Continuously Variable Transmission (CVT) (Service Information): Assembly: Assembly

Fig 1: CVT Externals - Exploded View

Courtesy of CHRYSLER GROUP, LLC

1- WASHER	16 - OIL STRAINER
2 - SHIFT LEVER	17 - PLAIN WASHER
3 - INHIBITOR SWITCH	18 - MANUAL LEVER
4 - CVT FLUID FILTER (Certain Models)	19 - BUSHING
5 - O-RING	20 - MANUAL VALVE
6 - CVT FLUID COOLER	21 - STEPPER MOTOR
7 - SHIM	22 - LIP SEAL
8 - OUTPUT SPEED SENSOR	23 - SNAP RING
9 - O-RING	24 - VALVE BODY HARNESS
10 - TRANSAXLE	25 - OIL PAN GASKET
11 - PULLEY RATIO LINKAGE	26 - OIL PAN
12 - SPRING	27 - TORQUE CONVERTER
13 - CONTROL VALVE	28 - O-RING
14 - BRACKET	29 - INPUT SPEED SENSOR
15 - O-RING	30 - O-RING

Fig 2: CVT Internals - Exploded View

Courtesy of CHRYSLER GROUP, LLC

1 - O-RING	24 - BAFFLE PLATE
2 - SIDE OIL SEAL	25 - DRIVEN SPROCKET (OIL PUMP)
3 - ADJUSTABLE SHIM	26 - BAFFLE PLATE
4 - OUTER RACE	27 - OIL PUMP
5 - REDUCTION GEAR ASSEMBLY	28 - LIP SEAL
6 - OUTER RACE	29 - SNAP RING
7 - ADJUSTABLE SHIM	30 - DRIVEN PLATES
8 - OUTER RACE	31 - NEEDLE BEARING
9 - DIFFERENTIAL ASSEMBLY	32 - SUN GEAR
10 - OUTER RACE	33 - NEEDLE BEARING
11 - FORWARD CLUTCH ASSEMBLY	34 - PLANETARY CARRIER
12 - NEEDLE BEARING	35 - NEEDLE BEARING
13 - SEAL RING	36 - SNAP RING
14 - OIL PUMP COVER	37 - RETAINING PLATE
15 - BAFFLE PLATE	38 - DRIVEN PLATES
16 - BRACKET	39 - DISH PLATE
17 - ADJUSTABLE SHIM	40 - SNAP RING
18 - ADJUSTABLE SHIM	41 - RETAINING PLATE
19 - CONVERTER HOUSING	42 - SPRING RETAINER ASSEMBLY
20 - CONVERTER HOUSING OIL SEAL	43 - REVERSE PLATE PISTON
21 - OIL PUMP CHAIN	44 - DETENT SPRING
22 - DRIVE SPROCKET	45 - TRANSAXLE CASE
23 - THRUST WASHER

Refer to the exploded views as necessary when performing the following steps.

Fig 3: Pin AT Sheave Height Sensor
Courtesy of CHRYSLER GROUP, LLC
Install the primary sheave (2) with the sheave height sensor, (3) spring and pin (1) into the belt side case.

Fig 4: Shim Under Sheave
Courtesy of CHRYSLER GROUP, LLC
Install the secondary sheave positioning shim (3) into the belt side cover.

Fig 5: Install Puller
Courtesy of CHRYSLER GROUP, LLC
Install Puller (special tool #9874, Compressor, Pulley) (1) and Insert (special tool #8513A, Insert, Crankshaft), (2) onto secondary sheave.

Fig 6: Drive Belt
Courtesy of CHRYSLER GROUP, LLC
Move the secondary sheave (3) close enough to the primary (2) sheave to allow the drive belt (1) to be put around both secondary and primary sheaves.
NOTE:
The drive belt is directional and will need to be installed in the same direction as noted in disassembly. if installed incorrectly failure will occur.
Install the drive belt (1).
CAUTION:
Do not over tighten the compressor tool. Tighten to no more than 7 N.m (50 in. lbs.).
Compress the secondary (3) sheave to the stop.
Install the drive belt (1) around both secondary (3) and primary (2) sheaves.
Install the primary sheave into place.
Remove Puller (special tool #9874, Compressor, Pulley) and Insert (special tool #8513A, Insert, Crankshaft) from the primary sheave.

Fig 7: Sheave Retaining Bolts
Courtesy of CHRYSLER GROUP, LLC
Install the bolts (2) that hold both sheaves to the case (1).

Fig 8: Bolts AT Drive Belt Assembly
Courtesy of CHRYSLER GROUP, LLC

CAUTION:
Remove moisture, oil, and used sealant from the sealant application surface. Make sure that the starting point and the ending point are between two bolt holes.
Apply Loctite 509 sealer onto the belt side of the transaxle case.
Install the belt side assembly to the transaxle case.
Install the case bolts (1) to hold the drive belt assembly (2) to the transaxle. tighten to 45 N.m (33 ft. lbs.).

Fig 9: Reverse Brake Piston
Courtesy of CHRYSLER GROUP, LLC

CAUTION:
Inspect the reverse brake piston and, if damaged, replace it before installation. Apply CVT fluid to the seal when installing the reverse brake piston.

NOTE:
Rotate reverse brake piston into place.
Rotate and install the reverse brake piston (1) into the transaxle case. Refer to Fig 9.

Fig 10: Retainer Assembly Return Spring
Courtesy of CHRYSLER GROUP, LLC
Align the return springs (3) of the spring retainer assembly (1) to the locating posts (2) of the reverse clutch piston. Refer to Fig 10.

Fig 11: Retaining Plate AT Transaxle
Courtesy of CHRYSLER GROUP, LLC

NOTE:
There is a notch in the retaining plate that points to the top of the case.
Install the retaining plate (1) into the transaxle case with the notch on the plate to the top (2). Refer to Fig 11.

Fig 12: Compress Clutches
Courtesy of CHRYSLER GROUP, LLC

CAUTION:
Set the spring compressor on top of the spring retainer assembly.
Compress the reverse brake return spring using Compressor (special tool #5058A, Compressor, Spring) (1) and Compressor (special tool #9875, Compressor) and install the snap ring into the transaxle case using a screwdriver. Refer to Fig 12.

Fig 13: Clutch Disc Stack Up
Courtesy of CHRYSLER GROUP, LLC
Install the dish plate (1) with the convex side down onto the reverse brake piston.
Install driven plate (2) and then a drive plate (6) until all the driven and drive plates are installed.
Install the retaining plate (3) into the reverse brake assembly.
Install the reverse brake snap ring (4) into the transaxle case.

Fig 14: Measure Clearance
Courtesy of CHRYSLER GROUP, LLC

CAUTION:
When conducting measurements, measure two or more places and calculate the average value.
Measure the clearance between the snap ring and the retaining plate (1). Refer to Fig 14. The correct clutch clearance is 1.2-1.5 mm (0.047-0.059 in.). If the clutch clearance is not within specifications, measure the existing retaining plate and select the correct retaining plate.

Fig 15: Needle Bearing AT Reverse Brake Piston
Courtesy of CHRYSLER GROUP, LLC

CAUTION:
Apply Vaseline or assembly lube when installing the needle bearing. Be careful to verify correct orientation of the needle bearing when installing it.

NOTE:
The inner race will need to face down.
Install the needle bearing (1) onto the reverse brake piston. Refer to Fig 15. Check for the direction of the needle bearing while installing.

Fig 16: Planetary Carrier Assembly
Courtesy of CHRYSLER GROUP, LLC

NOTE:
The inner race will need to face down
Install the planetary carrier assembly (1) onto the reverse brake. Refer to Fig 16.

Fig 17: Needle Bearing AT Sun Gear
Courtesy of CHRYSLER GROUP, LLC

CAUTION:
Apply Vaseline or assembly lube when installing the needle bearing. Be careful to verify correct orientation of the needle bearing when installing it.
Install the needle bearing (1) onto the primary pulley side of the sun gear. Refer to Fig 17.

Fig 18: Sun Gear AT Planetary Carrier
Courtesy of CHRYSLER GROUP, LLC
Install the sun gear (1) onto the planetary carrier. Refer to Fig 18.

Fig 19: Needle Bearing AT Forward Clutch
Courtesy of CHRYSLER GROUP, LLC

CAUTION:
Apply Vaseline or assembly lube when installing the needle bearing. Be careful to verify correct orientation of the needle bearing when installing it.

NOTE:
The inner race will need to face up.
Install the needle bearing (1) on the forward clutch drum side of the sun gear. Refer to Fig 19.

Fig 20: Forward Clutch Assembly
Courtesy of CHRYSLER GROUP, LLC
Install the forward clutch assembly (1) into the transaxle case. Refer to Fig 20.

Fig 21: End Play
Courtesy of CHRYSLER GROUP, LLC
Measure the total end play (2) in the following steps. Total end play should be 0.25 - 0.55 mm (0.010 - 0.022 in).

Fig 22: Measurement One
Courtesy of CHRYSLER GROUP, LLC

NOTE:
Gauge Bar (special tool #6311, Gauge Bar) can be used for doing the following measurement.
Measure the distance (1) from the oil pump cover installation surface of the transaxle case to the needle bearing installation surface of the forward clutch drum. Call this measurement one.

Fig 23: Measurement Two
Courtesy of CHRYSLER GROUP, LLC

NOTE:
Gauge Bar (special tool #6311, Gauge Bar) can be used for doing the following measurement.
Measure the distance (1 to 2) as shown in illustration. Call this measurement two.
Calculate the bearing thickness required to achieve the necessary end play with the following formula. The bearing thickness is equal to measurement one, minus measurement two minus, the nominal end play (0.40 mm or 0.016 "in).

Fig 24: Needle Bearing On The Forward Clutch Assembly
Courtesy of CHRYSLER GROUP, LLC

CAUTION:
Apply Vaseline or assembly lube when installing the needle bearing. Be careful to verify correct orientation of the needle bearing when installing it.
Install the selected needle bearing (1) on the forward clutch assembly. Refer to Fig 24.

Fig 25: Detente Spring
Courtesy of CHRYSLER GROUP, LLC
Install the detent spring (1) onto the transaxle case. Refer to Fig 25. Install the bolt to hold the detent spring to the transaxle case and tighten the mounting bolt to 7 N.m (61 in.lbs.).

Fig 26: Installing Outer Race Of Differential Bearing Into Converter Housing
Courtesy of CHRYSLER GROUP, LLC

Install the outer race of the differential bearing (1) into the converter housing using Installer (special tool #9668, Remover/Installer, Bearing Cup) and Installer (special tool #C-4628, Installer, Cup) on 4WD, use Installer (special tool #C-4628, Installer, Cup) on 2WD and Handle (special tool #C-4171, Driver Handle, Universal). Refer to Fig 26.

Fig 27: Measuring For Differential Preload Shim

Courtesy of CHRYSLER GROUP, LLC

1 - PRELOAD SHIM

2 - DIFFERENTIAL ASSEMBLY

3 - TRANSAXLE CASE

4 - CONVERTER HOUSING

CAUTION:

When adjusting the preload, apply CVT fluid on the bearing to make it roll smoothly. When conducting measurements, measure two or more places and calculate the average value.

Measure for the differential preload shim (1) in the following steps. Refer to Fig 27. Refer to the graphic as necessary when performing the steps.

Fig 28: Differential Measurement One
Courtesy of CHRYSLER GROUP, LLC

NOTE:
Gauge Bar (special tool #6311, Gauge Bar) can be used for doing the following measurement.
The required differential preload is 0.17 to 0.29 mm (0.007 0.011 to in).
Measure the distance (1-3) from the edge of the transaxle case to the select shim installation surface. This is differential measurement one.

Fig 29: Differential Measurement Two
Courtesy of CHRYSLER GROUP, LLC

NOTE:
Gauge Bar (special tool #6311, Gauge Bar) can be used for doing the following measurement.
Install the differential assembly on the converter case and measure the distance (differential measurement two) (1-2) from the differential hub to the surface of the converter housing. Refer to Fig 29.

Fig 30: Differential Measurement Three
Courtesy of CHRYSLER GROUP, LLC

NOTE:
Gauge Bar (special tool #6311, Gauge Bar) can be used for doing the following measurement.
Install the outer race for the differential side bearing and measure the distance (differential measurement three) (1-2) from the differential case to the outer race of the differential side bearing. Refer to Fig 30.
The thickness of the required select shim is calculated as follows: differential measurement one, minus differential measurement two, plus differential measurement three, plus 0.23 mm (0.009 in).

Fig 31: Select Shim AT Transaxle Case
Courtesy of CHRYSLER GROUP, LLC

CAUTION:
Do not re-use the select shim.
Install the chosen select shim (1) into the transaxle case. Refer to Fig 31.

Fig 32: Install Outer Race On Transaxle Case
Courtesy of CHRYSLER GROUP, LLC
Install the outer race (1) of the differential bearing on the transaxle case using the Installer (special tool #D-129, Installer, Bearing Cup) and Handle (special tool #C-4171, Driver Handle, Universal).

Fig 33: Install Outer Race Reduction Gear Into Converter Housing
Courtesy of CHRYSLER GROUP, LLC

Install the outer race (1) of the reduction gear bearing into the converter housing using Installer (special tool #C-4628, Installer, Cup) and Handle (special tool #C-4171, Driver Handle, Universal). Refer to Fig 33.

Fig 34: Measuring For Reduction Gear Preload Shim

Courtesy of CHRYSLER GROUP, LLC

1 - REDUCTION GEAR

2 - TRANSAXLE CASE

3 - PRELOAD SHIM

4 - BEARING OUTER RACE

The required preload on the reduction gear assembly is 0.13-0.19 mm (0.005-0.0075 in). Measure for the required preload shim (3) as follows: Refer to Fig 34.

Fig 35: Reduction Assembly Measurement One
Courtesy of CHRYSLER GROUP, LLC

NOTE:
Gauge Bar (special tool #6311, Gauge Bar) can be used for doing the following measurement.
Measure the distance (reduction assembly measurement one) (1-2) from the edge of the transaxle case to the select shim installation surface.

Fig 36: Reduction Assembly Measurement Two
Courtesy of CHRYSLER GROUP, LLC

NOTE:
Gauge Bar (special tool #6311, Gauge Bar) can be used for doing the following measurement.
Install the reduction gear assembly on the converter housing and measure the distance (reduction assembly measurement two) (1-2) from the top of the reduction gear assembly to the edge of the converter housing. Refer to Fig 36.

Fig 37: Reduction Assembly Measurement Three
Courtesy of CHRYSLER GROUP, LLC

CAUTION:
When adjusting the preload, apply CVT fluid on the bearing to make it roll smoothly. When conducting measurements, measure two or more places and calculate the average value.

NOTE:
Gauge Bar (special tool #6311, Gauge Bar) can be used for doing the following measurement.
Install the outer race of the reduction gear bearing and measure the distance (reduction assembly measurement three) (1-2) from the top of the reduction gear assembly to the outer race of the reduction gear bearing. Refer to Fig 37.
The thickness of the required select shim is calculated as follows: reduction assembly measurement one, minus reduction assembly measurement two, plus reduction assembly measurement three, plus 0.16 mm (0.006 in).

Fig 38: Select Shim AT Transaxle Case
Courtesy of CHRYSLER GROUP, LLC

CAUTION:
Do not re-use the select shim.
Install the chosen select shim (1) into the transaxle case. Refer to Fig 38.

Fig 39: Install Outer Race On Transaxle Case
Courtesy of CHRYSLER GROUP, LLC
Install the outer race (1) of the reduction gear bearing on the transaxle case using Installer (special tool #C-4628, Installer, Cup) and Handle (special tool #C-4171, Driver Handle, Universal). Refer to Fig 39.

Fig 40: Lip Seal AT The Transaxle Case
Courtesy of CHRYSLER GROUP, LLC

CAUTION:
Do not re-use the lip seal. Apply CVT fluid when installing the lip seal.
Install the new lip seal (1) on the transaxle case. Refer to Fig 40.

Fig 41: O-Ring AT The Oil Pump Mounting
Courtesy of CHRYSLER GROUP, LLC

CAUTION:
Do not re-use the o-ring. Apply CVT fluid when installing the O-ring.
Install the new o-ring (1) onto the oil pump mounting bolts. Refer to Fig 41. (Only for bolts installed from the outside of the transaxle case).

Fig 42: Oil Pump Retaining Bolts
Courtesy of CHRYSLER GROUP, LLC

NOTE:
One of the oil pump retaining bolts is installed from the outside of the transaxle case in the rear part of the oil pump.
Install the oil pump on the transaxle case. Install and tighten the mounting bolts (1) to 19 N.m (14 ft. Refer to Fig 42. lbs.) Install and tighten the mounting bolt (2) to 28 N.m (20 ft. lbs.).

Fig 43: Lip Seal AT Transaxle Case
Courtesy of CHRYSLER GROUP, LLC

CAUTION:
Do not re-use the lip seal. Apply CVT fluid when installing the lip seal.
Install the new lip seal (1) into the transaxle case. Refer to Fig 43.

Fig 44: Pin AT Manual Shaft
Courtesy of CHRYSLER GROUP, LLC
Install the manual shaft (1) into the case.
Install the pin at the manual shaft using a punch (2).
To install the valve body assembly on to the transaxle case, insert a 75 mm (3 in.) long 3 mm (0.118 in.) wide rod or wire into the linkage stopper hole of the valve body assembly to set the pulley ratio linkage in position.

Fig 45: Position Terminal Body
Courtesy of CHRYSLER GROUP, LLC
Position the locating tab (1) of the terminal body and install the terminal body into the transaxle case. Refer to Fig 45.

Fig 46: Control Valve Assembly From The
Courtesy of CHRYSLER GROUP, LLC
Install the valve body assembly (1) up from the bottom side and install it into the transaxle case. Refer to Fig 46.

Fig 47: Aligning Notch Of Pulley Ratio Linkage
Courtesy of CHRYSLER GROUP, LLC
Align the notch (1) of the pulley ratio linkage with the sheave position sensor (2). Refer to Fig 47.

Fig 48: Bushing AT The Control Valve
Courtesy of CHRYSLER GROUP, LLC

CAUTION:
Apply CVT fluid when installing the bushing.
Install the bushing (1) into the valve body assembly. Refer to Fig 48.

Fig 49: Bolts For Valve Body Assembly
Courtesy of CHRYSLER GROUP, LLC
Tighten the mounting bolts of the valve body assembly to 8 N.m (70 in. lbs).

Fig 50: Manual Lever
Courtesy of CHRYSLER GROUP, LLC
Install the manual lever (1) onto the manual shaft. Refer to Fig 50. Install and tighten the mounting nut to 22 N.m 194 in. lb.

Fig 51: Bracket AT Valve Body Assembly
Courtesy of CHRYSLER GROUP, LLC
Install the bracket (1) onto the valve body assembly. Refer to Fig 51. Install and tighten the mounting bolts to 8 N.m (70 in. lbs.).

Fig 52: Oil Strainer O - Ring
Courtesy of CHRYSLER GROUP, LLC

CAUTION:
Do not re-use the O-ring. Apply CVT fluid when installing the O-ring.
Install the new o-ring (1) onto the new oil strainer. Refer to Fig 52.

Fig 53: Oil Strainer
Courtesy of CHRYSLER GROUP, LLC
Install the new oil strainer (1) onto the valve body assembly. Refer to Fig 53. Install and tighten the mounting bolts to 8 N.m (70 in. lbs.).

Fig 54: Oil Pan Gasket
Courtesy of CHRYSLER GROUP, LLC

CAUTION:
Do not re-use the oil pan gasket. Remove any moisture, oil, and used gasket material from the surface where the new gasket is to be installed. When installing the oil pan gasket, align the dowel pin with the dowel pin hole in the oil pan gasket.
Install the oil pan gasket (1) onto the transaxle case. Refer to Fig 54.

Fig 55: Oil Pan
Courtesy of CHRYSLER GROUP, LLC

CAUTION:
When installing the oil pan, align the dowel pin of the transaxle case with the dowel pin hole of the oil pan.
Install the oil pan on the transaxle case (1). Refer to Fig 55. Install and tighten the mounting bolts to 8 N.m (70 in. lbs.).

Fig 56: Terminal Body
Courtesy of CHRYSLER GROUP, LLC
Install the snap ring (1) onto the terminal body. Refer to Fig 56.

Fig 57: Seal Rings
Courtesy of CHRYSLER GROUP, LLC

CAUTION:
Do not re-use the seal rings. Apply Vaseline or assembly lube when installing the seal rings.
Install the new seal rings (1) onto the reaction shaft support. Refer to Fig 57.

Fig 58: Reaction Shaft Support
Courtesy of CHRYSLER GROUP, LLC
Install the reaction shaft support (1) onto the transaxle case temporarily with the mounting bolts. Refer to Fig 58.

Fig 59: Baffle Plate 3
Courtesy of CHRYSLER GROUP, LLC
Install the baffle plate (1) temporarily with the mounting bolts. Refer to Fig 59.

Fig 60: Baffle Plate 2
Courtesy of CHRYSLER GROUP, LLC
Install the baffle plate (1). Refer to Fig 60. Install and tighten the mounting bolts to 6 N.m (52 in. lbs.).

Fig 61: Bracket
Courtesy of CHRYSLER GROUP, LLC
Install the bracket (1) as shown in illustration. Refer to Fig 61. Tighten the mounting bolts of the oil pump cover, baffle plate, and brackets to 26 N.m (19 in. lbs.).

Fig 62: Snap Ring AT Oil Pump
Courtesy of CHRYSLER GROUP, LLC
Install the snap ring (1) into the oil pump. Refer to Fig 62.

Fig 63: Thrust Washer AT Oil Pump Cover
Courtesy of CHRYSLER GROUP, LLC

CAUTION:
Be sure to align the pawl of the thrust washer with the alignment hole of the oil pump cover. Apply Vaseline or assembly lube when installing the thrust washer.
Install the thrust washer (1) onto the oil pump cover. Refer to Fig 63.

Fig 64: Oil Pump Chain
Courtesy of CHRYSLER GROUP, LLC

CAUTION:
When necessary to replace any of the driven sprocket, oil pump chain, or drive sprocket, replace all components as a matched set. Pull the driven sprocket up softly and check that the driven sprocket is securely installed.
Expand the snap ring (1).
Install the driven sprocket, oil pump chain (2) and drive sprocket (3).

Fig 65: Clearance Oil Pump Drive And Con
Courtesy of CHRYSLER GROUP, LLC
The required clearance for the oil pump drive sprocket is 0.10-0.23 mm (0.004-0.009 in.). Measure the clearance (1) between the oil pump drive sprocket (4) and the converter housing (5) in the following procedure: Refer to Fig 65.

Fig 66: Oil Pump Drive Sprocket Measurement One
Courtesy of CHRYSLER GROUP, LLC

NOTE:
Gauge Bar (special tool #6311, Gauge Bar) can be used for doing the following measurement.
Measure the distance (1-2) from the edge of the transaxle case to the select shim installation surface of the drive sprocket. Refer to Fig 66. This is the oil pump drive sprocket measurement one.

Fig 67: Oil Pump Drive Sprocket Measurement Two
Courtesy of CHRYSLER GROUP, LLC

NOTE:
Gauge Bar (special tool #6311, Gauge Bar) can be used for doing the following measurement.
Measure the distance (1-2) from the edge of the converter housing to the surface touching the select shim contact surface. Refer to Fig 67. This is the oil pump drive sprocket measurement two.
Calculate the thickness of the required select shim with the following formula: The select shim is equal to the oil pump drive sprocket measurement one, plus the oil pump drive sprocket measurement two, minus 0.16 mm (0.0065 in.).

Fig 68: Adjusting Shim AT Drive Sprocket
Courtesy of CHRYSLER GROUP, LLC
Install the chosen select shim (1) onto the drive sprocket. Refer to Fig 68.

Fig 69: Baffle Plate
Courtesy of CHRYSLER GROUP, LLC
Install the baffle plate (1) over the oil pump driven sprocket. Refer to Fig 69. Install and tighten the mounting nut to 6 N.m (52 in. lbs.).

Fig 70: Input Shaft O-Ring
Courtesy of CHRYSLER GROUP, LLC

CAUTION:
Do not re-use the O-ring. Apply CVT fluid when installing the O-ring.
Install the new o-ring (1) onto the input shaft. Refer to Fig 70.

Fig 71: Differential Assembly
Courtesy of CHRYSLER GROUP, LLC
Install the differential assembly (1) into the transaxle case. Refer to Fig 71.

Fig 72: Reduction Gear Assembly
Courtesy of CHRYSLER GROUP, LLC
Install the reduction gear assembly (1) into the transaxle case. Refer to Fig 72.

Fig 73: Install Converter Housing Oil Seal
Courtesy of CHRYSLER GROUP, LLC

CAUTION:
Do not re-use the converter housing oil seal (1). Apply CVT fluid when installing the converter housing oil seal (1).
Install the converter housing oil seal (1) into the converter housing with Installer (special tool #9858, Installer, Seal). Refer to Fig 73.

Fig 74: Apply Mopar Gasket Sealer
Courtesy of CHRYSLER GROUP, LLC
Apply MOPAR gasket sealer (1) on the converter housing installation surface of the transaxle case. Refer to Fig 74.
CAUTION:
Remove moisture, oil, and used sealant from the sealant application surface. Make sure that the starting point and the ending point are between two bolt holes.

Fig 75: Converter Housing Mounting Bolts
Courtesy of CHRYSLER GROUP, LLC
Install the converter housing on the transaxle case and tighten the bolts to 45 N.m (33 ft. lbs.).

Fig 76: Transmission Range Sensor
Courtesy of CHRYSLER GROUP, LLC
Install the transmission range sensor (TRS) (1) over the manual shaft and onto the transaxle case. Refer to Fig 76.

Fig 77: TRS Adjustment Tool
Courtesy of CHRYSLER GROUP, LLC

CAUTION:
Do not re-use the TRS transmission range sensor.
Put the manual shaft in the N position (3). Refer to Fig 77. Install Park Neutral Switch Adjustment Tool (special tool #9876, Adjustment Tool) (2) and adjust the position of the TRS (1).

Fig 78: Bolts AT TRS
Courtesy of CHRYSLER GROUP, LLC
Install and tighten the mounting bolts of the TRS to 6 N.m (49 in. lbs.).
Remove the TRS alignment tool from the TRS.

Fig 79: Shift Lever
Courtesy of CHRYSLER GROUP, LLC
Install the shift lever (1) onto the manual shaft. Refer to Fig 79. Install and tighten the mounting nut to 17 N.m (150 in. lbs.).

Fig 80: Input Speed Sensor O-Ring
Courtesy of CHRYSLER GROUP, LLC

CAUTION:
Do not re-use the O-ring. Apply CVT fluid when installing the O-ring.
Install the o-ring (1) onto the input speed sensor. Refer to Fig 80.

Fig 81: Input Speed Sensor
Courtesy of CHRYSLER GROUP, LLC
Install the input speed sensor (1) into the transaxle case. Refer to Fig 81. Install and tighten the mounting bolt to 6 N.m (52 in. lbs.).

Fig 82: Output Speed Sensor O-Ring
Courtesy of CHRYSLER GROUP, LLC

CAUTION:
Do not re-use the O-ring. Apply CVT fluid when installing the O-ring.
Install the new o-ring (1) onto the output speed sensor. Refer to Fig 82.

Fig 83: Output Speed Sensor
Courtesy of CHRYSLER GROUP, LLC

CAUTION:
Be sure to install the select shim between the secondary speed sensor and the converter housing before installing the secondary speed sensor.
Install the output speed sensor (1) into the converter housing. Refer to Fig 83. Install and tighten the mounting bolt to 6 N.m (52 in lbs.).

Fig 84: Fluid Filter
Courtesy of CHRYSLER GROUP, LLC

CAUTION:
Apply CVT fluid on the sealing area when installing the CVT fluid filter.
Install the CVT fluid filter (1) into the transaxle case (certain models).

Fig 85: CVT Fluid Filter O-Ring
Courtesy of CHRYSLER GROUP, LLC

CAUTION:
Do not re-use the O-ring. Apply CVT fluid when installing the O-ring.
Install the new o-ring (1) onto the CVT fluid filter.

Fig 86: Fluid Cooler
Courtesy of CHRYSLER GROUP, LLC
Install the CVT fluid cooler (1) onto the transaxle case. Refer to Fig 86. Install and tighten the mounting bolts to 4 N.m (37 in.lbs.).

Fig 87: Transmission Service Stand
Courtesy of CHRYSLER GROUP, LLC
Remove the Transmission Service Stand (special tool #9878, Stand, Transmission Service) (1) from the Belt side of the transmission case.

Fig 88: Measure Torque Converter To Transmission
Courtesy of CHRYSLER GROUP, LLC

NOTE:
Gauge Bar (special tool #6311, Gauge Bar) can be used for doing the following measurement.

NOTE:
When conducting measurements, measure two or more places and calculate the average value.
Install the torque converter on the transaxle and measure the dimension (1) to see if it is at least 13 mm. Refer to Fig 88. If the measurement is less than 13 mm, the torque converter is not fully installed.
NOTE:
Use the designated brand of CVT fluid. Use of other brands of CVT fluid other than the designated brand will deteriorate the driveability and the durability of the CVT, and will cause damage to the CVT.
Fill the transaxle with CVT fluid. Refer to FLUID, STANDARD PROCEDURE .