6F24 Automatic Transmission (Service Information): Assembly: Fwd

NOTE:

Thoroughly clean all components to remove metallic and fibrous materials that may have contaminated the transaxle during a component failure.

NOTE:

Inspect all components for excessive ware, spalled surfaces, or other obvious damage. Replace only damaged components that are serviceable with genuine Mopar Parts.

NOTE:

Not before assembling the transaxle, measure the Low-Reverse Brake and adjust if necessary. If the housing, differential, or the driven transfer gear was replaced, it will necessary to the establish proper bearing turning torque. If just the bearings are replaced it is not necessary to measure turn to torque valves. Refer to STANDARD PROCEDURES .

Fig 1: Transfer Drive Assembly

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Place the transfer drive assembly (1) into position in the transaxle case.

Fig 2: Transfer Drive Assembly & Bolts
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Install three bolts (2) to hold transfer drive assembly (1) to the transaxle housing. Refer to SPECIFICATIONS .
Install NEW inside and outside D-ring seals into the low & reverse brake piston (1).
Using specified transaxle fluid, lubricate the low & reverse brake piston (1) D-ring seals.

Fig 3: Low/Reverse Brake Piston
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Place low & reverse brake piston (1) in position in transaxle housing.
Push low & reverse brake piston downward into cylinder bore in the transaxle housing.

Fig 4: Low/Reverse Brake Piston Spring Retainer
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Place low & reverse brake piston spring retainer in position on the lo-reverse brake piston.

Fig 5: Special Tool #5058A-3
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(special tool #5058A-3, Screw, Forcing)

Fig 6: Special Tool #8621
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(special tool #8621, Compressor, Spring)

Fig 7: Special Tool #5058A-3
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Install spring compressor tools in position on transaxle.
Insert screw through center hole in spring compressor 8621. Insert the screw through the transfer gear and into the threaded cross bar across the bell housing opening.

Fig 8: Compressing Low/Reverse Spring Retainer
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Compress the low/reverse spring retainer.

Fig 9: Low/Reverse Brake Spring Retainer Snap Ring
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Install the snap ring (1) to hold the low/reverse brake spring retainer to the low/reverse brake piston.

Fig 10: Front Annulus Gear
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Place the front annulus gear (1) in position in the low/reverse brake assembly.

Fig 11: Front Annulus Gear Thrust Bearing And Race
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Place the front annulus gear thrust bearing and race (1) in position on the front annulus gear (2) hub.

Fig 12: Front Planetary Gear & Front Annulus Gear Assembly
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Place the front planetary gear (1) in position on the front annulus gear assembly (2).

Fig 13: Front Sun Gear
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Insert the front sun gear (1) into front planetary gear assembly.

Fig 14: Planetary Gear Hub Bearing And Race Set
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Place the bearing (2) and race (1) set in position on the planetary gear hub.

Fig 15: Middle Sun Gear & Planetary Gear Hub
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Insert the middle sun gear (1) in position in the in position on the front sun gear (2).

Fig 16: Front Planetary Gear Hub Thrust Washer
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Place the thrust washer (1) in position on the front planetary gear hub.

Fig 17: Middle/Rear Planetary Gear Assembly
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Place the middle/rear planetary gear assembly (1) in position in the planetary gear hub.

Fig 18: Rear Annulus Gear

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Place the rear annulus gear (1) in position on the middle/rear planetary gear assembly.

Fig 19: Rear Annulus Gear & Snap Ring
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Install the snap ring (2) to hold the rear annulus gear (1) into the front annulus gear hub.

Fig 20: Middle/Rear Planetary Gear Snap Ring
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Insert the snap ring into the groove in the middle/rear planetary gear.

Fig 21: One Way Clutch Inner Race
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Place the one way clutch inner race (1) in position on the middle/rear planetary gear.

Fig 22: One Way Clutch Race & Snap Ring
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Using long nose pliers (3), compress snap ring (1) to hold the one way clutch race (2) to the middle/rear planetary gear.

Fig 23: Low & Reverse Brake Pressure Plate, Cushion Plate, Plates, Discs, & Reaction Plate
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Install the low & reverse brake pressure plate (1), cushion plate (2), plates 3) discs (4), and the reaction plate (5), in order, into the transaxle.

Fig 24: Low/Reverse Brake & Snap Ring
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Install the snap ring (1) to hold low/reverse brake into the lowest snap ring land (2) in the transaxle.

Fig 25: One-Way-Clutch
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Lining up the two narrow lugs on the OWC to the two narrow slots on the transaxle housing insert the OWC (1) into the transaxle. Press down until it is seated. The OWC should rotate in a counterclockwise direction only.

Fig 26: One-Way-Clutch Snap Ring
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Install the snap ring (1) to hold the OWC to the transaxle housing
Turn transaxle over to gain access to the front of the transaxle.

Fig 27: Transfer Driven Gear Assembly & Transaxle
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Install the transfer driven gear (1) assembly in position in the transaxle (2).

Fig 28: Park Sprag Support Shaft & Transaxle Housing
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Install the park sprag support shaft (1) in position in the transaxle housing.

Fig 29: Park Sprag & Transaxle Housing
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Insert the park sprag (1) in position in the transaxle housing.

Fig 30: Park Sprag Spring, Shaft & Transaxle Housing
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Install the park sprag spring and shaft (1) in position in the transaxle housing.

Fig 31: Park Sprag Spring & Park Sprag
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Using a suitable hook tool (1), lift the park sprag spring (2) onto the park sprag.

Fig 32: Park Rod Guide & Bolts
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Install bolts to hold the park rod guide (1) in position on the transaxle housing.

Fig 33: Underdrive Brake Retainer & Transaxle Housing
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Place the underdrive brake retainer (2) in position on the transaxle housing (1).

Fig 34: Underdrive Brake Retainer & Bolts
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Install bolts (2) to hold the underdrive brake retainer (1) to the transaxle housing. Refer to SPECIFICATIONS .

Fig 35: Underdrive Brake Chamber & Transaxle Housing
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Place the underdrive brake chamber in position on the transaxle housing.

Fig 36: Underdrive Brake Chamber & Bolts
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Install bolts (1) to hold the underdrive brake chamber (2) to the transaxle housing. Refer to SPECIFICATIONS .

Fig 37: Underdrive Brake Piston & Location Tabs
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Install
NEW

D-ring outer seal and the O-ring inner seal in the lands on the underdrive piston.
Install the underdrive brake piston (1) in position on the underdrive brake piston chamber.
NOTE:
The location tabs (2) on the underdrive brake piston should be oriented toward the valve body opening in the transaxle.

Fig 38: Underdrive Spring Retainer & Underdrive Brake Piston
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Push underdrive brake piston (3) downward until it seats in the underdrive brake chamber.
Place the underdrive spring retainer (1) in position on the underdrive brake piston (2).

Fig 39: Tool Bolt & Tool Cross Bar
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Insert the bolt (3) for tool 5058A through tool 10426
Insert the tool bolt (3) with the spring compressor through the center of the transaxle (1) and out the back into the threaded center bore of the tool cross bar (2) spanning the back of the transaxle.

Fig 40: Tool 5058A & Tool 10426
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(special tool #5058A-3, Screw, Forcing)

Fig 41: Special Tool #5058A-3
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(special tool #10426, Compressor, Underdrive Spring)

Fig 42: Special Tool #10426
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Compress the underdrive springs (3) to gain access to the snap ring land.

Fig 43: Underdrive Spring Plate Snap Ring
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Install the snap ring (1) to hold the underdrive spring plate to the underdrive brake hub.
Remove the spring compressor tool from the transaxle.
Turn the transaxle over to gain access to the rear cover.

Fig 44: Thrust Bearing, Race Set & Middle/Rear Planetary Gear Assembly
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Place the thrust bearing (1) and race set into of the center of the middle/rear planetary gear assembly (2).

Fig 45: Thrust Washer & Planetary Gear Assembly Hub
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Place the thrust washer (1) in position on the middle/rear planetary gear.

Fig 46: Overdrive Clutch Assembly & One Way Clutch
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Install the overdrive clutch assembly (1) onto the one way clutch race (2).

Fig 47: Thrust Bearing & Overdrive Clutch Hub Assembly
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Install thrust bearing (1) onto the overdrive clutch hub (2) assembly with the rollers facing upward.

Fig 48: Transfer Port Seals
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Install the four seals (2) into transfer ports in transaxle housing.

Fig 49: Split Seal Rings & Rear Cover Hub
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Install the two split seal ring seals (2) into the lands in the rear cover (1) hub.

Fig 50: Selective Spacer, Bearing & Rear Cover
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Using assembly lube applied in the seat area of the rear cover (3), Install the selective spacer (1) onto the rear cover (2).
Apply a 3 mm (0.120 in.) bead of Dupont® Loctite™ 5460 Pink Flange Sealant or equivalent around the perimeter of the rear cover.

Fig 51: Rear Cover Separated From Transaxle
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Place the rear cover (1) in position on the transaxle.

Fig 52: Transaxle Rear Cover & Bolts
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Install bolts to hold the rear cover (1) to the transaxle. Refer to SPECIFICATIONS .
Turn transaxle over to gain access to the underdrive brake.

Fig 53: Underdrive Brake Plates, Discs & Drum
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Place underdrive brake plates and discs in position in underdrive brake drum.

Fig 54: Underdrive Brake, Underdrive Brake Drum, & Large Snap Ring
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Install large snap ring (3) to hold underdrive brake (1) into the underdrive brake drum.

Fig 55: Underdrive Brake Hub
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Install underdrive brake hub (1) assembly in position on transaxle.

Fig 56: Underdrive Brake Hub & Thrust Washer
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Install thrust washer (2) in position on the underdrive brake hub.

Fig 57: 3/5/R Clutch & 2/6 Brake Hub Assembly
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Install the 3/5/R clutch and 2/6 brake hub (1) assembly in position on the underdrive clutch.

Fig 58: 3/5/R Clutch & 2/6 Brake Hub, Thrust Bearing
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Install the thrust bearing (2) in position on the 3/5/R clutch and 2/6 brake hub.

Fig 59: 3/5/R Clutch Assembly, 3/5/R & 2/6 Brake Hub Assembly
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Install the 3/5/R clutch assembly (1) in position in the 3/5/R and 2/6 brake hub (2) assembly.

Fig 60: 2/6 Brake Select Thickness Reaction Plate & Hub
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Install 2/6 brake select thickness reaction plate (1) in position in the 2/6 brake hub.

Fig 61: 2/6 Brake Plates, Discs & Hub
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Install the 2/6 brake alternating the (1) plates (3) and discs (2) in position in the 2/6 brake hub.

Fig 62: 2/6 Brake Wave Plate & Hub
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Install 2/6 brake wave plate (1) in position in the 2/6 brake hub.

Fig 63: Split Ring Seals & Input Shaft
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Install two split ring seals (2) in the seal lands (2) in the input shaft (1).

Fig 64: Split Seal Rings & Fluid Pump Hub
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Install two split seal rings (3) in the lands (2) in fluid pump (1) hub.

Fig 65: Thrust Washer & Fluid Pump
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Apply a 3 mm (0.120 in.) bead of Dupont® Loctite™ 5460 Pink Flange Sealant or equivalent around the perimeter of the fluid pump sealing surface.
Using assembly lube, install the plastic thrust washer (2) in position on the underside of the fluid pump (1). There are three nubs that insert into holes in the fluid pump hub to prevent the thrust washer from rotating.

Fig 66: Fluid Pump Separated From Transaxle Housing
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Place the fluid pump (2) in position on the transaxle housing (1).

Fig 67: Fluid Pump & Bolts
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Install bolts (1) to hold fluid pump (3) to the trans axle housing (2). Refer to SPECIFICATIONS .
Install NEW o-ring seal in position in the groove in the fluid pump housing.

Fig 68: Fluid Filter Separated From Transaxle Housing
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Place the fluid filter (2) in position in the transaxle housing (1).

Fig 69: Fluid Filter, Fluid Pump & Bolts
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Install bolts (1) to hold the fluid filter to the fluid pump (3) housing. Refer to SPECIFICATIONS .

Fig 70: Small Transfer Port Seals
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Install seals in position in four small transfer ports (2) in the transaxle housing (1).

Fig 71: Large Transfer Port Seal
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Install seal in position in the large transfer port (1) in the axle housing (2).

Fig 72: Differential Assembly Separated From Transaxle Housing
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Place the differential assembly in position in the transaxle housing.
Apply a 3 mm (0.120 in.) bead of Dupont® Loctite™ 5460 Pink Flange Sealant or equivalent around the perimeter of the transaxle housing.

Fig 73: Bell Housing Separated From Transaxle
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If fluid guides and tube were removed during cleaning, install related components in the transaxle housing. Refer to SPECIFICATIONS .
Place the bell housing (1) in position on the transaxle (2).

Fig 74: Inside Bell Housing Bolts
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Install five bolts (1) on inside of the bell housing (2). Refer to SPECIFICATIONS .

Fig 75: Transaxle Housing & Bottom Bolts
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Install six bolts in the bottom (2) of the transaxle housing (1). Refer to SPECIFICATIONS .

Fig 76: Transaxle Housing & Bolts
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Install five bolts in the back (3) and five bolts in the top (2) of the transaxle housing (1). Refer to SPECIFICATIONS .

Fig 77: Park Rod & Park Rod Guide
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If seal required replacement, install the
NEW

lip seal in the manual shaft hole in the transaxle housing.
Insert the park rod (1) into the park rod guide.

Fig 78: Manual Shaft, Park Rod & Key Hole Slot
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Insert the manual shaft (1) into the bearing in the transaxle.
Push manual shaft (1) upward until park rod (2) engages the detent comb.
Rotate manual shaft (1) clockwise to lock the staked nub on the park rod (2) in the key hole slot (3) in the manual shaft detent comb.

Fig 79: Manual Shaft & Pin
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Install the pin (2) to hold the manual shaft (1) in the transaxle into the hole in the pan gasket flange.

Fig 80: Main Wire Harness & Sensors
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Place the main wire harness and sensors (1) in position on the transaxle.
Push the wire connector outward through to hole in the transaxle housing.

Fig 81: Wire Connector & Hold Down Bracket Separated From Transaxle
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Place the wire connector (1) hold down bracket (2) in position on the transaxle.

Fig 82: Hold Down Bracket, Wire Connector & Bolts
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Install bolt to hold the wire connector (1) hold down bracket (2) to the top of transaxle housing. Refer to SPECIFICATIONS .
Insert the speed sensors in position in the transaxle housing.

Fig 83: Speed Sensors, Main Wire Harness & Bolts
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Install bolts (1) to hold the speed sensors and main wire harness to transaxle. Refer to SPECIFICATIONS .

Fig 84: Transfer Port Seals
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Install the two seals into the transfer ports in transaxle housing.

Fig 85: Valve Body Separated From Transaxle
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The manual valve is loose after the valve body is removed and may fall out during installation.
Place the valve body (2) in position on the transaxle (1). Guide the pin on the manual valve into the slot in the manual shaft detent comb.

Fig 86: Valve Body Bolts
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Install bolts, 7 short (1) and 1 long (2) bolts, to hold the valve body to the transaxle. Refer to SPECIFICATIONS .

Fig 87: Detent Spring Separated From Valve Body
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Place the detent spring (2) in position on the valve body (1).

Fig 88: Manual Shaft Detent Spring & Valve Body
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Install the screw to hold the manual shaft detent spring (1) to the valve body (2). Refer to SPECIFICATIONS .

Fig 89: Solenoids & Connector
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Starting at the top solenoid valve, push inward at each solenoid (2) until the connector (3) is engaged.

Fig 90: Solenoid Valve Connector, Valve Body & Bolts
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Install bolts to hold the solenoid valve connector (2) to the valve body (1). Refer to SPECIFICATIONS .

Fig 91: Fluid Temperature Sensor, Valve Body & Bolt
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Insert the temperature sensor (1) into port in the valve body (2).
Install bolt to hold fluid temperature sensor (1) to the valve body (2). Refer to SPECIFICATIONS .

Fig 92: Valve Body Cover Separated From Transaxle
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Install a NEW gasket on the pan and place the pan (1) in position on the transaxle (2).

Fig 93: Valve Body Cover
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Install bolts to hold the valve body pan (2) to the transaxle (1). Refer to SPECIFICATIONS .

Fig 94: Cooler Tubes & Transaxle
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Place the cooler tubes (2) in position on the transaxle (1).
Install bolt to hold the cooler tube (2) bracket to the transaxle (1). Refer to SPECIFICATIONS .

Fig 95: Cooler Tubes & Banjo Bolts
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Install banjo bolts (2) to hold the cooler tubes (1) to the transaxle. Refer to SPECIFICATIONS .

Fig 96: Vent Tube Bracket & Bolt
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Place the vent tube (3) in position on the transaxle (1).
Install bolt to hold the vent tube bracket (2) to the transaxle housing. Refer to SPECIFICATIONS .

Fig 97: Vent Hose End & Nipple Adapter
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Push the vent hose end (1) onto of the nipple on the vent adaptor (2).

Fig 98: Vent Hose, Spring Clamp & Pliers
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Using common pliers (3), compress the hose spring clamp (2) and slide it up the vent hose (1) into position to hold the hose to the nipple.

Fig 99: Transmission Range Sensor Separated From Transaxle
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Place the TRS (1) in position on the transaxle.

Fig 100: Transmission Range Sensor
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Install bolts to hold the TRS (1) to the transaxle housing. Refer to SPECIFICATIONS .

Fig 101: Manual Lever & Manual Shaft
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Place the manual level (1) in position on the manual shaft.

Fig 102: Pin Punch, Manual Lever & Transmission Range Sensor
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Insert a suitable pin punch (2) or equivalent through the manual lever into the TRS switch (1) to hold lever in place.
Install the nut to hold the manual lever to the manual shaft. Refer to SPECIFICATIONS .

NOTE:

The transaxle can now be installed in a vehicle. Refer to INSTALLATION .