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

NOTE:

If the transaxle has not been drained before removal, fluid will spill from the valve body pan as it is removed.

Fig 1: Pin Punch, Manual Lever & Transmission Range Sensor
GC0154992Courtesy of CHRYSLER GROUP, LLC
  1. Insert a suitable pin punch (2) or equivalent through the manual lever into the TRS switch (1) to hold lever in place.
  2. Remove nut holding the manual lever to the manual shaft.
    Fig 2: Manual Lever & Manual Shaft
    GC0154877Courtesy of CHRYSLER GROUP, LLC
  3. Separate the manual level (1) from the manual shaft.
    Fig 3: Transmission Range Sensor
    GC0154904Courtesy of CHRYSLER GROUP, LLC
  4. Remove bolts holding the TRS (1) to the transaxle housing.
    Fig 4: Transmission Range Sensor Separated From Transaxle
    GC0154994Courtesy of CHRYSLER GROUP, LLC
  5. Separate the TRS (1) from the transaxle.
    Fig 5: Vent Hose, Spring Clamp & Pliers
    GC0154882Courtesy of CHRYSLER GROUP, LLC
  6. Using common pliers (3), compress the hose spring clamp (2) and slide it down the vent hose (1) away from the nipple adaptor.
    Fig 6: Vent Hose End & Nipple Adapter
    GC0154806Courtesy of CHRYSLER GROUP, LLC
  7. Pull the vent hose end (1) off of the nipple adaptor (2).
    Fig 7: Vent Tube Bracket & Bolt
    GC0154826Courtesy of CHRYSLER GROUP, LLC
  8. Remove bolt holding the vent tube bracket (2) to the transaxle housing.
  9. Separate the vent tube (3) from the transaxle (1).
    Fig 8: Cooler Tubes & Banjo Bolts
    GC0154866Courtesy of CHRYSLER GROUP, LLC
  10. Remove banjo bolts (2) holding the cooler tubes (1) to the transaxle.
    Fig 9: Cooler Tubes & Transaxle
    GC0154921Courtesy of CHRYSLER GROUP, LLC
  11. Remove bolt holding the cooler tube (2) bracket to the transaxle (1).
  12. Separate the cooler tubes from the transaxle.
    Fig 10: Valve Body Cover
    GC0154832Courtesy of CHRYSLER GROUP, LLC
  13. Position the transaxle over a suitable drain pan.
  14. Remove bolts holding the valve body cover (2) to the transaxle (1).
    Fig 11: Valve Body Cover Separated From Transaxle
    GC0154952Courtesy of CHRYSLER GROUP, LLC
  15. Separate the cover (1) from the transaxle (2).
    Fig 12: Fluid Temperature Sensor, Valve Body & Bolt
    GC0154725Courtesy of CHRYSLER GROUP, LLC
  16. Remove bolt holding fluid temperature sensor (1) to the valve body (2).
  17. Pull temperature sensor (1) straight out of the port in the valve body (2).
    Fig 13: Solenoid Valve Connector, Valve Body & Bolts
    GC0154964Courtesy of CHRYSLER GROUP, LLC
  18. Remove bolts holding the solenoid valve connector (2) to the valve body (1).
    Fig 14: Solenoids & Connector
    GC0154751Courtesy of CHRYSLER GROUP, LLC
  19. Starting at the bottom solenoid valve, using a suitable prying tool, pry outward at each solenoid (2) until the connector (3) is disengaged.
    Fig 15: Manual Shaft Detent Spring & Valve Body
    GC0154835Courtesy of CHRYSLER GROUP, LLC
  20. Remove the screw holding the manual shaft detent spring (1) to the valve body (2).
    Fig 16: Detent Spring Separated From Valve Body
    GC0154950Courtesy of CHRYSLER GROUP, LLC
  21. Separate the detent spring (2) from the valve body (1).
    Fig 17: Valve Body Bolts
    GC0154944Courtesy of CHRYSLER GROUP, LLC
  22. Remove bolts, 7 short (1) and 1 long (2) bolts, holding the valve body to the transaxle. The manual valve is loose after the valve body is removed and may fall out during removal. 
    Fig 18: Valve Body Separated From Transaxle
    GC0154718Courtesy of CHRYSLER GROUP, LLC
  23. Separate the valve body (2) from the transaxle (1).
    Fig 19: Transfer Port Seals
    GC0154989Courtesy of CHRYSLER GROUP, LLC
  24. Remove the two seals from the transfer ports in transaxle housing.
    Fig 20: Speed Sensors, Main Wire Harness & Bolts
    GC0154768Courtesy of CHRYSLER GROUP, LLC
  25. Remove bolts (1) holding the speed sensors and main wire harness to transaxle.
  26. Separate the speed sensors and main wire harness from the transaxle.
    Fig 21: Hold Down Bracket, Wire Connector & Bolts
    GC0154894Courtesy of CHRYSLER GROUP, LLC
  27. Remove bolt holding the wire connector (1) hold down bracket (2) to the top of transaxle housing.
    Fig 22: Wire Connector & Hold Down Bracket Separated From Transaxle
    GC0154956Courtesy of CHRYSLER GROUP, LLC
  28. Separate the wire connector (1) hold down bracket (2) from the transaxle.
    Fig 23: Pushing Wire Connector Into Housing
    GC0154970Courtesy of CHRYSLER GROUP, LLC
  29. Push the wire connector (1) inward to the inside of the transaxle housing.
    Fig 24: Main Wire Harness & Sensors
    GC0154834Courtesy of CHRYSLER GROUP, LLC
  30. Separate the main wire harness and sensors (1) from the transaxle.
    Fig 25: Manual Shaft, Pin & Magnet
    GC0154815Courtesy of CHRYSLER GROUP, LLC
  31. Using a suitable magnet (2), remove the pin (3) holding the manual shaft (1) in the transaxle from the hole in the pan gasket flange.
    Fig 26: Manual Shaft, Park Rod & Key Hole Slot
    GC0154756Courtesy of CHRYSLER GROUP, LLC
  32. Rotate manual shaft (1) counterclockwise to align the staked nub on the park rod (2) with the key hole slot (3) in the manual shaft detent comb.
  33. Push manual shaft (1) downward until park rod (2) disengages form the detent comb.
  34. Push the manual shaft (1) inward to the inside of the transaxle.
  35. Separate the manual shaft (1) from the transaxle.
    Fig 27: Park Rod & Park Rod Guide
    GC0154937Courtesy of CHRYSLER GROUP, LLC
  36. Disengage the park rod (1) from the park rod guide (2) in the transaxle housing.
  37. Separate the park rod (1) from the transaxle.
  38. Using a suitable tool, remove the lip seal from the manual shaft hole in the transaxle housing.
    Fig 28: Transaxle Housing & Bolts
    GC0154703Courtesy of CHRYSLER GROUP, LLC
  39. Remove five bolts from the back (3) and five bolts from the top (2) of the transaxle housing (1).
    Fig 29: Transaxle Housing & Bottom Bolts
    GC0154857Courtesy of CHRYSLER GROUP, LLC
  40. Remove six bolts from the bottom (2) of the transaxle housing (1).
    Fig 30: Inside Bell Housing Bolts
    GC0154974Courtesy of CHRYSLER GROUP, LLC
  41. Remove five bolts (1) from inside bell housing (2).
    Fig 31: Notch Locations At Top Of Case For Prying Case Halves Apart
    GC0154924Courtesy of CHRYSLER GROUP, LLC
  42. Using a suitable pry bar, pay the case halves apart in notch (2) location on top of the housing (1).
    Fig 32: Notch Locations At Bottom Of Case For Prying Case Halves Apart
    GC0154706Courtesy of CHRYSLER GROUP, LLC
  43. Pry the case halves apart in notch location (2) on the bottom of the housing (1).
    Fig 33: Bell Housing Separated From Transaxle
    GC0154905Courtesy of CHRYSLER GROUP, LLC
  44. Separate the bell housing (1) from the transaxle (2).
  45. Remove bolts holding the fluid guide to the transaxle housing.
  46. Separate the fluid guide from the transaxle.
  47. Remove bolts holding the lubrication tube to the transaxle.
  48. Separate the lubrication tube from the transaxle.
    Fig 34: Differential Assembly Separated From Transaxle Housing
    GC0154803Courtesy of CHRYSLER GROUP, LLC
  49. Separate the differential assembly (1) from the transaxle housing (2).
    Fig 35: Small Transfer Port Seals
    GC0154737Courtesy of CHRYSLER GROUP, LLC
  50. Remove seals from four small transfer ports (2) in the transaxle housing (1).
    Fig 36: Large Transfer Port Seal
    GC0154704Courtesy of CHRYSLER GROUP, LLC
  51. Remove seal from the large transfer port (1) in the axle housing (2).
    Fig 37: Fluid Filter, Fluid Pump & Bolts
    GC0154738Courtesy of CHRYSLER GROUP, LLC
  52. Remove bolts (1) holding the fluid filter to the fluid pump (3) housing.
    Fig 38: Fluid Filter Separated From Transaxle Housing
    GC0154880Courtesy of CHRYSLER GROUP, LLC
  53. Separate the fluid filter (2) from the transaxle housing (1).
    Fig 39: Fluid Pump Housing O-Ring Seal & Hook Tool
    GC0154752Courtesy of CHRYSLER GROUP, LLC
  54. Using a suitable hook tool (1), remove o-ring seal (4) from the groove (3) in the fluid pump housing (3).
    Fig 40: Fluid Pump & Bolts
    GC0154818Courtesy of CHRYSLER GROUP, LLC
  55. Remove bolts (1) holding fluid pump (3) to the trans axle housing (2).
    Fig 41: Fluid Pump Separated From Transaxle Housing
    GC0154732Courtesy of CHRYSLER GROUP, LLC
  56. Separate the fluid pump (2) from the transaxle housing (1).
    Fig 42: Thrust Washer & Fluid Pump
    GC0154789Courtesy of CHRYSLER GROUP, LLC
  57. Remove the plastic thrust washer (2) from 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 43: Split Seal Rings & Fluid Pump Hub
    GC0154878Courtesy of CHRYSLER GROUP, LLC
  58. Remove two split seal rings (3) from land-grooves (2) in fluid pump (1) hub.
    Fig 44: Split Ring Seals & Input Shaft
    GC0154914Courtesy of CHRYSLER GROUP, LLC
  59. Remove two split ring seals (2) from the input shaft (1).
    Fig 45: 2/6 Brake Wave Plate & Hub
    GC0154787Courtesy of CHRYSLER GROUP, LLC
  60. Remove 2/6 brake wave plate (1) from 2/6 brake hub.
    Fig 46: 2/6 Brake Plates, Discs & Hub
    GC0154782Courtesy of CHRYSLER GROUP, LLC
  61. Remove the 2/6 brake (1) plates (3) and discs (2) from the 2/6 brake hub.
    Fig 47: 2/6 Brake Select Thickness Reaction Plate & Hub
    GC0154698Courtesy of CHRYSLER GROUP, LLC
  62. Remove 2/6 brake select thickness reaction plate (1) from the 2/6 brake hub.
    Fig 48: 3/5/R Clutch Assembly, 3/5/R & 2/6 Brake Hub Assembly
    GC0154925Courtesy of CHRYSLER GROUP, LLC
  63. Remove the 3/5/R clutch assembly (1) from the 3/5/R and 2/6 brake hub (2) assembly.
    Fig 49: 3/5/R Clutch & 2/6 Brake Hub, Thrust Bearing
    GC0154786Courtesy of CHRYSLER GROUP, LLC
  64. Remove the thrust bearing (2) from the 3/5/R clutch and 2/6 brake hub. Mark the side toward 3/5/R clutch and 2/6 brake hub on bearing for installation orientation.
    Fig 50: 3/5/R Clutch & 2/6 Brake Hub Assembly
    GC0154743Courtesy of CHRYSLER GROUP, LLC
  65. Remove the 3/5/R clutch and 2/6 brake hub (2) assembly from the underdrive brake.
    Fig 51: Underdrive Brake Hub & Thrust Washer
    GC0154726Courtesy of CHRYSLER GROUP, LLC
  66. Remove thrust washer (2) from underdrive brake hub.
    Fig 52: Underdrive Brake Hub
    GC0154997Courtesy of CHRYSLER GROUP, LLC
  67. Remove underdrive brake hub (1) assembly from transaxle.
    Fig 53: Underdrive Brake, Underdrive Brake Drum, & Large Snap Ring
    GC0154908Courtesy of CHRYSLER GROUP, LLC
  68. Remove large snap ring (3) holding underdrive brake (1) into underdrive brake drum.
    Fig 54: Underdrive Brake Plates, Discs & Drum
    GC0154788Courtesy of CHRYSLER GROUP, LLC
  69. Separate underdrive brake plates and discs from underdrive brake drum.
  70. Turn the transaxle over to gain access to the rear cover.
    Fig 55: Transaxle Rear Cover & Bolts
    GC0154792Courtesy of CHRYSLER GROUP, LLC
  71. Remove bolts holding the rear cover (1) to the transaxle.
    Fig 56: Prying Locations At Rear Cover
    GC0154707Courtesy of CHRYSLER GROUP, LLC
  72. In three locations (1) on the rear cover, pry upward using a suitable pry bar (3).
    Fig 57: Rear Cover Separated From Transaxle
    GC0154715Courtesy of CHRYSLER GROUP, LLC
  73. Separate the rear cover (1) from the transaxle.
    Fig 58: Selective Spacer, Bearing & Rear Cover
    GC0154717Courtesy of CHRYSLER GROUP, LLC
  74. Remove the selective spacer (3) and bearing (1) from under rear cover (2).
    Fig 59: Split Seal Rings & Rear Cover Hub
    GC0154863Courtesy of CHRYSLER GROUP, LLC
  75. Remove the two split seal rings (2) from the lands in the rear cover (1) hub.
    Fig 60: Transfer Port Seals In Transaxle Housing
    GC0154902Courtesy of CHRYSLER GROUP, LLC
  76. Using a suitable hook tool (1), Remove the four seals (2) from transfer ports in transaxle housing.
    Fig 61: Thrust Bearing & Overdrive Clutch Hub Assembly
    GC0154812Courtesy of CHRYSLER GROUP, LLC
  77. Remove thrust bearing from the overdrive clutch hub assembly.
    Fig 62: Overdrive Clutch Assembly & One Way Clutch
    GC0154770Courtesy of CHRYSLER GROUP, LLC
  78. Remove the overdrive clutch assembly (1) from the one way clutch (2).
    Fig 63: Thrust Washer & Planetary Gear Assembly Hub
    GC0154849Courtesy of CHRYSLER GROUP, LLC
  79. Remove the plastic thrust washer (1) from the planetary gear assembly hub.
    Fig 64: Thrust Bearing, Race Set & Middle/Rear Planetary Gear Assembly
    GC0154777Courtesy of CHRYSLER GROUP, LLC
  80. Using a suitable hook tool, lift the thrust bearing (1) and race set out of the center of the middle/rear planetary gear assembly (2).
  81. Turn transaxle over to gain access to the underdrive springs.
    Fig 65: Tool 5058A & Tool 10426
    GC0154727Courtesy of CHRYSLER GROUP, LLC
  82. Insert the bolt for tool 5058A through tool 10426.
    Fig 66: Tool Bolt & Tool Cross Bar
    GC0154973Courtesy of CHRYSLER GROUP, LLC
  83. Insert the tool bolt with the spring compressor through the center of the transaxle and out the back into the threaded center bore of the tool cross bar spanning the back of the transaxle. Compress the underdrive springs (3) to gain access to the snap ring.
    Fig 67: Special Tool #5058A-3
    GC0140812Courtesy of CHRYSLER GROUP, LLC

    (special tool #5058A-3, Screw, Forcing)

    Fig 68: Special Tool #10426
    GC0157184Courtesy of CHRYSLER GROUP, LLC

    (special tool #10426, Compressor, Underdrive Spring)

    Fig 69: Underdrive Spring Plate Snap Ring
    GC0154809Courtesy of CHRYSLER GROUP, LLC
  84. Remove the snap ring holding the underdrive spring plate to the underdrive brake hub.
    Fig 70: Underdrive Spring Retainer & Underdrive Brake Piston
    GC0154780Courtesy of CHRYSLER GROUP, LLC
  85. Remove the spring compressor tool from the transaxle.
  86. Separate the underdrive spring retainer (1) from the underdrive brake piston (2).
    Fig 71: Underdrive Brake Piston & Underdrive Brake Chamber
    GC0154934Courtesy of CHRYSLER GROUP, LLC
  87. Using a suitable pick tool (2) lift the underdrive brake piston (3), in several locations, from the underdrive brake chamber.
    Fig 72: Underdrive Brake Piston & Location Tabs
    GC0154927Courtesy of CHRYSLER GROUP, LLC
  88. Remove the underdrive brake piston (1) from 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.

  89. Remove the D-ring outer seal and the O-ring inner seal from the underdrive piston.
    Fig 73: Underdrive Brake Chamber & Bolts
    GC0154799Courtesy of CHRYSLER GROUP, LLC
  90. Remove bolts (1) holding the underdrive brake chamber (2) to the transaxle housing.
    Fig 74: Underdrive Brake Chamber & Transaxle Housing
    GC0154969Courtesy of CHRYSLER GROUP, LLC
  91. Separate the underdrive brake chamber from the transaxle housing.
    Fig 75: Underdrive Brake Retainer & Impact Driver
    GC0154795Courtesy of CHRYSLER GROUP, LLC
  92. Mark the location and direction of the underdrive brake retainer in relation to the bolt holes in the transaxle housing to ensure proper installation.
  93. Using an impact driver (1), loosen the bolts holding the underdrive brake retainer (2) to the transaxle housing without damaging the Torx® drive heads.
    Fig 76: Underdrive Brake Retainer & Bolts
    GC0154932Courtesy of CHRYSLER GROUP, LLC
  94. Remove bolts (2) holding the underdrive brake retainer (1) to the transaxle housing.
    Fig 77: Underdrive Brake Retainer & Transaxle Housing
    GC0154851Courtesy of CHRYSLER GROUP, LLC
  95. Separate the underdrive brake retainer (2) from the transaxle housing (1).
    Fig 78: Park Rod Guide & Bolts
    GC0154963Courtesy of CHRYSLER GROUP, LLC
  96. Remove bolts holding the park rod guide (1) from the transaxle housing.
    Fig 79: Park Sprag Spring & Park Sprag
    GC0154739Courtesy of CHRYSLER GROUP, LLC
  97. Using a suitable hook tool (1), lift the park sprag spring (2) off the park sprag.
    Fig 80: Park Sprag Spring & Shaft
    GC0154811Courtesy of CHRYSLER GROUP, LLC
  98. Remove the park sprag spring and shaft (1) from the transaxle housing.
    Fig 81: Park Sprag & Transaxle Housing
    GC0154709Courtesy of CHRYSLER GROUP, LLC
  99. Separate the park sprag (1) from the transaxle housing.
    Fig 82: Park Sprag Support Shaft & Transaxle Housing
    GC0154958Courtesy of CHRYSLER GROUP, LLC
  100. Remove the park sprag support shaft (1) from the transaxle housing.
    Fig 83: Transfer Driven Gear Assembly & Transaxle
    GC0154907Courtesy of CHRYSLER GROUP, LLC
  101. Remove the transfer driven gear (1) assembly from the transaxle (2).
  102. Turn the transaxle over to gain access to the One-way-clutch.
    Fig 84: One-Way-Clutch Snap Ring
    GC0154800Courtesy of CHRYSLER GROUP, LLC
  103. Remove the snap ring (1) holding the OWC to the transaxle housing.
    Fig 85: One-Way-Clutch
    GC0154781Courtesy of CHRYSLER GROUP, LLC
  104. Separate the OWC (1) from the transaxle. Mark the one way clutch to aid installation orientation.
    Fig 86: Low/Reverse Brake & Snap Ring
    GC0154700Courtesy of CHRYSLER GROUP, LLC
  105. Remove the snap ring (2) holding low/reverse brake into transaxle.
    Fig 87: One Way Clutch Race & Snap Ring
    GC0154860Courtesy of CHRYSLER GROUP, LLC
  106. Separate the low & reverse brake pressure plate, cushion plate and discs and plates, in order, from transaxle.
  107. Compress snap ring (1) holding one way clutch race (2) into transaxle.
    Fig 88: One Way Clutch Inner Race
    GC0154702Courtesy of CHRYSLER GROUP, LLC
  108. Separate the one way clutch inner race (1) from the transaxle.
    Fig 89: Rear Annulus Gear & Snap Ring
    GC0154912Courtesy of CHRYSLER GROUP, LLC
  109. Remove the snap ring (2) holding the rear annulus gear (1) into transaxle.
    Fig 90: Rear Annulus Gear
    GC0154888Courtesy of CHRYSLER GROUP, LLC
  110. Separate the rear annulus gear (1) from the transaxle.
    Fig 91: Middle/Rear Planetary Gear Assembly
    GC0154764Courtesy of CHRYSLER GROUP, LLC
  111. Separate the middle/rear planetary gear assembly (1) and from the planetary gear hub.
    Fig 92: Front Planetary Gear Hub Thrust Washer
    GC0154724Courtesy of CHRYSLER GROUP, LLC
  112. Remove the thrust washer (1) from front planetary gear hub.
    Fig 93: Middle Sun Gear & Planetary Gear Hub
    GC0154926Courtesy of CHRYSLER GROUP, LLC
  113. Separate the middle sun gear (1) from the planetary gear hub (2).
    Fig 94: Planetary Gear Hub Bearing And Race Set
    GC0154916Courtesy of CHRYSLER GROUP, LLC
  114. Remove the bearing (2) and race (1) set from the planetary gear hub.
    Fig 95: Front Sun Gear
    GC0154945Courtesy of CHRYSLER GROUP, LLC
  115. Separate the front sun gear (1) from front planetary gear assembly.
    Fig 96: Front Planetary Gear & Front Annulus Gear Assembly
    GC0154755Courtesy of CHRYSLER GROUP, LLC
  116. Separate the front planetary gear (1) the front annulus gear assembly (2).
    Fig 97: Front Annulus Gear Thrust Bearing And Race
    GC0154745Courtesy of CHRYSLER GROUP, LLC
  117. Separate the front annulus gear thrust bearing and race from the front annulus gear hub,
    Fig 98: Front Annulus Gear
    GC0154848Courtesy of CHRYSLER GROUP, LLC
  118. Separate the front annulus gear (1) from the low/reverse brake assembly.
    Fig 99: Installing Special Tool #5058A-3
    GC0154830Courtesy of CHRYSLER GROUP, LLC
  119. Insert through center hole in Insert the screw through the transfer gear and into the threaded cross bar across the bell housing opening.
    Fig 100: Special Tool #5058A-3
    GC0140812Courtesy of CHRYSLER GROUP, LLC

    (special tool #5058A-3, Screw, Forcing)

    Fig 101: Special Tool #8621
    GC0139576Courtesy of CHRYSLER GROUP, LLC

    (special tool #8621, Compressor, Spring)

    Fig 102: Compressing Low/Reverse Spring Retainer
    GC0154839Courtesy of CHRYSLER GROUP, LLC
  120. Compress the low/reverse spring retainer.
    Fig 103: Low/Reverse Brake Spring Retainer Snap Ring
    GC0154773Courtesy of CHRYSLER GROUP, LLC
  121. Remove snap ring holding low/reverse brake spring retainer to the low/reverse brake piston.
  122. Remove spring compressor tools from transaxle.
    Fig 104: Low/Reverse Brake Piston Spring Retainer
    GC0154699Courtesy of CHRYSLER GROUP, LLC
  123. Remove low & reverse brake piston spring retainer.
    Fig 105: Low/Reverse Brake Piston
    GC0154825Courtesy of CHRYSLER GROUP, LLC
  124. Separate low & reverse brake piston (1) from the transaxle housing.
  125. Remove inside and outside D-ring seals from the low & reverse brake piston (1).
    Fig 106: Transfer Drive Assembly & Bolts
    GC0154947Courtesy of CHRYSLER GROUP, LLC
  126. Remove bolts (2) holding transfer drive assembly (1) to the transaxle housing.
    Fig 107: Transfer Drive Assembly
    GC0154760Courtesy of CHRYSLER GROUP, LLC
  127. Remove the transfer drive assembly (1) from the transaxle case
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