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8HP45 Automatic Transmission (Service Information): Assembly: Assembly

CAUTION:

A unique transmission fluid has been developed for the 8HP45 transmission. This fluid is NOT compatible with ATF+4 or any other current Chrysler transmission fluid. For specifics about this unique fluid see FLUIDS, LUBRICANTS AND GENUINE PARTS. Refer to CAPACITIES AND RECOMMENDED FLUIDS, SPECIFICATIONS .

CAUTION:

The Transmission Control Module (TCM), or Transmission Control Module Assembly (TCMA) is extremely sensitive to Electrostatic Discharge (ESD). Always use a ground strap and follow the ESD guidelines in ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES. Refer to STANDARD PROCEDURE . Failure to follow these instructions may result in damage to the TCM/TCMA.

NOTE:

If the transmission is being reconditioned (clutch/seal replacement) or replaced, it is necessary to perform the TCM Adaptation Procedure. Refer to appropriate diagnostic information .

Fig 1: Snap Ring & P4 Annulus Drum
GC0152178Courtesy of CHRYSLER GROUP, LLC
  1. Insert the P4 annulus (3) into the P4 annulus drum (2).
  2. Install the snap ring (1) into the P4 annulus drum (2).
    Fig 2: P4 Planetary Carrier/Output Shaft & P4 Annulus Drum
    GC0152270Courtesy of CHRYSLER GROUP, LLC
  3. Install the P4 planetary carrier\output shaft (2) into the P4 annulus drum (1).
    Fig 3: C Clutch & P4 Sun Gear/C/E Clutch Retainer
    GC0152177Courtesy of CHRYSLER GROUP, LLC
  4. Position the bearings on the top and the bottom of C clutch (1).
  5. Install the C clutch (1) into the P4 sun gear/C/E clutch retainer (2).
    Fig 4: E Clutch & P4 Sun Gear/C/E Clutch Retainer
    GC0152176Courtesy of CHRYSLER GROUP, LLC
  6. Install the needle bearing (2) onto the E clutch (1).
  7. Install the E clutch (1) into the P4 sun gear/C/E clutch retainer (3).
    Fig 5: Snap Ring & P4 Sun Gear/C/E Clutch Retainer
    GC0152175Courtesy of CHRYSLER GROUP, LLC
  8. Install the snap ring (1) into the P4 sun gear/C/E clutch retainer (2).
    Fig 6: P3 Annulus & P4 Sun Gear/C/E Clutch Retainer
    GC0152174Courtesy of CHRYSLER GROUP, LLC
  9. Install the P3 annulus (1) into the P4 sun gear/C/E clutch retainer (2).
    Fig 7: Snap Ring & P4 Sun Gear/C/E Clutch Retainer
    GC0152173Courtesy of CHRYSLER GROUP, LLC
  10. Install the snap ring (1) into the P4 sun gear/C/E clutch retainer (2).
    Fig 8: P4 Sun Gear/C/E Clutch Retainer & D Clutch Drum
    GC0152170Courtesy of CHRYSLER GROUP, LLC
  11. Install the P4 sun gear/C/E clutch retainer (1) into the D clutch drum (2).
    Fig 9: P3 Planetary Carrier & Snap Ring
    GC0152274Courtesy of CHRYSLER GROUP, LLC
  12. Install the needle bearing onto the planetary carrier.
  13. Install the P3 planetary carrier (2) in the D clutch drum.
  14. Install the snap ring (1).
    Fig 10: D Clutch Drum & P4 Annulus Drum
    GC0152172Courtesy of CHRYSLER GROUP, LLC
  15. Install the D clutch drum (1) into the P4 annulus drum (2).
    Fig 11: P2 Annulus/P3 Sun Gear
    GC0152151Courtesy of CHRYSLER GROUP, LLC
  16. Install the P2 annulus\P3 sun gear (1) onto the drum assembly (2).
    Fig 12: P2 Planetary Carrier
    GC0152150Courtesy of CHRYSLER GROUP, LLC
  17. Install the needle bearing (2) and washer.
  18. Install the input shaft with P2 planetary carrier (1) into the drum assembly.
    Fig 13: P1 Planetary Carrier & P1 Planetary Carrier
    GC0152148Courtesy of CHRYSLER GROUP, LLC
  19. Install P1/P2 sun gear into the bottom of the P1 planetary carrier (3).
  20. Install the P1 planetary carrier (3).
  21. Install the snap ring (1).
    Fig 14: P1 Annulus/B Clutch Hub Assembly, Needle Bearing And Holding Plate
    GC0152146Courtesy of CHRYSLER GROUP, LLC
  22. Install the needle bearing and holding plate (2) onto the P1 planetary carrier.
  23. Install the selectable shim to the P1 annulus/B clutch hub.
  24. Install the P1 annulus\B clutch hub assembly (1) onto the P4 annulus drum.
  25. Install the O-ring and five squared O-rings.
    Fig 15: P4 Annulus Drum Assembly, Assembly, Press Fixture & Splitter, Bearing/Gear
    GC0152139Courtesy of CHRYSLER GROUP, LLC
  26. Install the clutch pack (2).
    Fig 16: Output Needle Bearing/Rear Oil Dam, Thick Walled Side & Driver Handle, Universal
    GC0152285Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The (special tool #10373, Installer, Output Needle Bearing/Rear Oil Dam) (3) is a combination tool that is reversed to install the oil dam and output shaft inner needle bearing. For use to install the output shaft inner needle bearing, use the thick walled side (2) of the tool against the bearing.

  27. Using (special tool #10373, Installer, Output Needle Bearing/Rear Oil Dam) (3) and (special tool #C-4171, Driver Handle, Universal) (1), install the output shaft inner needle bearing.
  28. Install the snap ring.
    Fig 17: Output Needle Bearing/Rear Oil Dam, Thin Walled Side & Driver Handle, Universal
    GC0152286Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The (special tool #10373, Installer, Output Needle Bearing/Rear Oil Dam) (3) is a combination tool that is reversed to install the oil dam and output shaft inner needle bearing. For use to install the oil dam, use the thin walled side (2) of the tool against the oil dam.

  29. Using (special tool #10373, Installer, Output Needle Bearing/Rear Oil Dam) (3) and (special tool #C-4171, Driver Handle, Universal) (1), install the oil dam.
  30. Install the snap ring.
    Fig 18: Outer Bearing Snap Ring & Outer Needle Bearing
    GC0152266Courtesy of CHRYSLER GROUP, LLC
  31. Install the needle bearing (AWD) or ball bearing (RWD).
  32. Install the snap ring (1).
    Fig 19: P4 Annulus Drum Assembly
    GC0152145Courtesy of CHRYSLER GROUP, LLC
  33. Install the input/output shaft and P4 annulus drum assembly (1) into the case.
    Fig 20: Park Pawl Shaft Using A Suitable Pin Punch, Park Pawl And Spring
    GC0152144Courtesy of CHRYSLER GROUP, LLC
  34. From outside the transmission case, install the park pawl shaft and install the park pawl (1) and spring (2).
    Fig 21: Park Pawl Shaft Plug
    GC0152143Courtesy of CHRYSLER GROUP, LLC
  35. Install the park pawl shaft plug (1) into the rear of the case and tighten to 35 N.m (26 ft. lb.).
    Fig 22: Spacer & Selector Shaft Seal
    GC0152279Courtesy of CHRYSLER GROUP, LLC
  36. Using (special tool #6936, Spacer) (1), install the selector shaft seal (2).
    Fig 23: Selector Shaft, Suitable Pin Punch, Spring & Fork
    GC0152142Courtesy of CHRYSLER GROUP, LLC
  37. Install the shaft (4), spring (2), and fork (1) into the case.
  38. Install the roll pin into the selector shaft (4) using a suitable pin punch (3).
    Fig 24: Park Pawl Lock Rod & Fork
    GC0152141Courtesy of CHRYSLER GROUP, LLC
  39. Install the park pawl lock rod (1) onto the fork (2).
    Fig 25: Three Park Pawl Lock Rod Guide Plate Retaining Screws & Plate
    GC0152140Courtesy of CHRYSLER GROUP, LLC
  40. Position the park pawl lock rod guide plate (2), install the three park pawl lock rod guide plate retaining screws (1) and tighten to 10 N.m (89 in. lb.).
    Fig 26: Oil Pump Cover Lip Seal & Oil Pump Cover
    GC0152287Courtesy of CHRYSLER GROUP, LLC
  41. Install the oil pump cover lip seal (3) on the oil pump cover (2).
  42. Using (special tool #10375, Installer, Oil Pump Cover Oil Seal) (1), install the input shaft seal in the oil pump cover (2).
    Fig 27: Six Bolts, Oil Pump Housing & Oil Pump Cover
    GC0152253Courtesy of CHRYSLER GROUP, LLC
  43. Position the oil pump housing (2) and oil pump cover (3) together.
  44. Install the five bolts (1) and tighten to 5 N.m (44 in. lb.) plus 45°.
    Fig 28: Piston Retaining Ring And Piston
    GC0152254Courtesy of CHRYSLER GROUP, LLC
  45. Insert the piston and the retaining ring (1) into the housing.
    Fig 29: Oil Pump Housing Assembly
    GC0152251Courtesy of CHRYSLER GROUP, LLC
  46. Position the oil pump housing assembly (4) in a suitable arbor press.
  47. Using (special tool #8285, Compressor, Spring) (1), press on the fingers of the piston retaining ring to remove tension, and install the two halves of the split retainer ring (2).
    Fig 30: Outer Ring, Snap Ring & Spacers
    GC0152250Courtesy of CHRYSLER GROUP, LLC
  48. Install the hub (3).
  49. Install the clutches and spacers (4).
  50. Install the snap ring (2).
  51. Install the outer ring (1) (below B-piston).
    Fig 31: B-Piston Alignment Tab & B-Piston
    GC0152288Courtesy of CHRYSLER GROUP, LLC
  52. Position the B-piston alignment tab (2) above the notch and install B-piston (1) on the assembly.
    Fig 32: Input Shaft O-Ring & Small Pick
    GC0152105Courtesy of CHRYSLER GROUP, LLC
  53. Carefully position the oil pump housing assembly into the case.
  54. Install the new  input shaft O-ring.
    Fig 33: Pre Tighten Bolts One, Seven And Nine
    GC0152246Courtesy of CHRYSLER GROUP, LLC
  55. Install the thirteen oil pump cover retaining bolts and tighten the oil pump cover as follows:
    1. In order to seat the oil pump cover properly, pre tighten bolts one, seven and nine to 6 N.m (53 in. lb.).
    2. Working in a clockwise pattern, beginning with number one, tighten to 10 N.m (89 in. lb.).
    3. Working in a clockwise pattern, beginning with number one, tighten an additional 90°.
    Fig 34: Manual Park Release Lever & Nut & Tie Strap
    GC0152275Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The manual park release lever (2) can be reversed to release tension and ease the installation of the valve body assembly.

  56. Temporarily install the manual park release lever (2) to release tension on the shift fork as follows:
    1. Install the manual shift shaft lever (2) 180 degrees offset from its original position.
    2. Install the nut (1) and hand tighten.
    3. Turn the manual park release lever (2) and using a tie strap (3), secure the lever (2) into position so the park release fork is in the same position as it was before valve body assembly removal.
    Fig 35: Fluid Port, Two O-Rings, Compression Seal
    GC0152241Courtesy of CHRYSLER GROUP, LLC
  57. Install a new compression seal (3) into the transmission case.
  58. Install the fluid port (1) with new  O-rings to the transmission case.
    Fig 36: Pins, Valve Body Alignment & Valve Body Alignment Pins
    GC0152262Courtesy of CHRYSLER GROUP, LLC
  59. Install the (special tool #10379, Pins, Valve Body Alignment) (1) in the transmission case as guides for the valve body assembly.
    NOTE:

    Make sure the shift fork lines up properly.

  60. Using the valve body alignment pins (1) to guide, position the valve body assembly to the transmission.
    NOTE:

    After several bolts have been hand tightened, remove the guide pins (1).

  61. Install the fourteen valve body assembly retaining bolts and hand tighten.
    Fig 37: Remover/Installer, Guide Sleeve
    GC0152117Courtesy of CHRYSLER GROUP, LLC
  62. Using (special tool #10377, Remover/Installer, Guide Sleeve) (1) carefully install the electrical harness insulator (2) into the transmission case (3).
    Fig 38: Valve Body Assembly End Retainer Bolts
    GC0152103Courtesy of CHRYSLER GROUP, LLC
  63. Install the sensor (4) and the sensor retaining bolt (1) and hand tighten.
  64. Latch the electrical connector insulator lock (2) by pushing in.
  65. Install the valve body assembly end retainer bolts (3) and hand tighten.
    Fig 39: Valve Body Assembly Retaining Bolts 1-14
    GC0152118Courtesy of CHRYSLER GROUP, LLC
  66. Tighten the valve body assembly retaining bolts 1-18 in the sequence shown in illustration to 8 N.m (71 in. lbs.).
    Fig 40: Manual Park Release Lever Retaining Nut & Lever
    GC0152243Courtesy of CHRYSLER GROUP, LLC
  67. Remove the tie strap and return the manual release lever (1) to the original position.
  68. Install the nut (2) and tighten to 10 N.m (89 in. lbs.).
    Fig 41: Oil Pan Retaining Bolts Tightening Sequence
    GC0152239Courtesy of CHRYSLER GROUP, LLC
  69. Position the oil pan and gasket.
  70. Install the thirteen oil pan retaining bolts and using the sequence shown in illustration and tighten to 10 N.m (89 in. lbs.).
    Fig 42: AWD
    GC0152264Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    AWD only.

    CAUTION:

    The seal must be installed flush with the case. Driving the seal deeper could damage the seal causing a leak.

  71. Position the new output shaft seal (3) over the output shaft and against the transmission case.
  72. Using (special tool #8481, Installer, Gear) install the output shaft seal.
  73. Position the extension housing.
  74. Install the seven transmission housing extension bolts (2) and tighten to 27 N.m (20 ft. lbs.).
    Fig 43: RWD
    GC0152116Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    RWD only.

  75. Install the transmission output shaft washer.
    CAUTION:

    The seal must be installed flush with the case. Driving the seal deeper could damage the seal causing a leak.

  76. Position the new output shaft seal (3) over the output shaft and against the transmission case.
  77. Using (special tool #8481, Installer, Gear) install the output shaft seal.
  78. Install the transmission rear dust seal (2).
  79. Install the propeller shaft flange (1).
    Fig 44: RWD
    GC0152101Courtesy of CHRYSLER GROUP, LLC
  80. Install the new  propeller shaft flange nut and washer using a 34 mm 12 point socket (3) and (special tool #C-3281, Holder, Flange) (2) to hold the flange (1). Tighten to 60 N.m (44 Ft. lbs.).
  81. Stake the nut.
    Fig 45: RWD
    GC0152102Courtesy of CHRYSLER GROUP, LLC
  82. Install the torque converter (1). Refer to TORQUE CONVERTER, INSTALLATION .
  83. Before installing the transmission in the vehicle, pre-fill the transmission as outlined in FILL TRANSMISSION AFTER SERVICE. Refer to FLUID AND FILTER, STANDARD PROCEDURE .
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