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Transmission Reassembly

NOTE: Handle all parts carefully to avoid damaging bearings and mating surfaces. Lubricate all parts with clean transmission fluid or petroleum jelly as indicated. Use petroleum jelly on thrust washers and bearings to retain in place. Use new gaskets and seals.
  1. Install rear planetary gear, second brake drum and output shaft. No. 1 thrust bearing and race outer diameter is 2.272" (57.7 mm) and inside diameter is 1.543" (39.2 mm). Race faces down. Bearing rollers face up. Align teeth of second brake drum and clutch pack. Align rear planetary-output shaft assembly teeth with case slots. Install rear planetary snap ring. Chamfered side of snap ring faces up and toward case front. Using a feeler gauge, check first-reverse brake pack clearance 4-cylinder is .024-.069" (.61-1.75 mm) and 6-cylinder is .028-.079" (.70-2.00 mm). See Figure . Install second brake piston sleeve. Install second brake drum gasket with Gasket Installer (B.Vi FM-33). Gasket depth is 1.720" (43.7 mm). See Fig 1 .
  2. Install parking lock pawl, spring and pin. Install parking rod, bracket and bracket attaching bolts. Tighten bolts to 88 INCH lbs. (10 N.m). Verify park lock operation. Install No. 1 one-way clutch. Short flanged side of clutch faces up and toward case front. Install second brake pack. Install disc then plate. See SECOND BRAKE USAGE CHART  table. Install retainer with rounded edge facing disc. Install second brake pack snap ring. With feeler gauge, check brake clearance. 4-cylinder .035-.084" (.89-2.13 mm) and 6-cylinder .024-.078" (.61-1.98 mm).
    SECOND BRAKE USAGE

    Application Plates Discs Retainers
    4-Cylinder 4 4 1
    6-Cylinder 5 5 1
    Fig 1: Removing & Installing Second Brake Drum Gasket
    G92D13469Courtesy of CHRYSLER CORP.
  3. Install planetary sun gear and input drum. Use petroleum jelly to hold thrust washer in place. Install front planetary gear on sun gear. Install planetary snap ring on sun gear with Tool (B.Vi FM30). Install tabbed thrust race. Washer tabs face down and toward gear. Race outer diameter 1.882" (47.8 mm) and inside diameter is 1.350" (34.3 mm). Install second coast brake band and pin. Install retaining ring on pin.
  4. Install thrust bearing and race in forward-direct clutch. Verify foward-direct clutch thrust bearing size. See FORWARD-DIRECT CLUTCH THRUST BEARING IDENTIFICATION  table. Coat front planetary ring gear race with petroleum jelly and install in ring gear. Verify ring gear race size. Outer diameter 1.850" (47.0 mm) and inside diameter is 1.045" (26.5 mm). Align forward-direct clutch disc splines with a screwdriver. Align and install front planetary ring gear in forward-direct clutch. Install ring gear bearing and race. Verify bearing race size. See FRONT PLANETARY RING GEAR THRUST BEARING IDENTIFICATION  table.
    FORWARD-DIRECT CLUTCH THRUST BEARING IDENTIFICATION

    Application Outer Diameter - In. (mm) Inner Diameter - In. (mm)
    Race 1.925 (48.9) 1.024 (26.0)
    Bearing 1.839 (46.7) 1.024 (26.0)
    FRONT PLANETARY RING GEAR THRUST BEARING IDENTIFICATION

    Application Outer Diameter - In. (mm) Inner Diameter - In. (mm)
    Race 2.110 (53.6) 1.205 (30.6)
    Bearing 1.8781(47.7) 1.283 (32.6)
  5. Rotate front of transmission case downward and install assembled planetary gear-forward-direct clutch. Using a feeler gauge, check clearance between sun gear input drum and direct clutch drum. Clearance should be .386-.465" (9.8-11.8 mm). Coat thrust bearing and race assembly with petroleum jelly and install on clutch shaft. Verify bearing race size. Bearing and race outer diameter is 1.882" (47.8 mm) and inside diameter is 1.301" (33.0 mm). Assemble second coast brake piston components. Install assembled second coast brake piston in case. Install piston cover and new seal. Install snap ring. Check second brake piston stroke. Make reference mark on brake piston rod. Apply 57-114 psi air pressure through feed hole. Piston stroke length should be .059-.188 (1.5-4.8 mm).
  6. Coat thrust race and tabbed washer with petroleum jelly and install on overdrive support. Verify race size. Race outer diameter is 2.004" (50.9 mm) and inside diameter is 1.426" (36.2 mm). Using two long bolts to help align and guide into position install overdrive support in case. Install overdrive support snap ring. Chamfered side of snap ring faces up and toward case front. Install and tighten overdrive support bolts to 19 ft. lbs. (26 N.m). Check output shaft end play with dial indicator. See Fig 2 . End play should be .012-.034" (.30-.86 mm). If end play is incorrect, check for proper assembly of components.
  7. Install overdrive clutch pack. See OVERDRIVE CLUTCH PACK USAGE  table. Install thickest clutch plate first. Rounded edges of plate faces up. Install stepped ring retainer plate with flat side facing disc. Install brake pack snap ring. Check overdrive brake piston stroke. See Fig 3 . Mount Tool (B.Vi FM-35) in dial indicator and position Gauge Tool (B.Vi FM-35) against overdrive brake piston. Release brake piston with compressed air. Piston stroke length should be .052-.063" (1.32-1.62 mm) on 4-cylinder and .55-.66" (13.97-16.76 mm) on 6-cylinder. Remove dial indicator gauge tool. Remove overdrive clutch pack.
    OVERDRIVE CLUTCH PACK USAGE

    Application Plates Discs Retainers
    4-Cylinder 2 3 1
    6-Cylinder 3 4 1
    Fig 2: Checking Output Shaft End Play
    G00158882Courtesy of CHRYSLER CORP.
    Fig 3: Checking Overdrive Brake Piston Stroke
    G00158883Courtesy of CHRYSLER CORP.
  8. Coat overdrive lower race, thrust bearing and upper race with petroleum jelly and install in overdrive support. Verify bearing race sizes. See OVERDRIVE SUPPORT THRUST BEARING IDENTIFICATION  table.
    OVERDRIVE SUPPORT THRUST BEARING IDENTIFICATION

    Application Outer Diameter - In. (mm) Inner Diameter - In. (mm)
    Lower Race 1.882 (47.8) 1.350 (34.3)
    Bearing 1.878 (47.7) 1.287 (32.7)
    Upper Race 1.882 (47.8) 1.209 (30.7)
  9. Install overdrive planetary ring gear in support. Coat ring gear thrust race and bearing with petroleum jelly and install in gear. Verify bearing race size. See OVERDRIVE PLANETARY RING GEAR THRUST BEARING IDENTIFICATION  table. Coat tabbed thrust race with petroleum jelly and install on planetary gear. Race outer diameter is 1.646" (41.8 mm) and inside diameter is 1.067" (27.1 mm). Install assembled overdrive planetary gear and clutch. Coat input shaft thrust bearing and race assembly with petroleum jelly and install on clutch input shaft. Bearing and race outer diameter is 1.976" (50.2 mm) and inside diameter is 1.138" (28.9 mm).
    OVERDRIVE PLANETARY RING GEAR THRUST BEARING IDENTIFICATION

    Application Outer Diameter - In. (mm) Inner Diameter - In. (mm)
    Race 1.882 (47.8) .953 (24.2)
    Bearing 1.844 (46.8) 1.024 (26.0)
  10. Install overdrive brake pack. Install .157" (4.0 mm) thick plate first. Rounded edge of plate must face upward. Install a disc followed by a plate. Ensure stepped plate is installed last with flat-side of the plate facing disc. Install clutch pack snap ring. See OVERDRIVE BRAKE PACK USAGE  table.
    OVERDRIVE BRAKE PACK USAGE

    Application Plates Discs Retainers
    4-Cylinder 2 3 1
    6-Cylinder 3 4 1
  11. Coat oil pump thrust bearing race with petroleum jelly and install in oil pump. Bearing race outer diameter is 1.858" (47.2 mm) and inside diameter is 1.106" (28.1 mm). Lubricate and install new "O" ring on oil pump body. Install oil pump. Align pump and case bolt holes and carefully ease pump into place. See Fig 4 . Tighten oil pump bolts to 16 ft. lbs. (22 N.m). Verify input shaft operation. Shaft should rotate smoothly and not bind.
    12. CAUTION: DO NOT use force to seat the oil pump. Seal rings on the stator shaft could be damaged if they bind or stick to the direct clutch drum.
    NOTE: It is necessary to block drive clutch accumulator feed hole No. 8, in order to check direct clutch operation.
  12. Lubricate and install new "O" ring on throttle cable adapter and install cable. Operate clutches and brakes with compressed air applied through feed holes in case. See Figure . Listen for clutch and brake application. Repair fault before proceeding.
  13. Lubricate and install new "O" rings on accumulator pistons. Assemble and install accumulator piston components. See Figure .
  14. Install new check ball body and spring. Position valve body on case. Install detent spring. Align manual valve, detent spring and shift sector. Connect throttle cable to throttle valve cam. Install and tighten valve body-to-case bolts to 88 INCH lbs. (10 N.m). Connect valve body solenoid wires to solenoids. Install new "O" ring on solenoid harness adapter and secure adapter to case. Install valve body oil tubes. Tap tubes into place with a plastic mallet. Install new gaskets on oil screen. Install screen on valve body. Tighten screen bolts 88 INCH lbs. (10 N.m). Install magnet in oil pan. Ensure magnet does NOT interfere with valve body oil tubes. Apply Three-Bond TB1281 or equivalent sealer to sealing surface of oil pan. Sealer bead should be at least .040" (1 mm) wide. Install pan on case and tighten pan bolts to 65 INCH lbs. (7.4 N.m).
  15. Install speed sensor rotor and key on output shaft. Install spacer and speedometer drive gear on output shaft. Install snap ring. Apply bead of sealer to sealing surface at rear of case. Use Three-Bond TB1281 Loctite 518 or equivalent sealer. Install extension, or adapter housing on transmission. Tighten housing adapter bolts to 25 ft. lbs. (34 N.m). Install speed sensor. Tighten sensor bolt to 65 INCH lbs. (7.4 N.m) and connect sensor wire harness connector.
  16. Install speedometer driven gear. Tighten gear attaching bolt to 15 ft. lbs. (19 N.m). Install converter housing. Tighten 12-mm housing bolts to 42 ft. lbs. (57 N.m). Tighten 10 mm diameter housing bolts to 25 ft. lbs. (34 N.m).
  17. Install transmission shift control lever on manual valve shift. DO NOT install the lever attaching nut at this time. Move shift control lever all the way to rear. Move it two detent positions forward. Mount neutral safety switch on manual valve shaft and tighten switch adjusting bolt just enough to keep switch from moving. Install neutral switch tabbed washer and retaining nut. Tighten nut to 61 INCH lbs. (6.9 N.m). DO NOT bend washer tabs against nut at this time. Align neutral switch standard line with groove or flat on manual shaft. Tighten neutral switch adjusting bolt to 108 INCH lbs. (13 N.m). Install shift control lever on manual valve shaft. Tighten lever attaching nut to 12 ft. lbs. (16 N.m).
  18. Install retaining clamp for wire harness and throttle cable. Install torque converter. Verify converter is seated by measuring distance between converter housing flange and one converter mounting pad. Use straight edge and vernier calipers to measure distance. On 4-cylinder transmissions, distance should be .689" (17.5 mm). On 6-cylinder transmissions, distance should be .650" (16.5 mm). Install lower half of transmission fill tube. Install upper half after transmission is in vehicle.
Fig 4: Removing & Installing Oil Pump
G92F13461Courtesy of CHRYSLER CORP.
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