 1).
    Fig 1: Installing Both Output Bearing Cups
    G03634017Courtesy of DAIMLERCHRYSLER CORP.
  2. Install low/reverse piston retainer gasket (Fig 2). Make sure gasket holes line up with case.
    Fig 2: Installing Piston Retainer Gasket
    G03634018Courtesy of DAIMLERCHRYSLER CORP.
  3. Install low/reverse piston retainer (Fig 3).
    Fig 3: Installing Piston Retainer
    G03634019Courtesy of DAIMLERCHRYSLER CORP.
  4. Install low/reverse piston retainer-to-case bolts (Fig 4) and torque to 5 N.m (45 in. lbs.).
    Fig 4: Installing Piston Retainer Attaching Screws
    G03634020Courtesy of DAIMLERCHRYSLER CORP.
  5. Install low/reverse clutch piston (Fig 5).
    Fig 5: Installing Low/Reverse Clutch Piston
    G03634021Courtesy of DAIMLERCHRYSLER CORP.
  6. Assemble park guide bracket assembly (Fig 7) (Fig 6).
    Fig 6: Disconnecting Guide Bracket
    G03634022Courtesy of DAIMLERCHRYSLER CORP.
    Fig 7: Identifying Guide Bracket
    G03634023Courtesy of DAIMLERCHRYSLER CORP.
  7. Install guide bracket into position and insert pivot shaft (Fig 8).
    Fig 8: Installing Pivot Shaft And Guide Bracket
    G03634024Courtesy of DAIMLERCHRYSLER CORP.
  8. Install anchor shaft and plug (Fig 9). Make sure guide bracket and split sleeve are in contact with the rear of the transaxle case.
    Fig 9: Installing Anchor Shaft and Plug
    G03634025Courtesy of DAIMLERCHRYSLER CORP.
  9. Install low/reverse piston return spring (Fig 10).
    Fig 10: Low/Reverse Piston Return Spring
    G03634026Courtesy of DAIMLERCHRYSLER CORP.
  10. Install low/reverse spring compressor into position (Fig 11). Compress low/reverse piston and install snap ring as shown in (Fig 12).
    Fig 11: Installing Compressor Tool
    G03634027Courtesy of DAIMLERCHRYSLER CORP.
    Fig 12: Installing Snap Ring
    G03634028Courtesy of DAIMLERCHRYSLER CORP.
  11. Install rear carrier bearing cone using Tool 6053 (Fig 13).
    Fig 13: Installing Rear Carrier Bearing Cone
    G03634029Courtesy of DAIMLERCHRYSLER CORP.
  12. Install rear carrier assembly to transaxle case (Fig 14).
    Fig 14: Installing Rear Carrier Assembly
    G03634030Courtesy of DAIMLERCHRYSLER CORP.
  13. Install output gear bearing cone using Tool 5052 (Fig 15).
    Fig 15: Installing Output Gear Bearing Cone
    G03634031Courtesy of DAIMLERCHRYSLER CORP.
  14. OUTPUT GEAR BEARING ADJUSTMENT: 
    1. With output gear removed, install a 4.50 mm (0.177 in.) gauging shim (Fig 17) on the rear carrier assembly hub, using grease to hold the shim in place.
    2. Using Tool 6259, install output gear and bearing assembly. Torque to 271 N.m (200 ft. lbs.).
    3. Measure bearing end play. Attach Tool L-4432 to the gear (Fig 16).
    4. Push and pull the gear while rotating back and forth to ensure seating of bearing rollers.
    5. Using a dial indicator mounted to the transaxle case, measure output gear end play as shown in (Fig 16).
    6. Refer to the OUTPUT GEAR BEARING SHIM CHART  for the required shim to obtain proper bearing setting.
    7. Use Tool 6259 to remove the output gear retaining bolt and washer. To remove the output gear, use Tool L4407A.
    8. Remove the gauging shim and install the proper shim determined by the chart. Use grease to hold the shim in place.
    Fig 16: Checking Output Gear Bearings End Play
    G03634032Courtesy of DAIMLERCHRYSLER CORP.
    Fig 17: Identifying Output Gear And (Select) Shim
    G03634033Courtesy of DAIMLERCHRYSLER CORP.
    OUTPUT GEAR BEARING SHIM CHART

    End Play Shim Needed Part Number End Play Shim Needed Part Number
    0.05mm (0.002 in.) 4.42mm (0.174 in.) 4412830AB 0.53mm (0.021 in.) 3.94mm (0.155 in.) 4412818AB
    0.08mm (0.003 in.) 4.38mm (0.172 in.) 4412829AB 0.56mm (0.022 in.) 3.90mm (0.154 in.) 4412817AB
    0.10mm (0.004 in.) 4.38mm (0.172 in.) 4412829AB 0.58mm (0.023 in.) 3.90mm (0.154 in.) 4412817AB
    0.13mm (0.005 in.) 4.34mm (0.171 in.) 4412828AB 0.61mm (0.024 in.) 3.86mm (0.152 in.) 4412816AB
    0.15mm (0.006 in.) 4.30mm (0.169 in.) 4412827AB 0.64mm (0.025 in.) 3.82mm (0.150 in.) 4412815AB
    0.18mm (0.007 in.) 4.30mm (0.169 in.) 4412827AB 0.66mm (0.026 in.) 3.82mm (0.150 in.) 4412815AB
    0.20mm (0.008 in.) 4.26mm (0.168 in.) 4412826AB 0.69mm (0.027 in.) 3.78mm (0.149 in.) 4412814AB
    0.23mm (0.009 in.) 4.22mm (0.166 in.) 4412825AB 0.71mm (0.028 in.) 3.74mm (0.147 in.) 4412813AB
    0.25mm (0.010 in.) 4.22mm (0.166 in.) 4412825AB 0.74mm (0.029 in.) 3.74mm (0.147 in.) 4412813AB
    0.28mm (0.011 in.) 4.18mm (0.165 in.) 4412824AB 0.76mm (0.030 in.) 3.70mm (0.146 in.) 4412812AB
    0.30mm (0.012 in.) 4.14mm (0.163 in.) 4412823AB 0.79mm (0.031 in.) 3.66mm (0.144 in.) 4412811AB
    0.33mm (0.013 in.) 4.14mm (0.163 in.) 4412823AB 0.81mm (0.032 in.) 3.66mm (0.144 in.) 4412811AB
    0.36mm (0.014 in.) 4.10mm (0.161 in.) 4412822AB 0.84mm (0.033 in.) 3.62mm (0.143 in.) 4412810AB
    0.38mm (0.015 in.) 4.10mm (0.161 in.) 4412822AB 0.86mm (0.034 in.) 3.62mm (0.143 in.) 4412810AB
    0.41mm (0.016 in.) 4.06mm (0.160 in.) 4412821AB 0.89mm (0.035 in.) 3.58mm (0.141) 4412809AB
    0.43mm (0.017 in.) 4.02mm (0.158 in.) 4412820AB 0.91mm (0.036in.) 3.54mm (0.139 in.) 4412808AB
    0.46mm (0.018 in.) 4.02mm (0.158 in.) 4412820AB 0.94mm (0.037 in.) 3.54mm (0.139 in.) 4412808AB
    0.48mm (0.019 in.) 3.98mm (0.157 in.) 4412819AB 0.97mm (0.038 in.) 3.50mm (0.138 in.) 4412807AB
    0.51mm (0.020 in.) 3.94mm (0.155 in.) 4412818AB      
  15. Install the output gear and bearing assembly using Tool 6261 (Fig 18).
    Fig 18: Installing Output Gear
    G03634034Courtesy of DAIMLERCHRYSLER CORP.
  16. Install NEW output gear retaining bolt and washer (Fig 19). Using Tool 6259, torque output gear retaining bolt to 271 N.m (200 ft. lbs.) (Fig 20).
    Fig 19: Installing Output Gear Bolt And Washer
    G03634035Courtesy of DAIMLERCHRYSLER CORP.
    Fig 20: Tightening Output Gear to 271 N.m (200 ft. lbs.)
    G03634036Courtesy of DAIMLERCHRYSLER CORP.
  17. Using an inch pound torque wrench (Fig 21), check output shaft turning torque. Output shaft turning torque should be within 3-8 in. lbs.  If the turning torque is too high, install a 0.04 mm (0.0016 in.) thicker shim. If the turning torque is too low, install a 0.04 mm (0.0016 in.) thinner shim. Repeat until the proper turning torque of 3-8 in. lbs. is obtained.
    Fig 21: Checking Output Gear Bearings Turning Torque
    G03634037Courtesy of DAIMLERCHRYSLER CORP.
  18. Install output gear stirrup with serrated side out (Fig 22).
    Fig 22: Installing Stirrup
    G03634038Courtesy of DAIMLERCHRYSLER CORP.
  19. Install retaining strap.
  20. Install strap bolts but do not tighten at this time (Fig 23).
    Fig 23: Installing Strap Bolts
    G03634039Courtesy of DAIMLERCHRYSLER CORP.
  21. Rotate stirrup clockwise against flats of retaining bolt (Fig 24).
    Fig 24: Turning Stirrup Clockwise Against Bolt Flats
    G03634040Courtesy of DAIMLERCHRYSLER CORP.
  22. Torque stirrup strap bolts to 23 N.m (200 in. lbs.) (Fig 25).
    Fig 25: Tightening Stirrup Strap Bolts To 23 N.m (200 in.) lbs.)
    G03634041Courtesy of DAIMLERCHRYSLER CORP.
  23. Bend tabs on strap up against flats of bolts (Fig 26).
    Fig 26: Bend Tabs On Strap Up Against Flats Of Bolts
    G03634042Courtesy of DAIMLERCHRYSLER CORP.
  24. Install transfer shaft bearing cone using Tool 6052 (Fig 27).
    Fig 27: Installing Transfer Shaft Bearing Cone
    G03634043Courtesy of DAIMLERCHRYSLER CORP.
  25. Install bearing cup and oil baffle to transfer shaft (Fig 28).
    Fig 28: Installing Bearing Cup to Shaft
    G03634044Courtesy of DAIMLERCHRYSLER CORP.
  26. Using Tool 5049A, install transfer shaft (Fig 29).
    Fig 29: Installing Transfer Shaft
    G03634045Courtesy of DAIMLERCHRYSLER CORP.
  27. Using Tool 6051, install transfer shaft bearing snap ring (Fig 30).
    Fig 30: Installing Transfer Shaft Bearing Snap Ring
    G03634046Courtesy of DAIMLERCHRYSLER CORP.
  28. Install transfer shaft bearing cup into retainer using Tool 6061 (Fig 31).
    Fig 31: Installing Transfer Shaft Bearing Cup Into Retainer
    G03634047Courtesy of DAIMLERCHRYSLER CORP.
  29. Install bearing cup retainer to transaxle (Fig 32).
    Fig 32: Removing Bearing Cup Retainer
    G03634048Courtesy of DAIMLERCHRYSLER CORP.
  30. Install transfer gear bearing cone to transfer gear using Tool 5052 (Fig 33).
    Fig 33: Installing Transfer Gear Bearing Cone
    G03634049Courtesy of DAIMLERCHRYSLER CORP.
  31. TRANSFER GEAR BEARING ADJUSTMENT: 
    1. Install a 4.66 mm (0.184 in.) gauging shim on the transfer shaft (Fig 34).
    2. Install transfer shaft gear using Tool 6261. Using Tool 6259, install transfer shaft gear retaining nut to 271 N.m (200 ft. lbs.).
    3. Measure end play. Attach Tool L4432 to the transfer gear.
    4. Mount a steel ball with grease into the end of the transfer shaft.
    5. Push and pull the gear while rotating back and forth to ensure seating of the bearing rollers.
    6. Using a dial indicator, measure transfer shaft end play.
    7. Refer to the TRANSFER SHAFT BEARING SHIM CHART  for the required shim combination to obtain the proper bearing setting.
    8. Use Tool 6259 to remove the retaining nut and washer. Remove the transfer shaft gear using Tool L4407A.
    9. Remove the gauging shim (Fig 34) and install the proper shim indicated by the chart.
    Fig 34: Installing Transfer Shaft Gear and (Select) Shim
    G03634050Courtesy of DAIMLERCHRYSLER CORP.
    TRANSFER SHAFT BEARING SHIM CHART

    End Play Shim Needed Part Number End Play Shim Needed Part Number
    0.05mm (0.002 in.) 4.66mm (0.183 in.) 4505588AB 0.76mm (0.030 in.) 3.94mm (0.155 in.) 4412818AB
    0.08mm (0.003 in.) 4.62mm (0.182 in.) 4412835AB 0.79mm (0.031 in.) 3.90mm (0.154 in.) 4412817AB
    0.10mm (0.004 in.) 4.58mm (0.180 in.) 4412834AB 0.81mm (0.032 in.) 3.90mm (0.154 in.) 4412817AB
    0.13mm (0.005 in.) 4.58mm (0.180 in.) 4412834AB 0.84mm (0.033 in.) 3.86mm (0.152 in.) 4412816AB
    0.15mm (0.006 in.) 4.54mm (0.178 in.) 4412833AB 0.86mm (0.034 in.) 3.82mm (0.150 in.) 4412815AB
    0.18mm (0.007 in.) 4.50mm (0.177 in.) 4412832AB 0.89mm (0.035 in.) 3.82mm (0.150 in.) 4412815AB
    0.20mm (0.008 in.) 4.50mm (0.177 in.) 4412832AB 0.91mm (0.036 in.) 3.78mm (0.149 in.) 4412814AB
    0.23mm (0.009 in.) 4.46mm (0.175 in.) 4412831AB 0.94mm (0.037 in.) 3.74mm (0.147 in.) 4412813AB
    0.25mm (0.010 in.) 4.46mm (0.175 in.) 4412831AB 0.97mm (0.038 in.) 3.74mm (0.147 in.) 4412813AB
    0.28mm (0.011 in.) 4.42mm (0.174 in.) 4412830AB 0.99mm (0.039 in.) 3.70mm (0.146 in.) 4412812AB
    0.30mm (0.012 in.) 4.38mm (0.172 in.) 4412829AB 1.02mm (0.040 in.) 3.66mm (0.144 in.) 4412811AB
    0.33mm (0.013 in.) 4.38mm (0.172 in.) 4412829AB 1.04mm (0.041 in.) 3.66mm (0.144 in.) 4412811AB
    0.36mm (0.014 in.) 4.34mm (0.171 in.) 4412828AB 1.07mm (0.042 in.) 3.62mm (0.143 in.) 4412810AB
    0.38mm (0.015 in.) 4.30mm (0.169 in.) 4412827AB 1.08mm (0.043 in.) 3.62mm (0.143 in.) 4412810AB
    0.41mm (0.016 in.) 4.30mm (0.169 in.) 4412827AB 1.12mm (0.044 in.) 3.58mm (0.141) 4412809AB
    0.43mm (0.017 in.) 4.26mm (0.168 in.) 4412826AB 1.14mm (0.045 in.) 3.54mm (0.139 in.) 4412808AB
    0.46mm (0.018 in.) 4.22mm (0.166 in.) 4412825AB 1.17mm (0.046 in.) 3.54mm (0.139 in.) 4412808AB
    0.48mm (0.019 in.) 4.22mm (0.166 in.) 4412825AB 1.19mm (0.047 in.) 3.50mm (0.138 in.) 4412807AB
    0.50mm (0.020 in.) 4.18mm (0.165 in.) 4412824AB 1.22mm (0.048 in.) 3.46mm (0.136 in.) 4412806AB
    0.53mm (0.021 in.) 4.18mm (0.165 in.) 4412824AB 1.24mm (0.049 in.) 3.46mm (0.136 in.) 4412806AB
    0.56mm (0.022 in.) 4.14mm (0.163 in.) 4412823AB 1.27mm (0.050 in.) 3.42mm (0.135 in.) 4412805AB
    0.58mm (0.023 in.) 4.10mm (0.161 in.) 4412822AB 1.30mm (0.051 in.) 3.38mm (0.133 in.) 4412804AB
    0.61mm (0.024 in.) 4.10mm (0.161 in.) 4412822AB 1.32mm (0.052 in.) 3.38mm (0.133 in.) 4412804AB
    0.64mm (0.025 in.) 4.06mm (0.160 in.) 4412821AB 1.35mm (0.053 in.) 3.34mm (0.132 in.) 4412803AB
    0.66mm (0.026 in.) 4.02mm (0.158 in.) 4412820AB 1.37mm (0.054 in.) 3.34mm (0.132 in.) 4412803AB
    0.69mm (0.027 in.) 4.02mm (0.158 in.) 4412820AB 1.40mm (0.055 in.) 3.30mm (0.130 in.) 4412802AB
    0.71mm (0.028 in.) 3.98mm (0.157 in.) 4412819AB 1.45mm (0.057 in 3.26mm (0.128 in.) 4412801AB
    0.74mm (0.029 in.) 3.94mm (0.155 in.) 4412818AB 1.47mm (0.058 in.) 2.22mm (0.127 in.) 4505570AB
  32. Install the transfer shaft gear using Tool 6261 (Fig 35).
    Fig 35: Installing Transfer Shaft Gear
    G03634051Courtesy of DAIMLERCHRYSLER CORP.
    CAUTION: Install a NEW retaining nut, as the original nut MUST NOT be reused.
  33. Install the new retaining nut and washer.
  34. Using Tool 6259, torque transfer gear retaining nut to 271 N.m (200 ft. lbs.) (Fig 36).
    Fig 36: Tightening Transfer Gear Nut to 271 N.m (200 ft. lbs.)
    G03634052Courtesy of DAIMLERCHRYSLER CORP.
  35. Measure transfer shaft end play. Transfer shaft end play should be within 0.05-0.10 mm (0.002-0.004 in.)  . If the end play is too high, install a 0.04 mm (0.0016 in.) thicker shim. If the end play is too low, install a 0.04 mm (0.0016 in.) thinner shim. Repeat until 0.05-0.10 mm (0.002-0.004 in.) end play is obtained.
  36. Install a bead of Mopar® ATF RTV (MS-GF41) to transfer gear cover (Fig 37).
    Fig 37: Installing Rear Cover
    G03634053Courtesy of DAIMLERCHRYSLER CORP.
  37. Install transfer gear cover-to-case bolts and torque to 20 N.m (175 in. lbs.) torque (Fig 38).
    Fig 38: Installing Rear Cover Bolts
    G03634054Courtesy of DAIMLERCHRYSLER CORP.
  38. Install low/reverse clutch pack (Fig 39). Leave uppermost disc out until snap ring is installed.
    Fig 39: Installing Low/Reverse Clutch Pack
    G03634055Courtesy of DAIMLERCHRYSLER CORP.
  39. Install low/reverse reaction plate flat snap ring (Fig 40).
    Fig 40: Installing Low/Reverse Reaction Plate Snap Ring
    G03634056Courtesy of DAIMLERCHRYSLER CORP.
  40. Install remaining low/reverse clutch disc (Fig 41).
    Fig 41: Installing One Disc
    G03634057Courtesy of DAIMLERCHRYSLER CORP.
  41. Install low/reverse reaction plate with flat side up (Fig 42).
    Fig 42: Installing Low/Reverse Reaction Plate
    G03634058Courtesy of DAIMLERCHRYSLER CORP.
  42. Install tapered snap ring (with tapered side up) as shown in (Fig 43) (Fig 44).
    Fig 43: Installing Tapered Snap Ring Instructions
    G03634059Courtesy of DAIMLERCHRYSLER CORP.
    Fig 44: Installing Snap Ring
    G03634060Courtesy of DAIMLERCHRYSLER CORP.
  43. Set up dial indicator as shown in (Fig 45) to measure low/reverse clutch clearance. Press down on clutch pack with finger and zero dial indicator. Low/ Reverse clutch pack clearance is 0.89-1.47 mm (0.035-0.058 in.)  . Set up indicator and record measurement in four (4) places. Take average of readings and select the proper low/reverse reaction plate to achieve specifications.
    Fig 45: Checking Low/Reverse Clutch Clearance
    G03634061Courtesy of DAIMLERCHRYSLER CORP.
    LOW/REVERSE REACTION PLATE CHART

    PART NUMBER THICKNESS
    4799846AA 5.88 mm (0.232 in.)
    4799847AA 6.14 mm (0.242 in.)
    4799848AA 6.40 mm (0.252 in.)
    4799849AA 6.66 mm (0.262 in.)
    4799855AA 6.92 mm (0.273 in.)
  44. Install 2/4 clutch pack (Fig 46).
    Fig 46: Installing 2/4 Clutch Pack
    G03634062Courtesy of DAIMLERCHRYSLER CORP.
  45. Orient 2/4 clutch return spring to retainer as shown in (Fig 47), and install to transaxle (Fig 48).
    Fig 47: Proper Orientation of 2/4 Clutch Retainer and Spring
    G03634063Courtesy of DAIMLERCHRYSLER CORP.
    Fig 48: 2/4 Clutch Retainer
    G03634064Courtesy of DAIMLERCHRYSLER CORP.
  46. Using tool 5058, compress 2/4 clutch return spring just enough to install snap ring (Fig 49).
    Fig 49: Installing 2/4 Clutch Retainer Snap Ring
    G03634065Courtesy of DAIMLERCHRYSLER CORP.
  47. Install snap ring.
  48. Set up dial indicator as shown in (Fig 50) and measure 2/4 clutch clearance. Press down on clutch pack with finger and zero dial indicator. 2/4 clutch pack clearance is 0.76-2.64 mm (0.030-0.104 in.)  . Set up indicator and record measurement in four (4) places. Take average of readings. If clearance is outside this range, the clutch is assembled improperly. There is no adjustment for 2/4 clutch clearance. 
    Fig 50: Checking 2/4 Clutch Clearance
    G03634066Courtesy of DAIMLERCHRYSLER CORP.
  49. Install rear sun gear and #7 needle bearing (Fig 52).
    NOTE: The number seven needle bearing has three anti-reversal tabs and is common with the number five and number two position. The orientation should allow the bearing to seat flat against the rear sun gear (Fig 51). A small amount of petrolatum can be used to hold the bearing to the rear sun gear.
    Fig 51: Number 7 Bearing
    G03634067Courtesy of DAIMLERCHRYSLER CORP.
    Fig 52: Installing Rear Sun Gear and #7 Needle Bearing
    G03634068Courtesy of DAIMLERCHRYSLER CORP.
  50. Install front carrier/rear annulus assembly and #6 needle bearing (Fig 53).
    Fig 53: Installing Front Carrier And Rear Annulus Assembly
    G03634069Courtesy of DAIMLERCHRYSLER CORP.
  51. Install front sun gear assembly and #4 thrust washer (Fig 54).
    Fig 54: Installing Front Sun Gear Assembly
    G03634070Courtesy of DAIMLERCHRYSLER CORP.
  52. DETERMINING #4 THRUST PLATE THICKNESS / INPUT SHAFT END PLAY: 
    1. Select the thinnest #4 thrust plate thickness and install to input clutch assembly (Fig 55). Use petrolatum to retain.
      Fig 55: Select No. 4 Thrust Plate
      G03634071Courtesy of DAIMLERCHRYSLER CORP.
    2. Install input clutch assembly into position and verify that it is completely seated by viewing through input speed sensor hole. If view through input speed sensor hole is not as shown in (Fig 56), the input clutch assembly is not seated properly.
      Fig 56: Identifying Input Speed Sensor Hole
      G03634072Courtesy of DAIMLERCHRYSLER CORP.
    3. Remove oil pump o-ring (Fig 57). Be sure to reinstall oil pump o-ring after selecting the proper #4 thrust plate. 
      Fig 57: Removing Oil Pump O-Ring
      G03634073Courtesy of DAIMLERCHRYSLER CORP.
    4. Install pump and gasket to transmission. Install and torque bolts.
    5. Set up input shaft for measurement with Indicator Set C3339 and End Play Set 8266 as shown in (Fig 58).
      Fig 58: Measuring Input Shaft End Play Using End Play Set 8266
      G03634074Courtesy of DAIMLERCHRYSLER CORP.
    6. Measure the input shaft end play with the transaxle in the vertical position. Input shaft end play must be within 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.
    7. Refer to NO. 4 THRUST PLATE CHART  to select the proper No. 4 thrust plate:
    NO. 4 THRUST PLATE CHART

    PART NUMBER THICKNESS
    4431665AB 1.60mm (0.063 in.)
    3836237AB 1.73mm (0.068 in.)
    4431666AB 1.80mm (0.071 in.)
    3836238AB 1.96mm (0.077 in.)
    4431667AB 2.03mm (0.080 in.)
    3836239AB 2.16mm (0.085 in.)
    4431668AB 2.24mm (0.088 in.)
    3836240AB 2.39mm (0.094 in.)
    4431669AB 2.46mm (0.097 in.)
    3836241AB 2.62mm (0.103 in.)
    4446670AB 2.67mm (0.105 in.)
    4446671AB 2.90mm (0.114 in.)
  53. Install input clutch assembly (Fig 59).
    Fig 59: Installing Input Clutch Assembly
    G03634075Courtesy of DAIMLERCHRYSLER CORP.
  54. Install #1 caged needle bearing (Fig 60).
    Fig 60: Installing Caged Needle Bearing
    G03634076Courtesy of DAIMLERCHRYSLER CORP.
    CAUTION: The cooler bypass valve must be replaced if transaxle failure has occurred. Do not attempt to reuse or clean old valve.
  55. Install cooler bypass valve with o-ring end towards rear of case (Fig 61).
    Fig 61: Installing Cooler Bypass Valve
    G03634077Courtesy of DAIMLERCHRYSLER CORP.
  56. Install oil pump gasket (Fig 62).
    Fig 62: Installing Oil Pump Gasket
    G03634078Courtesy of DAIMLERCHRYSLER CORP.
  57. Install oil pump assembly (Fig 63).
    Fig 63: Installing Oil Pump
    G03634079Courtesy of DAIMLERCHRYSLER CORP.
  58. Install oil pump-to-case bolts and torque to 27 N.m (20 ft. lbs.) (Fig 64).
    Fig 64: Installing Pump-To-Case Bolts
    G03634080Courtesy of DAIMLERCHRYSLER CORP.
  59. Install low/reverse accumulator (Fig 65).
    Fig 65: Installing Low/Reverse Accumulator
    G03634081Courtesy of DAIMLERCHRYSLER CORP.
  60. Install low/reverse accumulator plug (Fig 66).
    Fig 66: Installing Low/Reverse Accumulator Plug (Cover)
    G03634082Courtesy of DAIMLERCHRYSLER CORP.
  61. Install low/reverse accumulator snap ring (Fig 67).
    Fig 67: Installing Low/Reverse Accumulator Snap Ring
    G03634083Courtesy of DAIMLERCHRYSLER CORP.
    NOTE: Depending on engine application, some accumulators will have two springs, and others will have one spring. The springs are color-coded for application and year.
  62. Install underdrive and overdrive accumulators (Fig 68) (Fig 69) (Fig 70).
    Fig 68: Identifying Accumulator (Underdrive)
    G03634084Courtesy of DAIMLERCHRYSLER CORP.
    Fig 69: Identifying Accumulator (Overdrive)
    G03634085Courtesy of DAIMLERCHRYSLER CORP.
    Fig 70: Installing Underdrive and Overdrive Accumulators
    G03634086Courtesy of DAIMLERCHRYSLER CORP.
  63. Install valve body to transaxle (Fig 71). Rotate manual valve shaft fully clockwise to ease installation. Make sure park rod rollers are positioned within park guide bracket.
    Fig 71: Installing Valve Body
    G03634087Courtesy of DAIMLERCHRYSLER CORP.
  64. Install and torque valve body-to-case bolts to 12 N.m (105 in. lbs.) (Fig 72).
    Fig 72: Installing Valve Body-to-Case Bolts
    G03634088Courtesy of DAIMLERCHRYSLER CORP.
  65. Install oil filter and new o-ring (Fig 73).
    Fig 73: Installing Oil Filter
    G03634089Courtesy of DAIMLERCHRYSLER CORP.
  66. Apply an 1/8" bead of Mopar® ATF RTV (MSGF41) to oil pan and immediately install to case (Fig 74).
    Fig 74: Installing Oil Pan
    G03634090Courtesy of DAIMLERCHRYSLER CORP.
  67. Install oil pan-to-case bolts and torque to 19 N.m (165 in. lbs.).
  68. Install solenoid/pressure switch assembly and gasket to case (Fig 75).
    Fig 75: Identifying Solenoid/Pressure Switch Assembly and Gasket
    G03634091Courtesy of DAIMLERCHRYSLER CORP.
  69. Install and tighten solenoid/pressure switch assembly-to-transaxle case bolts to 12 N.m (110 in. lbs.) (Fig 76).
    Fig 76: Installing Attaching Bolts
    G03634092Courtesy of DAIMLERCHRYSLER CORP.
  70. Install and torque input and output speed sensors to case to 27 N.m (20 ft. lbs.).
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