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Service Information: Assembly

NOTE: Clean and inspect all components. Replace any components which show evidence of excessive wear or scoring.
Fig 1: Installing Selector Shaft Seal
GC0005221Courtesy of DAIMLERCHRYSLER CORP.
1 - SEAL
2 - TOOL 8253
  1. Install the cooler filter bypass valve. Torque the bypass valve to specification. The valve uses a tapered pipe thread and excessive torque can damage the transmission case. Tighten the cooler filter bypass valve to 4.5 N.m (40 in.lbs.).
  2. Install a new selector shaft seal (1) using Seal Installer 8253 (2). See Fig 1
    Fig 2: Manual Shaft Lever
    G04285172Courtesy of DAIMLERCHRYSLER CORP.
    1 - MANUAL SHAFT LEVER
  3. Install the manual selector shaft and retaining screw. Tighten the manual selector shaft retaining screw to 28 N.m (250 in.lbs.).
  4. Install the manual shift lever (1) onto the manual selector shaft. Torque the retaining cross-bolt to 16 N.m (140 in.lbs.). See Fig 2.
    Fig 3: Removing/Installing Manual Shaft/Park Lock Components
    G04285170Courtesy of DAIMLERCHRYSLER CORP.
    1 - GUIDE
    2 - SNAP-RING
    3 - SHAFT
    4 - SPRING
    5 - PARK PAWL
    6 - MANUAL SHAFT/LEVER
    7 - PARK ROD
  5. Install the park pawl (5), spring (4), and shaft (3). See Fig 3
  6. Install the park rod (7) and e-clip. See Fig 3
  7. Install the park rod guide (1) and snap-ring (2). See Fig 3
    Fig 4: Installing Dipstick Tube Seal Using Tool 8254
    GC0005222Courtesy of DAIMLERCHRYSLER CORP.
    1 - TOOL 8254
    2 - SEAL
  8. Install a new dipstick tube seal (2) using Seal Installer 8254 (1). See Fig 4
    Fig 5: Removing/Installing 2C Clutch Pack
    GC0005212Courtesy of DAIMLERCHRYSLER CORP.
    1 - SNAP-RING
    2 - PLATE
    3 - DISC
    4 - REACTION PLATE
    NOTE: Before final assembly of transmission centerline, the 2C/4C clutch components should be installed into position and measured as follows:
  9. Install the 2C reaction plate (4) into the transmission case. See Fig 5
  10. Install the 2C clutch pack (2, 3) into the transmission case. See Fig 5
  11. Install the flat 2C clutch snap-ring (1) into the transmission case. See Fig 5
    Fig 6: Installing 4C Clutch Retainer/Bulkhead
    GC0005211Courtesy of DAIMLERCHRYSLER CORP.
    1 - SNAP-RING
    2 - 4C CLUTCH RETAINER/BULKHEAD
  12. Install the 4C retainer/bulkhead (2) into the transmission case. Make sure that the oil feed holes are pointing toward the valve body area. See Fig 6.
  13. Install the 4C retainer/bulkhead tapered snap-ring (1) into the transmission case. Make sure that the open ends of the snap-ring are located in the case opening toward the valve body area.
  14. Using a feeler gauge through the opening in the rear of the transmission case, measure the 2C clutch pack clearance between the 2C reaction plate and the transmission case at four different points. The average of these measurements is the 2C clutch pack clearance. The correct clutch clearance is 0.455-1.335 mm (0.018-0.053 in.). The reaction plate is not selective. If the clutch pack clearance is not within specification, the reaction plate, all the friction discs, and steels must be replaced.
  15. Remove the 4C retainer/bulkhead and all of the 2C clutch components from the transmission case.
    Fig 7: Removing/Installing Low/Reverse Clutch Retainer
    GC0005217Courtesy of DAIMLERCHRYSLER CORP.
    1 - LOW/REVERSE OVERRUNNING CLUTCH ASSEMBLY
    2 - SNAP-RING
  16. Install the low/reverse clutch assembly (1). See Fig 7. Make sure that the oil feed hole points toward the valve body area and that the bleed orifice is aligned with the notch in the rear of the transmission case.
  17. Install the snap-ring (2) to hold the low/reverse clutch retainer into the transmission case. The snap-ring is tapered and must be installed with the tapered side forward. Once installed, verify that the snap-ring is fully seated in the snap-ring groove. See Fig 7.
  18. Air check the low/reverse clutch and verify correct overrunning clutch operation.
    Fig 8: Removing/Installing Input/Reverse Planetary Assembly
    GC0005216Courtesy of DAIMLERCHRYSLER CORP.
    1 - INPUT/REVERSE PLANETARY ASSEMBLY
    2 - BEARING NUMBER 9
    3 - BEARING NUMBER 12
  19. Install the number 12 thrust bearing (3) over the output shaft and against the rear planetary gear set. The flat side of the bearing goes toward the planetary gearset and the raised tabs on the inner race should face the rear of the transmission.
  20. Install the reverse/input planetary assembly (1) through the low/reverse clutch assembly. See Fig 8
    Fig 9: Removing/Installing Park Sprag Gear
    GC0005215Courtesy of DAIMLERCHRYSLER CORP.
    1 - PARK SPRAG GEAR
  21. Install the park sprag gear (1) onto the output shaft. See Fig 9
    Fig 10: Removing/Installing Park Sprag Snap Ring
    GC0005214Courtesy of DAIMLERCHRYSLER CORP.
    1 - SNAP-RING
  22. Install the snap-ring (1) to hold the park sprag onto the output shaft. See Fig 10
    Fig 11: Removing/Installing 2C Clutch Pack
    GC0005212Courtesy of DAIMLERCHRYSLER CORP.
    1 - SNAP-RING
    2 - PLATE
    3 - DISC
    4 - REACTION PLATE
  23. Install the 2C reaction plate (4) into the transmission case. See Fig 11
  24. Install the 2C clutch pack (2, 3, 4) into the transmission case. See Fig 11
    Fig 12: Removing/Installing Reaction Annulus and Carrier
    GC0005213Courtesy of DAIMLERCHRYSLER CORP.
    1 - THRUST BEARING NUMBER 8 5 - THRUST BEARING NUMBER 7
    2 - THRUST BEARING NUMBER 9 6 - THRUST PLATE (SELECT)
    3 - REACTION PLANETARY CARRIER 7 - THRUST BEARING NUMBER 6
    4 - REACTION SUN GEAR 8 - REACTION ANNULUS
  25. Install the number 8 thrust bearing (1) inside the reaction carrier with the outer race against the reaction planetary carrier (3).
  26. Install the reaction planetary gear set and the number 9 thrust bearing (2), with the inner race against the reaction planetary carrier (3), into the transmission case. See Fig 12
  27. Install the flat 2C clutch snap-ring into the transmission case. See Fig 11
  28. Install the reaction sun gear (4) into the reaction planetary gear set. Make sure  the small shoulder is facing the front of the transmission. See Fig 12
  29. Install the number 7 thrust bearing (5) onto the reaction sun gear (4) with the inner race against the sun gear. See Fig 12
    Fig 13: Thrust Plate Alignment
    GC0005223Courtesy of DAIMLERCHRYSLER CORP.
    1 - LOCATING LUG (3)
    2 - THRUST PLATE
  30. Install the output shaft selective thrust plate (2) onto the reaction annulus with the oil grooves facing the annulus gear and the lugs (1) and notches aligned as shown. See Fig 13
    Fig 14: Removing/Installing Reaction Annulus and Carrier
    GC0005213Courtesy of DAIMLERCHRYSLER CORP.
    1 - THRUST BEARING NUMBER 8 5 - THRUST BEARING NUMBER 7
    2 - THRUST BEARING NUMBER 9 6 - THRUST PLATE (SELECT)
    3 - REACTION PLANETARY CARRIER 7 - THRUST BEARING NUMBER 6
    4 - REACTION SUN GEAR 8 - REACTION ANNULUS
  31. Install the number 6 thrust bearing (7) against the output shaft selective thrust plate (6) with the flat side against the thrust plate and the raised tabs on the inner race facing the front of the transmission. See Fig 14.
  32. Install the reaction annulus (8) into the reaction planetary gear set. See Fig 14
    Fig 15: Removing/Installing 4C Clutch Retainer/Bulkhead
    G04285163Courtesy of DAIMLERCHRYSLER CORP.
    1 - SNAP-RING
    2 - 4C CLUTCH RETAINER/BULKHEAD
  33. Install the 4C retainer/bulkhead (2) into the transmission case. Make sure that the oil feed holes are pointing toward the valve body area. Rotate the reaction annulus during the installation of the 4C retainer/bulkhead to ease installation.
  34. Install the 4C retainer/bulkhead tapered snap-ring (1) into the transmission case with the taper toward the front of the case. Make sure that the open ends of the snap-ring are located in the case opening toward the valve body area. See Fig 15.
  35. Air check the 2C and 4C clutch operation.
    Fig 16: Measuring Output Shaft End Play
    GC0005205Courtesy of DAIMLERCHRYSLER CORP.
    1 - TOOL 8261
    2 - TOOL 8266
    3 - TOOL C-3339
  36. Using Alignment Plate 8261 (1), Adapter 8266-17 from End-Play Tool Set 8266 (2) and Dial Indicator C-3339 (3), measure and record the output shaft end-play. The correct output shaft end-play is 0.22-0.55 mm (0.009-0.021 in.). Adjust as necessary. Install the chosen output shaft selective thrust plate and re-measure end-play to verify selection. See Fig 16.
  37. Apply a bead of RTV silicone and install the extension/adapter housing onto the transmission case.
  38. Install and torque the bolts to hold the extension/adapter housing onto the transmission case. The correct torque is 54 N.m (40 ft.lbs.).
    Fig 17: Removing/Installing Input Clutch Assembly
    GC0005210Courtesy of DAIMLERCHRYSLER CORP.
    1 - THRUST BEARING NUMBER 5
    2 - THRUST PLATE (SELECT)
    3 - INPUT CLUTCH ASSEMBLY
    4 - THRUST BEARING NUMBER 1
  39. Install the number 5 thrust bearing (1) and selective thrust plate (2) onto the 4C retainer/bulkhead. Be sure that the outer race of the bearing is against the thrust plate. See Fig 17.
  40. Install the input clutch assembly (3) into the transmission case. Make sure that the input clutch assembly is fully installed by performing a visual inspection through the input speed sensor hole. If the tone wheel teeth on the input clutch assembly are centered in the hole, the assembly is fully installed. See Fig 17.
  41. Install the number 1 thrust bearing (4) with the outer race up in the pocket of the input clutch assembly. See Fig 17
    Fig 18: Removing/Installing Oil Pump
    GC0005209Courtesy of DAIMLERCHRYSLER CORP.
    1 - OIL PUMP TO CASE BOLT (6)
    2 - OIL PUMP
  42. Install the oil pump (2) into the transmission case. See Fig 18
  43. Install the bolts (1) to hold the oil pump into the transmission case. Tighten the oil pump bolts to 28 N.m (250 in.lbs.).
    Fig 19: Measuring Input Shaft End Play
    GC0005204Courtesy of DAIMLERCHRYSLER CORP.
    1 - TOOL 8266
    2 - TOOL C-3339
  44. Using Adapter 8266-1 from End-Play Tool Set 8266 (1) and Dial Indicator C-3339 (2), measure and record the input shaft end-play. The correct end-play is 0.46-0.89 mm (0.018-0.035 in.). Adjust as necessary. Install the chosen thrust plate on the number 5 thrust bearing and re-measure end-play to verify selection. See Fig 19.
    NOTE: When measuring the input shaft end-play, two "stops" will be felt. When the input shaft is pushed inward and the dial indicator zeroed, the first "stop" felt when the input shaft is pulled outward is the movement of the input shaft in the input clutch housing hub. This value should not be included in the end-play measured value and therefore must be recorded and subtracted from the dial indicator reading.
    Fig 20: Removing/Installing Transmission Front Cover
    GC0005208Courtesy of DAIMLERCHRYSLER CORP.
    1 - INNER SNAP-RING
    2 - TRANSMISSION FRONT COVER
    3 - OUTER SNAP-RING
  45. Install the transmission front cover (2) into the transmission case. See Fig 20
  46. Install the outer snap-ring (3) to hold the transmission front cover (2) into the transmission case. See Fig 20
  47. Partially install the inner transmission front cover snap-ring (1) onto the oil pump. See Fig 20
    Fig 21: Seating Snap Ring Using Tool 8255
    GC0005224Courtesy of DAIMLERCHRYSLER CORP.
    1 - SNAP-RING INSTALLER 8255
    2 - SNAP-RING
  48. Using Snap-ring Installer 8255 (1), install the inner transmission front cover snap-ring (2) the remainder of the way onto the oil pump. See Fig 21
    Fig 22: Removing/Installing Valve Body Assembly
    GC0005207Courtesy of DAIMLERCHRYSLER CORP.
    1 - VALVE BODY TO CASE BOLT (6)
  49. Install the valve body. Verify that the pin on the manual lever has properly engaged the TRS selector plate. Tighten the valve body to transmission case bolts (1) to 12 N.m (105 in.lbs.). See Fig 22.
    Fig 23: Locating Primary Oil and Cooler Filters
    GC0005206Courtesy of DAIMLERCHRYSLER CORP.
    1 - PRIMARY OIL FILTER
    2 - COOLER RETURN FILTER
    3 - COOLER RETURN FILTER BYPASS VALVE
    4 - VALVE BODY
    CAUTION: The primary oil filter seal MUST be fully installed flush against the oil pump body. DO NOT install the seal onto the filter neck and attempt to install the filter and seal as an assembly. Damage to the transmission will result.
  50. Install a new primary oil filter seal in the oil pump inlet bore. Seat the seal in the bore with the butt end of a hammer, or other suitable tool.
  51. Install the primary oil filter (1) and the oil cooler return filter (2). Tighten the screw to hold the primary oil filter to the valve body to 4.5 N.m (40 in.lbs.). Using Filter Wrench 8321, tighten the cooler return oil filter to the transmission case to 9.5 N.m (7 ft.lbs.). See Fig 23.
  52. Apply RTV silicone to the oil pan and install the transmission oil pan. Tighten the bolts to 12 N.m (105 in.lbs.).
    Fig 24: Locating Input Speed, Output Speed and Line Pressure Sensors
    GC0005202Courtesy of DAIMLERCHRYSLER CORP.
    1 - OUTPUT SPEED SENSOR
    2 - LINE PRESSURE SENSOR
    3 - INPUT SPEED SENSOR
  53. Install the input (3), output (1), and line pressure sensors (2). See Fig 24. Tighten the bolts to 12 N.m (105 in.lbs.).
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