545RFE Automatic Transmission (Service Information): Retainer/Bulkhead-4C: Assembly

NOTE: Clean and inspect all components. Replace any components which show evidence of excessive wear or scoring.

Fig 1: 2C and 4C Clutch Components

Courtesy of DAIMLERCHRYSLER CORP.

1 - SEAL	8 - REACTION PLATE
2 - 2C PISTON	9 - SNAP-RING
3 - PLATE	10 - RETURN SPRING
4 - DISC	11 - SEAL
5 - 2C BELLEVILLE SPRING	12 - 4C PISTON
6 - SNAP-RING	13 - 4C RETAINER/BULKHEAD
7 - SNAP-RING (SELECT)	-

1. Install new seals (1, 11) on the 2C and 4C pistons or in the piston retainers. See Fig 1
2. Lubricate all seals with Mopar® ATF +4 prior to installation.
3. Install the 4C piston (12) into the 4C retainer/bulkhead (13). See Fig 1
4. Position the 4C piston return spring (10) onto the 4C piston (12).
   Fig 2: Compressing 4C Piston Return Spring Using Tool 8250

   Courtesy of DAIMLERCHRYSLER CORP.

   1 - PRESS

   2 - TOOL 8250

5. Using Spring Compressor 8250 (2) and a suitable shop press (1), compress the 4C piston return spring and install the snap-ring. See Fig 2
   Fig 3: 2C and 4C Clutch Components

   Courtesy of DAIMLERCHRYSLER CORP.

   1 - SEAL	8 - REACTION PLATE
   2 - 2C PISTON	9 - SNAP-RING
   3 - PLATE	10 - RETURN SPRING
   4 - DISC	11 - SEAL
   5 - 2C BELLEVILLE SPRING	12 - 4C PISTON
   6 - SNAP-RING	13 - 4C RETAINER/BULKHEAD
   7 - SNAP-RING (SELECT)	-

6. Assemble and install the 4C clutch pack (3, 4) into the retainer/bulkhead (13) with the steel separator plate against the piston. See Fig 3.
7. Install the 4C reaction plate (8) and snap-ring (7) into the retainer/bulkhead (13). The 4C reaction plate is non-directional. See Fig 3.
8. Measure the 4C clutch clearance. The correct clutch clearance is 0.770-1.390 mm (0.030-0.055 in.). The snap-ring (7) is selectable. Install the chosen snap-ring and re-measure to verify the selection.
9. Install the 2C piston (2) into the retainer/bulkhead (13). See Fig 3
10. Position the 2C Belleville spring (5) onto the 2C piston (2).
11. Position the 2C Belleville spring snap-ring (6) onto the 2C Belleville spring (5). See Fig 3
    Fig 4: Compressing 2C Belleville Spring Using Tool 8249

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - PRESS

    2 - TOOL 8249

12. Using Spring Compressor 8249 (2) and a suitable shop press (1), compress the Belleville spring until the snap-ring is engaged with the snap-ring groove in the retainer/bulkhead. See Fig 4.