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TRANSMISSION AND TRANSFER CASE

1. HolviniNn2ov 7 6 3AIHOHSAO f 5 LNOHJ OAH3S uvau GION3 IOS HONH3AOS 2 TRANSMISSION AND TRANSFER CASE SCHEMATICS AND DIAGRAMS Continued 21 226 15414 3AIHG NI MO TH Ol TOVHGAH LuHVd 15915 3AIHQ H3A31 HOLO3 13S yaris 10 NOLIVOIHSITI OL ANOYOL ONIIALL d 15 201 JAVA HOLMS MA j N3du5s sd 0 3unssadud TIl3 3u d 3AIHQHU3AO FATWA 1 GIONTIOS 2008 106 86580 AHOH3AO NOILOnS JAYA isd 5 agr H31H3ANOO SATVA ONIMLL 7 6 3KTVA LAIHS 2 1 Qc HONH3AOD 3 gt JAYA HE t isd op oL dunssaud ATLLOYHL OCA NS 5 JAYA JILLNHS NX 5 JILLOHHL isd 8 0 3unssdud UONHJAOD isd 97 02 J3unssaud INI HOJVITINTIOOV 2 6 JAYA JILLOHHL
2. CES 2 H3lHdANOD anouolr 1NOUJ E T E SNIVA 15008 SS TOS ci aon ES ib J N3duos SATVA IOH LNOO 141 8 2 1 AANO F ij 1 T FATWA LAIHS 6 2 M dolvinWnoov v HOLN19 WoivinWnoov OAH3S LNOHJ OAH3S HOLN19 GION3TIOS HONH3AOD HONH3AOD we 21 225 TRANSMISSION AND TRANSFER CASE 2 SCHEMATICS AND DIAGRAMS Continu
3. GION3 IOS YONYAA0D 2 TRANSMISSION AND TRANSFER CASE SCHEMATICS AND DIAGRAMS Continued 21 106 isd 8 0 3unssadud TII3 38d NOILONS 9 6 3unssaud dH31H3ANOO isd 76 0 55 JILLOHYHL 3dnssaqud HONH3AOS isd v6 25 3unsSaud 03 1997 21112 H31H3ANOO HV39 GHIHL 3AIHG NI MO TH 33400 Nn O L uv39 que NI HOLO3 3S SATVA d i74201 FATWA GIONdIOS 105 FATWA 5 t E SATVA ONIIALL 7 6 1 19 OL JAVA 15008 S SAWANMOCMODI SS FATWA TOHLNOD LAIHS 8 1 SATVA JILLNHS ATLLOYWHL 3ATVA HOLfTIO LNOYS OAYAS uvau 5 1 4 U31HJANOO 3n0u01 5 IMIYA 3ATVA L3IHS 2 1 N Orrid HONH3JAOD TEENS S 3ATVA L3IHS 6 0 Orid J31LLOHHL oMd HONH3AOD GION3 IOS HONHJAOD 21 107 TRANSMISSION AND TRANSFER CASE 2 SCHEMATICS AND DIAGRAMS Continued 9 isd 0 0 3unssaud 3901 dH31H3ANOO NOILOnS isd 001 0 dunssaud ATLLOYHL isd 09 0 3un
4. uaria 10 1 3998 27 GION310S 1 7 0 7 Md Tu 1 7 6 JILLOHYHL 1 6 uvau OAYAS 1 uvad 5 HONH3AOS HONH3AOD 21 112 TRANSMISSION AND TRANSFER CASE SPECIFICATIONS TRANSMISSION GENERAL 0 127 1 22 0 005 0 048 Component Planetary end play Input shaft end play Clutch pack clearance Front Clutch pack clearance Rear Front Clutch mm in 0 56 2 31 0 022 0 091 mm in 1 70 0 067 0 134 3 40mm in 0
5. H LNT H31H3ANOO HY39 3AIHG NI MOTA DITINVYGAH Q393201 O L uV39 3AIHQH3AO NI HOLO3 13S JAYA d 14001 INYA 2 1 GION310S dfi4201 105 3ATVA LIIHS 1 6 IAA 3 6 vE TEM v 3AIHQH3AO NOILVOIHS TI JAVA HOLIMS SATVA 18008 S S SWNASILLOHHL 5 FU SANANMOCDIODI JAVA TOH LNOO LAIHS 2 1 3ATVA 3 1LLOHS Ond 31L108HL 1 OAH3S LNOHA OAH3S Hari 110 aNDYOL N33H9S S3ATVA 3ATVA 141 5 2 1 S HONH3AOS JAVA L3IHS c Orid JILLOHHL HOLN19 uvad GION3TIOS HONH3AOD 2 TRANSMISSION AND TRANSFER CASE SCHEMATICS AND DIAGRAMS Continued 21 232 98PpIdqeog isd 8 0 3unssaud Til3 3ud 3AIlHQd3AO NOILONS isd 3unssaud H31H3ANOO isd 08 0 3unssdud YONYAAOD isd 86 60 LAIHS 8 1 52520 isd 29 49 3unssaud L MOT JILLOYHL 935019 15914 H3A31 HOLO3TI3S FATWA ONIIALL 201 SATVA dr 4001 aioNaTos dfM201 10S FATWA 1JIHS
6. Hv3d GION3 IOS HONH3AOS 103 21 TRANSMISSION AND TRANSFER CASE 2 SCHEMATICS AND DIAGRAMS Continued 154914 3AIHG NI MO TH Ol TOVHGAH LuHVd 15915 43441 HOLO3 13S yaris 10 NOLIVOIHSITI HOLN19 OL ANOYOL ONIALL dN 1907 JAVA HOLMS MA j N3du5s isd 5 0 3unssadud TIl3 3u d 3AIHQU3AO FATWA d 4201 GIONTIOS 00 106 86580 AHOH3AO NOILOnS JAYA isd 5 agr H31H3ANOO SATVA ONIMLL 7 6 3KTVA LAIHS 2 1 Qc HONH3AOD 3 2 JAYA Til MOIDIO HE isd op 01 dunssaud ATLLOYHL OCA NS 5 JAYA FILLNHS NS SS FTLLOYHL isd 8 0 3unssdud UONHJAOD isd 97 02 J3unssaud HOLVINWNDOV 2 6 JAYA JILLOHHL 2 a Sa HOLMIO Hv3H 1 Go HOLN190 1 HOL TIO GION3 IOS HONH3AOS OAH3S 6 LNOH4 2 TRANSMISSION AND TRANSFER CASE SCHEMATICS AND DIAGRAMS Continued 2
7. PINION J9321 385 Fig 20 Speedometer Pinion Adapter Components INSTALLATION 1 Thoroughly dean adapter flange and adapter mounting surface in housing Surfaces must be dean for proper adapter alignment and speedometer oper ation 2 Install new O rings on speed sensor and speed ometer adapter if necessary Fig 20 3 Lubricate sensor and adapter O rings with transmission fluid 4 Install vehide speed sensor in speedometer adapter Tighten sensor attaching screw to 2 3 N m 15 27 in lbs torque 5 Install speedometer pinion in adapter 6 Count number of teeth on speedometer pinion Do this before installing assembly in housing Then lubricate pinion teeth with transmission fluid 7 Note index numbers on adapter body Fig 21 These numbers will correspond to number of teeth on pinion 8 Install speedometer assembly in housing 9 Rotate adapter until required range numbers are at 6 o dock position Be sure range index num bers correspond to number of teeth on pinion gear 10 Install speedometer adapter damp and retain ing screw Tighten damp screw to 10 12 90 110 105 torque 11 Connect wires to vehicle speed sensor 12 Lower vehicle and top off transmission fluid level if necessary SPEEDOMETER ADAPTER INDEX NUMBER LOCATION 39321 386 Fig 21 Index Numbers Speedometer Pinion Adapter PARK NEUTRAL POSITION SWITCH REMOVAL 1 Raise
8. 3unss3ud NI DITINVYGAH JILLOYHL 9385012 dvd H3A31 HOLO3 T3S NOLLVOIHB TI OL 1 1 FATWA d 174001 HOLIMS Naduos 15008 l 11223 d 151201 GIONTIOS 105 AHQu3AO JAIA LJIHS 3ATVA TVONVIA ONIINLL t E 3ATVA TOH LNOO LAIHS 8 1 JAVA L3IHS 2 1 ond HONHJAOD TI rE JATA 3 LEOHS JAVA 141 8 6 2 JILLOYHL E 3ATVA FTLLOYHL ON 1d HONH3AOD n YOLVINANDOV v 5 uvad HOLN19 1 HOLN19 105 5 LNOu3 2 TRANSMISSION AND TRANSFER CASE SCHEMATICS AND DIAGRAMS Continued 21 224 41p49208 NOILOnS 69 29 3unssaud 39101 aALYAANOD isd 69 26 3unssaud TVYLNAN MO TH ATLLOYHL Q3SO IO TIVGLLO3N H3A31HOL9313S NOILvOIBBITI HOLMIO ENIIALL 1
9. 5 1 4 U31HJANOO 3n0u01 5 IMIYA 3ATVA L3IHS 2 1 N Orrid HONH3AOD TENG S 3ATVA L3IHS 6 0 Orid J31LLOHHL GION3 IOS YONYAA0D 21 229 TRANSMISSION AND TRANSFER CASE 2 SCHEMATICS AND DIAGRAMS Continued a3r1ddv 21112 H31H3ANOO HV39 3AIHG NI MO TH 33400 Nn 9 1 uv39o que NI HOLO3 3S SATVA d i 4201 54 8 0 3unssdud TII3 38d FATWA 01 4105 df343201 105 3ATVA 141 5 NOILONS isd 9 6 3unssaud d31H3ANOO SATVA ONIIALL 7 6 isd 76 0 55 SATLLOYHL 3unssaqud HONH3AOS isd 6 6 3unsSaud 1 19 OL JAVA 15008 S SAWANMOCMODI xy FATWA TOHLNOD LAIHS 8 1 SATVA JILLNHS 3ILLOHHL 3ATVA H LNTO LNOYS 5 LNOH4 OAYAS uvau U31HJANOO 3n0u01 5 IMIYA 3ATVA L3IHS 2 1 N Orrid HONH3JAOD TEENS S 3ATVA L3IHS 6 0 Orid J31LLOHHL GION3 IOS YONYAA0D 2 TRANSMISSION AND TRANSFER CASE SCHEMATICS AND D
10. 35 26 ft Ibs Bolts U J 19 17 ft Ibs 41 1RANSMISSION AND TRANSFER CASE 21 269 SPECIAL TOOLS SPECIAL TOOLS NV242 Puller Slinger MD 998056 A Installer C 4076 B Ml Installer MD 998323 Handle Universal C 4171 Installer Bearing 5064 v G Remover C 4210 S Installer 8128 21 270 TRANSMISSION AND TRANSFER CASE 7 SPECIAL TOOLS Continued Installer 5066 Installer Input Gear Bearing 7829 A Installer 6952 A Remover L 4454 m Cup 8148 SS Installer Bearing 8033 A Seal Protector 6992 Installer Seal 7884 Installer Pump Housing Seal 7888 Installer Boot Clamp C 4975 A 2 TRANSMISSION AND TRANSFER CASE 21 271 NV249 TRANSFER CASE INDEX page page GENERAL INFORMATION IBANSEER CASH 273 mIRC 271 DISASSEMBLY AND ASSEMBLY RECOMMENDED LUBRICANT AND 249 DIAGNOSIS 272 ERONT OUTPUT SHAET SEAU ENT P 274 BEAR RETAINER BUSHING AND SEAL 275 vim Paw ee ee 273 PTT 273 GENERAL INFORMATION GENERAL INFORM ATION The NV249 Fig 1 is an on demand 4 wheel drive transfer case with two operating ranges and a neu tral position Operating ranges are 4 high and 4 low The 4 low range is used for extra pulling power in off road
11. 2 a Sa Oo HOLMIO Hv3H 1 Go HOLN19 LNOYS HOL TIO GION3 IOS HONH3AOS 6 LNOH4 OAH3S 21 227 TRANSMISSION AND TRANSFER CASE SCHEMATICS AND DIAGRAMS Continued 2 aNOOHS NI DITINVYGAH Jd 1LLOHHL 5 NI H3A31 1 135 uario NOLIVOIHB TI isd 0 H3lHdANOO ANOYOL OL 3AIHQH3AO 3HnsSsdud i SATA ENIILL NOILLONS E O GION310S isd 1
12. 6952 79 2 N KY 226 ET Y 5 SPACER we TRANSFER CASE 80298363 80a50353 Fig 11 Slinger Stop Spacer and Snap ring 4 Remove rear seal from retainer Fig 12 Use pry tool or collapse seal with punch to remove it j S all Q TRANSFER CASE IX 2 Fig 9 Output Boot Typical 2 Using puller M D 998056 A remove rear slinger Fig 10 Fig 12 Rear Seal Removal 3 Remove slinger stop spacer and snap ring from output shaft Fig 11 SPECIAL TOOL MD998056 A REAR RETAINER OUTPUT SHAFT SEAL 80 50354 5 Remove rear output bearing 1 0 retaining ring Fig 13 TRANSFER CASE REAR BEARING 1 0 RETAINING RING 80a50352 80010964 Fig 10 Rear Slinger Removal Fig 13 Rear Bearing I D Retaining Ring Removal 2 DISASSEMBLY AND ASSEMBLY Continued 6 Remove speedometer adapter 7 Remove rear retainer bolts 8 Remove rear retainer Tap retainer with mallet and pry upward to break sealer bead Then slide retainer off case and output shaft Fig 14 REAR RETAINER 80010965 Fig 14 Rear Retainer Removal 9 Remove rear bearing O D retaining ring with snap ring pliers Then tilt pump and slide it off out put shaft Fig 15 80010966 Fig 15 Oil Pump Removal 10 Remove pickup tube O ring from pump Fig 16 but do not disassemble pump it is not a repair able part
13. z E tn 7 ke E 22 1 7 mE 18208 _ B JAYA HOLWINDAY EL DN CT SA INVA 1 6 FE 1 2 LY nnn T N D EE an 1JIHS 2 1 NOILONS dnd AANO F 7 T FATWA LAIHS 6 2 M isd 69 29 3unssaud 39101 aALYAANOD JATA HONH3AOD isd 69 26 3unssaud 7 6 HOLN19 HOLN19 OAUaS HONH3ACO 2 TRANSMISSION AND TRANSFER CASE SCHEMATICS AND DIAGRAMS Continued 21 102 8 isd 01 96 3unssaud dH31H3ANOO isd 001 06 IMYA JILLOYHL OL 563 ANIT isd 07 62 13IHS 8 1 isd 0 3unssaud JILLOHYHL SN ST isd 022 091 3unssaud 3SH3A3H NI Ol T
14. V wee PRESSURE SOLENOID PRESSURE SOLENOID RETAINER GOVERNOR 80315866 Fig 25 Pressure Solenoid VALVE BODY The valve body can be removed for service without having to remove the transmission assembly The valve body can be disassembled for deaning and inspection of the individual components Refer to 2 REMOVAL AND INSTALLATION Continued PRESSURE SOLENOID 2 2 LE 80315867 Fig 26 Pressure Solenoid O ring BN ae y C30 GOVERNOR SE 0 J BODY GASKET Fig 27 Governor Body and Gasket RETAINING CLIP 80315868 GOVERNOR BODY GOVERNOR PRESSURE SENSOR TRANSMISSION FLUID TEMPERATURE THERMISTOR 80a0c4fa Fig 28 Pressure Sensor and Disassembly and Assembly section for proper proce dures The only replaceable valve body components are e Manual lever TRANSMISSION AND TRANSFER CASE 21 35 Manual lever washer seal E dip and shaft seal Manual lever detent ball e Throttle lever Fluid filter Pressure adjusting screw bracket Governor pressure solenoid Governor pressure sensor e Converter clutch overdrive solenoid assembly and harness includes sump temperature thermistor e Governor housing gasket e Solenoid case connector O rings The remaining valve body components are serviced only as part of a complete valve body assembly REMOVAL 1 Shift transmission into NEUTRAL 2 Ra
15. 1 iy CLUTCH DRUM SPECIAL TOOL J9321 363 Fig 210 Direct Clutch Hub Retaining Ring Removal 2 SPECIAL TOOL DIRECT CLUTCH HUB DIRECT CLUTCH PACK J9321 365 Fig 211 Direct Clutch Pack Removal Geartrain 1 Remove direct clutch hub and spring Fig 212 2 Remove sun gear and spring plate Then remove planetary thrust bearing and planetary gear Fig 213 DIRECT DIRECT CLUTCH CLUTCH SPRING HUB J9121 311 Fig 212 Direct Clutch Hub And Spring Removal 3 Remove overrunning dutch assembly with expanding type snap ring pliers Fig 214 Insert pliers into dutch hub Expand pliers to grip hub splines and remove clutch with counterclockwise twisting motion 4 Remove thrust bearing from overrunning dutch hub 5 Remove overrunning clutch from hub 6 Mark position of annulus gear and direct clutch drum for assembly alignment reference Fig 215 Use small center punch or scriber to make alignment marks 2 DISASSEMBLY AND ASSEMBLY Continued PLANETARY PLANETARY CLUTCH GEAR THRUST SPRING BEARING PLATE SPRING PLATE SNAP RING J9121 312 Fig 213 Removing Sun Gear Thrust Bearing And Planetary Gear OVERRUNNING CLUTCH NEEDLE BEARING 8921 248 Fig 214 Overrunning Clutch Assembly Removal Installation DIRECT 8921 249 PUNCH Fig 215 Marking Direct Clutch Drum And Annulus Gear For Assembly Alignment TRANSMISSION AND TRANSFER CASE 21 205 7
16. 11 Remove seal from oil pump with pry tool 12 Remove bolts attaching rear case to front case Fig 17 Note position of the two black finish bolts at each end of the case These bolts go through the case dowels and require a washer under the bolt head 13 Remove rear case from front case Fig 18 Insert screwdrivers into slots cast into each end of case Then pry upward to break sealer bead and remove rear case CAUTION Do not pry on the sealing surface of either case half as the surfaces will become dam aged TRANSMISSION AND TRANSFER CASE 21 247 OIL PUMP O RING RR21F27 Fig 16 Pickup Tube O Ring Location SPLINE HEAD BOLT 1 CASE BOLT 5 DOWEL BOLT AND WASHER 2 410 A Fig 17 Spline And Dowel Bolt Locations SCREWDRIVER 80010969 SCREWDRIVER Fig 18 Loosening Removing Rear case 14 Remove oil pickup tube and screen from rear case Fig 19 21 248 TRANSMISSION AND TRANSFER CASE 2 DISASSEMBLY AND ASSEMBLY Continued 53 6 PICKUP PICKUP YOKE TUBE SCREEN 80010979 80010977 Fig 19 Oil Pickup Screen Hose And Tube Removal Fig 21 Yoke Removal YOKE AND RANGE LEVER REMOVAL SECTOR 1 Remove front yoke nut a Move range lever to 4L position b Remove nut with socket and impact wrench Fig 20 IMPACT WRENCH 80010943 Fig 22 Range Lever Removal OY AL
17. 30 Remove low reverse drum snap ring Fig 103 31 Remove low reverse drum and reverse band 32 Remove overrunning clutch roller and spring assembly as a unit Fig 104 GEARTRAIN AO AND INTERMEDIATE SHAFT ASSEMBLY 19121 217 Fig 102 Removing Planetary Intermediate Shaft Assembly LOW REVERSE DRUM OVERDRIVE PISTON RETAINER LOW REVERSE DRUM SNAP RING J9121 351 Fig 103 Removing Low Reverse Drum Snap Ring 33 Compress front servo rod guide about 1 8 inch with Valve Spring Compressor C 3422 B Fig 105 34 Remove front servo rod guide snap ring Exercise caution when removing snap ring Servo bore can be scratched or nicked if care is not exercised 35 Remove compressor tools and remove front servo rod guide spring and servo piston 2 DISASSEMBLY AND ASSEMBLY Continued c 7777 OVERRUNNING CLUTCH CLUTCH ASSEMBLY J9121 222 Fig 104 Overrunning Clutch Assembly Removal SPRING COMPRESSOR TOOL C 3422 B QUIDE SNAP RING 9121 136 Fig 105 Compressing Front Servo Rod Guide 36 Compress rear servo spring retainer about 1 16 inch with Valve Spring Compressor C 3422 B Fig 106 37 Remove rear servo spring retainer snap ring Then remove compressor tools and remove rear servo spring and piston 38 Inspect transmission components NOTE TO SERVICE THE OVERRUNNING CLUTCH CAM OR OVERDRIVE PISTON RETAINER REFER TO OVERRUN
18. 4 N m 35 in Ibs Bolt valve body to case 12 N m 100 in Ibs 21 236 TRANSMISSION AND TRANSFER CASE 2 SPECIFICATIONS Continued THRUST WASHER SPACER SNAP RING DIMENSIONS Front clutch thrust washer reaction shaft 1 55 mm 0 061 in support hub 2 15 mm 0 084 in 0 102 in Rear clutch thrust washer clutch retainer 1 55 mm 0 061 in Output shaft thrust plate output shaft pilot hub 1 5 1 6 mm 0 060 0 063 in Output shaft thrust washer rear clutch hub 1 3 1 4 mm 0 052 0 054 in 1 75 1 8 mm 0 068 0 070 in 2 1 2 2 mm 0 083 0 085 in Rear clutch pack snap ring 1 5 1 6 mm 0 060 0 062 in 1 9 1 95 mm 0 074 0 076 in Planetary geartrain snap ring 1 4 1 5 mm 0 055 0 059 in at front of output shaft 1 6 1 7 mm 0 062 0 066 in Overdrive piston thrust plate Thrust plate and spacer are select fit components Refer to size charts and Intermediate shaft spacer selection procedures in Overdrive Unit disassembly and assembly section PRESSURE TEST Overdrive clutch Fourth gear only Pressure should be 469 496 kPa 68 72 psi with closed throttle and increase to 620 896 kPa 90 130 psi at 1 2 to 3 4 throttle Line pressure at Closed throttle 372 414 kPa 54 60 psi accumulator Third gear only No more than 21 kPa 3 psi lower than line pressure 3 psi Rear servo 1 range No more than 21 kPa 3 psi lower than line pressure range 1103 kPa 160 psi at idle bu
19. 8 Install front bearing retainer Fig 67 Tighten retainer bolts to 16 ft Ibs 21 torque FRONT BEARING RETAINER 18921 276 Fig 67 Installing Front Bearing Retainer 21 260 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued SHIFT FORKS AND MAINSHAFT INSTALLATION 1 Install new sector shaft O ring and bushing Fig 68 NS Fig 68 Sector O Ring Bushing Installation 2 Install shift sector 3 Install new pads on low range fork if neces sary Fig 69 4 Assemble low range fork and hub Fig 69 5 Position low range fork and hub in case Be sure low range fork pin is engaged in shift sector slot Fig 70 J8921 278 Fig 69 Assembling Low Range Fork And Hub 4 J8921 263 Fig 70 Positioning Low Range Fork 6 Install first mainshaft bearing spacer on main shaft Fig 71 7 Install bearing rollers on mainshaft Fig 71 Coat bearing rollers with generous quantity of petroleum jelly to hold them in place 8 Install remaining bearing spacer on mainshaft Fig 71 Do not displace any bearings while install ing spacer MAINSHAFT BEARING ROLLERS BEARING SPACERS 18921 282 Fig 71 Installing Mainshaft Bearing Rollers Spacers 2 ___ TRANSMISSION AND TRANSFER CASE 21 261 DISASSEMBLY AND ASSEMBLY Continued 9 Install differential Fig 72 Do not displace mains
20. LOW RANGE GEAR SNAP RING J8921 267 Fig 40 Input Gear Snap Ring Removal 4 Remove input low range gear assembly from 19221 20 Ped Tool Handle C 4171 and Tool 7829A Fig 42 Low Range Gear Snap Ring Removal Installation 5 Remove low range gear snap ring Fig 42 6 Remove input gear retainer thrust washers THRUST WASHERS and input gear from low range gear Fig 43 SPECIAL TOOL C 4171 SPECIAL TOOL INPUT LOW LOW RANGE RANGE GEARS GEAR RETAINER J8921 214 Fig 41 Input And Low Range Gear Assembly Fig aa Lon Range Goar DISASSEmOY Removal 7 Inspect low range annulus gear Fig 44 Gear is not a serviceable component If damaged replace gear and front case as assembly 8 Remove oil seals from following components e front bearing retainer e rear retainer e oil pump e case halves 21 254 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued LOW RANGE ANNULUS GEAR 8921 270 Fig 44 Inspecting Low Range Annulus Gear DIFFERENTIAL DISASSEMBLY 1 Mark differential case halves for reference 2 Remove differential case bolts 3 Invert differential on workbench 4 Separate top case from bottom case Use slots in case halves to pry them apart Fig 45 5 Remove thrust washers and planet gears from case pins Fig 46 6 Remove mainshaft and sprocket gears from bottom case Fig 47 Note gear position for reference before separati
21. Shift Valve Flow Control The manual valve is operated by the gearshift link age and provides the operating range selected by the driver The 1 2 shift valve provides 1 2 or 2 1 shifts and the 2 3 shift valve provides 2 3 or 3 2 shifts The kickdown valve provides forced 3 2 or 3 1 downshifts depending on vehicle speed Downshifts occur when the throttle is opened beyond downshift detent position Detent is reached just before wide open throttle position The 2 3 valve throttle pressure plug provides 3 2 downshifts at varying throttle openings depending on vehicle speed The 1 2 shift control valve transmits 1 2 shift pres sure to the accumulator piston This controls kick down band capacity on 1 2 upshifts and 3 2 downshifts The 3 4 shift quick fill and timing valves plus the 3 4 accumulator are only actuated when the over drive solenoid is energized The solenoid contains a check ball that controls a vent port to the 3 4 valves The check ball either diverts line pressure away from or directly to the 3 4 valves The limit valve determines maximum speed at which a 3 2 part throttle kickdown can be made On TRANSMISSION AND TRANSFER CASE 21 7 transmissions without a limit valve maximum speed for a 3 2 kickdown is at detent position The 2 3 shuttle valve has two functions The first is fast front band release and smooth engagement during lift foot 2 3 upshifts The second is to regulate front dutch and band application
22. 4 Install retainer to hold pressure sensor to gov ernor body 5 Place gasket in position on back of governor body Fig 27 6 Place governor body in position on valve body 2 7 Install bolts to hold governor body to valve body 8 Lubricate O ring on pressure solenoid with transmission fluid 9 Align pressure solenoid to bore in governor body Fig 26 10 Push solenoid into governor body 11 Place solenoid retainer in position on governor Fig 25 12 Install screws to hold pressure solenoid retainer to governor body 13 Engage wire connectors into pressure sensor and solenoid Fig 24 14 Install transmission fluid pan and new filter 15 Lower vehicle and road test to verify repair V wee PRESSURE SOLENOID PRESSURE SOLENOID RETAINER GOVERNOR 80315866 Fig 25 Pressure Solenoid VALVE BODY The valve body can be removed for service without having to remove the transmission assembly The valve body can be disassembled for deaning and inspection of the individual components Refer to 2 REMOVAL AND INSTALLATION Continued PRESSURE SOLENOID 2 2 LE 80315867 Fig 26 Pressure Solenoid O ring BN ae y C30 GOVERNOR SE 0 J BODY GASKET Fig 27 Governor Body and Gasket RETAINING CLIP 80315868 GOVERNOR BODY GOVERNOR PRESSURE SENSOR TRANSMISSION FLUID TEMPERATURE
23. Fig 137 Front Servo REAR SERVO PISTON DISASSEMBLY 1 Remove small snap ring and remove plug and spring from servo piston Fig 138 2 Remove and discard servo piston seal ring TRANSMISSION AND TRANSFER CASE 21 65 ASSEMBLY 1 Lubricate piston and guide seals with petro leum jelly Lubricate other servo parts with ATF Plus 3 Type 7176 transmission fluid 2 Install new seal ring on servo piston 3 Assemble piston plug spring and new snap ring 4 Lubricate piston seal lip with petroleum jelly SNAP PISTON PISTON SPRING SNAP RING SEAL PLUG RETAINER RING 5 2 3 CUSHION PISTON PISTON SPRING SPRING 19121 64 Fig 138 Rear Servo Components OIL PUMP AND REACTION SHAFT SUPPORT DISASSEMBLY 1 Remove seal ring from housing and reaction shaft support Fig 139 2 Mark pump housing and support assembly for alignment reference 3 Remove bolts attaching pump body to support Fig 140 PUMP HOUSING SEAL RING Fig 139 Removing Pump Seal Ring 4 Separate support from pump housing Fig 141 5 Remove inner and outer gears from reaction shaft support Fig 142 6 If pump seal was not removed during transmis sion disassembly remove seal with punch and ham mer 7 Remove front dutch thrust washer from sup port hub Fig 143 21 66 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued REACTION g SHAFT SUPPORT 80a483e7
24. 176 193 194 211 212 19121 341 Fig 243 Intermediate Shaft End Play Spacer Selection OD THRUST PLATE SELECTION 1 Place overdrive unit in vertical position Mount it on blocks or in workbench with appropriate size mounting hole cut into it Be sure unit is facing upward for access to direct clutch hub Also be sure output shaft is not loaded and internal components are moved rearward for accurate measurement 2 Determine correct thickness overdrive piston thrust plate as follows a Position Gauge Tool 6311 across face of over drive case Then position Dial Caliper C 4962 over gauge tool Fig 244 b Measure distance to clutch hub thrust bear ing seat at four points 90 apart Then average measurements by adding them and dividing by 4 c Select and install required thrust plate from information in thrust plate chart Fig 245 3 Leave Alignment Tool 6227 2 in place Tool will keep planetary and clutch hub splines in alignment 2 until overdrive unit is ready for installation on trans mission 4 Transmission speed sensor can be installed at this time if desired However it is recommended that sensor not be installed until after overdrive unit is secured to transmission SPECIAL 215 TOOLCM962 DIRECT CLUTCH HUB THRUST BEARING SEAT SPECIAL TOOL 6311 J9221 48 Fig 244 Overdrive Piston Thrust Plate Measurement Spacer Thickness Inches End Play Measurement
25. 800010957 Fig 20 Yoke Nut Removal 2 Remove yoke If yoke is difficult to remove by hand remove it with bearing splitter or with stan dard two jaw puller Fig 21 Be sure puller tool is positioned on yoke and not on slinger as slinger will be damaged 3 Remove seal washer from front output shaft Discard washer as it should not be reused 4 Remove nut and washer that attach range lever to sector shaft Then move sector to neutral position and remove range lever from shaft Fig 22 RING J8921 251 FRONT OUTPUT SHAFT AND DRIVE CHAIN REMOVAL 1 Remove drive sprocket snap ring Fig 23 Fig 23 Drive Sprocket Snap Ring Removal 2 Remove drive sprocket and chain Fig 24 3 Remove front output shaft Fig 25 2 DISASSEMBLY AND ASSEMBLY Continued DRIVE DA SPROCKET 18921 252 Fig 24 Drive Sprocket And Chain Removal NB V dl 18921 253 Fig 25 Removing Front Output Shaft SHIFT FORKS AND MAINSHAFT REMOVAL AND DISASSEMBLY 1 Remove shift detent plug spring and pin Fig 26 2 Remove seal plug from low range fork lockpin access hole Then move shift sector to align low range fork lockpin with access hole 3 Remove range fork lockpin with size number one easy out tool as follows a Insert easy out tool through access hole in side of transfer case and into lock pin TRANSMISSION AND TRANSFER C
26. Correct valve body pressure adjustments as required 6 TPS Malfunction 6 Replace sensor check with DRB scan tool 7 PCM Malfunction 7 Check with DRB scan tool and replace if required 8 Valve Body Malfunction 8 Repair sticking 1 2 2 3 shift valves governor plugs 3 4 solenoid 3 4 shift valve 3 4 timing valve 21 20 TRANSMISSION AND TRANSFER CASE 2 DIAGNOSIS AND TESTING Continued CONDITION POSSIBLE CAUSES CORRECTION STUCK IN LOW GEAR 1 Throttle Linkage Misadjusted 1 Adjust linkage and repair linkage if worn or WILL NOT UPSHIFT Stuck damaged Check for binding cable or missing return spring 2 Gearshift Linkage Misadjusted 2 Adjust linkage and repair linkage if worn or damaged 3 Governor Component Electrical 3 Check operating pressures and test with Fault DRB scan tool repair faulty component 4 Front Band Out of Adjustment 4 Adjust Band 5 Clutch or Servo Malfunction 5 Air pressure check operation of clutches and bands Repair faulty component CREEPS IN NEUTRAL 1 Gearshift Linkage Misadjusted 1 Adjust linkage 2 Rear Clutch Dragging Warped 2 Disassemble and repair 3 Valve Body Malfunction 3 Perform hydraulic pressure test to determine cause and repair as required BUZZING NOISE 1 Fluid Level Low 1 Add fluid and check for leaks 2 Shift Cable Misassembled 2 Route cable away from engine and bell housing 3 Valve Body Misassembled 3 Remove disassem
27. FS ARD J low Wau THHS _ f 1NO34 1dVHS 13V HS 1ndino 31VIa3W3aLNI INOW 1 u3Li3ANOO NOLSId NOU anya 21 12 NISNOH AIGWASSV 14044115 14 5 NOISSIWSNVUL 21 4 TRANSMISSION AND TRANSFER CASE GENERAL INFORMATION Continued TRANSMISSION IDENTIFICATION Transmission identification numbers are stamped on the left side of the case just above the oil pan gas ket surface Fig 2 Refer to this information when ordering replacement parts PART NUMBER BUILD DATE SERIAL NUMBER 80011960 Fig 2 Transmission Part Serial Number Location RECOMM ENDED FLUID Plus 3 Type 7176 automatic trans mission fluid is the recommended fluid for Chrysler automatic transmissions Dexron fluid IS NOT recommended Clutch chatter can result from the use of improper fluid EFFECTS OF INCORRECT FLUID LEVEL A low fluid level allows the pump to take in air along with the fluid Air in the fluid will cause fluid pressures to be low and develop slower than normal If the transmission
28. INYA GION310S dfi4201 105 3ATVA LIIHS 3 6 3ATVA ONIALL 3 6 4 YOLVININNDOW v 3AIHQH3AO NOILVOIHS TI JAVA HOLIMS FATWA 18008 5 S SWNASTILLOHHL 5 RU JAVA NNOO JAVA TOH LNOO LAIHS 2 1 3ATVA 3 1LLOHS 311108HL 1 OAH3S LNOHA OAH3S Hari 110 aNDYOL N33H9S S3ATVA 3ATVA 141 5 2 1 S HONH3AOS JAVA L3IHS c Orid JILLOHHL HOLN19 uvad GION3TIOS HONH3AOD 21 109 TRANSMISSION AND TRANSFER CASE 2 SCHEMATICS AND DIAGRAMS Continued 98PpIdqeog isd 8 0 3unssaud Til3 3ud 3AIlHQd3AO NOILONS isd 3unssaud H31H3ANOO isd 08 0 3unssdud YONYAAOD isd 86 60 LAIHS 8 1 52520 isd 29 49 3unssaud L MOT JILLOYHL 935019 15914 1 IWANVW H3 A31 5 FATWA ONIIALL 201 SATVA dr 4001 aioNaTos dfM201 10S FATWA 1JIHS t 5 ONIIALL 3 6 FATWA AANO HOLM uoivinwnoov NOLIVOIHSITI HOLN19 INVA 15 TOHLNOO
29. Support output shaft flange with steel press plates as shown and center assembly under press ram 3 Apply press pressure slowly Compress hub and spring far enough to expose clutch hub retaining ring and relieve spring pressure on clutch pack snap ring Fig 200 4 Remove direct dutch pack snap ring Fig 201 21 80 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued 5 Remove direct clutch hub retaining ring Fig 202 6 Release press load slowly and completely Fig 203 7 Remove Special Tool 6227 1 Then remove clutch pack from hub Fig 203 SPECIAL PRESS TOOL RAM C 3995 A OR SIMILAR TOOL SPECIAL TOOL 6227 1 CLUTCH HUB PRESS BED PLATES 7 49321 398 Fig 200 Geartrain Mounted In Shop Press Geartrain Disassembly 1 Remove direct dutch hub and spring Fig 204 2 Remove sun gear and spring plate Then remove planetary thrust bearing and planetary gear Fig 205 3 Remove overrunning clutch assembly with expanding type snap ring pliers Fig 206 Insert pli ers into dutch hub Expand pliers to grip hub splines and remove dutch with counterclockwise twisting motion 4 Remove thrust bearing from overrunning dutch hub 5 Remove overrunning dutch from hub 6 Mark position of annulus gear and direct dutch drum for assembly alignment reference Fig 207 Use small center punch or scriber to make alignment marks 7 Remove direct dutch drum rear reta
30. and position drain pan under switch 2 Disconnec switch wires 3 Remove switch from case INSTALLATION 1 Move shift lever to Park and Neutral positions Verify that switch operating lever fingers are cen tered in switch opening in case Fig 22 2 Install new seal on switch and install switch in case Tighten switch to 34 N m 25 ft Ibs torque 2 REMOVAL AND INSTALLATION Continued NEUTRAL MANUAL LEVER AND 0 SWITCH PLUNGER IN REVERSE POSITION SSS LE 2 S 55 SWITCH CONTACT 80517014 Fig 22 Park Neutral Position Switch 3 Test continuity of new switch with 12V test lamp 4 Connect switch wires and lower vehicle 5b Top off transmission fluid level GEARSHIFT CABLE REMOVAL 1 Shift transmission into Park 2 Remove shift lever bezel and necessary console parts for access to shift lever assembly 3 Disconnect cable at shift lever and feed cable through dash panel opening to underside of vehide 4 Raise vehide 5 Disengage cable eyelet at transmission shift lever and pull cable adjuster out of mounting bracket Then remove old cable from vehicle INSTALLATION 1 Route cable through hole in dash panel Fully seat cable grommet into dash panel 2 Place the auto transmission manual shift con trol lever in Park detent rearmost position and rotate prop shaft to ensure transmission is in park 3 Connect shift c
31. ify that thrust washers thrust plates and seal rings are correctly positioned before assembly These parts can interfere with proper assembly if mis positioned The planetary geartrain front rear dutch assem blies and oil pump are all much easier to install when the transmission case is upright 1 Install rear servo piston spring and retainer Fig 107 Install spring on top of servo piston and install retainer on top of spring 2 Install front servo piston assembly spring and rod guide Fig 108 Servo 21 58 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued 3 Compress front rear servo springs with Valve Spring Compressor C 3422 B and install each servo snap ring Fig 109 SERVO PISTON PISTON SPRING SEAL RETAINER 19121 343 Fig 107 Rear Servo Components PISTON SERVO PISTON SNAP RING SEAL J9121 344 ROD SPRING GUIDE Fig 108 Front Servo Components 4 Lubricate dutch cam rollers with transmission fluid 5 Install rear band in case Fig 110 Be sure twin lugs on band are seated against reaction pin 6 Install low reverse drum and check overrun ning dutch operation as follows a Lubricate overrunning dutch race on drum hub with transmission fluid b Guide drum through rear band c Tilt drum slightly and start race on drum hub into overrunning dutch rollers d Press drum rearward and turn it in dock wise direction until drum seats in overrunning du
32. oil pump or input shaft c If propeller shaft does not turn and transmis sion is not noisy perform hydraulic pressure test to determine if problem is hydraulic or mechanical PARK NEUTRAL POSITION SWITCH The center terminal of the park neutral position switch is the starter circuit terminal It provides the ground for the starter solenoid circuit through the selector lever in PARK and NEUTRAL positions only The outer terminals on the switch are for the backup lamp circuit SWITCH TEST To test the switch remove the wiring connector Test for continuity between the center terminal and 21 10 TRANSMISSION AND TRANSFER CASE DIAGNOSIS AND TESTING Continued the transmission case Continuity should exist only when the transmission is in PARK or NEUTRAL Shift the transmission into REVERSE and test continuity at the switch outer terminals Continuity should exist only when the transmission is in REVERSE Continuity should not exist between the outer terminals and the case Check gearshift linkage adjustment before replac ing a switch that tests faulty OVERDRIVE ELECTRICAL CONTROLS The overdrive off switch valve body solenoid case connectors and related wiring can all be tested with a 12 volt test lamp or a volt ohmmeter Check conti nuity of each component when diagnosis indicates this is necessary Refer to Group 8W Wiring Dia grams for component locations and circuit informa tion Switch and solenoid continuity sh
33. 15 O D Check Valve Orifice Failed 15 Check for free movement and secure assembly in piston retainer Check ball bleed orifice SLIPS IN OVERDRIVE 1 Fluid Level Low 1 Add fluid and check for leaks FOURTH GEAR 2 Overdrive Clutch Pack Worn 2 Remove overdrive unit and rebuild clutch pack 3 Overdrive Piston Retainer Bleed 3 Disassemble transmission remove retainer Orifice Blown Out and replace orifice 4 Overdrive Piston or Seal 4 Remove overdrive unit Replace seals if Malfunction worn Replace piston if damaged If piston retainer is damaged remove and disassemble the transmission 5 3 4 Shift Valve Timing Valve or 5 Remove and overhaul valve body Replace Accumulator Malfunction accumulator seals Make sure all valves operate freely in bores and do not bind or stick Make sure valve body screws are correctly tightened and separator plates are properly positioned 21 24 TRANSMISSION AND TRANSFER CASE 2 DIAGNOSIS AND TESTING Continued CONDITION POSSIBLE CAUSES CORRECTION 6 Overdrive Unit Thrust Bearing 6 Disassemble overdrive unit and replace Failure thrust bearing NO 1 thrust bearing is between overdrive piston and clutch hub NO 2 thrust bearing is between the planetary gear and the direct clutch spring plate NO 3 thrust bearing is between overrunning clutch hub and output shaft 7 O D Check Valve Bleed Orifice 7 Check for function secure orifice insert in Fail
34. 2 DISASSEMBLY AND ASSEMBLY Continued LOW RANGE GEAR REAR TABBED THRUST WASHER J9321 36 Fig 42 Rear Tabbed Thrust Washer Removal CAUTION The bearing bores in various transfer case components contain oil feed holes Make sure replacement bearings do not block the holes BEARING AND SEAL INSTALLATION 1 Remove front output shaft seal from front case FRONT with pry tool Fig 43 TABBED THRUST WASHER CO OUTPUT 22 SEAL KTN 5 1 80411080 Fig 43 Remove Front Output Shaft Seal 2 Remove snap ring that retains front output shaft bearing in front case Fig 44 3 Using tool 6953 remove bearing from front case Fig 45 4 Using tool 6953 install new bearing 5 Install snap ring to hold bearing into case 19321 35 Install new front output seal in front case with Installer Tool 6952 A as follows Fig 41 Input Gear Removal a Place new seal on tool Garter spring on ASSEMBLY seal goes toward interior of case Lubricate transfer case components with b Start seal in bore with light taps from ham Dexron automatic transmission fluid or petroleum mer Fig 46 Once seal is started continue tap jelly where indicated during assembly 2 DISASSEMBLY AND ASSEMBLY Continued FRONT CASE o e FRONT BEARING BEARING Fig 44 Output Shaft Front Bearing Snap Ring Removal 9321 52 HANDLE C 4171
35. 3 Coat front clutch thrust washer with petroleum jelly to hold it in place Then install washer over reaction shaft hub and seat it on pump Fig 141 CAUTION The thrust washer bore I D is cham fered on one side Make sure the chamfered side is installed so it faces the pump TRANSMISSION AND TRANSFER CASE 21 185 4 Check seal rings on reaction shaft support Be sure rings are hooked together correctly Also be sure fiber thrust washer is in position Fig 142 Use extra petroleum jelly to hold washer in place if nec essary 5 Lubricate oil pump seals with petroleum Mopar ATF Plus 3 type 7176 6 Mount oil pump on pilot studs and slide pump into case opening Fig 143 Work pump into case by hand Do not use a mallet or similar tools to seat pump 7 Remove pilot studs and install oil pump bolts Tighten pump bolts alternately and evenly to fully seat pump in case Then final tighten pump bolts to 20 N m 15 ft Ibs torque 8 Verify correct installation Rotate input and intermediate shafts and check for bind If bind exists components are either mis assembled or not seated Disassemble and correct as necessary before proceed ing 10121 103 29 Fig 140 Oil Pump Gasket And Pilot Studs Ki CHAMFERED THRUST W SIDE OF WASHER WASHER O N 6 BORE GOES TOWARD NSAN pu J9421 189 297 zm 5 MANN AF 7 Fig 141 Front Clutch Thrust Washer 21 186 T
36. 9 Hydraulic Pressure Incorrect 9 Perform pressure test remove transmission and repair as needed 10 Reaction Shaft Seal Rings 10 Remove transmission remove oil Worn Broken pump and replace seal rings 11 Rear Clutch Input Shaft Rear 11 Remove and disassemble Clutch Seal Rings Damaged transmission and repair as necessary 12 Regulator Valve Stuck 12 Clean 13 Cooler Plugged 13 Transfer case failure can plug cooler NO DRIVE RANGE REVERSE OK 1 Fluid Level Low 1 Add fluid and check for leaks if drive is restored 2 Gearshift Linkage Cable Loose 2 Repair or replace linkage Misadjusted components 3 Rear Clutch Burnt 3 Remove and disassemble transmission and rear clutch and seals Repair replace worn or damaged parts as needed 4 Valve Body Malfunction 4 Remove and disassemble valve body Replace assembly if any valves or bores are damaged 5 Transmission Overrunning Clutch 5 Remove and disassemble Broken transmission Replace overrunning clutch 6 Input Shaft Seal Rings Worn 6 Remove and disassemble Damaged transmission Replace seal rings and any other worn or damaged parts 7 Front Planetary Failed Broken 7 Remove and repair 2 3RANSMISSION AND TRANSFER CASE 21 135 DIAGNOSIS AND TESTING Continued CONDITION POSSIBLE CAUSES CORRECTION NO DRIVE OR REVERSE 1 Fluid Level Low 1 Add fluid and check for leaks if drive VEHICLE WILL NOT
37. CAUTION Do not use tools to loosen or pry the connecting tube out of the valve body housings Loosen and remove the tube by hand only REGULATOR VALVE SWITCH 4 REGULATOR VALVE SPRING THROTTLE M VALVE DETENT AND SPRING 9321 155 Fig 54 Upper Housing Control Valve Locations 2 DISASSEMBLY AND ASSEMBLY Continued LOOSEN REMOVE THIS THESE 3 4 ACCUMULATOR HOUSING Fig 55 Accumulator Housing Screw Locations J9321 432 ACCUMULATOR HOUSING CONVERTER CLUTCH VALVE SPRING 3 4 5 CLUTCH VALVE VALVE SPRING a PLUG 19321 433 Fig 56 3 4 Shift And Converter Clutch Valve Springs And Plug CONVERTER CLUTCH VALVE SPRING AND 3 4 ACCUMULATOR HOUSING Fig 57 Accumulator Housing Valve Springs And Plug PLUG 9321 434 TRANSMISSION AND TRANSFER CASE 21 43 TUBE BRACE DOUBLE TAB Fig 58 Boost Valve Tube Brace 28 Turn valve body over so lower housing is facing upward Fig 60 In this position the two check balls in upper housing will remain in place and not fall out when lower housing and separator plate are removed 29 Remove screws attaching valve body lower housing to upper housing and transfer plate Fig J9521 101 LOWER HOUSING BOOST DISENGAGE UPPER THIS END OF HOUSING TUBE FIRST 19321 147 Fig 59 Boost Valve Tube 60 Note position of boost valve tube brace for assembly reference 30 Remove lo
38. Distance should be 33 4 mm 1 5 16 in If adjustment is required turn the adjusting screw in or out to obtain required distance setting 2 NOTE The 33 4 mm 1 5 16 in setting is approximate setting Manufacturing tolerances may make it necessary to vary from this dimension to obtain desired pressure One complete turn of the adjusting screw changes line pressure approximately 1 2 3 psi 9 kPa Turning the adjusting screw counterclockwise increases pressure while turning the screw clockwise decreases pressure WRENCH Fig 264 Line Pressure Adjustment THROTTLE PRESSURE ADJUSTMENT Insert Gauge Tool C 3763 between the throttle lever cam and the kickdown valve stem Fig 265 Push the gauge tool inward to compress the kick down valve against the spring and bottom the throt tle valve Maintain pressure against kickdown valve spring Turn throttle lever stop screw until the screw head touches throttle lever tang and the throttle lever cam touches gauge tool NOTE The kickdown valve spring must be fully compressed and the kickdown valve completely bottomed to obtain correct adjustment SPECIAL TOOL C 3763 POSITIONED HEX BETWEEN WRENCH THROTTLE IN THROTTLE LEVER AND LEVER KICKDOWN VALVE ADJUSTING ee d SCREW 19521 109 Fig 265 Throttle Pressure Adjustment 21 223 TRANSMISSION AND TRANSFER CASE 2 SCHEMATICS AND DIAGRAMS HYDRAULIC SCHEMATICS 97p1qe08 NOILONS
39. Drive seal into overdrive housing with Seal Installer C 3995 A Fig 19 3 Carefully guide propeller shaft slip yoke into housing and onto output shaft splines Align marks made at removal and connect propeller shaft to rear axle pinion yoke SPECIAL TOOL 3985 8 SEAL 19521 57 Fig 18 Removing Overdrive Housing Yoke Seal SPECIAL TOOL 3995 3972 SPECIAL TOOL 4471 19521 58 Fig 19 Installing Overdrive Housing Yoke Seal SPEEDOMETER ADAPTER Rear axle gear ratio and tire size determine speed ometer pinion requirements REMOVAL 1 Raise vehicle 2 Disconnect wires from vehicle speed sensor 3 Remove adapter damp and screw Fig 20 4 Remove speed sensor and speedometer adapter as assembly 5 Remove speed sensor retaining screw and remove sensor from adapter 6 Remove speedometer pinion from adapter 7 Inspect sensor and adapter O rings Fig 20 Remove and discard O rings if worn or damaged 8 Inspect terminal pins in speed sensor Clean pins with electrical spray deaner if dirty or oxidized Replace sensor if faulty or pins are loose severely corroded or damaged 21 32 TRANSMISSION AND TRANSFER CASE REMOVAL AND INSTALLATION Continued ITEM TORQUE 2 3 15 27 in lbs 10 12 Nem 90 110 in Ibs SENSOR ADAPTER CLAMP VEHICLE SPEED SENSOR SPEEDOMETER ADAPTER 2 5
40. E gt J9321 424 Fig 49 Throttle Lever E Clip And Washer 21 42 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued REMOVE REMOVE THIS SCREW LAST J9321 430 BRACKET Fig 52 Adjusting Screw Bracket Fastener 21 Turn upper housing over and remove switch valve regulator valve and spring and manual valve Fig 54 22 Remove kickdown detent kickdown valve and throttle valve and spring Fig 54 23 Loosen left side 3 4 accumulator housing attaching screw about 2 3 threads Then remove cen ter and right side housing attaching screws Fig 55 UPPER HOUSING SHUTTLE VALVE PRIMARY SPRING 258 2 3 GOVERNOR PLUG THROTTLE PLUG GOVERNOR 777 PLUG COVER Pg 7 2 GOVERNOR PLUG 2 24 Carefully rotate 3 4 accumulator housing upward and remove 3 4 shift valve spring and con verter clutch valve plug and spring Fig 56 25 Remove left side screw and remove 3 4 accu mulator housing from valve body Fig 57 SWITCH VALVE SPRING m LINE PRESSURE THROTTLE ADJUSTING SCREW PRESSURE PRESSURE BRACKET ADJUSTING REGULATOR SCREW VALVE SPRING J9321 431 Fig 53 Adjusting Screw Bracket And Spring 26 Bend back tabs on boost valve tube brace Fig 58 27 Remove boost valve connecting tube Fig 59 Disengage tube from upper housing port first Then rock opposite end of tube back and forth to work it out of lower housing
41. Fig 171 Use enough petroleum jelly to hold washer on gear Be sure all four washer tabs are seated in slots 7 Install spacer on sun gear Fig 172 8 Install thrust plate on sun gear Fig 173 Note that driving shell thrust plates are interchangeable Use either plate on sun gear and at front rear of shell 9 Hold sun gear in place and install thrust plate over sun gear at rear of driving shell Fig 174 10 Position wood block on bench and support sun gear on block Fig 175 This makes it easier to align and install sun gear lock ring Keep wood block handy as it will also be used for geartrain end play check 11 Align rear thrust plate on driving shell and install sun gear lock ring Be sure ring is fully seated in sun gear ring groove Fig 176 21 74 TRANSMISSION AND TRANSFER CASE 2 DISASSEMBLY AND ASSEMBLY Continued REAR ANNULUS GEAR TABBED THRUST WASHER REAR PLANETARY SPACER J9121 156 J9121 159 Fig 169 Assembling Rear Annulus And Planetary Gear REAR ANNULUS AND PLANETARY GEAR ASSEMBLY OUTPUT SHAFT J9121 161 J9121 157 Fig 173 Installing Driving Shell Front Thrust Plate Fig 170 Installing Rear Annulus And Planetary On On Sun Gear Output Shaft 12 Install assembled driving shell and sun gear FRONT on output shaft Fig 177 TABBED 13 Install rear thrust washer on front planetary gear Fig 178 Use enough petroleum jel
42. HOUSING REGULATOR VALVE SWITCH VALVE REGULATOR VALVE SPRING SHUTTLE VALVE PRIMARY SPRING gt 2 3 GOVERNOR PLUG yo KICKDOWN VALVE THROTILE PLUG KICKDOWN GOVERNOR 77 DETENT PLUG AND COVER SPRING J9321 155 Fig 79 Upper Housing Control Valve Locations UPPER HOUSING 1 2 SHIFT VALVE AND SPRING 2 3 SHIFT VALVE 2 3 AND SPRING PLUG LIMIT VALVE HOUSING THROTTLE PRESSURE SPRING K L VALVE uU AND SPRING PLUG LINE 4 PRESSURE PLUG LIMIT PRESSURE VALVE LIMIT PLUG RETAINER AND VALVE COVER SPRING COVER 19321 157 Fig 80 Upper Housing Shift Valve And Pressure Plug Locations 2 DISASSEMBLY AND ASSEMBLY Continued BOOST VALVE TUBE AND BRACE 1 Position valve body assembly so lower housing is fading upward Fig 81 2 Lubricate tube ends and housing ports with transmission fluid or petroleum jelly 3 Start tube in lower housing port first Then swing tube downward and work opposite end of tube into upper housing port Fig 81 4 Insert and seat each end of tube in housings 5 Slide tube brace under tube and into alignment with valve body screw holes Fig 82 6 Install and finger tighten three screws that secure tube brace to valve body housings Fig 82 7 Bend tube brace tabs up and against tube to hold it in position Fig 83 8 Tighten all valve body housing screws to 4 35 in Ibs torque after tube and bra
43. Ibs SENSOR SPEEDOMETER ADAPTER TRANSMISSION AND TRANSFER CASE 21 275 ADAPTER O RING SPEEDOMETER PINION ADAPTER Aa CLAMP 1 2 VEHICLE SPEED gt _ _ GP SENSOR J9321 385 Fig 5 Speedometer Components SPEEDOMETER INDEX ADAPTER NUMBER LOCATION OUTPUT SHAFT SEAL SPAN PRYBAR 227 J9321 386 80211085 Fig 6 Location Of Index Numbers Speedometer Adapter a Place new seal on tool Garter spring on seal goes toward interior of case b Start seal in bore with light taps from ham mer Fig 8 Once seal is started continue tapping seal into bore until installer tool seats against case REAR RETAINER BUSHING AND SEAL REMOVAL 1 Raise vehide 2 Remove rear propeller shaft Refer to Group 3 Differential and Driveline for proper procedure 3 Using a suitable pry tool or slide hammer mounted screw remove the rear retainer seal Fig 7 Remove Front Output Shaft Seal 4 Using Remover 6957 remove bushing from rear retainer Fig 9 INSTALLATION 1 Clean fluid residue from sealing surface and inspect for defects 2 Position replacement bushing in rear retainer with fluid port in bushing aligned with slot in retainer 3 Using Installer 8145 drive bushing into retainer until installer seats against case Fig 10 4 Using Installer C 3995 A install seal in rear retainer Fig 11 5 Install propeller shaft 6 Verify proper fluid level 7 Lower
44. M VALVE SHUTTLE VALVE PRIMARY SPRING GONERNOR PLUG e COVER SS e 19421 217 Fig 72 Shuttle And Boost Valve Components UPPER HOUSING 1 2 SHIFT VALVE AND SPRING 2 3 SHIFT VALVE 2 3 AND SPRING THROTTLE PLUG LIMIT VALVE HOUSING THROTTLE PRESSURE SPRING AND PLUG PLUG p ii VALVE AND SPRING SLEEVE d om 222 LINE KO PRESSURE NV PLUG UMIT PRESSURE VALVE LIMIT PLUG RETAINER AND VALVE COVER SPRING COVER 9321 157 Fig 73 Upper Housing Shift Valve And Pressure Plug Locations 2 21 168 TRANSMISSION AND TRANSFER CASE 2 DISASSEMBLY AND ASSEMBLY Continued VALVE BODY LOWER HOUSING 3 4 1 Remove timing valve cover ACCUMULATOR 2 Remove 3 4 timing valve and spring HOUSING 3 Remove 3 4 quick fill valve spring and plug 4 Remove 3 4 shift valve and spring 5 Remove converter dutch valve spring and plug ced Fig 74 Remove converter clutch timing valve retainer and valve spring 3 4 ACCUMULATOR HOUSING 1 Remove end plate from housing 2 Remove piston spring 3 Remove piston Remove and discard piston TEFLON SEALS seals Fig 75 PISTON SPRING ASSEMBLY CAUTION not force valves or plugs into place during reassembly If the valve body bores valves COVER PLATE and plugs are free of distortion or burrs the valve AND SCREWS body components should all slide into place easily In addi
45. Remove the overrunning clutch cam bolts 7 Remove the overrunning clutch cam ASSEMBLY 1 Examine bolt holes in overrunning clutch cam Note that one hole is not threaded Fig 132 This hole must align with blank area in clutch cam bolt drde Fig 133 Mark hole location on dutch cam and blank area in case with grease pencil paint stripe or scribe mark for assembly reference 2 Mark location of non threaded hole in dutch cam and blank area in bolt circle with grease pencil 3 Align and install overrunning dutch and cam in case Fig 134 Be sure cam is correctly installed Bolt holes in cam are slightly counter sunk on one side Be sure this side of cam faces rearward toward piston retainer TRANSMISSION AND TRANSFER CASE 21 63 OVERDRIVE CLUTCH PISTON PISTON AN INTERMEDIATE RETAINER SHAFT ALIGN MARKS IDENTIFYING NON THREADED HOLE IN CAM AND CASE OVERRUNNING ZCLUTCH ASSEMBLY 79121346 Fig 131 Overrunning Clutch Cam Removal NON THREADED HOLE OVERRUNNING CLUTCH CAM 19121 226 Fig 132 Location Of Non Threaded Hole In Clutch Cam 21 64 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued NS OVERRUNNING CLUTCH CAM SEAT IN CASE ON THREAD HOLE IN CLUTCH CAM ALIGNS HERE BLANK AREA OF SEAT J9121 541 Fig 133 Location Of Blank Area In Clutch Cam Bolt Circle ALIGN MARKS IDENTIFYING NON THREADED HOLE IN CAM AND CASE OVERRUNN
46. Remove yoke If yoke is difficult to remove by hand remove it with bearing splitter or with stan 2 dard two jaw puller Fig 22 Be sure puller tool is positioned on yoke and not on slinger as slinger will be damaged IMPACT WRENCH 355 9 800010957 N uia A Fig 22 Yoke Removal 4 Remove seal washer from front output shaft Discard washer as it should not be reused 5 Remove nut and washer that attach range lever to sector shaft Then move sector to neutral position and remove range lever from shaft Fig 23 80010977 SECTOR 80010943 Fig 23 Range Lever Removal 2 5 5 AND TRANSFER CASE 21 279 DISASSEMBLY AND ASSEMBLY Continued FRONT OUTPUT SHAFT AND DRIVE CHAIN REMOVAL 1 Support transfer case so rear case is facing upward 2 Remove bolts holding front case to rear case The case alignment bolt require flat washers Fig 24 3 Loosen rear case with flat blade screwdriver to break sealer bead Insert screwdriver blade only into notches provided at each end of case Fig 25 4 Remove rear case Fig 26 REAR HOUSING ALIGNMENT BOLT AND WASHER AT EACH END OF CASE TRANSFER CASE 80468d2a Fig 26 Rear Case Removal X G REAR CASE PRY TOOL 5 INCAS SION A E A 2 2 19321 14 19321 16 Fig 25 Loosening Rear Case Fig 27 Oil Pickup Tube Remova
47. Repair faulty component 21 138 TRANSMISSION AND TRANSFER CASE 2 DIAGNOSIS AND TESTING Continued CONDITION POSSIBLE CAUSES CORRECTION CREEPS IN NEUTRAL 1 Gearshift Linkage Misadjusted 1 Adjust linkage 2 Rear Clutch Dragging Warped 2 Disassemble and repair 3 Valve Body Malfunction 3 Perform hydraulic pressure test to determine cause and repair as required BUZZING NOISE 1 Fluid Level Low 1 Add fluid and check for leaks 2 Shift Cable Misassembled 2 Route cable away from engine and bell housing 3 Valve Body Misassembled 3 Remove disassemble inspect valve body Reassemble correctly if necessary Replace assembly if valves or springs are damaged Check for loose bolts or screws 4 Pump Passages Leaking 4 Check pump for porous casting Scores on mating surfaces and excess rotor clearance Repair as required Loose pump bolts 5 Cooling System Cooler Plugged 5 Flow check cooler circuit Repair as needed SLIPS IN REVERSE ONLY 5 Overdrive Direct Clutch Worn 5 Disassemble overdrive Repair as needed 6 Hydraulic Pressure Too Low 6 Perform hydraulic pressure tests to determine cause 7 Rear Servo Leaking 7 Air pressure check clutch servo operation and repair as required 8 Band Linkage Binding 8 Inspect and repair as required 2 5 5 AND TRANSFER CASE 21 139 DIAGNOSIS AND TESTING Continued CONDITION PO
48. SHAFT J9121 124 Fig 121 Installing Front Rear Clutch Assemblies BAND BAND LEVER STRUT FRONT BAND Fig 122 Front Band Linkage Installation TRANSMISSION AND TRANSFER CASE 21 61 25 Thread two Pilot Stud Tools C 3288 B into bolt holes in oil pump bore flange Fig 124 26 Align and install oil pump gasket Fig 124 SEAL RINGS J9121 194 Fig 123 Reaction Shaft Support Seal Rings And Front Clutch Thrust Washer PILOT STUD TOOLS C 3288 B J9121 195 Fig 124 Installing Pilot Studs And Oil Pump Gasket 27 Install oil pump Fig 125 Align and position pump on pilot studs Slide pump down studs and work it into front clutch hub and case by hand Then install 2 or 3 pump bolts to hold pump in place 28 Remove pilot stud tools and install remaining oil pump bolts Tighten bolts alternately in diagonal pattern to 20 N m 15 ft Ibs 29 Measure and if necessary correct input shaft end play as follows Fig 126 a Attach dial indicator to converter housing b Position indicator plunger against input shaft and zero indicator c Move input shaft in and out and record read ing End play should be 0 56 2 31 mm 0 022 21 62 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued y 9121 196 Fig 125 Installing Oil Pump Assembly In Case 0 091 in Proceed to next step if end play is not within specified limits d Intermediate shaft t
49. TRANSMISSION AND TRANSFER CASE 21 29 10 Mark torque converter and drive plate for assembly alignment Note that bolt holes in crank shaft flange drive plate and torque converter all have one offset hole 11 Rotate crankshaft in clockwise direction until converter bolts are accessible Then remove bolts one at a time Rotate crankshaft with socket wrench on dampener bolt 12 Mark propeller shaft and axle yokes for assembly alignment Then disconnect and remove propeller shaft On 4 x 4 models remove both propel ler shafts 13 Disconnec wires from park neutral position switch transmission solenoid and vehicle speed sen sor 14 Disconnect gearshift cable from transmission manual valve lever 15 Disconnect throttle valve cable from transmis sion bracket and throttle valve lever 16 On 4 x 4 models disconnect shift rod from transfer case shift lever or remove shift lever from transfer case 17 Disconnect transmission fluid cooler lines at transmission fittings and clips 18 Support rear of engine with safety stand or jack 19 Raise transmission slightly with service jack to relieve load on crossmember and supports 20 Remove bolts securing rear support and cush ion to transmission and crossmember Raise trans mission slightly slide exhaust hanger arm from bracket and remove rear support 21 Remove bolts attaching crossmember to frame and remove crossmember 22 On 4 x 4 models remove transfer
50. Tighten valve body screws to recom mended torque only LOWER HOUSING 1 Lubricate valves springs and the housing valve and plug bores with dean transmission fluid Fig 69 2 Install 3 4 timing valve spring and valve in lower housing 3 Install 3 4 quick fill valve in lower housing 4 Install 3 4 quick fill valve spring and plug in housing 5 Install timing valve end plate Tighten end plate screws to 4 N m 35 in Ibs torque 3 4 ACCUMULATOR 1 Lubricate accumulator piston seals and hous ing piston bore with dean transmission fluid Fig 70 2 Install new seal rings on accumulator piston 3 Install piston and spring in housing 4 Install end plate on housing TRANSFER PLATE 1 Install rear dutch and rear servo check balls in transfer plate Fig 71 2 Install filter screen in upper housing separator plate Fig 72 3 Align and position upper housing separator plate on transfer plate Fig 73 4 Install brace plate Fig 73 Tighten brace attaching screws to 4 N m 35 in Ibs torque 5 Install remaining separator plate attaching screws Tighten screws to 4 N m 35 in 165 torque 2 DISASSEMBLY AND ASSEMBLY Continued LOWER HOUSING PLUG 3 4 TIMING VALVE AND SPRING 3 4 SHIFT VALVE AND T SPRING SPRING TIMING VALVE CONVERTER RETAINER COVER 122 CLUTCH VALVE AND SPRING OVERDRIVE CONVERTER CLUTCH SOLENOID 99 TIMING VALVE AND SPRING CON
51. Use scriber or paint to make alignment marks 2 Place pump body on two wood blocks 3 Remove reaction shaft support bolts and sepa rate support from pump body Fig 158 4 Remove pump inner and outer gears Fig 159 5 Remove O ring seal from pump body Fig 160 Discard seal after removal 6 Remove oil pump seal with Remover Tool C 3981 Discard seal after removal OIL REACTION SHAFT SUPPORT J9321 176 Fig 158 Reaction Shaft Support OIL PUMP BUSHING REMOVAL 1 Position pump housing on dean smooth sur face with gear cavity facing down 2 Remove bushing with Tool Handle C 4171 and Bushing Remover SP 3550 Fig 161 REACTION SHAFT SUPPORT BUSHING REMOVAL 1 Assemble Cup Tool SP 3633 Nut SP 1191 and Bushing Remover SP 5301 Fig 163 2 TRANSMISSION AND TRANSFER CASE 21 191 DISASSEMBLY AND ASSEMBLY Continued GEAR PUMP BODY 3 Using wrench thread remover tool an addi BORE tional 3 4 turns into bushing to firmly engage tool 4 Tighten tool hex nut against cup tool to pull bushing from shaft Clean all chips from shaft and support after bushing removal ASSEMBLY OIL PUMP BUSHING INSTALLATION 1 Assemble Tool Handle C 4171 and Bushing Installer SP 5118 2 Place bushing on installer tool and start bush ing into shaft 3 Tap bushing into place until Installer Tool SP 5118 bottoms in pump cavity Keep tool and bush ing square with bore
52. bers correspond to number of teeth on pinion gear 10 Install speedometer adapter damp and retain ing screw Tighten damp screw to 10 12 N m 90 110 in Ibs torque 11 Connect wires to vehicle speed sensor 12 Lower vehicle and top off transmission fluid level if necessary 10 12 Nem 90 110 in Ibs SENSOR SPEEDOMETER 2 5 INDEX ADAPTER NUMBER LOCATION J9321 386 Fig 21 Index Numbers On Speedometer Pinion Adapter PARK NEUTRAL POSITION SWITCH REMOVAL 1 Raise vehicle and position drain pan under switch 2 Disconnec switch wires 3 Remove switch from case INSTALLATION 1 Move shift lever to Park and Neutral positions Verify that switch operating lever fingers are cen tered in switch opening in case Fig 22 2 Install new seal on switch and install switch in case Tighten switch to 34 N m 25 ft Ibs torque ITEM TORQUE ADAPTER ADAPTER 2 3 15 27 in Ibs RING SPEEDOMETER PINION ADAPTER CLAMP SL VEHICLE SPEED 6 SENSOR 19321 385 Fig 20 Speedometer Adapter Components 2 REMOVAL AND INSTALLATION Continued NEUTRAL MANUAL LEVER AND 0 SWITCH PLUNGER IN REVERSE POSITION SSS LE 2 S 55 SWITCH CONTACT 80517014 Fig 22 Park Neutral Position Switch 3 Test continuity of new switch with 12V test lamp 4 Connect switch wires a
53. case Fig 79 Rotate mainshaft slightly to engage 4 148 21 256 shaft with low range gears 17 Rotate mode fork pin into shift sector slot Fig 79 Assembled Mainshaft And Mode Fork 18 Install shift rail Fig 80 Be sure rail is Installation seated in both shift forks 2 DISASSEMBLY AND ASSEMBLY Continued 19 Rotate shift sector to align lockpin hole in low range fork with access hole in case 20 Insert an easy out in range fork lockpin to hold it securely for installation Fig 81 Lockpin is slightly tapered on one end Insert tapered end into fork and rail 21 Insert lockpin through access hole and into shift fork Fig 81 Then remove easy out and seat the pin with pin punch ACCESS EASY OUT J8921 254 Fig 81 Installing Low Range Fork Lockpin TRANSMISSION AND TRANSFER CASE 21 263 22 Install plug in lockpin access hole 23 Install detent plunger detent spring and detent plug in case Fig 82 FRONT OUTPUT SHAFT AND DRIVE CHAIN INSTALLATION 1 Install front output shaft Fig 83 2 Install drive chain Fig 83 Engage chain with front output shaft sprocket teeth 3 Install drive sprocket Fig 83 Engage drive sprocket teeth with chain Then engage sprocket splines with mainshaft splines 4 Install drive sprocket snap ring Fig 84 SPRING Fig 82 Detent Pin Spring And Plug Installation DRIVE se SPROCKET J8921 285 Fig 83 Drive Cha
54. park gear and monitors transmission output shaft rotating speed Speed sensor signals are triggered by the park gear lugs as they rotate past the sensor pickup face Input signals from the sensor are sent to the transmission control module for processing The vehicle speed sensor also serves as a backup for the transmission speed sensor Signals from this sensor are shared with the powertrain control module TRANSMISSION OUTPUT SHAFT SPEED SENSOR SEAL J9321 411 Fig 5 Transmission Output Speed Sensor THROTTLE POSITION SENSOR TPS The TPS provides throttle position input signals to the PCM This input signal is used to determine overdrive and converter dutch shift schedule and to select the proper governor curve POWERTRAIN CONTROL MODULE PCM The PCM controls operation of the converter dutch overdrive dutch and governor pressure sole noid The control module determines transmission shift points based on input signals from the transmission thermistor transmission output shaft speed sensor crankshaft position sensor vehide speed sensor throttle position sensor and battery temperature sen sor GOVERNOR PRESSURE CURVES There are four governor pressure curves pro grammed into the transmission control module The different curves allow the control module to adjust governor pressure for varying conditions One curve is used for operation when fluid temperature is at or below 1 C 30 F A second curve is used
55. shafts Do not attempt to straighten a bent shaft or correct a loose lever Replace these components if worn bent loose or damaged in any way TRANSMISSION AND TRANSFER CASE 21 91 Inspect all of the valve body mating surfaces for scratches nicks burrs or distortion Use a straight edge to check surface flatness Minor scratches may be removed with crocus doth using only very light pressure Minor distortion of a valve body mating surface may be corrected by smoothing the surface with a sheet of crocus doth Position the crocus doth on a surface plate sheet of plate glass or equally flat sur face If distortion is severe or any surfaces are heavily scored the valve body will have to be replaced CAUTION Many of the valves and plugs such as the throttle valve shuttle valve plug 1 2 shift valve and 1 2 governor plug are made of coated alumi num Aluminum components are identified by the dark color of the special coating applied to the sur face or by testing with a magnet Do not sand alu minum valves or plugs under any circumstances This practice could damage the special coating causing the valves plugs to stick and bind Inspect the valves and plugs for scratches burrs nicks or scores Minor surface scratches on steel valves and plugs can be removed with crocus cloth but do not round off the edges of the valve or plug lands Maintaining sharpness of these edges is vitally important The edges prevent foreign matt
56. 1 1 8 2 1 3ATVA 31LLOHS 31LLOHHL 1 5 1 NOLLvOIHS TI OL JAYA OAYAS H31HJANOD 3no0uol 5 JAVA 3ATVA TIVONVIA SATIVA L3IHS 2 1 HONH3AOD JAVA 1 1 5 6 2 ATLLOYWHL Orid HOLN19 GION31OS HONH3AOS 2 TRANSMISSION AND TRANSFER CASE SCHEMATICS AND DIAGRAMS Continued 21 110 6 isd 6 0 5534 1114 3 NOILOnS isd 9 9 3unssaud 3901 d31H3ANOO isd 29 9 3unssaud isd 2 TOYULNOD LAIHS 2 1 isd 29 99 3unssaud SANIT 245 IWNNVM AILLOYHL GAS0T19 uv35 GNOOAS 43431 8019313S UE nr 23 1 NOIL JHANTI OL FATWA HOLIMS MAJ dION310S df4201 7 HALYAANOD 3nouor N33uos 3w 18008 Cor zm 108 AHQH3AO muc JAWA IIHS ril 1 1 JAWA ONIIALL 7
57. 152 2 REMOVAL AND INSTALLATION TRANSFER CASE REMOVAL 1 Shift transfer case into Neutral 2 Raise vehide 3 Drain transfer case lubricant 4 Mark front and rear propeller shaft yokes for alignment reference 5 Support transmission with jack stand 6 Remove rear crossmember or skid plate 7 Disconnec front rear propeller shafts at trans fer case 8 Disconnect vehicle speed sensor wires 9 Disconnect transfer case linkage rod from range lever 10 Disconnect transfer case vent hose Fig 3 and indicator switch harness if necessary 11 Support transfer case with transmission jack 12 Secure transfer case to jack with chains 13 Remove nuts attaching transfer case to trans mission 14 Pull transfer case and jack rearward to disen gage transfer case 15 Remove transfer case from under vehicle TRANSFER CASE 80b09a89 Fig 3 Transfer Case Mounting INSTALLATION 1 Mount transfer case on a transmission jack 2 Secure transfer case to jack with chains 3 Position transfer case under vehide 4 Align transfer case and transmission shafts and install transfer case on transmission 5 Install and tighten transfer case attaching nuts to 35 N m 26 ft Ibs torque Fig 3 6 Connec vehide speed sensor wires and vent hose 7 Connect indicator switch harness to transfer case switch if necessary Secure wire harness to clips on transfer case TRANSMISSION AND T
58. 2 Fig 223 Insert tool through sun gear and into splines of both hubs Be sure alignment tool is fully seated before proceeding 17 Install direct dutch spring Fig 224 Be sure spring is properly seated on spring plate NOTE The 42RE transmission has 6 direct clutch discs and 5 clutch plates The 44RE transmission has 8 direct clutch discs and 7 clutch plates 2 DISASSEMBLY AND ASSEMBLY Continued SPECIAL TOOL 6227 2 ASSEMBLED DRUM AND ANNULUS GEAR PRESS J9321 395 Fig 223 Alignment Tool Installation SPECIAL TOOL 6227 2 BRE DIRECT CLUTCH PRESS PLATES 9321 396 Fig 224 Direct Clutch Spring Installation 18 Assemble and install direct clutch pack on hub as follows a Assemble clutch pack components Fig 225 or Fig 226 b Install direct clutch reaction plate on clutch hub first Note that one side of reaction plate is counterbored Be sure this side faces rear ward Splines at rear of hub are raised slightly Counterbore in plate fits over raised TRANSMISSION AND TRANSFER CASE 21 85 splines Plate should be flush with this end of hub Fig 227 Install first dutch disc followed by a steel plate until all discs and plates have been installed Install pressure plate This is last dutch pack item to be installed Be sure plate is installed with shoulder side facing upward Fig 228 19 Install clutch hub and dutch pack on direct dutch spring Fig 22
59. 4 Install differential mainshaft gear Fig 62 5 Align and position differential top case on bot tom case Fig 63 Align using scribe marks made at disassembly MAINSHAFT GEAR PLANET GEARS 6 J8921 280 Fig 62 Installing Mainshaft And Planet Gears 5 ALIGNMENT MARKS BOTTOM CASE J8921 281 Fig 63 Differential Case Assembly 2 DISASSEMBLY AND ASSEMBLY Continued 6 While holding differential case halves together invert the differential and start the differential case bolts 7 Tighten differential torque case bolts to specified INPUT GEAR LOW RANGE ASSEMBLY 1 Assemble low range gear input gear thrust washers input gear and input gear retainer Fig 64 2 Install low range gear snap ring Fig 65 THRUST WASHERS LOW RANGE GEAR RETAINER J8921 214 Fig 64 Low Range And Input Gear Assembly LOW RANGE GEAR SNAP RING J8921 269 Fig 65 Install Low Range Gear Snap Ring 3 Lubricate input gear and low range gears with automatic transmission fluid 4 Start input gear shaft into front case bearing TRANSMISSION AND TRANSFER CASE 21 259 5 Press input gear shaft into front bearing 6 Install new input gear snap ring Fig 66 J8921 267 Fig 66 Input Gear Snap Ring Installation 7 Apply 3 mm 1 8 in wide bead of Mopar gas ket maker or silicone adhesive sealer to seal surface of front bearing retainer
60. 4 Tighten adjusting screw to 8 72 in Ibs torque 42 44RE TRANSMISSION e Back off adjusting screw 4 turns e Hold adjusting screw in place and tighten lock nut to 34 N m 25 ft Ibs torque 5 Position new gasket on oil pan and install pan on transmission Tighten pan bolts to 17 N m 13 ft Ibs torque 6 Lower vehicle and refill transmission with Mopar ATF Plus 3 Type 7176 fluid VALVE BODY CONTROL PRESSURE ADJ USTMENTS There are two control pressure adjustments on the valve body e Line Pressure e Throttle Pressure Line and throttle pressures are interdependent because each affects shift quality and timing As a result both adjustments must be performed properly and in the correct sequence Adjust line pressure first and throttle pressure last 2 USTMENTS Continued LINE PRESSURE ADJUSTMENT Measure distance from the valve body to the inner edge of the adjusting screw with an accurate steel scale Fig 257 Distance should be 33 4 mm 1 5 16 in If adjustment is required turn the adjusting screw in or out to obtain required distance setting NOTE The 33 4 mm 1 5 16 in setting is approximate setting Manufacturing tolerances may make it necessary to vary from this dimension to obtain desired pressure One complete turn of the adjusting screw changes line pressure approximately 1 2 3 psi 9 kPa Turning the adjusting screw counterdockwise increases pressure while turni
61. 4 valves The limit valve determines maximum speed at which a 3 2 part throttle kickdown can be made On 2 transmissions without a limit valve maximum speed for a 3 2 kickdown is at detent position The 2 3 shuttle valve has two functions The first is fast front band release and smooth engagement during lift foot 2 3 upshifts The second is to regulate front dutch and band application during 3 2 down shifts The 3 4 timing valve is moved by line pressure coming through the 3 4 shift valve The timing valve holds the 2 3 shift valve in an upshift position The purpose is to prevent the 2 3 valve from up or down shifting before the 3 4 valve The 3 4 accumulator is mounted on the overdrive housing and performs the same function as the 2 3 accumulator it is used to smooth engagement during a 3 4 shift The switch valve directs fluid apply pressure to the converter clutch in one position and releases it in the opposite position It also directs oil to the cooling and lube circuits The switch valve regulates oil pressure to the torque converter by limiting maximum oil pressure to 130 psi OVERDRIVE OFF SWITCH The overdrive OFF control switch is located in the instrument panel The switch is a momentary contact device that signals the PCM to toggle current status of the overdrive function At key on overdrive operation is allowed Pressing the switch once causes the overdrive OFF mode to be entered and the over drive OFF swit
62. 5 Air pressure check servo operation and Malfunction repair as required 6 Overrunning Clutch Worn 6 Remove and inspect clutch Repair as required 7 Clutch Operation Faulty 7 Perform air pressure check and repair as required 2 Clutch Dragging Failed 2 Air pressure check clutch operation and repair as required 21 22 TRANSMISSION AND TRANSFER CASE 2 DIAGNOSIS AND TESTING Continued CONDITION POSSIBLE CAUSES CORRECTION 7 Planetary Gears Broken 7 Remove inspect and repair as required look for debris in oil pan 8 Converter Clutch Dragging 8 Check for plugged cooler Perform flow check Inspect pump for excessive side clearance Replace pump as required NO 4 3 DOWNSHIFT 1 Circuit Wiring and or Connectors 1 Test wiring and connectors with test lamp Shorted and volt ohmmeter Repair wiring as necessary Replace connectors and or harnesses as required 2 PCM Malfunction 2 Check PCM operation with DRB scan tool Replace PCM only if faulty 3 TPS Malfunction 3 Check TPS with DRB scan tool at PCM 4 Lockup Solenoid Not Venting 4 Remove valve body and replace solenoid assembly if plugged or shorted 5 Overdrive Solenoid Not Venting 5 Remove valve body and replace solenoid if plugged or shorted NO 4 3 DOWNSHIFT 1 Control Switch Open Shorted 1 Test and replace switch if faulty WHEN CONTROL 2 Overdrive Solenoid Connector 2 Test solenoids and replace if seized or SWITCH I
63. 5 Separate solenoid retainer from governor Fig 25 6 Pull solenoid from governor body Fig 26 7 Remove bolts holding governor body to valve body 8 Separate governor body from valve body Fig 27 9 Remove governor body gasket 10 Remove retainer holding pressure sensor to governor body 11 Pull pressure sensor from governor body Fig 28 INSTALLATION Before installing the pressure sensor and solenoid in the governor body replace O ring seals clean the gasket surfaces and replace gasket 1 Lubricate O ring on pressure sensor with transmission fluid 2 Align pressure sensor to bore in governor body Fig 28 3 Push pressure sensor into governor body 4 Install retainer to hold pressure sensor to gov ernor body 5 Place gasket in position on back of governor body Fig 27 6 Place governor body in position on valve body 2 7 Install bolts to hold governor body to valve body 8 Lubricate O ring on pressure solenoid with transmission fluid 9 Align pressure solenoid to bore in governor body Fig 26 10 Push solenoid into governor body 11 Place solenoid retainer in position on governor Fig 25 12 Install screws to hold pressure solenoid retainer to governor body 13 Engage wire connectors into pressure sensor and solenoid Fig 24 14 Install transmission fluid pan and new filter 15 Lower vehicle and road test to verify repair
64. 6 SERENE 5 E AANO B JAU ASAREE YOLVINANODOV v YOLWINANDOV m TOF AATWA TOHLNOO L4IHS 2 1 H BATVA LJIHS 2 1 9 HONHSAOD a 9 M 3ATVA TOHLNOO 14188 8 1 H 1714 1 md 3ATVA L4IHS 6 2 31LLOHHL 3ATVA om Sid JILLOHHL i 9Nd z g rg US 2 1 oOl 9 o 1 HOLD LNOUS HOLA GION310S HONH3AOD INOW OAH3S Hv3H 21 111 TRANSMISSION AND TRANSFER CASE 2 SCHEMATICS AND DIAGRAMS Continued isd 9 0 3anssadud Til3 38d NOILOnS isd 9 9 3unssaud 39101 d31H3ANOO isd 25 0 3unssaud HONH3AOSD isd 02 62 TOULNOD LAIHS 2 1 isd 76 0 3unssadud ATLLOYHL isd 56 29 3unssaud NMOGQGMOI 31LLOHHL TINA 3AIHO NI H3A31 HOLO3 13S uV39 5 LJIHSNMOG 2 6 31LLOHHL TINA 1 GNOOAS 1 NOLLvOIHS TI OL 3ATVA ONIIALL
65. 6 Clean dutch cam bore and case Be sure to remove all chips shavings generated during cam removal OVERDRIVE PISTON IN PISTON INTERMEDIATE SHAFT RETAINER SELECTIVE SPACER J9121 210 Fig 147 Overdrive Piston Removal ASSEMBLY 1 Temporarily install overdrive piston retainer in case Use 3 4 bolts to secure retainer 2 Align and start new dutch and spring retainer in case Be sure serrations on cam and in case are aligned Fig 149 Then tap cam into case just enough to hold it in place 3 Verify that cam is correctly positioned before proceeding any further Narrow ends of 21 188 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued PIN J PUNCH SUPPORT BOLT HOLES Fig 148 Overrunning Clutch Cam cam ramps should be to left when cam is viewed from front end of case Fig 149 4 Insert Adapter Tool SP 5124 into piston retainer Fig 150 5 Assemble Puller Bolt SP 3701 and Press Plate SP 3583 A Fig 151 CLUTCH J9321 244 ON CAM Fig 149 Positioning Replacement Clutch Cam Case 6 Install assembled puller plate and bolt Fig 152 Insert bolt through cam case and adapter tool Be sure plate is seated squarely on cam 7 Hold puller plate and bolt in place and install puller nut SP 3701 on puller bolt Fig 153 8 Tighten puller nut to press clutch cam into case Fig 153 Be sure cam is pressed into c
66. 96 Removing Installing Front Band Lever REAR CLUTCH FRONT CLUTCH J9121 124 Fig 97 Removing Front Rear Clutch Assemblies TRANSMISSION AND TRANSFER CASE 21 55 FRONT CLUTCH CLUTCH J9121 125 Fig 98 Separating Front Rear Clutch Assemblies 24 Remove intermediate shaft thrust washer from front end of shaft or from rear clutch hub Fig 99 25 Remove output shaft thrust plate from inter mediate shaft hub Fig 100 26 Slide front band off driving shell Fig 101 and remove band from case INTERMEDIATE SHAFT THRUST WASHER REAR CLUTCH RETAINER HUB INPUT SHAFT 19121 214 Fig 99 Removing Intermediate Shaft Thrust Washer 21 56 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued INTERMEDIATE SHAFT THRUST PLATE 19121 215 INTERMEDIATE SHAFT HUB Fig 100 Removing Intermediate Shaft Thrust Plate y 5 SDRIVING SHELL 2227 1 ON Fig 101 Front Band Removal Installation 27 Remove planetary geartrain as assembly Fig 102 Support geartrain with both hands during removal Do not allow machined surfaces on interme diate shaft or overdrive piston retainer to become nicked or scratched 28 If overdrive unit is not to be serviced install Alignment Shaft 6227 2 into the overdrive unit to prevent misalignment of the overdrive clutches dur ing service of main transmission components 29 Loosen rear band adjusting screw 4 5 turns
67. Apply air pressure to the rear servo apply passage The servo rod should extend and cause the band to tighten around the drum Spring pressure should release the servo when air pressure is removed CONVERTER HOUSING FLUID LEAK DIAGNOSIS When diagnosing converter housing fluid leaks two items must be established before repair 1 Verify that a leak condition actually exists 2 Determined the true source of the leak Some suspected converter housing fluid leaks may not be leaks at all They may only be the result of residual fluid in the converter housing or excess fluid spilled during factory fill or fill after repair Converter housing leaks have several potential sources Through careful observation a leak source can be identified before removing the transmission for repair Pump seal leaks tend to move along the drive hub and onto the rear of the converter Pump O ring or pump body leaks follow the same path as a seal leak Fig 10 Pump vent or pump attaching bolt leaks are generally deposited on the inside of the converter housing and not on the converter itself Fig 10 Pump seal or gasket leaks usually travel down the inside of the converter housing Front band lever pin plug leaks are generally deposited on the housing and not on the converter PUMP SEAL PUMP PUMP VENT BOLT REAR MAIN SEAL LEAK CONVERT ER HOUSING CONVERTER J9021 35 Fig 10 Converter Housing Leak Paths 2 TORQUE CONVERTER LEAK POIN
68. Clean and inspect the front clutch components Replace the dutch discs if warped worn scored burned or charred the lugs are damaged or if the facing is flaking off Replace the steel plates and reaction plate if heavily scored warped or broken Be sure the driving lugs on the discs and plate are also in good condition The lugs must not be bent cracked or damaged in any way Replace the piston springs and spring retainer if either are distorted warped or broken Check the lug grooves in the clutch piston retainer The steel plates should slide freely in the slots Replace the piston retainer if the grooves are worn or damaged Also check action of the check ball in the 21 218 TRANSMISSION AND TRANSFER CASE CLEANING AND INSPECTION Continued piston retainer The ball must move freely and not stick Replace the retainer bushing if worn scored or there is any doubt about bushing condition Inspect the piston and retainer seal surfaces for nicks or scratches Minor scratches can be removed with crocus cloth However replace the piston and or retainer if the seal surfaces are seriously scored Check the dutch piston check ball The ball should be securely in place Replace the piston if the ball is missing or seized in place REAR CLUTCH Clean the dutch components with solvent and dry them with compressed air Check condition of the input shaft seal rings It is not necessary to remove or replace rings unless they are bro
69. Connect Faulty 4 Connectors spread open Repair 5 Valve Body Manual Lever 5 Inspect lever assembly and replace if Assembly Bent Worn Broken damaged NO REVERSE OR SLIPS 1 Direct Clutch Pack front clutch 1 Disassemble unit and rebuild clutch pack IN REVERSE Worn 2 Rear Band Misadjusted 2 Adjust band 3 Front Clutch Malfunctioned 3 Air pressure test clutch operation Remove Burned and rebuild if necessary 4 Overdrive Thrust Bearing Failure 4 Disassemble geartrain and replace bearings 5 Direct Clutch Spring Collapsed 5 Remove and disassemble unit Check Broken clutch position and replace spring 2 3RANSMISSION AND TRANSFER CASE 21 25 DIAGNOSIS AND TESTING Continued CONDITION POSSIBLE CAUSES CORRECTION OIL LEAKS 1 Speedometer Adapter Leaks 1 Replace both adapter seals 2 Fluid Lines and Fittings 2 Tighten fittings If leaks persist replace Loose Leaks Damaged fittings and lines if necessary 3 Fill Tube where tube enters 3 Replace O ring seal Inspect tube for case Leaks Damaged cracks in fill tube 4 Pressure Port Plug Loose 4 Tighten to correct torque Replace plug or Loose Damaged reseal if leak persists 5 Pan Gasket Leaks 5 Tighten pan screws 150 in Ibs If leaks persist replace gasket 6 Valve Body Manual Lever Shaft 6 Replace shaft seal Seal Leaks Worn 7 Rear Bearing Access Plate 7 Replace gasket Tighten screws Leaks 8 Gasket Damag
70. Disconnect CLEAR return line at cover plate and place it in a drain pan 10 Turn pump ON for 30 seconds to purge flush ing solution from cooler and lines Turn pump OFF 11 Place CLEAR suction line into a one quart container of Mopar ATF Plus 3 type 7176 automatic transmission fluid 12 Turn pump ON until all transmission fluid is removed from the one quart container and lines This purges any residual cleaning solvent from the trans mission cooler and lines Turn pump OFF 13 Disconnect alligator clips from battery Recon nect flusher lines to cover plate and remove flushing adapters from cooler lines ALUMINUM THREAD REPAIR Damaged or worn threads in the aluminum tran saxle case and valve body can be repaired by the use of Heli Coils or equivalent This repair consists of drilling out the worn out damaged threads Then tap the hole with a special Heli Coil tap or equivalent and installing a Heli Coil insert or equivalent into the hole This brings the hole back to its original thread size Heli Coil or equivalent tools and inserts are readily available from most automotive parts suppli ers REMOVAL AND INSTALLATION TRANSMISSION The overdrive unit can be removed and serviced separately It is not necessary to remove the entire transmission assembly to perform overdrive unit repairs 2 REMOVAL AND INSTALLATION Continued If only the overdrive unit requires service refer to the overdrive unit re
71. Fig 191 DRIVING SHELL Ww 1 ASSEMBLED FRONT PLANETARY AND ANNULUS GEARS 19121 76 Fig 190 Installing Front Planetary And Annulus Gear Assembly SNAP R PLANETARY RING SNAP PLIERS RING 19121 77 Fig 191 Installing Planetary Snap Ring 15 Turn planetary geartrain over Position wood block under front end of intermediate shaft and sup port geartrain on shaft Be sure all geartrain parts 2 have moved forwrd against planetary snap ring This is important for accurate end play check 16 Check planetary geartrain end play with feeler gauge Fig 192 Insert gauge between rear annulus gear and shoulder on intermediate shaft as shown End play should be 0 15 to 1 22 mm 0 006 to 0 048 in 17 If end play is incorrect install thinner thicker planetary snap ring as needed REAR ANNULUS OUTPUT SHAFT e FEELER GAUGE J9121 78 Sa ae EE Fig 192 Checking Planetary Geartrain End Play OVERDRIVE UNIT DISASSEMBLY 1 Remove transmission speed sensor and O ring seal from overdrive case Fig 193 SOCKET AND WRE SPEED SENSOR Fig 193 Transmission Speed Sensor Removal Installation 2 DISASSEMBLY AND ASSEMBLY Continued 2 Remove overdrive piston thrust bearing Fig 194 OVERDRIVE PISTON 1 Remove overdrive piston thrust plate Fig 195 Retain thrust plate It is a select fit part and may possibly be reused THRUST BEARING OVE
72. Fig 60 N SECTOR A BUSHING Fig 59 Sector O Ring And Bushing Installation 3 Install new pads on range fork Fig 61 if nec essary 4 Install clutch sleeve in range fork Fig 61 5 Install assembled range fork and clutch sleeve Fig 62 6 Insert range fork pin in sector Then rotate sec tor and seat clutch gear in low range gear 2 DISASSEMBLY AND ASSEMBLY Continued 22 9323 Fig 60 Shift Sector Installation RANGE RANGE FORK FORK AND PADS RAIL CLUTCH SLEEVE J9321 62 Fig 61 Assembling Range Fork And Clutch Sleeve 7 Verify that range fork rail is seated in case bushing and that clutch sleeve is properly engaged in low range gear 8 Rotate sector to Neutral position CLUTCH SLEEVE Fig 62 Range Fork And Clutch Sleeve Installation TRANSMISSION AND TRANSFER CASE 21 287 9 Install new O ring on detent plug Fig 63 10 Lubricate detent plunger with transmission fluid or light coat of petroleum jelly 11 Install detent plunger spring and plug Fig 63 12 Verify that plunger is properly engaged in sector DETENT PLUNGER DETENT SPRING DETENT PLUG J9321 22 Fig 63 Shift Detent Components 13 Insert mainshaft into input gear pilot bearing FRONT OUTPUT SHAFT AND DRIVE CHAIN INSTALLATION 1 Lubricate front output shaft sprocket assembly drive chain and drive sprocket with transmission fluid 2 Assemble d
73. INTERMEDIATE CLUTCH SHAFT DIFFERENTIAL MAINSHAFT J8921 262 J8921 260 Fig 32 Intermediate Clutch Shaft Removal rig eet Difetential 10 Remove differential snap ring Fig 33 11 Remove differential Fig 34 12 Remove differential needle bearings and both needle bearing thrust washers from mainshaft 13 Slide low range fork pin out of shift sector slot Fig 35 14 Remove low range fork and hub Fig 36 15 Remove shift sector Fig 37 DIFFERENTIAL SNAP 4 18921 261 18921 263 Fig 33 Differential Snap Ring Removal hig 29 Disengaging Low Hange Fork 21 252 TRANSMISSION AND TRANSFER CASE 2 DISASSEMBLY AND ASSEMBLY Continued SHIFT SECTOR BUSHING FORK HUB J8921 207 8921 264 Fig 38 Sector Bushing And O Ring Removal INPUT GEAR LOW RANGE ASSEMBLY REM OVAL AND DISASSEMBLY 1 Remove front bearing retainer bolts 2 Remove front bearing retainer Carefully pry retainer loose with screwdriver Fig 39 Position screwdriver in slots cast into retainer 3 Remove input gear snap ring Fig 40 RETAINER SLOT Fig 37 Shift Sector Position 16 Remove shift sector bushing and O ring Fig 38 J8921 266 Fig 39 Front Bearing Retainer Removal 2 5 55 AND TRANSFER CASE 21 253 DISASSEMBLY AND ASSEMBLY Continued
74. Inches 1 7500 1 7649 1 7650 1 7799 1 7800 1 7949 1 7950 1 8099 1 8100 1 8249 1 8250 1 8399 1 8400 1 8549 1 8550 1 8699 1 8700 1 8849 1 8850 1 8999 J9121 342 Fig 245 Overdrive Piston Thrust Plate Selection OVERDRIVE PISTON ASSEMBLY 1 Install new seals on over drive piston 2 Stand transmission case upright on bellhous ing 3 Position Guide Ring 8114 1 on outer edge of overdrive piston retainer 4 Position Seal Guide 8114 2 on inner edge of overdrive piston retainer 5 Install overdrive piston in overdrive piston retainer by aligning locating lugs on overdrive piston to the two mating holes in retainer a Aligning locating lugs on overdrive piston to the two mating holes in retainer b Lubricate overdrive piston seals with Door Ease or equivalent 2 DISASSEMBLY AND ASSEMBLY Continued Install piston over Seal Guide 8114 2 and inside Guide Ring 8114 1 d Push overdrive piston retainer e Verify that the locating lugs entered the lug bores in the retainer 6 Install intermediate shaft spacer on intermedi ate shaft 7 Install overdrive piston thrust plate on over drive piston 8 Install overdrive piston thrust bearing on over drive piston 9 Install transmission speed sensor and O ring seal in overdrive case Fig 185 into position in CLEANING AND INSPECTION VALVE BODY Clean the valve housings valves plugs springs
75. Installation INTERM EDIATE SHAFT SPACER SELECTION 1 Place overdrive unit in vertical position Mount it on blocks or in workbench with appropriate size mounting hole cut into it Be sure unit is facing upward for access to direct dutch hub Also be sure output shaft is not loaded and internal components are moved rearward for accurate measurement 2 Determine correct thickness intermediate shaft spacer as follows a Insert Special Tool 6312 through sun gear planetary gear and into pilot bushing in output shaft Be sure tool bottoms against planetary shoulder b Position Gauge Tool 6311 across face of over drive case Fig 249 Then position Dial Caliper C 4962 over gauge tool c Extend sliding scale of dial caliper downward through gauge tool slot until scale contacts end of Gauge Alignment Tool 6312 Lock scale in place Remove dial caliper tool and note distance mea sured Fig 249 2 DISASSEMBLY AND ASSEMBLY Continued d Select proper thickness end play spacer from spacer chart based on distance measured Fig 250 e Remove Gauge Alignment Tool 6312 SPECIAL TOOL C 4962 7 SPECIAL TOOL 6311 SPECIAL TOOL 6312 J9221 47 Fig 249 Shaft End Play Measurement Measurement Spacer Thickness Inches Inches 7336 7505 158 159 7506 7675 1175 176 7676 7855 193 194 7856 8011 211 212 19121 341 Fig 250 Intermediate Shaft End Play Spacer Selection OD THRUST PLA
76. K RETAINER Fig 14 Loosening Rear Retainer 6 Remove speedometer drive gear Fig 17 7 Remove rear bearing snap ring 8 Remove rear bearing Note position of bearing locating ring groove for assembly reference 9 Disengage oil pickup tube from oil pump and remove oil pump assembly Fig 18 10 Remove pick up tube o ring from oil pump Fig 19 if necessary Do not disassemble the oil pump it is not serviceable TRANSMISSION AND TRANSFER CASE 21 277 PARALLEL 92 saw RING PLIERS J9321 6 Fig 15 Disengaging Rear Bearing Locating Ring REAR RETAINER REAR CASE J9321 7 Fig 16 Rear Retainer Removal MAINSHAFT SPEEDOMETER DRIVE GEAR J9321 8 Fig 17 Speedometer Drive Gear Removal VISCOUS COUPLER REM OVAL 1 Remove oil pump locating snap ring and vis cous coupling snap ring from mainshaft Fig 20 2 Remove viscous coupling from mainshaft Fig 20 YOKE AND RANGE LEVER REM OVAL 1 Remove transfer case indicator switch 2 Remove front yoke nut as follows a Move range lever to 4L position 21 278 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued Fig 18 Rear Bearing and Oil Pump Removal OIL PUMP O RING RR21F27 Fig 19 Pick up Tube O ring Location TRANSFER CASE VISCOUS COUPLING MAINSHAFT RINGS 80468d25 Fig 20 Viscous Coupling Removal b Remove nut with socket and impact wrench Fig 21 3
77. Locations In Upper Housing J9321 154 2 Be sure filter screen is seated in proper housing recess 3 Install the ECE check ball into the transfer plate Fig 61 The ECE check ball is approximately 4 8 mm 3 16 in in diameter 4 Position lower housing separator transfer plate Fig 76 5 Install lower housing on assembled transfer plate and upper housing Fig 77 6 Install and start all valve body screws by hand except for the screws to hold the boost valve tube brace Save those screws for later installation Then tighten screws evenly to 4 N m 35 in Ibs torque Start at center and work out to sides when tighten ing screws Fig 77 plate on TRANSFER FILTER SCREEN PLATE SEPARATOR J9321 439 Fig 75 Installing Transfer Plate On Upper Housing BE SURE TO ALIGN LOWER HOUSING OVERDRIVE SEPARATOR PLATE J9321 441 Fig 76 Lower Housing Separator Plate UPPER HOUSING VALVE AND PLUG Refer to Fig 78 Fig 79 and Fig 80 to perform the following steps 1 Lubricate valves plugs springs with dean transmission fluid 2 DISASSEMBLY AND ASSEMBLY Continued VALVE BODY SCREWS 13 TRANSFER PLATE J9321 442 Fig 77 Installing Lower Housing On Transfer Plate And Upper Housing 2 Assemble regulator valve line pressure plug sleeve throttle plug and spring Insert assembly in upper housing and install cover plate Tighten cover plate screws to 4 35 i
78. PARK NEUTRA POSITION SWITCH CONNECTOR TERMINAL 19321 387 Fig 29 Transmission Case Connector INSTALLATION 1 Check condition of O ring seals on valve body harness connector Fig 31 Replace seals on tor body if cut or worn 2 Check condition of manual lever shaft seal in transmission case Replace seal if lip is cut or worn Install new seal with 15 16 deep well socket Fig 32 3 Check condition of seals on accumulator piston Fig 33 Install new piston seals if necessary 21 156 TRANSMISSION AND TRANSFER CASE REMOVAL AND INSTALLATION Continued VALVE BODY WIRE HARNESS GOVERNOR PRESSURE SOLENOID GOVERNOR PRESSURE SENSOR J9321 388 Fig 30 Valve Body 4 Place valve body manual lever in low 1 posi tion so ball on park lock rod will be easier to install in sprag 5 Lubricate shaft of manual lever with petroleum jelly This will ease inserting shaft through seal in case 6 Lubricate seal rings on valve body harness con nector with petroleum jelly 7 Position valve body in case and work end of park lock rod into and through sprag Turn pro peller shaft to align sprag and park lock teeth if nec essary The rod will click as it enters pawl Move rod to check engagement CAUTION It is possible for the park rod to dis place into a cavity just above the pawl sprag during installation Make sure the rod is actually engaged in the pawl and has not displaced in
79. Polish the hub and 2 REMOVAL AND INSTALLATION Continued notches with 320 400 grit paper or crocus cloth if nec essary The hub must be smooth to avoid damaging the pump seal at installation 1 Lubricate converter hub and oil pump seal lip with transmission fluid 2 Place torque converter in position on transmis sion CAUTION Do not damage oil pump seal or bushing while inserting torque converter into the front of the transmission 3 Align torque converter to oil pump seal open ing 4 Insert torque converter hub into oil pump 5 While pushing torque converter inward rotate converter until converter is fully seated in the oil pump gears 6 Check converter seating with a scale and straightedge Fig 17 Surface of converter lugs should be 1 2 in to rear of straightedge when con verter is fully seated 7 If necessary temporarily secure converter with C damp attached to the converter housing 8 Install the transmission in the vehicle 9 Fill the transmission with the recommended fluid STRAIGHTEDGE Fig 17 Checking Torque Converter Seating YOKE SEAL REPLACEM ENT REMOVAL 1 Raise vehide 2 Mark propeller shaft and axle yoke for align ment reference 3 Disconnect and remove propeller shaft 4 Remove old seal with Seal Remover C 3985 B Fig 18 from overdrive housing TRANSMISSION AND TRANSFER CASE 21 31 INSTALLATION 1 Place seal in position on overdrive housing 2
80. Remove adjusting screw bracket line pressure adjusting screw pressure regulator valve spring and switch valve spring Fig 58 Do not remove throt tle pressure adjusting screw from bracket and do not disturb setting of either adjusting screw during removal 22 Turn upper housing over and remove switch valve regulator valve and spring and manual valve Fig 59 23 Remove kickdown detent kickdown valve and throttle valve and spring Fig 59 24 Loosen left side 3 4 accumulator housing attaching screw about 2 3 threads Then remove cen ter and right side housing attaching screws Fig 60 25 Carefully rotate 3 4 accumulator housing upward and remove 3 4 shift valve spring and con verter clutch valve plug and spring Fig 61 26 Remove left side screw and remove 3 4 accu mulator housing from valve body Fig 62 27 Bend back tabs on boost valve tube brace Fig SWITCH LINE VALVE PRESSURE 4 SPRING m THROTTLE PRESSURE ADJUSTING SCREW PRESSURE ADJUSTING REGULATOR BRACKET SCREW VALVE SPRING J9321 431 Fig 58 Adjusting Screw Bracket And Spring 21 164 TRANSMISSION AND TRANSFER CASE 2 DISASSEMBLY AND ASSEMBLY Continued UPPER HOUSING REGULATOR VALVE SWITCH VALVE REGULATOR VALVE SPRING S SHUTTLE VALVE PRIMARY SPRING qs T GOVERNOR PLUG GOVERNOR PLUG MANUAL VALVE PLUG e THROTTLE M KICKXDOWN GOVERN
81. Remove direct clutch drum rear retaining ring Fig 216 8 Remove direct clutch drum outer retaining ring Fig 217 9 Mark annulus gear and output shaft for assem bly alignment reference Fig 218 Use punch or scriber to mark gear and shaft DIRECT CLUTCH DRUM ANNULUS GEAR 19121 292 Fig 216 Clutch Drum Inner Retaining Ring Removal RETAINING RING Fig 217 Clutch Drum Outer Retaining Ring Removal 10 Remove snap ring that secures annulus gear on output shaft Fig 219 Use two screwdrivers to unseat and work snap ring out of groove as shown 11 Remove annulus gear from output shaft Fig 220 Use rawhide or plastic mallet to tap gear off shaft GEAR CASE AND PARK LOCK 1 Remove locating ring from gear case 2 Remove park pawl shaft retaining bolt and remove shaft and spring 3 Remove reaction plug snap ring and remove reaction plug 4 Remove output shaft seal 21 206 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued OUTPUT 5 2 gt 3 C PUNCH 19221 46 Fig 218 Marking Annulus Gear And Output Shaft For Assembly Alignment OUTPUT SHAFT ANNULUS GEAR ANNULUS GEAR J9021 288 Fig 220 Annulus Gear Removal 2 ASSEMBLY GEARTRAIN AND DIRECT CLUTCH 1 Soak direct clutch and overdrive clutch discs in Mopar ATF Plus 3 type 7176 transmission fluid Allow discs to soak for 10 20 minute
82. Sharp edges are vital as they pre vent foreign matter from getting between the valve and valve bore Do not reuse oil seals gaskets seal rings or O rings during overhaul Replace these parts as a matter of course Also do not reuse snap rings or E clips that are bent or distorted Replace these parts as well Lubricate transmission parts with Mopar ATF Plus Type 7176 transmission fluid during overhaul and assembly Use petroleum jelly Mopar Door Ease or Ru Glyde to prelubricate seals O rings and thrust washers Petroleum jelly can also be used to hold parts in place during reassembly 2 TRANSMISSION CASE CLEANING AND INSPECTION Clean the case in a solvent tank Flush the case bores and fluid passages thoroughly with solvent Dry the case and all fluid passages with compressed air Be sure all solvent is removed from the case and that all fluid passages are dear NOTE Do not use shop towels or rags to dry the case or any other transmission component unless they are made from lint free materials Lint will stick to case surfaces and transmission components and circulate throughout the transmission after assem bly A sufficient quantity of lint can block fluid pas sages and interfere with valve body operation Inspect the case for cracks porous spots worn bores or damaged threads Damaged threads can be repaired with Helicoil thread inserts However the case will have to be replaced if it exhibits any type of da
83. Switch valve and spring pressure adjusting screw and bracket assembly throttle lever manual lever and shaft seal throttle lever shaft seal washer and E dip fluid filter and screws detent ball and spring valve body screws governor pressure solenoid governor pressure sensor and retaining clip park lock rod and E dip TRANSMISSION GENERAL INFORMATION Inspect the transmission bushings during overhaul Bushing condition is important as worn scored bush ings contribute to low pressures clutch slip and accelerated wear of other components However do not replace bushings as a matter of course Replace bushings only when they are actually worn or scored Use recommended tools to replace bushings The tools are sized and designed to remove install and seat bushings correctly The bushing replacement tools are included in Bushing Tool Set C 3887 B Presized service bushings available for replacement purposes Only the sun gear bushings are not serviced Low cost of the sun gear assembly makes it easier to simply replace the gear and bush ings as an assembly Heli Coil inserts can be used to repair damaged stripped or worn threads in aluminum parts These inserts are available from most automotive parts suppliers Stainless steel inserts are recommended The use of crocus cloth is permissible where neces sary providing it is used carefully When used on shafts or valves use extreme care to avoid rounding off sharp edges
84. THERMISTOR 80a0c4fa Fig 28 Pressure Sensor and Disassembly and Assembly section for proper proce dures The only replaceable valve body components are e Manual lever TRANSMISSION AND TRANSFER CASE 21 155 Manual lever washer seal E dip and shaft seal Manual lever detent ball e Throttle lever Fluid filter Pressure adjusting screw bracket Governor pressure solenoid Governor pressure sensor e Converter clutch overdrive solenoid assembly and harness includes sump temperature thermistor e Governor housing gasket e Solenoid case connector O rings The remaining valve body components are serviced only as part of a complete valve body assembly REMOVAL 1 Shift transmission into NEUTRAL 2 Raise vehicle 3 Remove gearshift and throttle levers from shaft of valve body manual lever 4 Disconnect wires at solenoid case connector Fig 29 5 Position drain pan under transmission oil pan 6 Remove transmission oil pan and gasket 7 Remove fluid filter from valve body 8 Remove bolts attaching valve body to transmis sion case 9 Lower valve body enough to remove accumula tor piston and springs 10 Work manual lever shaft and electrical con nector out of transmission case 11 Lower valve body rotate valve body away from case pull park rod out of sprag and remove valve body Fig 30 SOLENOID CASE CONNECTOR Seve a
85. Tighten all valve body housing screws to 4 35 in Ibs torque after tube and brace are installed Tighten screws in diagonal pattern starting at center and working outward 3 4 ACCUMULATOR 1 Position converter clutch valve and 3 4 shift valve springs in housing Fig 89 2 Loosely attach accumulator housing with right side screw Fig 89 Install only one screw at this time as accumulator must be free to pivot upward for ease of installation 3 Install 3 4 shift valve and spring 4 Install converter clutch timing valve spring HOUSING DISENGAGE UPPER THIS END OF HOUSING TUBE FIRST J9321 147 Fig 86 Boost Valve Tube 5 Position plug on end of converter clutch valve spring Then compress and hold springs and plug in place with fingers of one hand 6 Swing accumulator housing upward over valve springs and plug 7 Hold accumulator housing firmly in place and install remaining two attaching screws Be sure springs and clutch valve plug are properly seated Fig 90 Tighten screws to 4 N m 35 in Ibs 2 DISASSEMBLY AND ASSEMBLY Continued BOOST VALVE TUBE TUBE BRACE J9521 107 Fig 87 Boost Valve Tube And Brace BEND TABS UP AGAINST TUBE AS SHOWN J9521 108 Fig 88 Securing Boost Valve Tube With Brace Tabs RIGHT SIDE SCREW CONVERTER CLUTCH VALVE SPRING 3 4 SHIFT VALVE SPRING 3 4 ACCUMULATOR J9321 160 Fig 89 Converter Clutch And 3 4 Shift
86. Venting 4 Remove valve body and replace solenoid assembly if plugged or shorted 5 Overdrive Solenoid Not Venting 5 Remove valve body and replace solenoid if plugged or shorted 6 Valve Body Valve Sticking 6 Repair stuck 3 4 shift valve or lockup timing valve NO 4 3 DOWNSHIFT WHEN 1 Control Switch Open Shorted 1 Test and replace switch if faulty CONTROL SWITCH IS TURNED 2 Overdrive Solenoid Connector 2 Test solenoids and replace if seized OFF Shorted or shorted 3 PCM Malfunction 3 Test with DRB scan tool Replace PCM if faulty 4 Valve Body Stuck Valves 4 Repair stuck 3 4 lockup or lockup timing valve CLUNK NOISE FROM DRIVELINE 1 Transmission Fluid Low 1 Add Fluid ON CLOSED THROTTLE 4 3 2 Throttle Cable Misadjusted 2 Adjust cable DOWNSHIFT 3 Overdrive Clutch Select Spacer 3 Replace overdrive piston thrust Wrong Spacer plate spacer 2 5 5 AND TRANSFER CASE 21 141 DIAGNOSIS AND TESTING Continued CONDITION POSSIBLE CAUSES CORRECTION 3 4 UPSHIFT OCCURS 1 Overdrive Solenoid Connector or 1 Test connector and wiring for IMMEDIATELY AFTER 2 3 SHIFT Wiring Shorted loose connections shorts or ground and repair as needed 2 TPS Malfunction 2 Test TPS and replace as necessary Check with DRB scan tool 3 POM Malfunction 3 Test PCM with DRB scan tool and replace controller if faulty 4 Overdrive Solenoid Malfunction 4 Replace
87. and both sprockets if the chain is stretched distorted or if any of the links bind Replace the bearings if rough or noisy LOW RANGE ANNULUS GEAR Inspect annulus gear condition carefully The gear is only serviced as part of the front case If the gear is damaged it will be necessary to replace the gear and front case as an assembly Do not attempt to remove the gear Fig 96 8001094b Fig 95 Seal Contact Surface Of Yoke Slinger FRONT REAR CASES AND FRONT RETAINER Inspect the cases and retainer for wear and dam age Clean the sealing surfaces with a scraper and all purpose cleaner This will ensure proper sealer adhe sion at assembly Replace the input retainer seal do not reuse it Check case condition If leaks were a problem look for gouges and severe scoring of case sealing sur faces Also make sure the front case mounting studs are in good condition 21 268 TRANSMISSION AND TRANSFER CASE CLEANING AND INSPECTION Continued 39021 16 Fig 96 Low Range Annulus Gear Check the front case mounting studs and vent tube The tube can be secured with Loctite 271 or 680 if loose The stud threads can be deaned up with a die if necessary Also check condition of the fill drain plug threads in the rear case The threads can be repaired with a thread chaser or tap if necessary Or the threads can be repaired with Helicoil stainless steel inserts if required OIL PUMP OIL PICKUP Examine the oil pump
88. and link in case Fig 128 3 Install low reverse drum Fig 129 Slide drum through rear band onto piston retainer hub and into engagement with overrunning dutch and race 2 19121 89 Fig 128 Rear And Link 221 9 _ AQO REAR BAND LINK M HUB OF OVERDRIVE PISTON RETAINER Zt Fig 129 Low Reverse Drum 4 Install thrust washer in low reverse drum spot face Fig 130 Use petroleum jelly to hold washer in place 5 Install snap ring that secures low reverse drum to piston retainer hub Fig 130 6 Insert band reaction pin part way into case and band link Fig 131 7 Install rear band adjusting lever reaction lever and strut Fig 132 Be sure levers and strut are aligned and engaged before seating band reaction pin in case 2 DISASSEMBLY AND ASSEMBLY Continued Tu OS G2 RSE DRUM 73 2 TABBED WASHER 7 4 9521 89 Fig 130 Low Heverse Drum Snap Ring REACTION PIN O RINGS J9121 91 Fig 131 Rear Band Reaction Pin PLANETARY GEARTRAIN FRONT REAR CLUTCH AND FRONT BAND 1 Remove Alignment Shaft 6227 2 if installed previously 2 Install assembled intermediate shaft and plan etary geartrain Fig 133 Support shaft carefully during installation Do not allow shaft bearing bushing surfaces to become nicked scratched 3 Lubricate intermediate shaft thrust plate with petroleum jelly and
89. auxiliary transmission fluid cooler a heavy duty cooling sys tem and the engine axle ratio combination needed to handle heavy loads FLUID CONTAMINATION Transmission fluid contamination is generally a result of e adding incorrect fluid failure to clean dipstick and fill tube when checking level e engine coolant entering the fluid internal failure that generates debris overheat that generates sludge fluid break down failure to reverse flush cooler and lines after repair failure to replace contaminated converter after repair The use of non recommended fluids can result in transmission failure The usual results are erratic shifts slippage abnormal wear and eventual failure due to fluid breakdown and sludge formation Avoid this condition by using recommended fluids only The dipstick cap and fill tube should be wiped dean before checking fluid level Dirt grease and other foreign material on the cap and tube could fall into the tube if not removed beforehand Take the time to wipe the cap and tube clean before withdraw ing the dipstick Engine coolant in the transmission fluid is gener ally caused by a cooler malfunction The only remedy is to replace the radiator as the cooler in the radiator is not a serviceable part If coolant has circulated through the transmission for some time an overhaul may also be necessary especially if shift problems had developed The transmission cooler and lines sh
90. be flushed The cooler bypass valve in the transmission must be replaced also The torque converter must also be replaced This will insure that metal particles or sludged oil are not later transferred back into the reconditioned or replaced transmission The only recommended procedure for flushing cool ers and lines is to use Tool 6906 Cooler Flusher WARNING WEAR PROTECTIVE EYEWEAR THAT MEETS THE REQUIREMENTS OF OSHA AND ANSI 287 1 1968 WEAR STANDARD INDUSTRIAL RUB BER GLOVES KEEP LIGHTED CIGARETTES SPARKS FLAMES AND OTHER IGNITION SOURCES AWAY FROM THE AREA TO PREVENT THE IGNITION OF COMBUSTI BLE LIQUIDS AND GASES KEEP A CLASS B FIRE EXTINGUISHER IN THE AREA WHERE THE FLUSHER WILL BE USED KEEP THE AREA WELL VENTILATED DO NOT LET FLUSHING SOLVENT COME IN CON TACT WITH YOUR EYES OR SKIN IF EYE CONTAM INATION OCCURS FLUSH EYES WITH WATER FOR 15 TO 20 SECONDS REMOVE CONTAMINATED CLOTHING AND WASH AFFECTED SKIN WITH SOAP AND WATER SEEK MEDICAL ATTENTION COOLER FLUSH USING TOOL 6906 1 Remove cover plate filler plug on Tool 6906 Fill reservoir 1 2 to 3 4 full of fresh flushing solution Flushing solvents are petroleum based solutions gen erally used to dean automatic transmission compo nents DO NOT use solvents containing acids water gasoline or any other corrosive liquids 2 Reinstall filler plug on Tool 6906 2 3 Verify pump power switch is turned OFF nec red alligator clip to positi
91. bearing with Installer 8128 Fig 49 Output Shaft Rear Bearing Installation Depth Handle C 4171 Fig 53 15 Remove front bearing retainer seal with suit able pry tool 16 Install new front bearing retainer with Installer 7884 Fig 54 9 Using Remover C 4210 and Handle C 4171 drive input shaft bearing from inside the annulus gear opening in the case Fig 50 10 Install locating ring on new bearing 11 Position case so forward end is facing upward 12 Using Remover C 4210 and Handle C 4171 drive input shaft bearing into case The bearing locating ring must be fully seated against case sur face Fig 51 2 DISASSEMBLY AND ASSEMBLY Continued 80a11090 Fig 52 Remove Input Gear Pilot Bearing HANDLE 4171 INSTALLER 8128 INPUT GEAR 80a98364 Fig 53 Install Input Gear Pilot Bearing INPUT AND LOW RANGE GEAR ASSEMBLY 1 Lubricate gears and thrust washers Fig 55 with recommended transmission fluid 2 Install first thrust washer in low range gear Fig 55 Be sure washer tabs are properly aligned in gear notches TRANSMISSION AND TRANSFER CASE 21 285 FRONT SPECIAL N TOOL RETAINER 7884 19521 41 Fig 54 Install Front Bearing Retainer Seal 3 Install input gear in low range gear Be sure input gear is fully seated 4 Install remaining thrust washer in low range gear and on top of input gear Be sure washer tabs are properly aligned in gear not
92. drive solenoid during the 3 4 upshift This causes the solenoid check ball to dose the vent port allowing line pressure from the 2 3 shift valve to act directly on the 3 4 upshift valve Line pressure on the 3 4 shift valve overcomes valve spring pressure moving the valve to the upshift position This action exposes the feed passages to the 3 4 timing valve 3 4 quick fill valve 3 4 accumulator and ultimately to the overdrive piston Line pressure through the timing valve moves the overdrive piston into contact with the overdrive clutch The direct clutch is disengaged before the overdrive clutch is engaged The boost valve provides increased fluid apply pressure to the overdrive clutch during 3 4 upshifts and when accel erating in fourth gear The 3 4 accumulator cushions overdrive clutch engagement to smooth 3 4 upshifts The accumulator is charged at the same time as apply pressure acts against the overdrive piston CONVERTER CLUTCH ENGAGEMENT Converter clutch engagement in third or fourth gear range is controlled by sensor inputs to the pow ertrain control module Inputs that determine clutch engagement are coolant temperature engine rpm vehicle speed throttle position and manifold vac uum The torque converter clutch is engaged by the clutch solenoid on the valve body The clutch can be engaged in third and fourth gear ranges depending on overdrive control switch position If the overdrive control switch is in the normal ON posi
93. dutch piston from dutch retainer Remove piston by rotating it up and out of retainer 6 Remove seals from clutch piston and clutch retainer hub Discard both seals as they are not reus able ASSEMBLY 1 Soak dutch discs in transmission fluid while assembling other clutch parts 2 Install new seals on piston and in hub of retainer Be sure lip of each seal faces interior of dutch retainer 3 Lubricate lips of piston and retainer seals with liberal quantity of Mopar Door Ease Then lubricate retainer hub bore and piston with light coat of trans mission fluid 4 Install dutch piston in retainer Fig 154 Use twisting motion to seat piston in bottom of retainer CAUTION Never push the clutch piston straight in This will fold the seals over causing leakage and clutch slip 5 Position spring in clutch piston Fig 155 6 Position spring retainer on top of piston spring Fig 156 Make sure retainer is properly installed Small raised tabs should be facing upward Semicircular lugs on underside of retainer are for positioning retainer in spring 2 TRANSMISSION AND TRANSFER CASE 21 69 DISASSEMBLY AND ASSEMBLY Continued RETAINER HUB FAL 5 CLUTCH SNAP RING PISTON WAVED PISTON SPRING SPRING RETAINER SNAP RING PRESSURE CLUTCH PLATE PISTON SEAL FRONT CLUTCH RETAINER 5 19321 222 Fig 152 42 Front Clutch Components S FRONT Se COMPRESSOR FRONT CLUTCH 2
94. from full forward position This is 2 range 4 Move transmission throttle lever from full for ward to full rearward position and read pressure on gauge 5 Line pressure should be 54 60 psi 372 414 kPa with throttle lever forward and gradually increase to 90 96 psi 621 662 kPa as lever is moved rearward Test Three Transmission In D Range Third Gear NOTE This test checks pressure regulation and condition of the clutch circuits Both test gauges are required for this test 1 Turn OD switch off 2 Leave vehicle on hoist and leave Gauge C 3292 in place at accumulator port 3 Move Gauge C 3293 SP over to front servo port for this test 4 Have helper start and run engine at 1600 rpm for this test 5 Move transmission shift lever two detents rear ward from full forward position This is D range 6 Read pressures on both gauges as transmission throttle lever is gradually moved from full forward to full rearward position e Line pressure at accumulator in D range third gear should be 54 60 psi 372 414 kPa with throttle lever forward and increase as lever is moved rear ward e Front servo pressure in D range third gear should be within 3 psi 21 kPa of line pressure up to kickdown point Test Four Transmission In Reverse NOTE This test checks pump output pressure reg ulation and the front clutch and rear servo circuits Use 300 psi Test Gauge C 3293 SP for this test 1 Leave vehicle on hois
95. gear and pump housing should also be 0 010 to 0 19 mm 0 0035 to 0 0075 in Measure clearance with an appropriate feeler gauge FRONT CLUTCH Clean and inspect the front clutch components Replace the clutch discs if warped worn scored burned or charred or if the facing is flaking off Replace the steel plates if heavily scored warped or broken Be sure the driving lugs on the plates are in good condition The lugs must not be bent cracked or damaged in any way Replace the clutch spring and spring retainer if either is distorted warped or broken Check the lug grooves in the clutch retainer The steel plates should slide freely in the slots Replace the retainer if the grooves are worn or damaged Check action of the check ball in the retainer Fig 248 The ball must move freely and not stick 21 94 TRANSMISSION AND TRANSFER CASE CLEANING AND INSPECTION Continued NOTE Inspect the clutch retainer bushings care fully Fig 249 The retainer bushings are NOT ser viceable It will be necessary to replace the retainer if either bushing is scored or worn Inspect the piston and retainer seal surfaces for nicks or scratches Minor scratches can be removed with crocus cloth However replace the piston and or retainer if the seal surfaces are seriously scored RETAINER CHECK BALL J9121 368 Fig 248 Front Clutch Piston Retainer Check Ball Location FRONT CLUTCH RETAINER BUSHINGS NON SERVICEABLE
96. necessary because normal converter flushing procedures will not remove all contami nants ELECTRONIC LOCK UP TORQUE CONVERTER The torque converter is a hydraulic device that couples the engine crankshaft to the transmission 2 GENERAL INFORMATION Continued The torque converter consists of an outer shell with an internal turbine a stator an overrunning clutch an impeller and an electronically applied converter dutch Torque multiplication is created when the sta tor directs the hydraulic flow from the turbine to rotate the impeller in the direction the engine crank shaft is turning The turbine transfers power to the planetary gear sets in the transmission The transfer of power into the impeller assists torque multiplica tion At low vehide speed the overrunning dutch holds the stator stationary during torque multiplica tion and allows the stator to freewheel at high vehi de speed The converter dutch engagement reduces engine speed Clutch engagement also provides reduced transmission fluid temperatures The torque converter hub drives the transmission oil fluid pump The torque converter is a sealed welded unit that is not repairable and is serviced as an assembly CAUTION The torque converter must be replaced if a transmission failure results in large amounts of metal or fiber contamination in the fluid TRANSMISSION GEAR RATIOS Gear ratios are Ast 2 74 1 e 2nd 1541 e 3rd 1 00 1 4th 0 69 1
97. or damaged Also be sure transmission dowel pins are seated in engine block and protrude far enough to hold transmission in alignment 10 Raise transmission and align converter with drive plate and converter housing with engine block 11 Move transmission forward Then raise lower or tilt transmission to align converter housing with engine block dowels 12 Rotate converter so alignment marks scribed on converter are aligned with mark on driveplate 13 Carefully work transmission forward and over engine block dowels until converter hub is seated in crankshaft 14 Install bolts attaching converter housing to engine 15 Install rear support Then lower transmission onto crossmember and install bolts attaching trans mission mount to crossmember 16 Remove engine support fixture 17 Install crankshaft position sensor 18 Install vehicle speed sensor and speedometer adapter 2 19 Install new plastic retainer grommet on shift linkage rod or lever that was disconnected Grommets should not be reused Use pry tool to remove rod from grommet and cut away old grom met Use pliers to snap new grommet into lever and to snap rod into grommet at assembly 20 Connect gearshift and throttle valve cable to transmission 21 Connect wires to park neutral position switch transmission solenoid s and oxygen sensor Be sure transmission harnesses are properly routed CAUTION It is essential that correct len
98. parts cleaning solution only Do not use gasoline kerosene or any type of caustic solution Do not immerse any of the electrical components in deaning solution Clean the governor solenoid and sensor and the dual solenoid and harness assembly by wiping them off with dry shop towels only Dry all except the electrical parts with compressed air Make sure all passages are dean and free from obstructions Do not use rags or shop towels to dry or wipe off valve body components Lint from these materials can stick to valve body parts interfere with valve operation and clog filters and fluid passages Wipe the governor pressure sensor and solenoid valve with dry lint free shop towels only The O rings on the sensor and solenoid valve are the only serviceable com ponents Be sure the vent ports in the solenoid valve are open and not blocked by dirt or debris Replace the valve and or sensor only when DRB scan tool diagnosis indicates this is necessary Or if either part has sus tained physical damage dented deformed broken etc CAUTION Do not turn the small screw at the end of the solenoid valve for any reason Turning the screw in either direction will ruin solenoid calibration and result in solenoid failure In addition the filter on the solenoid valve is NOT serviceable Do not try to remove the filter as this will damage the valve hous ing Inspect the throttle and manual valve levers and shafts Fig 253 Do not attempt
99. parts except the bearings with com pressed air Allow bearings to air dry Do not use shop towels for wiping parts dry unless the towels are made from a lint free material A suf ficient quantity of lint from shop towels cloths rags etc could plug the transmission filter and fluid pas sages Discard the old case gasket and seals Do not attempt to salvage these parts They are not reus able Replace any of the overdrive unit snap rings if distorted or damaged Minor nicks or scratches on components can be smoothed with crocus cloth However do not attempt to reduce severe scoring on any components with abrasive materials Replace severely scored compo nents do not try to salvage them Check condition of the park lock components and the overdrive case Replace the case if cracked scored or damaged Replace the park lock pawl plug or spring if worn or damaged Be sure the bullet at the end of the park lock rod is in good condition Replace the rod if the bullet is worn or the rod itself is bent or distorted Do not attempt to straighten the rod Check the bushings in the overdrive case Replace the bushings if severely scored or worn Also replace the case seal if loose distorted or damaged Examine the overdrive and direct clutch discs and plates Replace the discs if the facing is worn 2 CLEANING AND INSPECTION Continued severely scored or burned and flaking off Replace the clutch plates if worn heavily sco
100. pickup parts Replace the pump if any part appears to be worn or damaged Do not disassemble the pump as individual parts are not available The pump is only available as a complete assembly The pickup screen hose and tube are the only serviceable parts and are available separately ADJ USTMENTS SHIFT LINKAGE ADJUSTMENT 1 Shift transfer case into 4L position 2 Raise vehicle 3 Loosen lock bolt on adjusting trunnion Fig 97 4 Be sure linkage rod slides freely in trunnion Clean rod and apply spray lube if necessary 5 Verify that transfer case range lever is fully engaged in 4L position 6 Tighten adjusting trunnion lock bolt 7 Lower vehicle 2 TRANSFER CASE SHIFT LEVER ASSEMBLY TRANSFER CASE RANGE FLOORPAN LEVER SHAFT TRUNNION LOCK BOLT LINKAGE BRACKET 20 ADJUSTING TRUNNION LEVER HART ROD SH TORRACKET 19521 163 Fig 97 Shift Linkage SPECIFICATIONS TORQUE DESCRIPTION TORQUE Plug Detent 16 24 N m 12 18 ft Ibs Bolt Diff Case 17 27 N m 15 24 ft 165 Plug Drain Fill 20 25 N m 15 25 ft Ibs Bolt Front Brg Retainer 16 27 N m 12 20 ft Ibs Bolt Case Half 35 46 N m 26 34 ft Ibs Nut Front Yoke 122 176 N m 90 130 ft Ibs Screw Oil Pump 1 2 1 8 N m 12 15 in Ibs Nut RangeLever 27 34 N m 20 25 ft Ibs Bolt Rear Retainer 35 46 N m 26 34 ft Ibs Nuts Mounting
101. separate rod from manual lever Fig 48 16 Remove and washer that retains throt tle lever shaft in manual lever Fig 49 17 Remove manual lever and throttle lever Fig 50 Rotate and lift manual lever off valve body and throttle lever shaft Then slide throttle lever out of valve body 18 Position magnet next to detent housing to catch detent ball and spring Then carefully remove Retainer Tool 6583 and remove detent ball and spring Fig 51 19 Remove screws attaching pressure adjusting screw bracket to valve body and transfer plate Fig 52 Hold bracket firmly against spring tension while removing last screw 2 3RANSMISSION AND TRANSFER CASE 21 41 DISASSEMBLY AND ASSEMBLY Continued SPECIAL TOOL 6583 POSITIONED ON DETENT HOUSING ROD THROTTLE LEVER MANUAL 9521 178 ASSEMBLY J9321 425 Fig 47 Detent Ball And Sprin 8 PM Fig 50 Manual And Throttle Lever MANUAL DETENT DETENT DETENT HOUSING SPRING BALL PENCIL MAGNET ROD J9121 81 J9321 426 Fig 48 Park Rod Fig 51 Detent Ball And Spring _ THROTTLE 20 Remove adjusting screw bracket line pressure adjusting screw pressure regulator valve spring and switch valve spring Fig 53 Do not remove throt tle pressure adjusting screw from bracket and do not disturb setting of either adjusting screw during removal MANUAL SHAFT E CLIP AND WASHER
102. sit uations Engine torque is distributed to the front and rear axles through a viscous coupling Nearly all the available engine torque is directed to the rear wheels during normal driving situations when slippery con ditions are encountered the variable viscous directs torque to the front wheels as necessary The NV249 low range is provided by a gear reduction system for J8921 243 Fig 1 NV249 Transfer Case ADJUSTMENTS D 293 SPECIFICATIONS 293 SPECIAL TOOLS 294 increased low speed off road torque capability This range is designed for temporary use only Transfer case operating ranges are selected with a floor mounted shift lever The shift lever is connected to the transfer case range lever by an adjustable linkage rod Range positions are marked on the shifter bezel plate TRANSFER CASE IDENTIFICATION A circular I D tag is attached to the rear case of each NV249 transfer case Fig 2 The tag provides the transfer case model number assembly number serial number and low range ratio The transfer case serial number also represents the date of build TAG 7 I AQ pour 9 FILL PLUG DRAIN PLUG Fig 2 Transfer Case I D Tag 80b09a60 21 272 TRANSMISSION AND TRANSFER CASE GENERAL INFORMATION Continued RECOMM ENDED LUBRICANT AND FILL LEVEL Mopar Dexron 11 or ATF Plus are the only lubri cants recommended
103. so selector rod slides freely in trunnion 4 Verify that shift lever on transfer case is in Neutral position 5 Tighten trunnion 96 180 in Ibs torque 6 Lower vehicle enough for entry into driver seat but keep all wheels off shop floor 7 Verify correct linkage adjustment Start engine shift transmission into gear and shift transfer case into all ranges Be sure transfer case is fully engaged in high and low range Readjust linkage if necessary 8 Shut engine off and lower vehicle completely lock bolt to 11 20 RIVNUT 4 B 11 14 Nem 97 123 TORQUE SHAFT TRANSFER CASE BRACKET TRANSFER CASE SHIFT LEVER TORQUE SHAFT TRANSMISSION AND TRANSFER CASE 21 293 SPECIFICATIONS TORQUE DESCRIPTION TORQUE Bolt crossmember 41 47 N m 30 35 ft Ibs Plug Detent 16 24 12 18 ft Ibs Plugs drainffill 41 54 N m 30 40 ft Ibs Switch Electric 20 34 N m 15 25 ft Ibs Bolts front brg retainer 16 24 12 18 ft 165 Bolts case half 27 34 N m 20 25 ft Ibs Nut output yoke 122 176 N m 90 130 ft 165 Bolts rear extension 27 34 N m 20 25 ft Ibs Lock nut shift 27 34 N m 20 25 ft Ibs Bolt shift rod 11 20 N m 96 180 in 165 Nuts T case mount 5844 33 41 N m 24 30 ft Ibs Bolt U joint clamp 16 22 N m 12 16 ft 165 SHIFT LE
104. switch indicator light illuminates only when the over drive switch is turned to the OFF position or when illuminated by the transmission control module 3 4 SHIFT SEQUENCE The overdrive clutch is applied in fourth gear only The direct clutch is applied all ranges except fourth gear Fourth gear overdrive range is electron ically controlled and hydraulically activated Various sensor inputs are supplied to the powertrain control module to operate the overdrive solenoid on the valve body The solenoid contains a check ball that opens and closes a vent port in the 3 4 shift valve feed pas sage The overdrive solenoid and check ball are not energized in first second third or reverse gear The vent port remains open diverting line pressure from the 2 3 shift valve away from the 3 4 shift valve The overdrive control switch must be in the ON position 21 8 TRANSMISSION AND TRANSFER CASE DESCRIPTION AND OPERATION Continued to transmit overdrive status to the PCM A 3 4 upshift occurs only when the overdrive solenoid is energized by the PCM The PCM energizes the over drive solenoid during the 3 4 upshift This causes the solenoid check ball to dose the vent port allowing line pressure from the 2 3 shift valve to act directly on the 3 4 upshift valve Line pressure on the 3 4 shift valve overcomes valve spring pressure moving the valve to the upshift position This action exposes the feed passages to the 3 4 timing valve 3 4 qu
105. the O D switch is OFF Engagement occurs when the vehicle is cruising at a steady speed after the vehicle has warmed up The torque converter dutch disengages when the vehide begins to go uphill or the accelerator is applied The torque converter dutch feature increases fuel econ omy and reduces the transmission fluid temperature The 46RE transmission is cooled by an integral fluid cooler inside the radiator 2 TRANSMISSION AND TRANSFER CASE GENERAL INFORMATION Continued 21 120 UOISSIUISUEA 9 28 68108 YANIVLSY NOLSId 12 5 ESI JAIHQH3AO SATIVA 3AIHQH3AO loauia 14 5 31VIQ3IAH3 LNI 7IV3S LAVHS LNdLno uvao AHVI3NV Id H LNT uvau l9auld HO1fY1O H LNT S3lHVL3NV ld HOLNTS HOLNT9 dvad H3lHdJANOO 3nouol 2 GENERAL INFORMATION Continued TRANSMISSION IDENTIFICATION Transmission identification numbers are stamped on the left side of the case just above the oil pan gas ket surface Fig 2 Refer to this information when ordering replacement parts PART NUMBER BUILD DATE SERIAL NUMBER 80011960 Fig 2 Transmission Part Serial Number Location RECOMM ENDED FLUID Plus 3 Type 7176 automatic trans mission fluid is the recommended fluid for Chrysler automatic
106. the right rear of the transmission case The overdrive dutch pressure port is at the left rear of the case 2 DIAGNOSIS AND 5 Continued ACCUMULATOR GOVERNOR J9321 137 Fig 8 Pressure Test Port Locations Test One Transmission In Manual Low NOTE This test checks pump output pressure reg ulation and condition of the rear clutch and servo circuit Both test gauges are required for this test 1 Connec tachometer to engine Position tachom eter so it can be observed from driver seat if helper will be operating engine Raise vehicle on hoist that will allow rear wheels to rotate freely 2 Connec 100 psi Gauge C 3292 to accumulator port Then connect 300 psi Gauge C 3293 SP to rear servo port 3 Disconnec throttle and gearshift cables from levers on transmission valve body manual shaft 4 Have helper start and run engine at 1000 rpm 5 Move transmission shift lever fully forward into 1 range 6 Gradually move transmission throttle lever from full forward to full rearward position and note pressures on both gauges Line pressure at accumulator port should be 54 60 psi 372 414 kPa with throttle lever forward and gradually increase to 90 96 psi 621 662 kPa as throttle lever is moved rearward Rear servo pressure should be same as line pres sure within 3 psi 20 68 kPa TRANSMISSION AND TRANSFER CASE 21 129 Test Two Transmission In 2 Range NOTE This test check
107. this group for proper procedures GOVERNOR 11 Install fluid filter and pan BODY 12 Lower vehicle 13 Fill transmission with recommended fluid and road test vehide to verify repair RETAINING CLIP 80315868 GOVERNOR BODY GOVERNOR PRESSURE SENSOR TRANSMISSION FLUID TEMPERATURE THERMISTOR PRESSURE SOLENOID 80a0c4fa RETAINER Fig 95 Governor Pressure Sensor GOVERNOR PRESSURE uM RE Fig 98 Pressure Solenoid Retainer PRESSURE ZZ ENSOR 7 2 RS SENSOR 5 ASG 7 o 5 4 279 lt lt Kod To f 99 1 47 17 GOVERNOR 7 Fig 96 Governor Pressure Solenoid TRANSMISSION GOVERNOR DISASSEMBLY 1 Drain fluid from transmission 2 Clean exterior of transmission with suitable solvent or pressure washer 3 Remove torque converter from front of trans mission 80315865 Fig 99 Governor Pressure Sensor And Solenoid Connectors 21 176 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued 4 Remove throttle and shift levers from valve body manual shaft and throttle lever shaft 5 Place transmission in vertical position 6 Measure and record the input shaft end play measurement 7 Mount transmission in repair stand C 3750 B or similar type stand Fig 100 Fig 100 Repair Stand 8 Remove fluid pan and filter 9 Remove park neutral position switch and seal Fig 1
108. through sun gear and into splines of both hubs Be sure alignment tool is fully seated before proceeding 21 208 TRANSMISSION AND TRANSFER CASE 2 DISASSEMBLY AND ASSEMBLY Continued CLUTCH OVERRUNNING SPRING PLANETARY DRUM CLUTCH PLATE THRUST BEARING ASSEMBLY EXPANDING TYPE SNAP RING OVERRUNNING CLUTCH ASSEMBLY SEATED IN OUTPUT SHAFT J9121 326 Fig 229 Planetary Thrust Bearing Installation ANNULUS 7 GEAR J9121 314 Fig 227 Overrunning Clutch Installation PLANETARY GEAR SUN GEAR AND SPRING PLATE ASSEMBLY 19121 327 Fig 230 Sun Gear Installation SPECIAL TOOL 6227 2 ANNULUS SUN GEAR a 19121 324 ASSEMBLED DRUM AND Fig 228 Planetary Gear Installation ANNULUS 17 Install direct clutch spring Fig 232 Be sure GEAR spring is properly seated on spring plate 18 Assemble and install direct clutch pack on hub as follows PRESS a Assemble clutch pack components Fig 233 PLATES icm b Install direct dutch reaction plate on dutch 22 hub first Note that one side of reaction plate B 1 counterbored sure this side faces J9321 395 ward Splines at rear of hub are raised Fig 231 Alignment Tool Installation 2 5 5 AND TRANSFER CASE 21 209 DISASSEMBLY AND ASSEMBLY Continued SPECIAL REACTION TOOL PLATE 6227 2 BR COUNTERBORE DIRECT CLUTCH S
109. to transfer plate Fig 42 4 Remove retainer plate governor body and gas ket from transfer plate Fig 43 5 Disconnect wires from governor pressure sen sor if not done previously 6 Remove governor pressure sensor from gover nor body Sensor is retained in body with M shaped spring dip Fig 44 Remove clip with small pointed tool and slide sensor out of body 7 Remove governor pressure solenoid by pulling it straight out of bore in governor body Fig 45 Remove and discard solenoid O rings if worn cut or torn PRESSURE 4251 SENSOR F ANN 9 A 227193 ff PRESSURE SOLENOID GOVERNOR 80315865 Fig 41 Governor Pressure Solenoid And Sensor Wire Locations PRESSURE SOLENOID RETAINER GOVERNOR 80315866 Fig 42 Governor Body And Retainer Plate Attaching Screw 52 20 GOVERNOR SS S 9 BODY 80315868 Fig 43 Governor Body And Gasket RETAINING CLIP GOVERNOR BODY GOVERNOR PRESSURE SENSOR TRANSMISSION FLUID TEMPERATURE THERMISTOR 80a0c4fa Fig 44 Governor Pressure Sensor 2 DISASSEMBLY AND ASSEMBLY Continued PRESSURE SOLENOID A 80315867 Fig 45 Governor Pressure Solenoid 8 Remove transmission fluid filter 9 Remove small shoulder bolt that secures sole noid harness case connector to 3 4 accumulator hous ing Fig 46 Retain shoulder bolt Either tape it to harness or thread it back into accumulator housing afte
110. was not removed from lever assem bly work rod down through floorpan opening Then position lever assembly on floorpan install assembly attaching screws 2 Install console Refer to Group 23 Body for proper procedures 3 Raise vehicle 4 Connect trunnion to torque shaft arm Or slide shift rod into trunnion on range lever Be sure shift rod slides freely in trunnion 5 Verify that range lever is in 4L position Then tighten trunnion lock bolt 6 Lower vehicle and check transfer case shift operation SPEEDOMETER REMOVAL 1 Raise vehicle 2 Disconnect wires from vehicle speed sensor 3 Remove adapter clamp and screw Fig 5 4 Remove speed sensor and speedometer adapter as an assembly 5 Remove speed sensor retaining screw and remove sensor from adapter 21 244 TRANSMISSION AND TRANSFER CASE REMOVAL AND INSTALLATION Continued RIVNUT 4 TORQUE 3 4 Nem 27 35 in Ibs B 11 14 Nem 97 123 in Ibs 8 14 Nem 72 120 in Ibs TORQUE SHAFT TRANSFER CASE BRACKET TRANSFER CASE SHIFT LEVER TORQUE SHAFT 2 SHIFT LEVER ASSEMBLY FLOORPAN TRUNNION LOCK BOLT 9 SELECTOR ROD AND TRUNNION SHIFT LEVER SHAFT 19321 185 Fig 4 Shift Linkage Remove speedometer pinion from adapter Replace pinion if chipped cracked or worn 7 Inspect sensor and adapter O rings Fig 5 Remove and discard O rings if wor
111. when fluid temperature is at or above 10 C 50 F during nor mal city or highway driving A third curve is used during wide open throttle operation The fourth curve is used when driving with the transfer case in low range 2 DESCRIPTION AND OPERATION Continued SHIFT VALVE OPERATION The shift valves are moved by a combination of throttle and governor pressure The governor pres sure is generated by electrical components The conditions under which a shift to fourth will not occur are e Overdrive switch is Off e Transmission fluid temperature is below 10 C 50 F or above 121 C 250 F e Shift to third not yet completed e Vehicle speed too low for 3 4 shift to occur Battery temperature below 5 HYDRAULIC CONTROL SYSTEM The hydraulic control system provides fully auto matic operation The system performs five basic func tions which are pressure supply pressure regulation flow control clutch band application and lubrication PRESSURE REGULATION The pressure regulator valve maintains line pres sure The amount of pressure developed is controlled by throttle pressure which is dependent on the degree of throttle opening The regulator valve is located in the valve body The throttle valve determines line pressure and shift speed Governor pressure increases in propor tion to vehide speed The throttle valve controls upshift and downshift speeds by regulating pressure according to throttle position
112. 01 10 Remove valve body and electronic governor 11 Remove accumulator outer spring piston and inner spring Fig 102 Note position of piston and springs for assembly reference Remove and discard piston seals if worn or cut SOLENOID CONNECTOR NEUTRAL SWITCH 80b17181 Fig 101 Park Neutral Position Switch 2 12 Remove pump seal with suitable tool or slide hammer mounted screw 13 Remove front band lever pin access plug Fig 103 Use square end of 1 4 in drive extension to remove plug as shown OUTER SPRING ACCUMULATOR PISTON gt INNER SPRING 19121 208 Fig 102 Accumulator Component Removal go FRONT BAND REACTION PIN EXTENSION ND RATCHET 19121 17 Fig 103 Front Band Lever Pin Access Plug 14 Remove oil pump and reaction shaft support assembly as follows a Tighten front band adjusting screw until band is tight around front dutch retainer Fig 104 This will prevent retainer from coming out with pump and possibly damaging clutch or pump components ADJUSTING SCREW 5 16 OPEN END WRENCH 19121 13 Fig 104 Tightening Front Band To Hold Front Clutch In Place 2 5 5 AND TRANSFER CASE 21 177 DISASSEMBLY AND ASSEMBLY Continued b Remove oil pump bolts Thread Slide Hammer Tools C 3752 into threaded holes in flange of oil pump housing Fig 105 d Remove oi
113. 045 in If dearance is incorrect steel plates discs selec tive snap ring and pressure plates may have to be changed The selective snap ring thicknesses are 107 109 in 098 100 095 097 083 085 in 2 DISASSEMBLY AND ASSEMBLY Continued SHAFT SHAFT md THRUST WASHER METAL CLUTCH REAR CLUTCH PISTON PISTON SPRING WAVE SPRING REAR CLUTCH SNAP RING PLIERS ND Fig 158 Removing Installing Input Shaft Snap Ring 076 078 in 071 073 in e 060 062 in 16 Coat rear dutch thrust washer with petro leum jelly and install washer over input shaft and into dutch retainer Fig 164 Use enough petroleum jelly to hold washer in place 17 Set rear dutch aside for installation during final assembly 39121 149 TRANSMISSION AND TRANSFER CASE 21 71 REAR INPUT ires CLUTCH SHAFT artic RETAINER SHAFT WASHER FRONT FIBER SHAFT SEAL REAR RING SEAL TEFLON CLUTCH RING PACK METAL RETAINER SEAL RING PRESSURE PLATE CLUTCH BOTTOM DISCS 4 PRESSURE 19121 539 5 SEAL RINGS J9121 538 Fig 159 Rear Clutch Retainer And Input Shaft Seal Ring Installation PLANETARY GEARTRAIN OUTPUT SHAFT DISASSEMBLY 1 Remove planetary snap ring Fig 165 21 72 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued BE SURE RING ENDS ARE HOOK
114. 1 104 8 isd 6 0 3unssdud 1114 38 4 3AIHQH3AO NOILOnS isd 8 9 6568 aan d31H3ANOO isd 01 80 3unssadud LAIHS 2 1 isd 76 0 dunssaud JILLOYHL isd 0 3unssdud HONHJAOD isd 5 INIT aNOOHS NI DITINVYGAH JILLOHHL 5 uario NI H3A31 1 135 NOLIVOIHB TI OL H3lHdANOO ANOYOL 5 GION310S Ad fe JAWA L3IHS t 1 3KTVA TWONVAL ODN US d E INVA LAIHS 251 H E 5 H HONH3AOS 5 2 1 T 5 a ES 5 E E SENS
115. 1 93 do not need to be replaced unless cracked broken or severely worn 3 Inspect the pump and support components Replace the pump or support if the seal ring grooves or machined surfaces are worn scored pitted or damaged Replace the pump gears if pitted worn chipped or damaged 4 Inspect the pump bushing Then check the reaction shaft support bushing Replace either bush ing only if heavily worn scored or damaged It is not necessary to replace the bushings unless they are actually damaged 5 Install the gears in the pump body and mea sure pump component clearances as follows a Clearance between outer gear and reaction shaft housing should be 0 010 to 0 063 mm 0 0004 to 0 0025 in Clearance between inner gear and reaction shaft housing should be 0 010 to 0 063 mm 0 0004 to 0 0025 in Both dearances can be measured at the same time by 1 Installing the pump gears in the pump housing II Position an appropriate piece of Plasti gage across both gears Align the plastigage to a flat area on the reaction shaft housing IV Install the reaction shaft to the pump housing V Separate the reaction shaft housing from the pump housing and measure the Plastigage following the instructions supplied with it b Clearance between inner gear tooth outer gear should be 0 08 to 0 19 mm 0 0035 to 0 0075 in Measure clearance with an appropriate feeler gauge c Clearance between outer
116. 2 TRANSMISSION AND TRANSFER CASE 21 1 TRANSMISSION AND TRANSFER CASE CONTENTS 42 44 AUTOMATIC TRANSMISSION INDEX page page GENERAL INFORMATION OVERDRIVE ELECTRICAL CONTROLI 10 2 44 BE TRANSMISSION 2 PABK NELITBAL POSITION SWIICH 9 CAUSES BURNTFLUID 4 PRELIMINARY DIAGNOSIS 8 EFFECTS OF INCORRECT FLUID 4 10 LOCK UP SIAU TEST 14 TORQUE CONVERTER 4 HROTILE VALVE CABIFl 10 D CONTAMINATION 4 SERVICE PROCEDURES GEARSHIFT MECHANISM 5 RECOMMENDED 4 ONVERTER DRAINBACK TRANSMISSION GEAR RATIOS CHECK VALVE SERVICE D AND HEPLA B 4 SHIET SEQUENCH BRAKE TRANSMISSION SHIFT INTERLOCK MECHANISM ON H H O ENGA AIR TESTING TRANSMISSION CLUTCH AND BAND OPERATION CONVERTER STALL TEST 14 ERONT CLUTCH 68 DIAGNOSIS TABLES AND CHARTS RE TRANSMISSION 1 16 GEARSHIFT CABLEI YDRAULIC PR TESTI 11 OVERDRIVE UNI 21 2 TRANSMISSION AND TRANSFER CASE RANSMISSION THROTTLE VALVE CABLE ADJUSTMENT SPECIFICATIONS TRANSMISSION SPECIAL TOOLS GENERAL INFORMATION 42 44 RE TRANSMISSION The 42 44RE is a four speed fully automatic tra
117. 2 3575 CLUTCH SPRING RETAINER RETAINER SNAP RING SPRING RETAINER N 19121 147 Fig 153 Compressing Front Clutch Piston Spring 7 Compress piston spring and retainer with Com pressor Tool C 3575 A Fig 153 Then install new snap ring to secure spring retainer and spring 8 Install dutch plates and discs Fig 152 Install steel plate then disc until all plates and discs are installed The front clutch uses 4 dutch discs and CLUTCH J9121 146 Fig 154 Front Clutch Piston Installation plates in a 42RE transmission In a 44RE transmis sion 5 discs and plates are used 9 Install pressure plate and waved snap ring Fig 152 Front dutch clearance specifications for the 42RE and 44RE transmission are the same Clearance should be 1 70 to 3 40 mm 0 067 to 0 134 If dearance is incorrect dutch discs plates pressure plates and snap ring may have to be changed 21 70 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued RETAINER CLUTCH SPRING PISTON SMALL TABS ON RETAINER FACE UPWARD J9321 224 Fig 156 Correct Spring Retainer Installed Position REAR CLUTCH DISASSEMBLY 1 Remove fiber thrust washer from forward side of dutch retainer 2 Remove input shaft front rear seal rings 3 Remove selective dutch pack snap ring Fig 157 4 Remove top pressure plate clutch discs steel plates bottom pressure plate and wave snap ri
118. 20 34 N m 15 25 ft 165 torque 2 Lubricate yoke hub with transmission fluid and install yoke on front shaft TRANSMISSION AND TRANSFER CASE 21 265 SPECIAL TOOL MD998323 SPECIAL TOOL 80a98368 Fig 90 Rear Seal Installation SPECIAL TOOL C 4975 A 80a50357 Fig 91 Slinger Boot Installation 3 Install new seal washer on front shaft 4 Install yoke on front shaft Secure yoke with new nut CLEANING AND INSPECTION NV242 TRANSFER CASE Clean the transfer case parts with a standard parts cleaning solvent Remove all traces of sealer from the cases and retainers with a scraper and all purpose deaner Use compressed air to remove sol vent residue from oil feed passages in the case halves retainers gears and shafts The oil pickup screen can be cleaned with solvent Shake excess solvent from the screen after deaning and allow it to air dry Do not use compressed air MAINSHAFT SPROCKET HUB INSPECTION Inspect the splines on the hub and shaft and the teeth on the sprocket Minor nicks and scratches can 21 266 TRANSMISSION AND TRANSFER CASE CLEANING AND INSPECTION Continued be smoothed with an oilstone However replace any part is damaged Check the contact surfaces in the sprocket bore and on the mainshaft Minor nicks and scratches can be smoothed with 320 400 grit emery cloth but do not try to salvage the shaft if nicks or wear is severe INPUT GEAR AND PLANETARY CARRIER Check the teeth on th
119. 3 Turn remover tool hex nut down against remover cup to pull bushing from shaft Clean all chips from shaft after bushing removal 4 Lightly grip old bushing in vise or with pliers and back remover tool out of bushing 5 Assemble Bushing Installer Tools C 4171 and SP 5325 Fig 146 6 Slide new bushing onto Installer Tool SP 5325 7 Position reaction shaft support upright a dean smooth surface 8 Align bushing in bore Then tap bushing into place until Bushing Installer SP 5325 bottoms 9 Clean reaction shaft support thoroughly after installing bushing SPECIAL TOOL 4171 SPECIAL TOOL 5 1191 SPECIAL TOOL SP 3633 SPECIAL TOOL SP 5324 SPECIAL TOOL SP 5325 BUSHING REMOVAL BUSHING INSTALLATION J9221 243 Fig 146 Replacing Reaction Shaft Support Bushing ASSEMBLY 1 Lubricate gear bore in pump housing with transmission fluid 2 Lubricate pump gears with transmission fluid 3 Support pump housing on wood blocks Fig 147 4 Install outer gear in pump housing Fig 147 Gear can be installed either way it is not a one way fit 5 Install pump inner gear Fig 148 CAUTION The pump inner gear is a one way fit The bore on one side of the gear inside diameter LD is chamfered Be sure the chamfered side faces forward to front of pump TRANSMISSION AND TRANSFER CASE 21 67 PUMP P HOUSING SNS BLOCKS J9321 219 Fig 147 Support
120. 321 170 Fig 176 Driving Shell Thrust Washer Removal 6 Remove tabbed thrust washer from rear plane tary gear Fig 178 Note washer position on gear for assembly reference 7 Remove rear planetary gear and rear annulus gear from intermediate shaft Fig 179 8 Remove thrust plate from rear annulus gear Fig 180 ASSEMBLY 1 Lubricate sun gear and planetary gears with transmission fluid during assembly Use petroleum jelly to lubricate intermediate shaft bushing surfaces thrust washers and thrust plates and to hold these parts in place during assembly 2 Install front snap ring on sun gear and install gear in driving shell Then install thrust plate over TRANSMISSION AND TRANSFER CASE 21 197 INTERMEDIATE SHAFT DRIVING SHELL SUN GEAR J9321 171 Fig 177 Sun Gear And Driving Shell Removal SUN REAR GEAR 5 PLANETARY THRUST WASHER DRIVING SHELL J9321 172 Fig 178 Rear Planetary Thrust Washer Removal INTERMEDIATE REAR REAR SHAFT ANNULUS PLANETARY GEAR GEAR J9321 173 Fig 179 Rear Planetary And Annulus Gear Removal sun gear and against rear side of driving shell Fig 181 Install rear snap ring to secure sun gear and thrust plate in driving shell 3 Install rear annulus gear on intermediate shaft Fig 182 21 198 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued REAR ANNULUS GEAR THRUST PLATE J9321 174 Fig 180 Rear Annulus Thrust
121. 5 Remove transmission oil pan remove gasket drain oil and reinstall pan If overdrive unit had malfunctioned or if fluid is contaminated remove entire transmission If diag nosis indicated overdrive problems only remove just the overdrive unit 7 Support transmission with transmission jack 8 Remove vehide speed sensor and speedometer adapter if necessary 9 Remove bolts attaching overdrive unit to trans mission Fig 34 CAUTION Support the overdrive unit with a jack before moving it rearward This is necessary to pre vent damaging the intermediate shaft Do not allow the shaft to support the entire weight of the over drive unit OVERDRIVE UNIT J9021 83 Fig 34 Overdrive Unit Bolts 10 Carefully work overdrive unit off intermediate shaft Do not tilt unit during removal Keep it as level as possible 11 If overdrive unit does not require service immediately insert Alignment Tool 6227 2 in splines of planetary gear and overrunning clutch to prevent splines from rotating out of alignment If misalign TRANSMISSION AND TRANSFER CASE 21 157 ment occurs overdrive unit will have to be disassem bled in order to realign splines 12 Remove and retain overdrive piston thrust bearing Bearing may remain on piston or in clutch hub during removal 13 Position drain pan on workbench 14 Place overdrive unit over drain pan Tilt unit to drain residual fluid from case 15 Examine fl
122. 583 21 117 21 118 TRANSMISSION AND TRANSFER CASE 2 46 AUTOMATIC TRANSMISSION INDEX page page GENERAL INFORMATION IBANSMISSION PROCEDUBH 147 GRE TRANSMISSION BRAKE TRANSMISSION SHIFT INTERLOCK MECHANISM AIR TESTING TRANSMISSION CLUTCH AND BAND OPERATION RANSMISSION THROTTLE VALVE CABLE AD MEN 2 SCHEMATICS AND DIAGRAMS HYDRAULIC SCHEMATICS 223 SPECIFICATIONS 235 GENERAL INFORMATION 46RE TRANSMISSION The 46RE is a four speed fully automatic transmis sion with an electronic governor Fig 1 First through third gear ranges are provided by the dutches bands overrunning clutch and planetary gear sets in the transmission Fourth gear range is provided by the overdrive unit that contains an over drive dutch direct dutch planetary gear set and overrunning dutch The overdrive dutch is applied in fourth gear only The direct clutch is applied in all ranges except fourth gear The 46RE is equipped with a lock up dutch in the torque converter The torque converter clutch is controlled by the Power TRANSMISSION AND TRANSFER CASE 21 119 SPECIAL TOOLS train Control Module PCM The torque converter dutch is hydraulically applied and is released when fluid is vented from the hydraulic circuit by the torque converter control TCC solenoid on the valve body The torque converter clutch engages in fourth gear and in third gear when
123. 81 1 40 0 022 0 037 mm in Overdrive clutch disc usage 44RE 4 discs 42RE 6 discs 44RE 8 discs Direct clutch disc usage 42RE Band adjustment from 72 in lbs Front band Rear band 44RE Band adjustment from 72 in lbs Front band Back off 2 1 4 turns Rear band Back off 4 turns Recommended fluid Mopar ATF Plus 3 type 7176 GEAR RATIOS e 1ST GEAR 2 74 2ND GEAR 1 54 3RD GEAR 1 00 4TH GEAR 0 69 REV GEAR 2 21 Back off 3 5 8 turns Back off 4 turns 2 TORQUE DESCRIPTION TORQUE Fitting cooler line at trans 18 N m 13 ft Ibs Bolt torque convertor 31 N m 23 ft Ibs Bolt nut crossmember 68 N m 50 ft Ibs Bolt driveplate to crankshaft 75 N m 55 ft Ibs Plug front band reaction 17 N m 13 ft Ibs Locknut front band adj 34 N m 25 ft Ibs Switch park neutral 34 N m 25 ft Ibs Bolt fluid 17 N m 13 ft Ibs Screws fluid filter 4 N m 35 in Ibs Bolt pump 20 N m 15 ft Ibs Bolt overrunning clutch cam 17 N m 13 ft 165 Bolt O D totrans 34 25 ft Ibs Bolt O D piston retainer 17 N m 13 ft Ibs Plug pressure test port 14 N m 10 ft Ibs Bolt reaction shaft support 20 N m 15 ft Ibs Locknut rear 41 N m 30 ft Ibs Bolt speedometer adapter 11 N m 8 ft Ibs Bolt valve body to cas
124. 9 b 9 2 hole Be sure that the vehicle is level to ensure accurate fluid level check Correction Stop vehicle and shift into desired range Or reduce speed to 3 4 km h 2 3 mph before attempting to shift Stop vehicle shift transmission to neutral shift transfer case to 2H mode and operate vehicle on 2H on dry paved surface Lubricate repair or replace linkage or tighten loosen components as necessary Drain and refill to edge of fill hole with MOPAR ATF PLUS Type 7176 or DEXRON Automatic Transmission Fluid Disassemble unit and replace worn or damaged components as necessary Drain and refill to edge of fill hole with MOPAR ATF PLUS Type 7176 or DEXRON Automatic Transmission Fluid Check for leaks and repair if necessary unit is still noisy after drain and refill disassembly and inspection may be required to locate source of noise Stop vehicle shift transfer case to Neutral then shift back into AL position Tighten lubricate or repair linkage as necessary Disassemble unit and repair as necessary Disassemble unit and repair as necessary Drain to correct level Clear or replace vent if necessary Replace seals Be sure seal lip faces interior of case when installed Also be sure yoke seal surfaces are not scored or nicked Remove scores and nicks with fine sandpaper or replace yoke s if necessary Operate 2H on hard surface paved roads J9021
125. 9 5 LJIHSNMOG 2 6 31LLOHHL TINA ONIENG 1 GNOOAS 1 HOLM 4 NOLLvOIHS TI OL 3ATVA ONIIALL uaria 10 1 3998 27 GION310S 4 T Md YHOLVINANDOV 7 6 FILLOYHL HOLN19 1 6 uvau OAYAS 1 uvad 5 HONH3AOS HONH3AOD 2 SPECIFICATIONS RE TRANSMISSION GENERAL Oil pump gear
126. 9 Be sure hub is started on sun gear splines before proceeding WARNING THE NEXT STEP GEARTRAIN ASSEMBLY INVOLVES COMPRESSING THE DIRECT CLUTCH HUB AND SPRING IT IS EXTREMELY IMPORTANT THAT PROPER EQUIPMENT BE USED TO COMPRESS THE SPRING AS SPRING FORCE IS APPROXIMATELY 830 POUNDS USE COMPRES SOR TOOL 6227 AND HYDRAULIC TYPE SHOP PRESS WITH A MINIMUM RAM TRAVEL OF 6 INCHES THE PRESS MUST ALSO HAVE A BED THAT CAN BE ADJUSTED UP OR DOWN AS REQUIRED RELEASE CLUTCH SPRING TENSION SLOWLY AND COMPLETELY TO AVOID PERSONAL INJURY 20 Position Compressor Tool 6227 1 on clutch hub 21 Compress dutch hub and spring just enough to place tension on hub and hold it in place 22 Slowly compress clutch hub and spring Com press spring and hub only enough to expose ring grooves for clutch pack snap ring and clutch hub retaining ring 23 Realign clutch pack on hub and seat clutch discs and plates in clutch drum 24 Install direct clutch pack snap ring Fig 230 Be very sure snap ring is fully seated in clutch drum ring groove 25 Install clutch hub retaining ring Fig 231 Be very sure retaining ring is fully seated in sun gear ring groove 26 Slowly release press ram remove compressor tools and remove geartrain assembly GEAR CASE ASSEMBLY 1 Position park pawl and spring in case and install park pawl shaft Verify that end of spring with 90 bend is hooked to pawl and straight end of spring is seated
127. 9 9 i NT E ES IATA nn isd 02 82 L dunssaud O 14 5 6 1 EN d WU LJIHS 2 1 2 anal a JILLOYHL m Ex ACCOR IC DOA frets 2 SS 1 P ma 3 5 JATVA m tz isd 76 0 pm 3unss3ud e E YONHAAOD i ii p6 PE TE i 2 1 4 HO LN19 HWS dvi GION30S OAH3S LNOYS 2 TRANSMISSION AND TRANSFER CASE SCHEMATICS AND DIAGRAMS Continued 21 228 88 08 isd 8 0 3unssdud 1114 3 NOILONS 9 6 3unssaud dH31H3ANOO isd 76 0 553 JILLOHYHL 3dnssaqud HONH3AOS isd v6 25 3unsSaud LON H LNT H31H3ANOO HV39 GHIHL 3AIHG NI Or TnVHGAH Q334900 Nn O L uv39o que NI HOLO3 3S FATWA d i74001 IANYA 1 GIONdIOS df34201 105 FATWA IHS SATVA ONIIALL 7 6 1 1NOH4 JAVA 15008 S SATWANMOCMODI FATWA TOHLNOD LAIHS 8 1 SATVA JILLNHS ATLLOYWHL 3ATVA HOLfTIO LNOYS OAYAS uvau
128. 949 138 140 1 7950 1 8099 153 155 1 8100 1 8249 168 170 1 8250 1 8399 183 185 1 8400 1 8549 198 200 1 8550 1 8699 213 215 1 8700 1 8849 228 230 243 245 1 8850 1 8999 J9121 342 Fig 252 Overdrive Piston Thrust Plate Selection OVERDRIVE PISTON 1 Install new seals on overdrive piston 2 Stand transmission case upright on bellhousing 3 Position Guide Ring 8114 1 on outer edge of overdrive piston retainer 4 Position Seal Guide 8114 3 on inner edge of overdrive piston retainer 5 Install overdrive piston in overdrive piston retainer by a Aligning locating lugs on overdrive piston to the two mating holes in retainer b Lubricate overdrive piston seals with Mopar Door Ease or equivalent c Install piston over Seal Guide 8114 3 and inside Guide Ring 8114 1 d Push overdrive piston into position in retainer e Verify that the locating lugs entered the lug bores in the retainer 6 Install intermediate shaft spacer on intermedi ate shaft 21 214 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued 7 Install overdrive piston thrust plate on over drive piston 8 Install overdrive piston thrust bearing on over drive piston 9 Install transmission speed sensor and O ring seal in overdrive case Fig 193 CLEANING AND INSPECTION VALVE BODY Clean the valve housings valves plugs springs and separator plates with a standard
129. AGEMENT 1 Fluid Level Low 1 Correct level and check for leaks FROM NEUTRAL TO DRIVE OR REVERSE 2 Filter Clogged 2 Change filter 3 Gearshift Linkage Misadjusted 3 Adjust linkage and repair linkage if worn or damaged 4 Torque Converter Drain Back Oil 4 If vehicle moves normally after 5 seconds drains from torque converter into after shifting into gear no repair is necessary transmission sump If longer inspect pump bushing for wear Replace pump house 5 Rear Band Misadjusted 5 Adjust band 6 Valve Body Filter Plugged 6 Replace fluid and filter If oil pan and old fluid were full of clutch disc material and or metal particles overhaul will be necessary 7 Oil Pump Gears Worn Damaged 7 Remove transmission and replace oil pump 2 3RANSMISSION AND TRANSFER CASE 21 17 DIAGNOSIS AND TESTING Continued CONDITION POSSIBLE CAUSES CORRECTION 8 Governor Circuit and Solenoid 8 Test with DRB scan tool and repair as Valve Electrical Fault required 9 Hydraulic Pressure Incorrect 9 Perform pressure test remove transmission and repair as needed 10 Reaction Shaft Seal Rings 10 Remove transmission remove oil pump Worn Broken and replace seal rings 11 Rear Clutch Input Shaft Rear 11 Remove and disassemble transmission Clutch Seal Rings Damaged and repair as necessary 12 Regulator Valve Stuck 12 i2 Clean 13 Cooler Plugged Transfer ca
130. ALSO HARSH AT TIMES leaks if low 2 Fluid Filter Clogged 2 Replace filter If filter and fluid contained clutch material or metal particles an overhaul may be necessary Perform lube flow test 3 Throttle Linkage Misadjusted 3 Adjust linkage as described in service section 4 Throttle Linkage Binding 4 Check cable for binding Check for return to closed throttle at transmission 5 Gearshift Linkage Cable 5 Adjust linkage cable as described in Misadjusted service section 6 Clutch or Servo Failure 6 Remove valve body and air test clutch and band servo operation Disassemble and repair transmission as needed 7 Governor Circuit Electrical Fault 7 Test using DRB scan tool and repair as required 8 Front Band Misadjusted 8 Adjust band 9 Pump Suction Passage Leak 9 Check for excessive foam on dipstick after normal driving Check for loose pump bolts defective gasket Replace pump assembly if needed NO REVERSE D RANGES Ok 1 Gearshift Linkage Cable 1 Repair or replace linkage parts as Misadjusted Damaged needed 2 Park Sprag Sticking 2 Replace overdrive annulus gear 3 Rear Band Misadjusted Worn 3 Adjust band replace 4 Valve Body Malfunction 4 Remove and service valve body Replace valve body if any valves or valve bores are worn or damaged 5 Rear Servo Malfunction 5 Remove and disassemble transmission Replace worn damaged servo parts as necessary 6 Direct Clutch in Overdriv
131. ASE 21 249 SPRING 9121 426 Fig 26 Detent Component Removal b Tap easy out tool into lock pin with hammer until tool is securely engaged into the lock pin c Install a t handle such as from a tap and die set onto the easy out tool d Securely tighten the t handle onto the tool one motion pull upward and turn the t handle counter clockwise to remove the lock pin 4 Remove shift rail by pulling it straight up and out of fork Fig 27 5 Remove mode fork and mainshaft as assembly Fig 28 6 Remove mode shift sleeve and mode fork assembly from mainshaft Fig 29 Note position of mode sleeve in fork and remove sleeve J8921 255 Fig 27 Shift Rail Removal 21 250 TRANSMISSION AND TRANSFER CASE 2 DISASSEMBLY AND ASSEMBLY Continued 7 Remove intermediate dutch shaft snap ring Fig 30 8 Remove dutch shaft thrust ring Fig 31 9 Remove intermediate clutch shaft Fig 32 HE s SS 4 INTERMEDIATE CLUTCH SHAFT J8921 258 Fig 30 Intermediate Clutch Shaft Snap Ring Removal Torn MODE SLEEVE FORK ASSEMBLY mmp J8921 259 Fig 31 Clutch Shaft Thrust Ring Removal J8921 257 Fig 29 Mode Fork And Sleeve Removal 2 5 15 51 0 AND TRANSFER CASE 21 251 DISASSEMBLY AND ASSEMBLY Continued
132. CLUTCH ASSEMBLY 1 Install overdrive dutch reaction ring first Reaction ring is flat with notched ends Fig 238 2 Install wave spring on top of reaction ring Fig 239 Reaction ring and wave ring both fit in same ring groove Use screwdriver to seat each ring securely in groove Also ensure that the ends of the two rings are offset from each other 2 DISASSEMBLY AND ASSEMBLY Continued REACTION PLATE 2 COUNTERBORE FLUSH WITH END OF HUB CLUTCH HUB J9121 329 Fig 227 Correct Position Of Direct Clutch Reaction Plate DIRECT CLUTCH PRESSURE PLATE 1 CLUTCH m PACK SIDE OF ME PLATE FACES SRL UPWARD J9121 330 Fig 228 Correct Position Of Direct Clutch Pressure Plate TRANSMISSION AND TRANSFER CASE 21 87 CLUTCH HUB DIRECT CLUTCH PACK CLUTCH DRUM J9321 397 Fig 229 Direct Clutch Pack And Clutch Hub Installation SPECIAL TOOL 6227 1 Fig 230 Direct Clutch Pack Snap Ring Installation SPECIAL TOOL 6227 1 CLUTCH HUB RETAINING RING Win J9321 401 Fig 231 Clutch Hub Retaining Ring Installation 21 88 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued REACTION PLUG SNAP RING DO NOT OVERCOMPRESS TO INSTALL 10 TUS PARK LOCK REACTION LOCATING PIN PLUG J9121 338 Fig 232 Reaction Plug Locating Pin And Snap Ring REACTION PLUG SNAP RING 5 8921 240 PLIERS F
133. CONVERTER HUB WELD OUTSIDE DIAMETER RH254 STARTER RING GEAR Fig 11 Converter Leak Points Typical 3 Remove oil pump and remove pump seal Inspect pump housing drainback and vent holes for obstructions Clear holes with solvent and wire 4 Inspect pump bushing and converter hub If bushing is scored replace it If converter hub is scored either polish it with crocus doth or replace converter 5 Install new pump seal O ring and gasket Replace oil pump if cracked porous or damaged in any way Be sure to loosen the front band before installing the oil pump damage to the oil pump seal may occur if the band is still tightened to the front dutch retainer 6 Loosen kickdown lever pin access plug three turns Apply Loctite 592 or Permatex No 2 to plug threads and tighten plug to 17 N m 150 in Ibs torque 7 Adjust front band 8 Lubricate pump seal and converter hub with transmission fluid or petroleum jelly and install con verter 9 Install dust shield 10 Lower vehicle transmission and converter housing 21 16 TRANSMISSION AND TRANSFER CASE 2 DIAGNOSIS AND TESTING Continued DIAGNOSIS TABLES AND CHARTS RE The hydraulic flow charts in the Schematics and TRANSMISSION Diagrams section of this group outline fluid flow and The diagnosis charts provide additional reference hydraulic circuitry Circuit operation is provided for when diagnosing a transmission fau
134. CTRICAL CONTROLS The overdrive off switch valve body solenoid case connectors and related wiring can all be tested with a 12 volt test lamp or a volt ohmmeter Check conti nuity of each component when diagnosis indicates this is necessary Refer to Group 8W Wiring Dia grams for component locations and circuit informa tion Switch and solenoid continuity should be checked whenever the transmission fails to shift into fourth gear range BRAKE TRANSMISSION SHIFT INTERLOCK 1 Verify that the key can only be removed in the PARK position 2 When the shift lever is in PARK And the shift handle pushbutton is in the OUT position the igni tion key cylinder should rotate freely from OFF to LOCK When the shifter is in any other gear or neu tral position the ignition key cylinder should not rotate to the LOCK position 3 Shifting out of PARK should be possible when the ignition key cylinder is in the OFF position 4 Shifting out of PARK should not be possible while applying 25 10 maximum handle pushbutton force and ignition key cylinder is in the RUN or START positions unless the foot brake pedal is depressed approximately 1 2 inch 12mm 5 Shifting out of PARK should not be possible when the ignition key cylinder is in the ACCESSORY or LOCK positions 6 Shifting between any gears NEUTRAL or into PARK may be done without depressing foot brake pedal with ignition switch in RUN or START posi tions and vehicle stationary
135. Do not allow bushing to become cocked during installation 4 Stake pump bushing in two places with blunt punch Remove burrs from stake points with knife OUTER blade Fig 162 GEAR J9321 177 REACTION SHAFT SUPPORT BUSHING INSTALLATION Fig 159 Pump Gear 1 Place reaction shaft support upright on a clean 2 Hold cup tool firmly against reaction shaft smooth surface Thread remover tool into bushing as far as possible by hand OIL PUMP BODY 7 OIL SEAL SEAL RINGS REACTION SHAFT SUPPORT O RING INNER GEAR 1 THRUST WASHER SELECTIVE Fig 160 Oil Pump And Reaction Shaft Components 21 192 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued BUSHING REMOVAL SPECIAL SPECIAL TOOL PUMP HOUSING 5 3550 BUSHING SPECIAL SPECIAL TOOL TOOL x CE 2 SP 5118 BUSHING INSTALLATION J9221 244 Fig 161 Oil Pump Bushing S e RH285 Fig 162 Staking Deburring Oil Pump Bushing 2 Assemble Bushing Installer Tools C 4171 and SP 5302 Then slide new bushing onto installer tool Fig 163 3 Start bushing in shaft Tap bushing into shaft until installer tool bottoms against support flange 4 Clean reaction shaft support thoroughly after bushing replacement to remove any chips 1 Lubricate pump gears with transmission fluid and install them in pump body 2 Install thrust washer on reaction shaf
136. E VALVE P d COVER UPPER X 9 HOUSING 172 THROTTLE 9 PLUG SHUTTLE VALVE PRIMARY S SPRING GOVERNOR PLUG SIS e COVER J9421 217 Fig 83 Shuttle And Boost Valve Components UPPER HOUSING REGULATOR VALVE SWITCH VALVE 22223 YX REGULATOR VALVE SPRING SHUTTLE 4 VALVE PRIMARY SPRING GOVERNOR 2 3 PLUG GOVERNOR PLUG MANUAL VALVE THROTILE PLUG THROTTLE KICKDOWN GOVERNOR 77 GO VALVE DETENT PLUG AND COVER SPRING J9321 155 Fig 84 Upper Housing Control Valve Locations 21 172 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued UPPER HOUSING PRESSURE SPRING VALVE PRESSURE PLUG AND SPRING 222295 2 1 2 SHIFT VALVE AND SPRING 2 3 SHIFT VALVE AND SPRING PLUG LIMIT VALVE HOUSING LIMIT PRESSURE VALVE LIMIT PLUG RETAINER AND VALVE COVER SPRING COVER 19321 157 Fig 85 Upper Housing Shift Valve And Pressure Plug Locations 3 Start tube in lower housing port first Then BOOSI LOWER swing tube downward and work opposite end of tube into upper housing port Fig 86 4 Insert and seat each end of tube in housings 5 Slide tube brace under tube and into alignment with valve body screw holes Fig 87 6 Install and finger tighten three screws that secure tube brace to valve body housings Fig 87 7 Bend tube brace tabs up and against tube to hold it in position Fig 88 8
137. ED TOGETHER AFTER INSTALLATION METAL REAR SEAL RING TEFLON FRONT SEAL RING SQUEEZE RING TOGETHER SLIGHTLY BEFORE INSTALLATION FOR BETTER FIT J9121 151 Fig 160 Input Shaft Seal Ring Identification REAR CLUTCH RETAINER J9121 152 Fig 161 Pressing Input Shaft Into Rear Clutch Retainer 2 Remove front annulus and planetary assembly from driving shell Fig 165 3 Remove snap ring that retains front planetary gear in annulus gear Fig 166 4 Remove tabbed thrust washer and tabbed thrust plate from hub of front annulus Fig 167 5 Separate front annulus and planetary gears Fig 167 2 REAR CLUTCH RETAINER PISTON r SPRING WAVE SPRING PISTON J9121 153 Fig 162 Piston Spring Wave Spring Position DIAL INDICATOR CLUTCH STAND 80a483ec Fig 163 Checking Rear Clutch Pack Clearance CLUTCH DTE THRUST WASHER UN Cy 227 K 80844514 Fig 164 Installing Rear Clutch Thrust Washer 6 Remove front planetary gear front thrust washer from annulus gear hub 7 Separate and remove driving shell rear plane tary and rear annulus from output shaft Fig 168 2 DISASSEMBLY AND ASSEMBLY Continued 8 Remove front planetary rear thrust washer from driving shell 9 Remove tabbed thrust washers from rear plan etary gear 10 Remove l
138. ELY 830 POUNDS USE COMPRES SOR TOOL C 6227 1 AND HYDRAULIC TYPE SHOP PRESS WITH A MINIMUM RAM TRAVEL OF 6 INCHES THE PRESS MUST ALSO HAVE A BED THAT CAN BE ADJUSTED UP OR DOWN AS REQUIRED RELEASE CLUTCH SPRING TENSION SLOWLY AND COMPLETELY TO AVOID PERSONAL INJURY 2 20 Position Compressor Tool 6227 1 on clutch hub 21 Compress clutch hub and spring just enough to place tension on hub and hold it in place 22 Slowly compress clutch hub and spring Com press spring and hub only enough to expose ring grooves for clutch pack snap ring and clutch hub retaining ring 23 Realign clutch pack on hub and seat clutch discs and plates in clutch drum 24 Install direct clutch pack snap ring Fig 237 Be very sure snap ring is fully seated in clutch drum ring groove 25 Install clutch hub retaining ring Fig 238 Be very sure retaining ring is fully seated in sun gear ring groove 26 Slowly release press ram remove compressor tools and remove geartrain assembly SPECIAL 1 CLUTCH 109 6227 1 J9321 400 Fig 237 Direct Clutch Pack Snap Ring Installation SPECIAL TOOL 6227 1 CLUTCH HUB RETAINING RING J9321 401 Fig 238 Clutch Hub Retaining Ring Installation GEAR CASE 1 Position park pawl and spring in case and install park pawl shaft Verify that end of spring 2 TRANSMISSION AND TRANSFER CASE 21 211 DISASSEMBLY AND ASSEMBLY Continue
139. ENERAL INFORMATION Continued TAG 7 RECOMMENDED LUBRICANT AND FILL LEVEL 7 Ox Recommended lubricant for the NV242 transfer case is Mopar Dexron 11 or ATF Plus type 7176 FILL PLUG Approximate lubricant fill capacity is 1 35 liters 2 85 pints The fill and drain plugs are both in the rear case 17 Fig 2 Correct fill level is to the bottom edge of the fill plug hole Be sure the vehide is level to ensure an accurate fluid level check ess LM LA 20 39 DRAIN PLUG 80b09a60 Fig 2 Fill Drain Plug And Tag Locations DIAGNOSIS AND TESTING NV242 DIAGNOSIS DIAGNOSIS CHART Transfer case difficult to shift or will Transfer case shift linkage Repair or replace linkage as not shift into desired range Insufficient or incorrect lubricant Drain and refill transfer case with A correct type and quantity of lubricant 3 Internal transfer case 3 Repair or replace components as components binding worn or necessary damaged Transfer case noisy in all drive 1 Insufficient or incorrect lubricant 1 Drain and refill transfer case with modes the correct type and quantity of lubricant Lubricant leaking from transfer case 1 Transfer case overfilled 1 Drain lubricant to the correct seals or vent level 2 Transfer case vent closed or 2 Clean or replace vent as restricted 3 Transfer case seals damaged 3 Replace s
140. FLUSHING SOLVENT COME IN CON TACT WITH YOUR EYES OR SKIN IF EYE CONTAM INATION OCCURS FLUSH EYES WITH WATER FOR 15 TO 20 SECONDS REMOVE CONTAMINATED CLOTHING AND WASH AFFECTED SKIN WITH SOAP AND WATER SEEK MEDICAL ATTENTION COOLER FLUSH USING TOOL 6906 1 Remove cover plate filler plug on Tool 6906 Fill reservoir 1 2 to 3 4 full of fresh flushing solution Flushing solvents are petroleum based solutions gen erally used to dean automatic transmission compo nents DO NOT use solvents containing acids water gasoline or any other corrosive liquids 2 Reinstall filler plug on Tool 6906 2 3 Verify pump power switch is turned OFF nec red alligator clip to positive battery post Connect black alligator clip to a good ground 4 Disconnect the cooler lines at the transmission NOTE When flushing transmission cooler and lines ALWAYS reverse flush 5 Connect the BLUE pressure line to the OUT LET From cooler line 6 Connect the CLEAR return line to the INLET To cooler line 7 Turn pump ON for two to three minutes to flush cooler s and lines Monitor pressure readings and clear return lines Pressure readings should sta bilize below 20 psi for vehicles equipped with a sin gle cooler and 30 psi for vehicles equipped with dual coolers If flow is intermittent or exceeds these pres sures replace cooler 8 Turn pump OFF 9 Disconnect CLEAR suction line from reservoir at cover plate
141. Fig 140 Pump Support Bolts REACTION PUMP HOUSING SHAFT SUPPORT J9321 213 Fig 141 Separating Pump Housing From Reaction Shaft Support REACTION SHAFT SUPPORT INNER OUTER GEAR GEAR J9321 214 Fig 142 Pump Gear Removal OIL PUMP BUSHING REPLACEMENT 1 Remove pump bushing with Tool Handle C 4171 and Bushing Remover SP 3551 from Tool Set 3887 Fig 144 2 Install new pump bushing with Tool Handle C 4171 and Bushing Installer SP 5117 Fig 144 Bushing should be flush with pump housing bore 3 Stake new pump bushing in two places with blunt punch Fig 145 Remove burrs from stake points with knife blade afterward 2 BUSHING REACTION SHAFT HUB 72 1 e 27 5 5 o THRUST WASHER 80a483e8 Fig 143 Support Hub Thrust Washer SPECIAL TOOL 4171 SPECIAL TOOL PUMP HOUSING 5 3551 BUSHING SPECIAL TOOL 4171 SPECIAL TOOL SP 5117 BUSHING INSTALLATION J9221 242 Fig 144 Removing Oil Pump Bushing Fig 145 Staking Oil Pump Bushing 2 DISASSEMBLY AND ASSEMBLY Continued REACTION SHAFT SUPPORT BUSHING REM OVAL 1 Assemble Bushing Remover Tools SP 1191 3633 and 5324 Fig 146 Do not clamp any part of reaction shaft or support in vise 2 Hold Cup Tool SP 3633 firmly against reaction shaft and thread remover SP 5324 into bushing as far as possible by hand Then thread remover tool 3 4 additional turns into bushing with a wrench
142. Fig 20 4 Remove speed sensor and speedometer adapter as assembly 5 Remove speed sensor retaining screw and remove sensor from adapter 6 Remove speedometer pinion from adapter 7 Inspect sensor and adapter O rings Fig 20 Remove and discard O rings if worn or damaged 8 Inspect terminal pins in speed sensor Clean pins with electrical spray deaner if dirty or oxidized Replace sensor if faulty or pins are loose severely corroded or damaged 21 152 TRANSMISSION AND TRANSFER CASE REMOVAL AND INSTALLATION Continued INSTALLATION 1 Thoroughly dean adapter flange and adapter mounting surface in housing Surfaces must be dean for proper adapter alignment and speedometer oper ation 2 Install new O rings on speed sensor and speed ometer adapter if necessary Fig 20 3 Lubricate sensor and adapter O rings with transmission fluid 4 Install vehide speed sensor in speedometer adapter Tighten sensor attaching screw to 2 3 N m 15 27 in lbs torque 5 Install speedometer pinion in adapter 6 Count number of teeth on speedometer pinion Do this before installing assembly in housing Then lubricate pinion teeth with transmission fluid 7 Note index numbers on adapter body Fig 21 These numbers will correspond to number of teeth on pinion 8 Install speedometer assembly in housing 9 Rotate adapter until required range numbers are at 6 o dock position Be sure range index num
143. IAGRAMS Continued 21 230 9 isd 0 0 3unssaud 3901 dH31H3ANOO NOILOnS isd 001 0 dunssaud ATLLOYHL isd 09 0 3unssadud YONYSAOD isd 061 66 3unss3ud INIT 1 LON H LNT H3183ANOO HV39 04 3AIHG G3520 IND 9 1 HV3O 3AIHQH3AO NI H3 A31 HO12313S JAWA ONIIALL d 154001 3ATVA aioNanos 108 SATVA 5 1 6 ONIIALL 4 6 AANO bE 3 7 6 HOLfTIO S3AIHQH3AO uou1viniNwnoov NOLIVOIHB TI HOL TIO 150089 SANA NAOCDIODI S FATWA 141 5 2 1 Q JATA JILLNHS ATLLOYHL LNOYS OAd3S LNOHH NOILVOIHSfY1 OL 984 oc p oe 1 OAu3S uvau U3lH3ANOO 3n0H0L N33uos 3ATVA TV INVIA FATWA LAIHS 2 1 ON 1d HONH3AOD DR SENG 5 L3IHS 6 2 Ord JILLOYHL 2 HOLMIO HV3H GION3 10S HONH3ACD 21 231 TRANSMISSION AND TRANSFER CASE 2 SCHEMATICS AND DIAGRAMS Continued 28 NOILONS isd 09 9 lt 5 39101 dH31H3ANOO isd 001 0 3unssaud JILLOHYHL isd 09 0 3unssadud UONH3JAOD isd 01 96 3unss3ud INIT
144. IAMETER CHECK 80b17019 BALL 1 J9321 154 Fig 62 Transfer Plate Fig 65 Check Ball Locations In Upper Housing 2 3TRANSMISSION AND TRANSFER CASE 21 45 DISASSEMBLY AND ASSEMBLY Continued 2 Remove governor plug and shuttle valve covers Fig 67 3 Remove E dip that secures shuttle valve sec ondary spring on valve stem Fig 66 4 Remove throttle plug primary spring shuttle valve secondary spring and spring guides Fig 67 5 Remove boost valve retainer spring and valve if not previously removed 6 Remove throttle plug and 1 2 and 2 3 governor plugs Fig 54 7 Turn upper housing around and remove limit valve and shift valve covers Fig 68 8 Remove limit valve housing Then remove retainer spring limit valve and 2 3 throttle plug from limit valve housing Fig 68 9 Remove 1 2 shift control valve and spring Fig 68 f Fig 66 Shuttle Valve E Clip And Secondary Spring 10 Remove 1 2 shift valve and spring Fig 68 E CLIP SHUTTLE VALVE SECONDARY 19121 179 Location 11 Remove 2 3 shift valve and spring from valve Tuy fia 68 d 3 Remove 3 4 quick fill valve spring and plug 12 Remove pressure plug cover Fig 68 4 Remove 3 4 shift valve and spring 13 Remove line pressure plug sleeve throttle 5 Remove converter clutch valve spring and plug pressure plug and spring Fig 68 Fig 69 VALVE BODY LOWER HOUSING 1 Remove timing
145. ID 1 Turn valve body assembly over so accumulator side of transfer plate is facing down 2 Install new O rings on governor pressure sole noid and sensor Fig 95 3 Lubricate solenoid and sensor O rings with dean transmission fluid 4 Install governor pressure sensor in governor body Then secure sensor with M shaped retaining dip Fig 95 5 Install governor pressure solenoid in governor body Fig 96 Push solenoid in until it snaps into place in body 6 Position governor body gasket on transfer plate Fig 97 2 KICKDOWN 2 VALVE Fig 92 Manual And Throttle Lever Alignment SOLENOID HARNESS CASE CONNECTOR ACCUMULATOR HOUSING Fig 93 Solenoid Harness Case Connector Shoulder Bolt OVERDRIVE CONVERTER T SOLENOID ACCUMULATOR WIRE 2 HARNESS 3 ve PLATE X 10321 458 Fig 94 Solenoid Harness Routing 2 5 55 AND TRANSFER CASE 21 175 DISASSEMBLY AND ASSEMBLY Continued 7 Install retainer plate on governor body and around solenoid Fig 98 Be sure solenoid connector is positioned in retainer cutout 8 Align screw holes in governor body and trans fer plate Then install and tighten governor body screws to 4 N m 35 in 165 torque 9 Connect harness wires to governor pressure solenoid and governor pressure sensor Fig 99 10 Perform Line Pressure and Throttle Pressure adjustments refer to adjustment section of
146. ING CLUTCH ASSEMBLY Fig 134 Overrunning Clutch Installation 4 Verify that non threaded hole in clutch cam is properly aligned Check alignment by threading a bolt into each bolt hole Adjust dutch cam position if necessary 5 Install and tighten overrunning clutch bolts to 17 13 ft Ibs torque Note that dutch cam bolts are shorter than piston retainer bolts 6 Install new gasket at rear of transmission case Use petroleum jelly to hold gasket in place Be sure to align governor feed holes in gasket with feed pas sages in case Fig 135 Also install gasket before overdrive piston retainer Center hole in gasket is smaller than retainer and cannot be installed over retainer 7 Position overdrive piston retainer on transmis sion case and align bolt holes in retainer gasket and case Fig 136 Then install and tighten retainer bolts to 17 N m 13 ft Ibs torque 8 Install new seals on over drive piston 9 Stand transmission case upright on bellhous ing 2 GASKET SURE V GOVERNOR TUBE FEED E HOLES IN CASE AND GASKET ARE ALIGNED J9121 349 Fig 135 Installing Aligning Case Gasket S r Se 0 25 LE PISTON 222 gt lt gt RETAINER mame RETAINER BOLTS J9321 464 Fig 136 Aligning Overdrive Piston Retainer 10 Position Guide Ring 8114 1 on outer edge of overdrive piston retainer 11 Position Se
147. Increase vehide speed gradually until 3 4 shift occurs and nate gauge pressure 8 Pressure should be 469 496 kPa 68 72 psi with closed throttle and increase to 620 827 kPa 90 120 psi at 1 2 to 3 4 throttle Note that pressure can increase to around 896 kPa 130 psi at full throttle 9 Return to shop or move vehide off chassis dyno PRESSURE TEST ANALYSIS CHART TEST CONDITION INDICATION Line pressure OK during Pump and regulator valve any one test OK Line pressure OK in R Leakage in rear clutch but low in D 2 1 area seal rings clutch seals Overdrive clutch piston seal or check ball problem Pressure OK in 1 2 but Leakage in front clutch low and R area Pressure OK in 2 but low Leakage in rear servo in R and 1 Front servo pressure low Leakage in servo broken in 2 servo ring or cracked Servo piston Pressure low in D Fourth Gear Range Pressure low in all positions Clogged filter stuck regulator valve worn or faulty pump low oil level Governor pressure too high at idle speed Governor pressure solenoid valve system fault Refer to diagnostic book Faulty governor pressure solenoid transmission control module or governor pressure sensor Clogged fluid cooler or lines seal rings leaking worn pump bushings pump clutch retainer or clogged filter Line pressure high Output shaft plugged Sticky regulator valve Line pressure low Sticky regulator valve clogged filter
148. Inspect the pump bushing Then check the reaction shaft support bushing Replace either bushing only if heavily worn scored or damaged It is not necessary to replace the bushings unless they are actually dam aged 1 Install the gears in the pump body and mea sure pump component clearances as follows a Clearance between outer gear and reaction shaft housing should be 0 010 to 0 063 mm 0 0004 TRANSMISSION AND TRANSFER CASE 21 217 to 0 0025 in Clearance between inner gear and reaction shaft housing should be 0 010 to 0 063 mm 0 0004 to 0 0025 in Both clearances can be measured at the same time by 1 Installing the pump gears in the pump housing II Position an appropriate piece of Plasti gage across both gears Align the plastigage to a flat area on the reaction shaft housing IV Install the reaction shaft to the pump housing V Separate the reaction shaft housing from the pump housing and measure the Plastigage following the instructions supplied with it b Clearance between inner gear tooth outer gear should be 0 08 to 0 19 mm 0 0035 to 0 0075 in Measure clearance with an appropriate feeler gauge Fig 256 c Clearance between outer gear and pump housing should also be 0 010 to 0 19 mm 0 0035 to 0 0075 in Measure clearance with an appropriate feeler gauge INNER GEAR OUTER GEAR 29 19521 103 Fig 256 Checking Pump Gear Clearance FRONT CLUTCH
149. J9321 223 Fig 249 Retainer Bushing Location Inspection REAR CLUTCH Clean the clutch components with solvent and dry them with compressed air Do not use rags or shop towels to dry any of the clutch parts Lint from such materials will adhere to component surfaces and could restrict or block fluid passages after assembly Replace the clutch discs if warped worn scored burned charred the lugs are damaged or if the fac ing is flaking off Replace the top and bottom pres sure plates if scored warped or cracked Be sure the driving lugs on the pressure and clutch plates are 2 also good condition The lugs must not be bent cracked or damaged in any way Replace the piston spring and wave spring if either part is distorted warped or broken Check the lug grooves in the dutch retainer The dutch and pressure plates should slide freely in the slots Replace the retainer if the grooves are worn or damaged Also check action of the check balls in the retainer and piston Each check ball must move freely and not stick Replace the retainer bushing if worn scored or doubt exists about bushing condition Inspect the piston and retainer seal surfaces for nicks or scratches Minor scratches can be removed with crocus cloth However replace the piston and or retainer if the seal surfaces are seriously scored Check condition of the fiber thrust washer and metal output shaft thrust washer Replace either washer if worn or damag
150. JAWA IIHS 7 6 ril 1 1 SATA 1 8 ui AATWA TOHLNOO L4IHS 2 1 Ee Em 2 3ATVA L3IHS 8 1 1 B d J 9 21 HONH3AOD HOIND HE 2 11 TOHLNOO 14188 8 1 1 i H 1714 1 E ond 3ATVA 14186 Z 31LLOHHL m om Orid JILLOHHL Od HONH3AOS demum HOLVINWNDO 7 6 7 RE 1 of 4 HOLM LNOUS HOLA GION31OS 3AIHQU3AO omas 1 4 OAH3S uvdd 2 TRANSMISSION AND TRANSFER CASE SCHEMATICS AND DIAGRAMS Continued 21 234 0 isd 9 0 3anssadud Til3 38d NOILOnS isd 9 9 lt 5 39101 d31H3ANOO isd 25 0 3Junssaqud HONH3AOS isd 02 60 TOULNOD LAIHS 2 1 isd 76 0 lt 55 4 ATLLOYHL isd 56 29 3unssaud 31LLOHHL TINA H3A31 HOLO3 13S uV3
151. LE CAUSES CORRECTION NO 3 4 UPSHIFT 1 Dash O D Switch In OFF 1 Turn control switch to ON position Position 2 Overdrive Circuit Fuse Blown 2 Replace fuse Determine why fuse failed and repair as necessary i e shorts or grounds in circuit 3 O D Switch Wire Shorted Open 3 Check wires connections with 12V test Cut lamp and voltmeter Repair damaged or loose wire connection as necessary 4 Distance or Coolant Sensor 4 Test both sensors with test lamp or Malfunction volt ohmmeter and replace faulty sensor 5 TPS Malfunction 5 Check with DRB scan tool and replace if necessary 6 Neutral Switch to PCM Wire 6 Test switch as described in service section Shorted Cut and replace if necessary Engine no start 7 PCM Malfunction 7 Check with DRB scan tool and replace if necessary 8 Overdrive Solenoid Shorted 8 Replace solenoid if shorted or open and Open repair loose or damaged wires DRB scan tool 9 Solenoid Feed Orifice in Valve 9 Remove disassemble and clean valve Body Blocked body thoroughly Check feed orifice 10 Overdrive Clutch Failed 10 Disassemble overdrive and repair as needed 11 Hydraulic Pressure Low 11 Pressure test transmission to determine cause 12 Valve Body Valve Stuck 12 Repair stuck 3 4 shift valve 3 4 timing valve 13 O D Piston Incorrect Spacer 13 Remove unit check end play and install correct spacer 14 Overdrive Piston Seal Failure 14 Replace both seals
152. MOVE is restored 2 Gearshift Linkage Cable Loose Misadjusted 3 U Joint Axle Transfer Case Broken 4 Filter Plugged 5 Oil Pump Damaged 6 Valve Body Malfunctioned 7 Transmission Internal Component Damaged 2 Inspect adjust and reassemble linkage as needed Replace worn damaged parts 3 Perform preliminary inspection procedure for vehicle that will not move Refer to procedure in diagnosis section 4 Remove and disassemble transmission Repair or replace failed components as needed Replace filter If filter and fluid contained clutch material or metal particles an overhaul may be necessary Perform lube flow test Flush oil Replace cooler as necessary 5 Perform pressure test to confirm low pressure Replace pump body assembly if necessary 6 Check and inspect valve body Replace valve body as assembly if any valve or bore is damaged Clean and reassemble correctly if all parts are in good condition 7 Remove and disassemble transmission Repair or replace failed components as needed 8 Park Sprag not Releasing Check 8 Remove disassemble repair Stall Speed Worn Damaged Stuck 9 Torque Converter Damage 9 Inspect and replace as required 21 136 TRANSMISSION AND TRANSFER CASE 2 DIAGNOSIS AND TESTING Continued CONDITION POSSIBLE CAUSES CORRECTION SHIFTS DELAYED OR ERRATIC 1 Fluid Level Low High 1 Correct fluid level and check for SHIFTS
153. N POSSIBLE CAUSES CORRECTION OIL LEAKS 1 Speedometer Adapter Leaks 1 Replace both adapter seals 2 Fluid Lines and Fittings 2 Tighten fittings If leaks persist Loose Leaks Damaged replace fittings and lines if necessary 3 Fill Tube where tube enters 3 Replace O ring seal Inspect tube case Leaks Damaged for cracks in fill tube 4 Pressure Port Plug Loose 4 Tighten to correct torque Replace Loose Damaged plug or reseal if leak persists 5 Pan Gasket Leaks 5 Tighten pan screws 150 in Ibs If leaks persist replace gasket 6 Valve Body Manual Lever Shaft 6 Replace shaft seal Seal Leaks Worn 7 Rear Bearing Access Plate Leaks 7 Replace gasket Tighten screws 8 Gasket Damaged or Bolts are 8 Replace bolts or gasket or tighten Loose both 9 Adapter Extension Gasket 9 Replace gasket Damaged Leaks Damaged 10 Neutral Switch Leaks Damaged 10 Replace switch and gasket 11 Converter Housing Area Leaks 11 Check for leaks at seal caused by worn seal or burr on converter hub cutting seal worn bushing missing oil return oil in front pump housing or hole plugged Check for leaks past O ring seal on pump or past pump to case bolts pump housing porous oil coming out vent due to overfill or leak past front band shaft access plug 12 Pump Seal Leaks Worn 12 Replace seal Damaged 13 Torque Converter Weld 13 Replace converter Leak Cracked Hub 14 Case Porosity Leaks 14 Replace
154. NING CLUTCH CAM SERVICE IN THIS SECTION ASSEMBLY Do not allow dirt grease or foreign material to enter the case or transmission components during assembly Keep the transmission case and compo nents clean Also make sure the tools and workbench area used for assembly operations are equally dean TRANSMISSION AND TRANSFER CASE 21 57 FRONT SERVO 7 SNAP RING SPECIAL TOOL o REAR A 5 SERVO SX c INN waraas Fig 106 Compressing Rear Servo Spring Shop towels used for wiping off tools and hands must be made from lint free material Lint will stick to transmission parts and could interfere with valve operation or even restrict fluid passages Lubricate the transmission components with Mopar transmission fluid during reassembly Use Mopar Door Ease or Ru Glyde on seals and O rings to ease installation Petroleum jelly can also be used to hold thrust washers thrust plates and gaskets in position during assembly However do not use chassis grease bear ing grease white grease or similar lubricants on transmission part These types of lubricants can eventually block or restrict fluid passages and inter fere with valve operation Use petroleum jelly only Do not force parts into place The transmission components and subassemblies are easily installed by hand when properly aligned If part seems extremely difficult to install it is either misaligned or incorrectly assembled Also ver
155. O IA OC H1 0 pecu s Rye S 8 FATWA 14IHS 5 2 JILLOHHL INT 3ATVA LINK e 21 2 i LLOHHL i YONHSAOD MS HOLWINWINDOV v E oQU n o 2 1 4 HOLT Onde uydu GION310S HONH3AOD OAH3S 1 21 105 TRANSMISSION AND TRANSFER CASE 2 SCHEMATICS AND DIAGRAMS Continued LON H LNT H31H3ANOO HV39 3AIHG NI Or TnVHGAH 08 O L que HOLO3 3S FATWA d i74001 isd 8 0 3unssdud 1114 3 1 105 df34201 105 3ATVA 1 6 NOILONS isd 3unssaud dH31H3ANOO SATVA ONIIALL 7 6 isd 76 0 553 JILLOHYHL 3dnssaqud HONH3AOS isd v6 25 3unsSaud 1 1NOH4 JAVA 15008 S SATWANMOCMODI FATWA TOHLNOD LAIHS 8 1 SATVA JILLNHS ATLLOYWHL 3ATVA HOLfTIO LNOYS 5 1 4 OAYAS uvau U31HJANOO 3n0u01 5 IMIYA 3ATVA L3IHS 2 1 N Orrid HONH3AOD TENG S 3ATVA L3IHS 6 0 Orid J31LLOHHL
156. OKE SEAL WASHER J9321 2 Fig 74 Yoke Seal Washer Installation 2 Install coupling retaining snap ring first Fig 75 Be sure snap ring is fully seated before proceed ing 3 Install oil pump locating snap ring on main shaft Fig 75 REAR RETAINER AND OIL PUMP INSTALLATION 1 Install new O ring on flanged end of oil pickup tube 2 Install oil pump Fig 76 21 290 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued VISCOUS COUPLING SNAP RING e J9321 17 Fig 75 Viscous Coupling And Oil Pump Snap Ring Installation 3 Insert oil pickup tube in pump Fig 77 4 Install rear bearing on mainshaft Fig 77 Locating ring groove in bearing goes toward end of mainshaft 5 Install rear bearing retaining snap ring Fig 78 6 Install speedometer drive gear Fig 79 7 Install rear bearing locating ring in rear retainer if ring was removed during overhaul J9321 10 Fig 77 Rear Bearing Installation 4 PY REAR SNAP 1 BEARING RING PUERS SNAP RING J9321 9 Fig 78 Rear Bearing Snap Ring Installation J9321 8 Fig 79 Speedometer Drive Gear Installation 8 Apply 3 mm 1 8 in wide bead of Mopar gas ket maker or silicone adhesive sealer to mounting surface of rear retainer Allow sealer to set up slightly before proceeding 9 Slide rear retainer onto mainshaft Fig 80 10 Spread rear bearing locating ring and slide rear
157. OR 7 VALVE DETENT PLUG AND COVER SPRING J9321 155 Fig 59 Upper Housing Control Valve Locations LOOSEN REMOVE THIS THESE SCREWS 3 4 ACCUMULATOR HOUSING J9321 432 Fig 60 Accumulator Housing Screw Locations CONVERTER US CONVERTER CLUTCH CLUTCH 34 VALVE VALVE ACCUMULATOR SPRING AND SPRING HOUSING PLUG 9321 434 Fig 62 Accumulator Housing Valve Springs And Plug BOOST TUBE BRACE VALVE DOUBLE TAB 3 4 Sh DE 5 5 CLUTCH VALVE VALVE SPRING PLUG 19321 433 Fig 61 3 4 Shift And Converter Clutch Valve Springs And Plug 2 DISASSEMBLY AND ASSEMBLY Continued 28 Remove boost valve connecting tube Fig 64 Disengage tube from upper housing port first Then rock opposite end of tube back and forth to work it out of lower housing CAUTION not use tools to loosen or pry the connecting tube out of the valve body housings Loosen and remove the tube by hand only 29 Turn valve body over so lower housing is fac ing upward Fig 65 In this position the two check balls in upper housing will remain in place and not fall out when lower housing and separator plate are removed 30 Remove screws attaching valve body lower housing to upper housing and transfer plate Fig 65 Note position of boost valve tube brace for assembly reference 31 Remove lower housing and overdrive separa tor plate from transfer plate Fig 65 32 Remove the ECE check ball from the tra
158. POSITION Reverse Drive Range First Second Third Fourth 2 Range Manual Second 2 OVERDRIVE CLUTCHES OVERRUN CLUTCH OVERDRIVE CLUTCH OVERRUN CLUTCH 19421 218 Clutch Band Application Chart running clutch are applied in all ranges except fourth gear For example If slippage occurs in first gear in D and 2 range but not in 1 range the transmission overrunning dutch is faulty Similarly if slippage occurs any two forward gears the rear clutch is slipping Applying the same method of analysis note that the front and rear clutches are applied simulta neously only in D range third and fourth gear If the transmission slips in third gear either the front dutch or the rear dutch is slipping If the transmission slips in fourth gear but not in third gear the overdrive dutch is slipping By select ing another gear which does not use these clutches the slipping unit can be determined For example if the transmission also slips in Reverse the front dutch is slipping If the transmission does not slip in Reverse the rear dutch is slipping If slippage occurs during the 3 4 shift or only in fourth gear the overdrive clutch is slipping Simi larly if the direct dutch were to fail the transmis sion would lose both reverse gear and overrun braking in 2 position manual second gear If the transmission will not shift to fourth gear the control switch overdrive solenoid or related wirin
159. PRING PRESS PLATES DIRECT CLUTCH REACTION PLATE FLUSH WITH END OF HUB 22 9321 396 Fig 232 Direct Clutch Spring Installation slightly Counterbore in plate fits over raised xi d splines Plate should be flush with this end of hub Fig 234 19121379 c Install first clutch disc followed by a steel plate until all discs and plates have been installed d Install pressure plate This is last dutch pack item to be installed Be sure plate is installed with shoulder side facing upward Fig 235 19 Install clutch hub and clutch pack on direct dutch spring Fig 236 Be sure hub is started on sun gear splines before proceeding Fig 234 Correct Position Of Direct Clutch Reaction Plate CLUTCH DISCS 8 CLUTCH REACTION PLATE PLATES 7 J9521 50 Fig 233 46RE Direct Clutch Pack Components 21 210 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued DIRECT CLUTCH PRESSURE PLATE CLUTCH 2 SURE SHOULDER SIDE OF PLATE FACES UPWARD J9121 330 Fig 235 Correct Position Of Direct Clutch Pressure Plate CLUTCH HUB DIRECT CLUTCH PACK CLUTCH DRUM 19321 397 Fig 236 Direct Clutch Pack Clutch Hub Installation WARNING THE NEXT STEP GEARTRAIN ASSEMBLY INVOLVES COMPRESSING THE DIRECT CLUTCH HUB AND SPRING IT IS EXTREMELY IMPORTANT THAT PROPER EQUIPMENT BE USED TO COMPRESS THE SPRING AS SPRING FORCE IS APPROXIMAT
160. PUT SHAFT SEAL 80411089 Fig 50 Remove Front Output Shaft Seal INSTALLER 6952 7 TRANSFER CASE 80298363 Fig 51 Install Front Output Shaft Seal 21 256 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued 6 Remove input gear bearing with Tool Handle C 4171 and Remover C 4210 Fig 52 7 Install snap ring on new input gear bearing 8 Install new input gear bearing with Tool Han dle C 4171 and Remover C 4210 Install bearing far enough to seat snap ring against case Fig 53 SPECIAL TOOL CAVI SPECIAL TOOL C 4210 J9521 43 Fig 52 Input Gear Bearing Removal SNAP INPUT RING SHAFT BEARING OO oC 2 18921 219 Fig 53 Seating Input Gear Bearing 2 9 Remove the input gear pilot bearing by insert ing a suitably sized drift into the splined end of the input gear and driving the bearing out with the drift and a hammer Fig 54 10 Install new pilot bearing with Installer 8128 and Handle C 4171 Fig 55 80a11090 Fig 54 Remove Input Gear Pilot Bearing HANDLE 4171 INSTALLER 8128 INPUT GEAR 80a98364 Fig 55 Install Input Gear Pilot Bearing 2 DISASSEMBLY AND ASSEMBLY Continued 11 Install new seal in front bearing retainer with Installer 7884 Fig 56 Sa FRONT BEARING NE RETAINER SPECIAL TOOL 7884 19521 41 Fig 56 Front Bearing Retainer Seal Installa
161. Plate Removal 4 Install thrust plate in annulus gear Fig 183 Be sure plate is seated on shaft splines and against gear 5 Install rear planetary gear in rear annulus gear Fig 184 Be sure planetary carrier is seated against annulus gear DRIVING SUN SHELL GEAR SUN GEAR REAR RETAINING RING J9321 175 Fig 181 Sun Gear Installation OUTPUT SHAFT J9121 68 Fig 182 Installing Rear Annulus Gear On Intermediate Shaft 2 THRUST PLATE J9121 69 Fig 183 Installing Rear Annulus Thrust Plate REAR ANNULUS GEAR REAR PLANETARY GEAR 29121 70 Fig 184 Installing Rear Planetary Gear 6 Install tabbed thrust washer on front face of rear planetary gear Fig 185 Seat washer tabs in matching slots in face of gear carrier Use extra petroleum jelly to hold washer in place if desired 7 Lubricate sun gear bushings with petroleum jelly or transmission fluid REAR PLANETARY TABBED RUST Waste Fig 185 Installing Rear Planetary Thrust Washer 2 DISASSEMBLY AND ASSEMBLY Continued 8 Install sun gear and driving shell on interme diate shaft Fig 186 Seat shell against rear plane tary gear Verify that thrust washer on planetary gear was not displaced during installation 9 Install tabbed thrust washer in driving shell Fig 187 be sure washer tabs are seated in tab slots of driving shell Use extra petroleum jelly to hold washer in place if desired 10 In
162. RANSFER CASE 21 273 8 Align and connect propeller shafts Refer to Group 3 Differential and Driveline for proper proce dures and specifications 9 Fill transfer case with correct fluid Check transmission fluid level Correct as necessary 10 Install rear crossmember or skid plate Tighten crossmember bolts to 41 N m 30 ft Ibs torque 11 Remove transmission jack and support stand 12 Connect shift rod to transfer case range lever 13 Adjust transfer case shift linkage 14 Lower vehicle and verify transfer case shift operation SHIFT LEVER REMOVAL 1 Shift transfer case into 4L 2 Raise vehicle 3 Loosen adjusting trunnion locknut and slide shift rod out of trunnion Fig 4 If rod lacks enough travel to come out of trunnion push trunnion out of torque shaft 4 Lower vehicle 5 Remove console Refer to Group 23 Body for proper procedures 6 Remove screws attaching lever assembly to floorpan and remove assembly and shift rod if left attached INSTALLATION 1 If shift rod was not removed from lever assem bly work rod down through floorpan opening Then position lever assembly on floorpan install assembly attaching screws 2 Install console Refer to Group 23 Body for proper procedures 3 Raise vehicle 4 Connect trunnion to torque shaft arm Or slide shift rod into trunnion on range lever Be sure shift rod slides freely in trunnion 5 Verify that range lev
163. RANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued SEAL REACTION RINGS SHAFT SUPPORT THRUST WASHER FIBER J9121 104 Fig 142 Reaction Shaft Seal Ring And Thrust Washer SEAT OIL PUMP IN CASE BY HAND N PILOT STUDS WHEN PUMP 15 SEATED J9121 105 Fig 143 Oil Pump INPUT SHAFT END PLAY CHECK NOTE Overdrive unit must be installed in order to correctly measure the input shaft end play 1 Check input shaft end play as follows 2 Attach dial indicator to converter housing Fig 144 Position indicator plunger against input shaft and zero indicator 2 3 Move input shaft and out and record read ing 4 End play should be 0 86 2 13 mm 0 034 0 084 5 If end play is incorrect change intermediate shaft thrust washer The thrust washer controls end play and is available in three thicknesses for adjust ment purposes TRANSMISSION Fig 144 Checking Input Shaft End Play ACCUMULATOR VALVE BODY OIL PAN AND TORQUE CONVERTER 1 Install accumulator inner spring piston and outer spring Fig 145 2 Verify that park neutral position switch has not been installed in case Valve body can not be installed if switch is in position 3 Install new valve body manual shaft seal in case Fig 146 Lubricate seal lip and manual shaft with petroleum jelly Start seal over shaft and into case Seat seal with 15 16 inch deep well socket 4 In
164. RDRIVE PISTON THRUST Fig 194 Overdrive Piston Thrust Bearing Removal Installation P od OVERDRIVE 2 X Jas iun OVERDRIVE 5222 PISTON SPACER SELECT FIT Fig 195 Overdrive Piston Thrust Plate Removal Installation 2 Remove intermediate shaft spacer Fig 196 Retain spacer It is a select fit part and may possibly be reused 3 Remove overdrive piston from retainer Fig 197 OVERDRIVE CLUTCH PACK 1 Remove overdrive clutch pack wire retaining ring Fig 198 2 Remove overdrive dutch pack Fig 199 3 Note position of dutch pack components for assembly reference Fig 200 TRANSMISSION AND TRANSFER CASE 21 201 INTERMEDIATE SHAFT INTERMEDIATE SHAFT SPACER SELECT FIT 39 9 121 208 Fig 196 Intermediate Shaft Spacer Location OVERDRIVE PISTON PISTON RETAINER J9121 299 Fig 197 Overdrive Piston Removal OVERDRIVE CLUTCH PACK RETAINING M 2 19321 352 Fig 198 Removing Overdrive Clutch Pack Retaining Ring 21 202 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued OVERDRIVE CLUTCH PACK 3 c 19321 353 Fig 199 Overdrive Clutch Pack Removal REACTION PLATE PRESSURE CLUTCH DISCS 4 J9321 227 Fig 200 46RE Overdrive Clutch Component Position OVERDRIVE GEARTRAIN 1 Remove overdrive clutch wave spring Fig 201 2 Remove overdrive clutch reaction snap ring Fig 202 Note that snap ring is l
165. REMOVER INSTALLER 6953 80a1108e Fig 45 Remove Output Shaft Front Bearing ping seal into bore until installer tool bottoms against case TRANSMISSION AND TRANSFER CASE 21 283 INSTALLER oe 6952 A 7 TRANSFER CASE 80298363 Fig 46 Front Output Seal Installation 7 Remove the output shaft rear bearing with the screw and jaws from Remover L 4454 and Cup 8148 Fig 47 SPECIAL TOOL i v n T D L 4454 3 REAR CASE SPECIAL TOOL pum 8148 dE D C y CAS a 2 c E b 80498366 Fig 47 Output Shaft Rear Bearing Removal 21 284 TRANSMISSION AND TRANSFER CASE 2 DISASSEMBLY AND ASSEMBLY Continued 8 Install new bearing with Tool Handle C 4171 and Installer 5066 Fig 48 The bearing bore is chamfered at the top Install the bearing so it is flush with the lower edge of this chamfer Fig 49 e S SG SP CIAL E TOOL SPECIAL TOOL oe C 4210 1 Z 19521 43 HANDLE 2273 4171 6 Fig 50 Input Shaft Bearing Removal 5066 Le OUTPUT SHAFT INNER RING SHAFT INSTALLER BEARING BEARING SEATED AT LOWER EDGE OF CHAMFER J8921 219 Fig 51 Seating Input Shaft Bearing 13 Remove input gear pilot bearing by inserting a suitably sized drift into the splined end of the input gear and driving the bearing out with the drift and a hammer Fig 52 14 Install new pilot
166. Remove E dip that secures shuttle valve sec ondary spring on valve stem Fig 71 4 Remove throttle plug primary spring shuttle valve secondary spring and spring guides Fig 72 5 Remove boost valve retainer spring and valve if not previously removed 6 Remove throttle plug and 1 2 and 2 3 governor plugs Fig 59 7 Turn upper housing around and remove limit valve and shift valve covers Fig 73 8 Remove limit valve housing Then remove retainer spring limit valve and 2 3 throttle plug from limit valve housing Fig 73 9 Remove 1 2 shift control valve and spring Fig 73 2 10 Remove 1 2 shift valve and spring Fig 73 11 Remove 2 3 shift valve and spring from valve body Fig 73 12 Remove pressure plug cover Fig 73 13 Remove line pressure plug sleeve throttle pressure plug and spring Fig 73 SMALL DIAMETER CHECK BALLS 6 LARGE DIAMETER CHECK BALL 1 J9321 154 Fig 70 Check Ball Locations In Upper Housing SECONDARY E CLIP 121179 Fig 71 Shuttle Valve E Clip And Secondary Spring Location 2 5 5 AND TRANSFER CASE 21 167 DISASSEMBLY AND ASSEMBLY Continued SPRING B RETAINER E CUP 2 BOOST VALVE SPRING BOOST GUIDES VALVE 29 BOOST SHUTTLE VALVE d 7 VAVE COVER SECONDARY SPRING SHUTTLE VALVE COVER UPPER HOUSING 47 THROTTLE PLUG
167. Rev 221 GEARSHIFT MECHANISM The shift mechanism is cable operated and pro vides six shift positions The shift positions are e Park P Reverse R Neutral N Drive D Manual Second 2 e Manual Low 1 Manual low 1 range provides first gear only Overrun braking is also provided in this range Man ual second 2 range provides first and second gear only Drive range provides first second third and overdrive fourth gear ranges The shift into overdrive fourth gear range occurs only after the transmission has completed the shift into D third gear range No further movement of the shift mechanism is required to complete the 3 4 shift TRANSMISSION AND TRANSFER CASE 21 5 DESCRIPTION AND OPERATION ELECTRONIC GOVERNOR Governor pressure is controlled electronically Com ponents used for governor pressure control include e Governor body Valve body transfer plate Governor pressure solenoid valve Governor pressure sensor Fluid temperature thermistor Throttle position sensor TPS Transmission speed sensor Powertrain control module PCM GOVERNOR PRESSURE SOLENOID VALVE The solenoid valve is a duty cyde solenoid which regulates the governor pressure needed for upshifts and downshifts It is an electro hydraulic device located in the governor body on the valve body trans fer plate Fig 3 The inlet side of the solenoid valve is exposed to normal transmission line pressure The outlet side of the valve le
168. S 19021 83 Fig 34 Overdrive Unit Bolts 10 Carefully work overdrive unit off intermediate shaft Do not tilt unit during removal Keep it as level as possible 11 If overdrive unit does not require service immediately insert Alignment Tool 6227 2 in splines of planetary gear and overrunning dutch to prevent splines from rotating out of alignment If misalign ment occurs overdrive unit will have to be disassem bled in order to realign splines 12 Remove and retain overdrive piston thrust bearing Bearing may remain on piston or in dutch hub during removal 13 Position drain pan on workbench 14 Place overdrive unit over drain pan Tilt unit to drain residual fluid from case TRANSMISSION AND TRANSFER CASE 21 37 15 Examine fluid for clutch material or metal fragments If fluid contains these items overhaul will be necessary 16 If overdrive unit does not require any service leave alignment tool in position Tool will prevent accidental misalignment of planetary gear and over running clutch splines INSTALLATION 1 Be sure overdrive unit Alignment Tool 6227 2 is fully seated before moving unit If tool is not seated and gear splines rotate out of alignment overdrive unit will have to be disassembled in order to realign splines 2 overdrive piston retainer was not removed during service and original case gasket is no longer reusable prepare new gasket by trimming it 3 Cut out old case gasket a
169. S TURNED OFF Shorted shorted 3 PCM Malfunction 3 Test with DRB scan tool Replace PCM if faulty 4 Valve Body Stuck Valves 4 Repair stuck 3 4 lockup or lockup timing valve CLUNK NOISE FROM 1 Transmission Fluid Low 1 Add Fluid DRIVELINE ON CLOSED 2 Throttle Cable Misadjusted 2 Adjust cable THROTTLE 4 3 DOWNSHIFT 3 Overdrive Clutch Select Spacer 3 Replace overdrive piston thrust plate Wrong Spacer spacer 3 4 UPSHIFT OCCURS 1 Overdrive Solenoid Connector or 1 Test connector and wiring for loose IMMEDIATELY AFTER 2 3 Wiring Shorted connections shorts or ground and repair as SHIFT needed 2 TPS Malfunction 2 Test TPS and replace as necessary Check with DRB scan tool 3 PCM Malfunction 3 Test PCM with DRB scan tool and replace controller if faulty 4 Overdrive Solenoid Malfunction 4 Replace solenoid 5 Valve Body Malfunction 5 Remove disassemble clean and inspect valve body components Make sure all valves and plugs slide freely in bores Polish valves with crocus cloth if needed WHINE NOISE RELATED 1 Fluid Level Low 1 Add fluid and check for leaks TO ENGINE SPEED 2 Shift Cable Incorrect Routing 2 Check shift cable for correct routing Should not touch engine or bell housing 6 Valve Body Valve Sticking 6 Repair stuck 3 4 shift valve or lockup timing valve 2 3RANSMISSION AND TRANSFER CASE 21 23 DIAGNOSIS AND TESTING Continued CONDITION POSSIB
170. SMISSION CLUTCH AND BAND OPERATION Air pressure testing can be used to check transmis sion front rear dutch and band operation The test can be conducted with the transmission either in the vehicle or on the work bench as a final check after overhaul Air pressure testing requires that the oil pan and valve body be removed from the transmission The servo and clutch apply passages are shown Fig 9 FRONT SERVO RELEASE PUMP SUCTION 9 PUMP PRESSURE FRONT 2 CLUTCH 2 APPLY Q CLUTCH APPLY TO TORQUE JN CONVERTOR TORQUE D zCONVERTERZZCOOLER 80b1717e Fig 9 Air Pressure Test Passages Front Clutch Air Test Place one or two fingers on the clutch housing and apply air pressure through front dutch apply pas sage Piston movement can be felt and a soft thump heard as the dutch applies Rear Clutch Air Test Place one or two fingers on the clutch housing and apply air pressure through rear clutch apply passage 21 132 TRANSMISSION AND TRANSFER CASE DIAGNOSIS AND TESTING Continued Piston movement can be felt and a soft thump heard as the clutch applies Front Servo Air Test Apply air pressure to the front servo apply pas sage The servo rod should extend and cause the band to tighten around the drum Spring pressure should release the servo when air pressure is removed Rear Servo Air Test
171. SSIBLE CAUSES CORRECTION SLIPS IN FORWARD DRIVE 1 Fluid Level Low 1 Add fluid and check for leaks RANGES 2 Fluid Foaming 2 Check for high oil level bad pump gasket or seals dirt between pump halves and loose pump bolts Replace pump if necessary 3 Throttle Linkage Misadjusted 3 Adjust linkage 4 Gearshift Linkage Misadjusted 4 Adjust linkage 5 Rear Clutch Worn 5 Inspect and replace as needed 6 Low Hydraulic Pressure Due to 6 Perform hydraulic and air pressure Worn Pump Incorrect Control tests to determine cause Pressure Adjustments Valve Body Warpage or Malfunction Sticking Leaking Seal Rings Clutch Seals Leaking Servo Leaks Clogged Filter or Cooler Lines 7 Rear Clutch Malfunction Leaking 7 Air pressure check clutch servo Seals or Worn Plates operation and repair as required 8 Overrunning Clutch Worn Not 8 Replace Clutch Holding Slips in 1 Only SLIPS IN LOW GEAR D ONLY Overrunning Clutch Faulty Replace overrunning clutch BUT NO IN 1 POSITION GROWLING GRATING OR 1 Drive Plate Broken 1 Replace SCRAPING NOISES 2 Torque Converter Bolts Hitting Dust 2 Dust shield bent Replace or repair Shield 3 Planetary Gear Set Broken Seized 3 Check for debris in oil pan and repair as required 4 Overrunning Clutch Worn Broken 4 Inspect and check for debris in oil pan Repair as required 5 Oil Pump Components Scored 5 Remove inspect and repair as Binding required 6 Ou
172. SSION FLUID TEMPERATURE THERMISTOR 80a0c4fa Fig 4 Governor Pressure Sensor GOVERNOR BODY AND TRANSFER PLATE The transfer plate is designed to supply transmis sion line pressure to the governor pressure solenoid valve and to return governor pressure The governor pressure solenoid valve is mounted in the governor body The body is bolted to the lower side of the transfer plate Fig 4 The transfer plate channels line pressure to the solenoid valve through the governor body It also channels governor pressure from the solenoid valve to the governor circuit It is the solenoid valve that develops the necessary gover nor pressure TRANSMISSION FLUID TEMPERATURE THERMISTOR Transmission fluid temperature readings are sup plied to the transmission control module by the ther mistor The temperature readings are used to control engagement of the fourth gear overdrive dutch the converter dutch and governor pressure Normal resistance value for the thermistor at room tempera ture is approximately 1000 ohms The PCM prevents engagement of the converter dutch and overdrive dutch when fluid temperature is below approximately 10 C 50 F If fluid temperature exceeds 126 C 260 F the PCM causes a 4 3 downshift and engage the con verter dutch Engagement is according to the third gear converter dutch engagement schedule The overdrive OFF lamp in the instrument panel illuminates when the shift back to third occurs The transmis
173. Snap Ring SELECTIVE SNAP RING SNAP RING PLIERS J9121 170 Fig 183 Installing Planetary Selective Snap Ring 2 Remove overdrive piston thrust bearing Fig 186 OVERDRIVE PISTON DISASSEMBLY 1 Remove overdrive piston thrust plate Fig 187 Retain thrust plate It is a select fit part and may possibly be reused 2 Remove intermediate shaft spacer Fig 188 Retain spacer It is a select fit part and may possibly be reused 3 Remove overdrive piston from retainer Fig 189 OVERDRIVE CLUTCH PACK DISASSEMBLY 1 Remove overdrive dutch pack wire retaining ring Fig 190 2 Remove overdrive clutch pack Fig 191 NOTE The 42RE transmission has three clutch discs and two clutch plates The 44RE transmission has four clutch discs and three clutch plates 2 3RANSMISSION AND TRANSFER CASE 21 77 DISASSEMBLY AND ASSEMBLY Continued THRUST BEARING OVERDRIVE PISTON THRUST 9321 351 Fig 186 Overdrive Piston Thrust Bearing Removal Installation ovea 4 9121 171 2 Fig 184 Checking Planetary Geartrain End Play OVER PISTON SPACER SELECT FIT SPEED Fig 187 Overdrive Piston Thrust Plate Removal SENSOR Installation O RING INTERMEDIATE SHAFT 10321 348 Fig 185 Transmission Speed Sensor Removal Installation 3 Note position of dutch pack components for assembly reference Fig 192 INTERMEDIATE SHAF
174. T E THRUST PLATE J9121 215 Fig 115 Installing Intermediate Shaft Thrust Plate place if necessary ek 13 Align clutch discs in front clutch and install 1 front dutch on rear dutch Fig 118 Rotate front LEVER dutch retainer back and forth until completely PIVOT seated on rear dutch retainer De 14 Coat intermediate shaft thrust washer with petroleum jelly Then install washer in rear clutch 19121 352 hub Fig 119 Use enough petroleum jelly to hold Fig 113 Rear Band Lever And Pivot Pin Installation 21 60 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued INPUT SHAFT TEFLON SEAL RING METAL SEAL RING REAR CLUTCH RETAINER Fig 116 Input Shaft Seal Ring Location REAR CLUTCH RETAINER REAR CLUTCH THRUST WASHER FIBER washer in place Be sure grooved side of washer faces rearward toward output shaft as shown Also note that washer only fits one way in clutch hub Note thickness of this washer It is a select fit part and is used to control transmission end play E REAR ASSEMBLY J9121 190 Fig 118 Assembling Front And Rear Clutch Units 2 INTERMEDIATE SHAFT THRUST REAR CLUTCH RETAINER HUB INPUT SHAFT J9121 214 Fig 119 Installing Intermediate Shaft Thrust Plate 15 Align drive teeth on rear clutch discs with small screwdriver Fig 120 This makes installation on front planetary easier 16 Raise front end of transmission up
175. T SPACER OVERDRIVE GEARTRAIN DISASSEMBLY SELECT FIT 1 Remove overdrive dutch wave spring Fig SS J9121 298 2 193 Fig 188 Intermediate Shaft Spacer Location 21 78 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued OVERDRIVE PISTON PISTON RETAINER J9121 299 Fig 189 Overdrive Piston Removal OVERDRIVE CLUTCH PACK RETAINING RING 19321 352 Fig 190 Removing Overdrive Clutch Pack Retaining Ring OVERDRIVE CLUTCH PACK 3 c 19321 353 Fig 191 Overdrive Clutch Pack Removal 2 Remove overdrive clutch snap ring Fig 194 Note that snap ring is located in same groove as wave spring 3 Remove Torx head screws that attach access cover and gasket to overdrive case Fig 195 4 Remove access cover and gasket Fig 196 5 Expand output shaft bearing snap ring with expanding type snap ring pliers Then push output 2 PRESSURE PLATE TO FRONT OVERDRIVE CLUTCH DISC 3 CLUTCH PLATE 2 REACTION PLATE TO REAR J9321 354 Fig 192 42RE Overdrive Clutch Component Position lt 2 19321 355 Fig 193 Overdrive Clutch Wave Spring Removal Installation REACTION RING CLUTCH HUB J9321 356 Fig 194 Overdrive Clutch Reaction Snap Ring Removal Installation shaft forward to release shaft bearing from locating ring Fig 197 6 Lift gear case up and off geartrain assembly Fi
176. TE SELECTION 1 Place overdrive unit in vertical position Mount it on blocks or in workbench with appropriate size mounting hole cut into it Be sure unit is facing upward for access to direct clutch hub Also be sure output shaft is not loaded and internal components are moved rearward for accurate measurement 2 Determine correct thickness overdrive piston thrust plate as follows a Position Gauge Tool 6311 across face of over drive case Then position Dial Caliper C 4962 over gauge tool Fig 251 b Measure distance to clutch hub thrust bear ing seat at four points 90 apart Then average measurements by adding them and dividing by 4 c Select and install required thrust plate from information in thrust plate chart Fig 252 3 Leave Alignment Tool 6227 2 in place Tool will keep planetary and dutch hub splines in alignment until overdrive unit is ready for installation on transmission 4 Transmission speed sensor can be installed at this time if desired However it is recommended that TRANSMISSION AND TRANSFER CASE 21 213 sensor not be installed until after overdrive unit is secured to transmission SPECIAL 215 TOOLC4962 DIRECT CLUTCH HUB THRUST BEARING SEAT SPECIAL Fig 251 Overdrive Piston Thrust Plate Measurement End Play Measurement Spacer Thickness Inches Inches 1 7500 1 7649 108 110 1 7650 1 7799 123 125 1 7800 1 7
177. TING SCREW TO ONLY 5 N m 50 IN LBS IF ADAPTER IS USED J9121 233 Fig 262 Band Adjustment Adapter Tool 21 222 TRANSMISSION AND TRANSFER CASE ADJ USTMENTS Continued REAR BAND ADJUSTMENT The transmission oil pan must be removed for access to the rear band adjusting screw 1 Raise vehicle 2 Remove transmission oil pan and drain fluid 3 Loosen band adjusting screw locknut 5 6 turns Be sure adjusting screw turns freely in lever 4 Tighten adjusting screw to 8 N m 72 in Ibs torque Fig 263 5 Back off adjusting screw 2 turns 6 Hold adjusting screw in place and tighten lock nut to 34 N m 25 ft Ibs torque 7 Position new gasket on oil pan and install pan on transmission Tighten pan bolts to 17 N m 13 ft 165 torque 8 Lower vehicle and refill transmission with Mopar ATF Plus Type 7176 fluid VALVE BODY CONTROL PRESSURE ADJ USTMENTS There are two control pressure adjustments on the valve body e Line Pressure e Throttle Pressure LOW REVERSE BAND ADJUSTMENT ig 263 Rear Band Adjustment Screw Location Line and throttle pressures are interdependent because each affects shift quality and timing As a result both adjustments must be performed properly and in the correct sequence Adjust line pressure first and throttle pressure last LINE PRESSURE ADJUSTMENT Measure distance from the valve body to the inner edge of the adjusting screw with an accurate steel scale Fig 264
178. TS Possible sources of converter leaks are 1 Leaks at the weld joint around the outside diameter weld Fig 11 2 Leaks at the converter hub weld Fig 11 TORQUE CONVERTER HUB WELD OUTSIDE DIAMETER WELD RH254 STARTER RING GEAR Fig 11 Converter Leak Points Typical CONVERTER HOUSING AREA LEAK CORRECTION 1 Remove converter 2 Tighten front band adjusting screw until band is tight around front dutch retainer This prevents front rear dutches from coming out when oil pump is removed 3 Remove oil pump and remove pump seal Inspect pump housing drainback and vent holes for obstructions Clear holes with solvent and wire 4 Inspect pump bushing and converter hub If bushing is scored replace it If converter hub is scored either polish it with crocus doth or replace converter 5 Install new pump seal O ring and gasket Replace oil pump if cracked porous or damaged in any way Be sure to loosen the front band before installing the oil pump damage to the oil pump seal may occur if the band is still tightened to the front clutch retainer 6 Loosen kickdown lever pin access plug three turns Apply Loctite 592 or Permatex No 2 to plug threads and tighten plug to 17 N m 150 in Ibs torque 7 Adjust front band 8 Lubricate pump seal and converter hub with transmission fluid or petroleum jelly and install con verter 9 Install dust shield 10 Lower vehicle transmission an
179. UID FLUID LEVEL LEVEL 804dBeae Fig 12 Dipstick Fluid Level Marks Typical FLUID AND FILTER REPLACEMENT Refer to the Maintenance Schedules in Group O Lubrication and Maintenance for proper service intervals The service fluid fill after a filter change is approximately 3 8 liters 4 0 quarts 2 1 Hoist and support vehicle safety stands 2 Place a large diameter shallow drain pan beneath the transmission pan 3 Remove bolts holding front and sides of pan to transmission Fig 13 4 Loosen bolts holding rear of pan to transmis sion 5 Slowly separate front of pan away from trans mission allowing the fluid to drain into drain pan 6 Hold up pan and remove remaining bolt hold ing pan to transmission 7 While holding pan level lower pan away from transmission 8 Pour remaining fluid in pan into drain pan 9 Remove screws holding filter to valve body Fig 14 10 Separate filter from valve body and pour fluid in filter into drain pan 11 Dispose of used trans fluid and filter properly PAN 80b170e7 TRANSMISSION FILTER 80b170e8 Fig 14 Transmission Filter Typical 2 SERVICE PROCEDURES Continued INSPECTION Inspect bottom of pan and magnet for excessive amounts of metal A light coating of clutch or band material on the bottom of the pan does not indicate a problem unless accompanied by slipping condition or shift lag If fluid and pan are contam
180. VER TUBE 19321 467 Fig 50 Boost Valve Cover Location COVER BOOST SCREWS VALVE SPRING COVER AND VALVE 2 RETAINER o oak ROD J9121 81 BOOST Fig 53 Park Rod _ THROTTLE BOOST VALVE BOOST SPRING VALVE 19321 468 Fig 51 Boost Valve Components 15 Secure detent ball and spring with Retainer Tool 6583 Fig 52 16 Remove park rod E dip and separate rod from MANUAL manual lever Fig 53 SHAFT 17 Remove E dip and washer that retains throt tle lever shaft in manual lever Fig 54 18 Remove manual lever and throttle lever Fig 55 Rotate and lift manual lever off valve body and throttle E CLIP AND 0 lever shaft Then slide throttle lever out of valve body WASHER Ge 9321 424 19 Position pencil magnet next to detent housing to catch detent ball and spring Then carefully Fig 54 Throttle Lever E Clip And Washer cA dd SPECIAL 9 TOOL 6583 POSITIONED ON DETENT SS HOUSING PARK ROD THROTTLE LEVER MANUAL LEVER ASSEMBLY J9321 425 J9521 178 Fig 52 Detent Ball And Spring Fig 55 Manual And Throttle Lever 2 DISASSEMBLY AND ASSEMBLY Continued DETENT BALL DETENT HOUSING DETENT SPRING PENCIL MAGNET J9321 426 Fig 56 Detent Ball And Spring REMOVE BRACKET REMOVE THIS SCREW LAST J9321 430 BRACKET Fig 57 Adjusting Screw Bracket Fastener TRANSMISSION AND TRANSFER CASE 21 163 21
181. VER ASSEMBLY FLOORPAN TRUNNION LOCK BOLT SELECTOR ROD AND TRUNNION SHIFT LEVER TORQUE SHAFT ROD FRAME BRACKET J9321 185 Fig 84 Transfer Case Shift Linkage 21 294 TRANSMISSION AND TRANSFER CASE 2 SPECIAL TOOLS NV249 TRANSFER CASE C Installer C 3995 A Installer 5066 Pd Installer 6952 A Handle C 4171 Installer 6953 Installer 8145 Remover 6957 BEY S Remover C 4210 2 SPECIAL TOOLS Continued Remover L 4454 m Cup 8148 TRANSMISSION AND TRANSFER CASE 21 295 Installer 8128 Installer 7884
182. VERTER CLUTCH SOLENOID 7 SOLENOID GASKET CASE CONNECTOR OVERDRIVE SEPARATOR PLATE 80468d95 Fig 69 Lower Housing Shift Valves And Springs 3 4 REAR REAR ACCUMULATOR CLUTCH SERVO HOUSING CHECK BALL E Pn BALL TRANSFER ACCUMULATOR PISTON TEFLON SEALS PISTON SPRING COVER PLATE AND SCREWS 804d8eb9 Fig 70 Accumulator Housing Components ACCUMULATOR END PLATE TRANSMISSION AND TRANSFER CASE 21 47 3 4 ACCUMULATOR PISTON AND SPRING 3 4 ACCUMULATOR HOUSING J9321 437 Fig 71 Rear Clutch And Rear Servo Check Ball Locations UPPER AND LOWER HOUSING 1 Position upper housing so internal passages and check ball seats are facing upward Then install check balls in housing Fig 74 Seven check balls are used The single large check ball is approxi mately 8 7 mm 11 32 in diameter The single small check ball is approximately 4 8 mm 3 16 in in 21 48 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued UPPER HOUSING REN SEPARATOR PLATE 0 Eas ER J9321 440 Fig SEPARATOR TRANSFER PLATE PLATE J9321 150 Fig 73 Brace Plate diameter The remaining 6 check balls are approxi mately 6 3 mm 1 4 in in diameter 2 Position assembled transfer plate and upper housing separator plate on upper housing Fig 75 SMALL DIAMETER CHECK BALLS 6 LARGE DIAMETER CHECK BALL 1 Fig 74 Check Ball
183. VO PISTON DISASSEMBLY 1 Remove seal ring from rod guide Fig 156 2 Remove small snap ring from servo piston rod Then remove piston rod spring and washer from piston 3 Remove and discard servo component O ring and seal rings ASSEMBLY Clean and inspect front servo components 1 Lubricate new O ring and seal rings with petroleum jelly and install them on piston guide and rod 2 Install rod in piston Install spring and washer on rod Compress spring and install snap ring Fig 156 PISTON RINGS SNAP RING PISTON SERVO PISTON ROD 0 1 7 GUIDE 0 SEAL RING PISTON ROD SPRING SERVO SPRING WASHER SNAP RING 80315881 Fig 156 Front Servo REAR SERVO PISTON DISASSEMBLY 1 Remove small snap ring and remove plug and spring from servo piston Fig 157 2 Remove and discard servo piston seal ring ASSEMBLY 1 Lubricate piston and guide seals with petro leum jelly Lubricate other servo parts with Mopar ATF Plus 3 Type 7176 transmission fluid 2 Install new seal ring on servo piston 3 Assemble piston plug spring and new snap ring 4 Lubricate piston seal lip with petroleum jelly 2 SNAP PISTON PISTON SPRING SNAP RING SEAL PLUG RETAINER RING 5 e 1 1 4 CUSHION PISTON PISTON SPRING SPRING 19121 64 Fig 157 Rear Servo Components OIL PUMP AND REACTION SHAFT SUPPORT DISASSEMBLY 1 Mark position of support in oil pump body for assembly alignment reference
184. Valve Springs TRANSMISSION AND TRANSFER CASE 21 173 CONVERTER CLUTCH VALVE PLUG ACCUMULATOR BOX 9521 180 Fig 90 Seating 3 4 Accumulator On Lower Housing VALVE BODY FINAL 1 Install boost valve valve spring retainer and cover plate Tighten cover plate screws to 4 N m 35 165 torque 2 Insert manual lever detent spring in upper housing 3 Position detent ball on end of spring Then hold detent ball and spring in detent housing with Retainer Tool 6583 Fig 91 4 Install throttle lever in upper housing Then install manual lever over throttle lever and start manual lever into housing 5 Align manual lever with detent ball and man ual valve Hold throttle lever upward Then press down on manual lever until fully seated Remove detent ball retainer tool after lever is seated 6 Then install manual lever seal washer and E dip 7 Verify that throttle lever is aligned with end of kickdown valve stem and that manual lever arm is engaged in manual valve Fig 92 8 Position line pressure adjusting screw in adjusting screw bracket 9 Install spring on end of line pressure regulator valve 10 Install switch valve spring on tang at end of adjusting screw bracket 11 Install manual valve 12 Install throttle valve and spring 13 Install kickdown valve and detent 14 Install pressure regulator valve 15 Install switch valve 16 Position adjusting screw bracket on v
185. able to shifter mechanism by snapping cable retaining ears into shifter bracket and press cable end fitting onto lever ball stud 4 Place the floor shifter lever in park position Ensure that the pawl is seated within the confines of the adjustment gauge clip 5 Snap the cable into the transmission bracket so the retaining ears are engaged and connect cable end fitting onto the manual control lever ball stud 6 Lock shift cable into position by pushing upward on the adjusting lock button 7 Remove and discard the shift cable adjustment gauge clip from the park gate of the shifter TRANSMISSION AND TRANSFER CASE 21 33 BRAKE TRANSMISSION SHIFT INTERLOCK REMOVAL 1 Lower the steering column 2 Remove two screws retaining the interlock mechanism to the column Fig 23 Unsnap the mechanism from column MOUNTING STEERING SCREWS COLUMN X INTERLOCK MECHANISM J9319 28 Fig 23 Interlock Mechanism on Column 3 Remove the center console and related trim Refer to Group 23 Body for proper procedures 4 Disconnect and remove the cable from the shift bracket 5 Remove the wire connector at the solenoid on the cable 6 Remove the accelerator pedal the cable routes under the pedal Refer to Group 14 Fuel Systems for proper procedures 7 Release the cable from the accelerator pedal dip 8 Remove the carpet as necessary to remove the cable INSTALLATION NOTE The gearshift cab
186. accelerator pedal imme diately transmission clutch slippage is occurring 7 a second stall test is required cool down fluid before proceeding Shift into NEUTRAL and run engine at 1000 rpm for 20 30 seconds to cool fluid STALL TEST ANALYSIS Stall Speed Too High If the stall speed exceeds 2500 rpm transmission clutch slippage is indicated Stall Speed Low Low stall speed with a properly tuned engine indi cate a torque converter overrunning clutch problem The condition should be confirmed by road testing A stall speed 250 350 rpm below normal indicates the converter overrunning clutch is slipping The vehicle also exhibits poor acceleration but operates normally once highway cruise speeds are reached Torque con verter replacement will be necessary TRANSMISSION AND TRANSFER CASE 21 131 Stall Speed Normal But Acceleration Poor If stall speeds are normal 1800 2300 rpm but abnormal throttle opening is required for accelera tion or to maintain cruise speed the converter over running clutch is seized The torque converter will have to be replaced Converter Noise During Test A whining noise caused by fluid flow is normal dur ing a stall test However loud metallic noises indi cate a damaged converter To confirm that the noise is originating from the converter operate the vehide at light throttle in DRIVE and NEUTRAL on a hoist and listen for noise coming from the converter hous ing AIR TESTING TRAN
187. ads to the valve body governor circuit The solenoid valve regulates line pressure to pro duce governor pressure The average current sup plied to the solenoid controls governor pressure One amp current produces zero kPa psi governor pres sure Zero amps sets the maximum governor pres sure The powertrain control module PCM turns on the trans control relay which supplies electrical power to the solenoid valve Operating voltage is 12 volts DC The PCM controls the ground side of the sole noid using the governor pressure solenoid control cir cuit SOLENOID FILTER GOVERNOR PRESSURE SOLENOID J9321 408A Fig 3 Governor Pressure Solenoid Valve GOVERNOR PRESSURE SENSOR The governor pressure sensor measures output pressure of the governor pressure solenoid valve Fig 4 The sensor output signal provides the necessary feedback to the PCM This feedback is needed to ade quately control governor pressure 21 6 5 15510 AND TRANSFER CASE DESCRIPTION AND OPERATION Continued RETAINING CLIP GOVERNOR BODY GOVERNOR PRESSURE SENSOR TRANSMISSION FLUID TEMPERATURE THERMISTOR 80a0c4fa Fig 4 Governor Pressure Sensor GOVERNOR BODY AND TRANSFER PLATE The transfer plate is designed to supply transmis sion line pressure to the governor pressure solenoid valve and to return governor pressure The governor pressure solenoid valve is mounted in the governor body The body is bolted to the low
188. against case 2 Install pawl shaft retaining bolt Tighten bolt to 27 N m 20 ft Ibs torque 3 Install park lock reaction plug Note that plug has locating pin at rear Fig 232 Be sure pin is seated in hole in case before installing snap ring 21 86 TRANSMISSION AND TRANSFER CASE 2 DISASSEMBLY AND ASSEMBLY Continued REACTION DIRECT PLATE CLUTCH DISCS 6 PRESSURE PLATE CLUTCH PLATES 5 J9321 368 Fig 225 42RE Direct Clutch Pack Components CLUTCH DISCS 8 PRESSURE PLATE CLUTCH REACTION PLATE PLATES 7 J9521 50 Fig 226 44RE Direct Clutch Pack Components 4 Install reaction plug snap ring Fig 233 Com press snap ring only enough for installation do not distort it 5 Install new seal in gear case On 4x4 gear case use Tool Handle C 4171 and Installer C 3860 A to seat seal in case On 4 x 2 gear case use same Han dle C 4171 and Installer C 3995 A to seat seal in case 6 Verify that tab ends of rear bearing locating ring extend into access hole in gear case Fig 234 7 Support geartrain on Tool 6227 1 Fig 235 Be sure tool is securely seated in dutch hub 8 Install overdrive gear case on geartrain Fig 235 9 Expand front bearing locating ring with snap ring pliers Fig 236 Then slide case downward until locating ring locks in bearing groove and release snap ring 10 Install locating ring access cover and gasket in overdrive unit case Fig 237 OVERDRIVE
189. age Note if shifts are harsh spongy delayed early or if part throttle downshifts are sensitive Slippage indicated by engine flare usually means dutch band or overrunning dutch problems If the condition is advanced an overhaul will be necessary to restore normal operation A slipping dutch or band can often be determined by comparing which internal units are applied in the various gear ranges The Clutch and Band Applica tion chart provides a basis for analyzing road test results ANALYZING ROAD TEST Refer to the Clutch and Band Application chart and note which elements are in use in the various gear ranges Note that the rear clutch is applied in all forward ranges D 2 1 The transmission overrunning clutch is applied in first gear D 2 and 1 ranges only The rear band is applied in 1 and R range only Note that the overdrive clutch is applied only in fourth gear and the overdrive direct dutch and over 2 DIAGNOSIS AND TESTING Continued TRANSMISSION CLUTCHES AND BANDS SHIFT LEVER POSITION Reverse Drive Range First Second Third Fourth 2 Range Manual Second TRANSMISSION AND TRANSFER CASE 21 11 OVERDRIVE CLUTCHES OVERRUN CLUTCH OVERDRIVE CLUTCH OVERRUN CLUTCH 19421 218 Clutch Band Application Chart running clutch are applied in all ranges except fourth gear For example If slippage occurs in first gear in D and 2 range but not in 1 range the transmission o
190. aintains line pres sure The amount of pressure developed is controlled by throttle pressure which is dependent on the degree of throttle opening The regulator valve is located in the valve body The throttle valve determines line pressure and shift speed Governor pressure increases in propor tion to vehide speed The throttle valve controls upshift and downshift speeds by regulating pressure according to throttle position Shift Valve Flow Control The manual valve is operated by the gearshift link age and provides the operating range selected by the driver The 1 2 shift valve provides 1 2 or 2 1 shifts and the 2 3 shift valve provides 2 3 or 3 2 shifts The kickdown valve provides forced 3 2 or 3 1 downshifts depending on vehicle speed Downshifts occur when the throttle is opened beyond downshift detent position Detent is reached just before wide open throttle position The 2 3 valve throttle pressure plug provides 3 2 downshifts at varying throttle openings depending on vehicle speed The 1 2 shift control valve transmits 1 2 shift pres sure to the accumulator piston This controls kick down band capacity on 1 2 upshifts and 3 2 downshifts The 3 4 shift quick fill and timing valves plus the 3 4 accumulator are only actuated when the over drive solenoid is energized The solenoid contains a check ball that controls a vent port to the 3 4 valves The check ball either diverts line pressure away from or directly to the 3
191. al Guide 8114 2 on inner edge of overdrive piston retainer 12 Install overdrive piston in overdrive piston retainer by aligning locating lugs on overdrive piston to the two mating holes in retainer a Aligning locating lugs on overdrive piston to the two mating holes in retainer 2 DISASSEMBLY AND ASSEMBLY Continued b Lubricate overdrive piston seals with Mopar Door Ease or equivalent Install piston over Seal Guide 8114 2 and inside Guide Ring 8114 1 d Push overdrive piston retainer e Verify that the locating lugs entered the lug bores in the retainer into position in NOTE INSTALL THE REMAINING TRANSMISSION COMPONENTS AND OVERDRIVE UNIT FRONT SERVO PISTON DISASSEMBLY 1 Remove seal ring from rod guide Fig 137 2 Remove small snap ring from servo piston rod Then remove piston rod spring and washer from pis ton 3 Remove and discard servo component O ring and seal rings ASSEMBLY Clean and inspect front servo components 1 Lubricate new O ring and seal rings with petroleum jelly and install them on piston guide and rod 2 Install rod in piston Install spring and washer on rod Compress spring and install snap ring Fig 137 3 Set servo components aside for installation dur ing transmission reassembly PISTON RINGS PISTON SERVO PISTON ROD 0 1 7 GUIDE 0 SEAL RING SNAP RING PISTON ROD SPRING SERVO SPRING WASHER SNAP RING 803f588f
192. alve body Align valve springs and press bracke into place Install short upper bracket screws first and long bottom screw last Verify that valve springs and bracket are properly aligned Then tighten all three bracket screws to 4 35 in Ibs torque 21 174 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued 17 Lubricate solenoid case connector O rings and shaft of manual lever with light coat of petroleum jelly 18 Obtain new fluid filter for valve body but do not install filter at this time 19 If line pressure and or throttle pressure adjustment screw settings were not disturbed con tinue with overhaul or reassembly However if adjustment screw settings were moved or changed readjust as described in Valve Body Control Pressure Adjustment procedure 20 Attach solenoid case connector to 3 4 accumu lator with shoulder type screw Connector has small locating tang that fits in dimple at top of accumula tor housing Fig 93 Seat tang in dimple before tightening connector screw 21 Install solenoid assembly and gasket Tighten solenoid attaching screws to 8 72 in lbs torque 22 Verify that solenoid wire harness is properly routed Fig 94 Solenoid harness must be clear of manual lever and park rod and not be pinched between accumulator housing and cover SPECIAL TOOL 6583 POSITIONED ON DETENT J9521 178 Fig 91 Detent Ball Spring GOVERNOR BODY SENSOR AND SOLENO
193. and separator plates with a standard parts cleaning solution only Do not use gasoline kerosene or any type of caustic solution Do not immerse any of the electrical components in deaning solution Clean the governor solenoid and sensor and the dual solenoid and harness assembly by wiping them off with dry shop towels only Dry all except the electrical parts with compressed air Make sure all passages are dean and free from obstructions Do not use rags or shop towels to dry or wipe off valve body components Lint from these materials can stick to valve body parts interfere with valve operation and clog filters and fluid passages Wipe the governor pressure sensor and solenoid valve with dry lint free shop towels only The O rings on the sensor and solenoid valve are the only service able components Be sure the vent ports in the sole noid valve are open and not blocked by dirt or debris Replace the valve and or sensor only when DRB scan tool diagnosis indicates this is necessary Or if either part has sustained physical damage dented deformed broken etc CAUTION Do not turn the small screw at the end of the solenoid valve for any reason Turning the screw in either direction will ruin solenoid calibra tion and result in solenoid failure In addition the filler on the solenoid valve is NOT serviceable Do not try to remove the filter as this will damage the valve housing Inspect the throttle and manual valve levers and
194. ap ring Fig 125 5 Lubricate front servo piston components and servo bore in case with transmission fluid 6 Install front servo piston in bore Carefully run small suitable tool around piston ring to press it back into groove and ease installation Fig 126 Rotate piston into bore at same time Rock piston slightly to ease piston ring past snap ring groove and into bore TRANSMISSION AND TRANSFER CASE 21 181 REAR SERVO PISTON Se iH Se Fig 123 Rear Servo Piston SPRING RETAINER NS SERVO SPRING 7 RETAINER RETAINER NK SNAP J9121 40 RING 2 Fig 125 Rear Servo Snap Ring 7 Bottom front servo piston in bore and install servo spring 8 Install front servo piston rod guide as follows 21 182 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued USE SUITABLE TOOL TO HELP SEAT PISTON RING SERVO PISTON 7 9121 98 Fig 126 Front Servo Piston a Place Tool SP 5560 or similar size tool on guide and position C clamp on tool and case Fig 127 b Slowly compress rod guide while simulta neously easing seal ring into bore with suitable tool 9 Install rod guide snap ring Fig 127 C CLAMP GUIDE SMALL SCREWDRIVER Fig 127 Front Servo Rod Guide And Snap Ring OVERRUNNING CLUTCH REAR BAND AND LOW REVERSE DRUM 1 Install overrunning dutch components if not yet installed 2 Position rear band
195. art must be possible e PARK POSITION apply rearward force on cen ter of handle and remove pressure Engine start must be possible e NEUTRAL POSITION engine start must be possible e NEUTRAL POSITION ENGINE RUNNING AND BRAKES APPLIED Apply forward force on center of shift handle Transmission should not be able to shift into reverse detent TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT The transmission throttle valve is operated by a cam on the throttle lever The throttle lever is oper ated by an adjustable cable Fig 258 The cable is attached to an arm mounted on the throttle lever shaft A retaining clip at the engine end of the cable is removed to provide for cable adjustment The retaining dip is then installed back onto the throttle valve cable to lock in the adjustment A correctly adjusted throttle valve cable will cause the throttle lever on the transmission to move simul taneously with the throttle body lever from the idle position Proper adjustment will allow simultaneous movement without causing the transmission throttle lever to either move ahead of or lag behind the lever on the throttle body TRANSMISSION THROTTLE VALVE CABLE ACCELERATOR CABLE SN CABLE ENGINE BRACKET Fig 258 Throttle Cable Attachment At Engine 2 Checking Throttle Valve Cable Adjustment 1 Turn ignition key to OFF position 2 Remove air deaner 3 Verify that lever on throttle body is at curb idle positi
196. ary gear in annulus gear Fig 220 Be sure planetary pinions are fully seated in annulus gear before proceeding CLUTCH OVERRUNNING DRUM CLUTCH ASSEMBLY EXPANDING TYPE SNAP RING OVERRUNNING CLUTCH ASSEMBLY SEATED IN OUTPUT SHAFT CLUTCH DRUM b ANNULUS 2 GEAR J9121 314 Fig 219 Overrunning Clutch Installation PLANETARY GEAR 9 9121 324 Fig 220 Planetary Gear Installation 12 Coat planetary thrust bearing and bearing contact surface of spring plate with generous amount of petroleum jelly This will help hold bearing in place during installation 13 Install planetary thrust bearing on sun gear Fig 221 Slide bearing onto gear and seat it against 2 spring plate as shown Bearing fits way only If it does not seat squarely against spring plate remove and reposition bearing 14 Install assembled sun gear spring plate and thrust bearing Fig 222 Be sure sun gear and thrust bearing are fully seated before proceeding PLANETARY THRUST BEARING SPRING J9121 326 Fig 221 Planetary Thrust Bearing Installation SUN GEAR AND SPRING PLATE ASSEMBLY J9121 327 Fig 222 Sun Gear Installation 15 Mount assembled output shaft annulus gear and dutch drum in shop press Direct clutch spring hub and dutch pack are easier to install with assem bly mounted in press 16 Align splines in hubs of planetary gear and overrunning dutch with Alignment tool 6227
197. ase evenly and does not become cocked 9 Remove dutch cam installer tools 10 Stake case in 12 places around clutch cam to help secure cam in case Use blunt punch or chisel to stake case 2 SPECIAL TOOL SP5124 PISTON RETAINER Fig 150 Positioning Adapter Tool In Overdrive Piston PULLER BOLT SP 3701 PRESS PLATE 5 3583 10121 58 Fig 151 Assembling Clutch Cam Bolt And Press Plate 11 Remove piston retainer from case Cover retainer with plastic sheeting or paper to keep it dust free 12 Clean case and cam thoroughly Be sure any chips shavings generated during cam installation are removed from case 13 Install new gasket at rear of transmission case Use petroleum jelly to hold gasket in place Be sure to align governor feed holes in gasket with feed passages in case Fig 154 Also install gasket before overdrive piston retainer Center hole in gasket is smaller than retainer and cannot be installed over retainer 2 DISASSEMBLY AND ASSEMBLY Continued BE SURE PLATE SP 3583 A IS SEATED SQUARELY ON CAM J9221 37 Fig 152 Positioning Puller Plate On Clutch Cam TIGHTEN NUT TO DRAW CAM INTO CASE NUT IS PART OF BOLT SP3701 SPECIAL TOOL SP3583 A SPECIAL TOOL SP3701 SPECIAL TOOL SP5124 J9521 105 Fig 153 Pressing Overrunning Clutch Cam Into Case 14 Position overdrive piston retainer on trans mi
198. ating with a scale and straightedge Fig 17 Surface of converter lugs should be 1 2 in to rear of straightedge when con verter is fully seated 7 If necessary temporarily secure converter with C damp attached to the converter housing 8 Install the transmission in the vehicle 9 Fill the transmission with the recommended fluid STRAIGHTEDGE Fig 17 Checking Torque Converter Seating YOKE SEAL REPLACEM ENT REMOVAL 1 Raise vehide 2 Mark propeller shaft and axle yoke for align ment reference 3 Disconnect and remove propeller shaft 4 Remove old seal with Seal Remover C 3985 B Fig 18 from overdrive housing TRANSMISSION AND TRANSFER CASE 21 151 INSTALLATION 1 Place seal in position on overdrive housing 2 Drive seal into overdrive housing with Seal Installer C 3995 A Fig 19 3 Carefully guide propeller shaft slip yoke into housing and onto output shaft splines Align marks made at removal and connect propeller shaft to rear axle pinion yoke SPECIAL TOOL 3985 8 SEAL 19521 57 Fig 18 Removing Overdrive Housing Yoke Seal SPECIAL TOOL 3995 3972 SPECIAL TOOL 4471 19521 58 Fig 19 Installing Overdrive Housing Yoke Seal SPEEDOMETER ADAPTER Rear axle gear ratio and tire size determine speed ometer pinion requirements REMOVAL 1 Raise vehicle 2 Disconnect wires from vehicle speed sensor 3 Remove adapter damp and screw
199. bands as follows a Loosen locknut on each band adjusting screw 4 5 turns b Tighten both adjusting screws to 8 N m 72 in Ibs Back off front band adjusting screw 2 7 8 turns d Back off rear band adjusting screw 2 turns e Hold each adjusting screw in position and tighten locknut to 34 N m 25 ft Ibs torque 2 Install magnet in oil pan Magnet seats on small protrusion at corner of pan 3 Position new oil pan gasket on case and install oil pan Tighten pan bolts to 17 N m 13 ft Ibs 4 Install throttle valve and shift selector levers on valve body manual lever shaft TRANSMISSION AND TRANSFER CASE 21 187 5 Apply small quantity of dielectric grease to ter minal pins of solenoid case connector and neutral switch 6 Fill transmission with recommended fluid Refer to Service Procedures section of this group 7 Road test vehicle to verify repair OVERRUNNING CLUTCH CAM OVERDRIVE PISTON RETAINER NOTE TO SERVICE THE OVERRUNNING CLUTCH CAM AND THE OVERDRIVE PISTON RETAINER THE TRANSMISSION GEARTRAIN AND OVERDRIVE UNIT MUST BE REMOVED FROM THE TRANSMIS SION DISASSEMBLY 1 Remove the overdrive piston Fig 147 2 Remove the overdrive piston retainer bolts 3 Remove overdrive piston retainer 4 Remove case gasket 5 Tap old cam out of case with pin punch Insert punch through bolt holes at rear of case Fig 148 Alternate position of punch to avoid cocking cam dur ing removal
200. bearing in overdrive unit sliding hub Use petroleum jelly to hold bearing in position CAUTION Be sure the shoulder on the inside diameter of the bearing is facing forward 8 Verify that splines in overdrive planetary gear and overrunning dutch hub are aligned with Align ment Tool 6227 2 Overdrive unit cannot be installed if splines are not aligned If splines have rotated out of alignment unit will have to be disassembled to realign splines 9 Carefully slide Alignment Tool 6227 2 out of overdrive planetary gear and overrunning dutch splines 10 Raise overdrive unit and carefully slide it straight onto intermediate shaft Insert park rod into park lock reaction plug at same time Avoid tilting overdrive during installation as this could cause planetary gear and overrunning clutch splines to rotate out of alignment If this occurs it will be nec essary to remove and disassemble overdrive unit to realign splines 11 Work overdrive unit forward on intermediate shaft until seated against transmission case 12 Install bolts attaching overdrive unit to trans mission unit Tighten bolts in diagonal pattern to 34 N m 25 ft lbs 13 Install speed sensor and speedometer adapter Be sure to index adapter 2 14 Connect speed sensor overdrive wires 15 Align and install propeller shaft OVERDRIVE HOUSING BUSHING REMOVAL 1 Remove overdrive housing yoke seal 2 Insert Remover 6957 into overdrive housin
201. bearing into overdrive housing Fig 39 4 Using a suitable driver inserted through the rear end of housing drive bearing from housing INSTALLATION 1 Place replacement bearing in position in hous ing 2 Using a suitable driver drive bearing into housing until the snap ring groove is visible 3 Install snap ring to hold bearing into housing Fig 39 4 Install overdrive geartrain into housing 5 Install overdrive unit in vehicle OVERDRIVE HOUSING SNAP RING 80315860 Fig 39 Output Shaft Rear Bearing 2 REMOVAL AND INSTALLATION Continued OUTPUT SHAFT FRONT BEARING REMOVAL 1 Remove overdrive unit from the vehicle 2 Remove overdrive geartrain from housing 3 Remove snap ring holding output shaft front bearing to overdrive geartrain Fig 40 4 Pull bearing from output shaft INSTALLATION 1 Place replacement bearing in position geartrain with locating retainer groove toward the rear 2 Push bearing onto shaft until the snap ring groove is visible 3 Install snap ring to hold bearing onto output shaft Fig 40 4 Install overdrive geartrain into housing 5 Install overdrive unit in vehide OUTPUT SHAFT FRONT BEARING SNAP RING OVERDRIVE GEARTRAIN GROOVE OUTPUT TO REAR SHAFT 80315861 Fig 40 Output Shaft Front Bearing DISASSEMBLY AND ASSEMBLY VALVE BODY Remove the valve body from the transmission refer to Removal and Installation pro
202. ble inspect valve bogy Reassemble correctly if necessary Replace assembly if valves or springs are damaged Check for loose bolts or screws 4 Pump Passages Leaking 4 Check pump for porous casting scores on mating surfaces and excess rotor clearance Repair as required Loose pump bolts 5 Cooling System Cooler Plugged 5 Flow check cooler circuit Repair as needed 6 Overrunning Clutch Damaged 6 Replace clutch SLIPS IN REVERSE 1 Fluid Level Low 1 Add fluid and check for leaks ONLY 2 Gearshift Linkage Misadjusted 2 Adjust linkage 3 Rear Band 3 Adjust band 4 Rear Band Worn 4 Replace as required 5 Overdrive Direct Clutch Worn 5 Disassemble overdrive Repair as needed 6 Hydraulic Pressure Too Low 6 Perform hydraulic pressure tests to determine cause 7 Rear Servo Leaking 7 Air pressure check clutch servo operation and repair as required 8 Band Linkage Binding 8 Inspect and repair as required 2 5 AND TRANSFER CASE 21 21 DIAGNOSIS AND TESTING Continued CONDITION POSSIBLE CAUSES CORRECTION SLIPS IN FORWARD 1 Fluid Level Low 1 Add fluid and check for leaks DRIVE RANGES 2 Fluid Foaming 2 Check for high oil level bad pump gasket or seals dirt between pump halves and loose pump bolts Replace pump if necessary 3 Throttle Linkage Misadjusted 3 Adjust linkage 4 Gearshift Linkage Misadjusted 4 Adjust l
203. ble and repair transmission as needed 7 Governor Circuit Electrical Fault 7 Test using DRB scan tool and repair as required 8 Front Band Misadjusted 8 Adjust band 9 Pump Suction Passage Leak 9 Check for excessive foam on dipstick after normal driving Check for loose pump bolts defective gasket Replace pump assembly if needed NO REVERSE D 1 Gearshift Linkage Cable 1 Repair or replace linkage parts as needed RANGES Ok Misadjusted Damaged 2 Park Sprag Sticking 2 Replace overdrive annulus gear 3 Rear Band Misadjusted Worn 3 Adjust band replace 4 Valve Body Malfunction 4 Remove and service valve body Replace valve body if any valves or valve bores are worn or damaged 5 Rear Servo Malfunction 5 Remove and disassemble transmission Replace worn damaged servo parts as necessary 6 Direct Clutch in Overdrive Worn 6 Disassemble overdrive Replace worn or damaged parts 7 Front Clutch Burnt 7 Remove and disassemble transmission Replace worn damaged clutch parts as required 2 3RANSMISSION AND TRANSFER CASE 21 19 DIAGNOSIS AND TESTING Continued CONDITION POSSIBLE CAUSES CORRECTION HAS FIRST REVERSE 1 Governor Circuit Electrical Fault 1 Test using DRB scan tool and repair as ONLY NO 1 2 OR 2 3 required UPSHIFT 2 Valve Body Malfunction 2 Repair stuck 1 2 shift valve or governor plug 3 Front Servo Kickdown Band 3 Repair replace Damaged Bu
204. body be removed from the transmission The servo and clutch apply passages are shown Fig 9 REAR SERVO FRONT SERVO APPLY C APPLYe 9 o ING S o 7 FROM 16i COOLER 80a3b18b Fig 9 Air Pressure Test Passages Front Clutch Air Test Place one or two fingers on the clutch housing and apply air pressure through front clutch apply pas sage Piston movement can be felt and a soft thump heard as the clutch applies 2 DIAGNOSIS AND 5 Continued Rear Clutch Air Test Place one or two fingers on the dutch housing and apply air pressure through rear dutch apply passage Piston movement can be felt and a soft thump heard as the clutch applies Front Servo Apply Air Test Apply air pressure to the front servo apply pas sage The servo rod should extend and cause the band to tighten around the drum Spring pressure should release the servo when air pressure is removed Rear Servo Air Test Apply air pressure to the rear servo apply passage The servo rod should extend and cause the band to tighten around the drum Spring pressure should release the servo when air pressure is removed CONVERTER HOUSING FLUID LEAK DIAGNOSIS When diagnosing converter housing fluid leaks two items must be established before repair 1 Verify that a leak condition actually exists 2 Determined the true source of the leak Some susp
205. case 23 Remove all converter housing bolts 24 Carefully work transmission and torque con verter assembly rearward off engine block dowels 25 Hold torque converter in place during trans mission removal 26 Lower transmission and remove assembly from under the vehicle 27 To remove torque converter carefully slide torque converter out of the transmission INSTALLATION 1 Check torque converter hub and hub drive notches for sharp edges burrs scratches or nicks Polish the hub and notches with 320 400 grit paper and crocus cloth if necessary The hub must be smooth to avoid damaging pump seal at installation 2 Lubricate converter drive hub and oil pump seal lip with transmission fluid 3 Lubricate converter pilot hub with transmis sion fluid 4 Align converter and oil pump 21 30 5 15510 AND TRANSFER CASE REMOVAL AND INSTALLATION Continued 5 Carefully insert converter in oil pump Then rotate converter back and forth until fully seated in pump gears 6 Check converter seating with steel scale and straightedge Fig 16 Surface of converter lugs should be 1 2 in to rear of straightedge when con verter is fully seated 7 Temporarily secure converter with C clamp STRAIGHTEDGE Fig 16 Typical Method Of Checking Converter Seating 8 Position transmission on jack and secure it with chains 9 Check condition of converter driveplate Replace the plate if cracked distorted
206. case NOISY OPERATION IN FOURTH 1 Overdrive Clutch Discs Plates or 1 Remove unit and rebuild clutch GEAR ONLY Snap Rings Damaged pack 2 Overdrive Piston or Planetary 2 Remove and disassemble unit Thrust Bearing Damaged Replace either thrust bearing if damaged 3 Output Shaft Bearings Scored 3 Remove and disassemble unit Damaged Replace either bearing if damaged 4 Planetary Gears Worn Chipped 4 Remove and overhaul overdrive unit 5 Overdrive Unit Overrunning 5 Remove and overhaul overdrive Clutch Rollers Worn Scored unit 21 146 TRANSMISSION AND TRANSFER CASE SERVICE PROCEDURES FLUID LEVEL CHECK Transmission fluid level should be checked monthly under normal operation If the vehide is used for trailer towing or similar heavy load hauling check fluid level and condition weekly Fluid level is checked with the engine running at curb idle speed the transmission in NEUTRAL and the transmission fluid at normal operating temperature FLUID LEVEL CHECK PROCEDURE 1 Transmission fluid must be at normal operat ing temperature for accurate fluid level check Drive vehide if necessary to bring fluid temperature up to normal hot operating temperature of 82 C 180 F 2 Position vehide on level surface 3 Start and run engine at curb idle speed 4 Apply parking brakes 5 Shift transmission momentarily into all gear ranges Then shift transmission back to Neutral 6 Clean top of filler tube and dips
207. ce are installed Tighten screws in diagonal pattern starting at center and working outward LOWER HOUSING DISENGAGE UPPER THIS END OF HOUSING TUBE FIRST 19321 147 5 VALVE TUBE TUBE BRACE 19521 107 Fig 82 Boost Valve Tube And Brace TRANSMISSION AND TRANSFER CASE 21 51 BEND TABS UP AGAINST TUBE AS SHOWN J9521 108 Fig 83 Securing Boost Valve Tube With Brace Tabs 3 4 ACCUMULATOR 1 Position converter dutch valve and 3 4 shift valve springs in housing Fig 84 2 Loosely attach accumulator housing with right side screw Fig 84 Install only one screw at this time as accumulator must be free to pivot upward for ease of installation 3 Install 3 4 shift valve and spring 4 Install converter dutch timing valve and spring 5 Position plug on end of converter dutch valve spring Then compress and hold springs and plug in place with fingers of one hand 6 Swing accumulator housing upward over valve springs and plug 7 Hold accumulator housing firmly in place and install remaining two attaching screws Be sure springs and dutch valve plug are properly seated Fig 85 Tighten screws to 4 35 in Ibs VALVE BODY FINAL 1 Install boost valve valve spring retainer and cover plate Tighten cover plate screws to 4 N m 35 165 torque 2 Insert manual lever detent spring in upper housing 3 Position detent ball on end of spring Then hold detent ball and spr
208. cedures section in this group DISASSEMBLY CAUTION Do not clamp any valve body compo nent in a vise This practice can damage the com ponent resulting in unsatisfactory operation after assembly and installation Do not use pliers to remove any of the valves plugs or springs and do not force any of the components out or into place The valves and valve body housings will be dam aged if force is used Tag or mark the valve body springs for reference as they are removed Do not allow them to become intermixed TRANSMISSION AND TRANSFER CASE 21 39 1 Remove fluid filter 2 Disconnect wires from governor pressure sen sor and solenoid 3 Remove screws attaching governor body and retainer plate to transfer plate 4 Remove retainer plate governor body and gas ket from transfer plate 5 Disconnect wires from governor pressure sen sor if not done previously 6 Remove governor pressure sensor from gover nor body Sensor is retained in body with M shaped spring clip Remove dip with small pointed tool and slide sensor out of body 7 Remove governor pressure solenoid by pulling it straight out of bore in governor body Remove and discard solenoid O rings if worn cut or torn 8 Remove small shoulder bolt that secures sole noid harness case connector to 3 4 accumulator hous ing Fig 41 Retain shoulder bolt Either tape it to harness or thread it back into accumulator housing after connector removal 9 Unho
209. ch lamp to be illuminated Pressing the switch a second time causes normal overdrive operation to be restored and the overdrive lamp to be turned off The overdrive OFF mode defaults to ON after the ignition switch is cycled OFF and ON The normal position for the control switch is the ON posi tion The switch must be in this position to energize the solenoid and allow a 3 4 upshift The control switch indicator light illuminates only when the over drive switch is turned to the OFF position or when illuminated by the transmission control module 3 4 SHIFT SEQUENCE The overdrive clutch is applied in fourth gear only The direct clutch is applied all ranges except fourth gear Fourth gear overdrive range is electron ically controlled and hydraulically activated Various sensor inputs are supplied to the powertrain control module to operate the overdrive solenoid on the valve body The solenoid contains a check ball that opens and closes a vent port in the 3 4 shift valve feed pas sage The overdrive solenoid and check ball are not energized in first second third or reverse gear The vent port remains open diverting line pressure from the 2 3 shift valve away from the 3 4 shift valve The overdrive control switch must be in the ON position 2 DESCRIPTION AND OPERATION Continued to transmit overdrive status to the PCM A 3 4 upshift occurs only when the overdrive solenoid is energized by the PCM The PCM energizes the over
210. ches 5 Install retainer on input gear and install snap ring RETAINER PLATE INPUT GEAR SNAP RING LOW RANGE GEAR THRUST WASHERS 19321 50 Fig 55 Input Low Range Gear Components 21 286 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued INPUT GEAR LOW RANGE INSTALLATION 1 Align and install low range input gear assem bly in front case Fig 56 Be sure low range gear pinions are engaged in annulus gear and that input gear shaft is fully seated in front bearing 2 Install snap ring to hold input low range gear into front bearing Fig 57 ANNULUS GEAR J9321 61 Fig 56 Input Low Range Gear Installation INPUT GEAR Fig 57 Install Snap Ring 3 Clean gasket sealer residue from retainer and inspect retainer for cracks or other damage 4 Apply a 3 mm 1 8 in bead of Mopar gasket maker or silicone adhesive to sealing surface of retainer 5 Align cavity in seal retainer with fluid return hole in front of case CAUTION Do not block fluid return cavity on seal ing surface of retainer when applying Mopar gas ket maker or silicone adhesive sealer Seal failure and fluid leak can result 2 6 Install bolts to hold retainer to transfer case Fig 58 Tighten to 21 16 ft 106 of torque Fig 58 Install Front Bearing Retainer SHIFT FORKS AND MAINSHAFT INSTALLATION 1 Install new sector shaft O ring and bushing Fig 59 2 Install shift sector
211. ck ball installation 9 Axle Pinion Flange Loose 9 Replace nut and check pinion threads before installing new nut Replace pinion gear if threads are damaged 10 Clutch band or planetary 10 Remove disassemble and repair component damaged transmission as necessary 11 Converter Clutch Faulty 11 Replace converter and flush cooler and line before installing new converter 21 134 TRANSMISSION AND TRANSFER CASE 2 DIAGNOSIS AND TESTING Continued CONDITION POSSIBLE CAUSES CORRECTION DELAYED ENGAGEMENT FROM 1 Fluid Level Low 1 Correct level and check for leaks NEUTRAL TO DRIVE OR 2 Filter 2 Filter Clogged 2 2 Changefilter filter REVERSE 3 BID Linkage Misadjusted linkage and repair linkage if worn or damaged 4 Torque Converter Drain Back Oil 4 If vehicle moves normally after 5 drains from torque converter into seconds after shifting into gear no transmission sump repair is necessary If longer inspect pump bushing for wear Replace pump house 5 Rear Band Misadjusted 5 Adjust band 6 Valve Filter Plugged 6 Replace fluid and filter If oil pan and old fluid were full of clutch disc material and or metal particles overhaul will be necessary 7 Oil Pump Gears Worn Damaged 7 Remove transmission and replace oil pump 8 Governor Circuit and Solenoid 8 Test with DRB scan tool and repair Valve Electrical Fault as required
212. cles that are drivable and an alternate proce dure for disabled vehicles will not back up or move forward VEHICLE IS DRIVEABLE 1 Check for transmission fault codes using DRB scan tool 2 Check fluid level and condition 3 Adjust throttle and gearshift linkage if com plaint was based on delayed erratic or harsh shifts 4 Road test and note how transmission upshifts downshifts and engages 21 126 TRANSMISSION AND TRANSFER CASE DIAGNOSIS AND TESTING Continued STEERING COLUMN ASSEMBLY SCREW ALIGNING PIN INTERLOCK CABLE 2 DASH PANEL CLIP CABLE UNDER RIGHT STUD ACCELERATOR PEDAL CLIP ON TUNNEL INSULATION ADJUSTMENT J9519 66 Fig 6 Ignition Interlock Cable Routing SLIDER RETURN LOCKED SPRING RUN ACC START SLIDER UNLOCKED 2 4 INTERLOCK CAM J9319 47 Fig 7 Ignition Key Cylinder Actuation 5 Perform stall test if complaint is based on slug gish acceleration Or if abnormal throttle opening is needed to maintain normal speeds with a properly tuned engine 6 Perform hydraulic pressure test if shift prob lems were noted during road test 7 Perform air pressure test to check dutch band operation VEHICLE IS DISABLED 1 Check fluid level and condition 2 Check for broken or disconnected gearshift or throttle linkage 3 Check for cracked leaking cooler lines or loose or missing pressure port plugs 4 Ra
213. d with 90 bend is hooked to pawl and straight end of Aie TAB ENDS spring is seated against case OF LOCATING 2 Install pawl shaft retaining bolt Tighten bolt RING to 27 N m 20 ft Ibs torque 3 Install park lock reaction plug Note that plug has locating pin at rear Fig 239 Be sure pin is seated in hole in case before installing snap ring 4 Install reaction plug snap ring Fig 240 Com press snap ring only enough for installation do not distort it REACTION PLUG SNAP RING DO NOT OVERCOMPRESS TO INSTALL Fig 241 Correct Hear Bearing Locating Ring Eo Position PARK TS LOCK REACTION LOCATING SIN PLUG J9121 338 Fig 239 Reaction Plug Locating Pin And Snap Ring REACTION PLUG SNAP RING GEARTRAIN ASSEMBLY GEAR CASE J9321 360 Fig 242 Overdrive Gear Case Installation EXPAND BEARING 5 USE dde ct PLIERS 8921 WITH SNAP 0 RING PLIERS Fig 240 Reaction Plug And Snap Ring Installation 5 Install new seal in gear case Use Handle C 4171 and Installer C 3995 A to seat seal in case 6 Verify that tab ends of rear bearing locating ring extend into access hole in gear case Fig 241 7 Support geartrain on Tool 6227 1 Fig 242 Be sure tool is securely seated in dutch hub 8 Install overdrive gear case on geartrain Fig 242 9 Expand front bearing locating ring with snap ring pliers Fig 243 Then slide case downward until locating ring l
214. d or cannot be hooked together PLANETARY GEARTRAIN OUTPUT SHAFT Clean the intermediate shaft and planetary compo nents in solvent and dry them with compressed air Inspect the planetary gear sets and annulus gears The planetary pinions shafts washers and retaining 2 pins serviceable However if a pinion carrier is damaged the entire planetary gear set must be replaced as an assembly Replace the annulus gears if the teeth are chipped broken or worn or the gear is cracked Replace the planetary thrust plates and the tabbed thrust wash ers if cracked scored or worn Inspect the machined surfaces of the intermediate shaft Be sure the oil passages are open and clear Replace the shaft if scored pitted or damaged Inspect the sun gear and driving shell If either component is worn or damaged remove the sun gear rear retaining ring and separate the sun gear and thrust plate from the driving shell Then replace the necessary component Replace the sun gear as an assembly if the gear teeth are chipped or worn Also replace the gear as an assembly if the bushings are scored or worn The sun gear bushings are not serviceable Replace the thrust plate if worn or severely scored Replace the driving shell if distorted cracked or damaged in any way Replace all snap rings during geartrain assembly Reusing snap rings is not recommended OVERDRIVE UNIT Clean the geartrain and case components with sol vent Dry all
215. d replace the gear and bush ings as an assembly The gear and bushings are not serviced separately The planetary carrier and pinions must be in good condition Also be sure the pinion pins are secure and in good condition Replace the carrier if worn or dam aged Inspect the overrunning clutch and race The race surface should be smooth and free of scores Replace the overrunning dutch assembly or the race if either assembly is worn or damaged in any way Inspect the output shaft and governor components Replace the shaft pilot bushing and inner bushing if damaged Replace either shaft bearing if rough or noisy Replace the bearing snap rings if distorted or cracked Check the machined surfaces on the output shaft These surfaces should dean and smooth Very minor nicks or scratches be smoothed with crocus cloth Replace the shaft if worn scored or damaged in any way Inspect the output shaft bushings The small bush ing is the intermediate shaft pilot bushing The large bushing is the overrunning dutch hub bushing Replace either bushing if scored pitted cracked or worn USTMENTS BRAKE TRANSMISSION SHIFT INTERLOCK The park interlock cable is part of the brake shift lever interlock system Correct cable adjustment is important to proper interlock operation The gear shift and park lock cables must both be correctly adjusted in order to shift out of Park Park Interlock Cable Adjustment Procedure 1 Shift in
216. d converter housing 2 DIAGNOSIS AND 5 Continued DIAGNOSIS TABLES AND CHARTS RE TRANSMISSION The diagnosis charts provide additional reference when diagnosing a transmission fault The charts provide general information on a variety of transmis sion overdrive unit and converter dutch fault condi tions TRANSMISSION AND TRANSFER CASE 21 133 The hydraulic flow charts in the Schematics and Diagrams section of this group outline fluid flow and hydraulic circuitry Circuit operation is provided for neutral third fourth and reverse gear ranges Nor mal working pressures are also supplied for each of the gear ranges DIAGNOSIS CHARTS CONDITION POSSIBLE CAUSES CORRECTION HARSH ENGAGEMENT FROM 1 Fluid Level Low 1 Add Fluid NEUTRAL TO DRIVE OR 2 Throttle Linkage Misadjusted 2 Adjust linkage setting may be too REVERSE long 3 Mount and Driveline Bolts Loose 3 Check engine mount transmission mount propeller shaft rear spring to body bolts rear control arms crossmember and axle bolt torque Tighten loose bolts and replace missing bolts 4 U Joint Worn Broken 4 Remove propeller shaft and replace U Joint 5 Axle Backlash Incorrect 5 Check per Service Manual Correct as needed 6 Hydraulic Pressure Incorrect 6 Check pressure Remove overhaul or adjust valve body as needed 7 Band Misadjusted 7 Adjust rear band 8 Valve Body Check Balls Missing 8 Inspect valve body for proper che
217. during 3 2 down shifts The 3 4 timing valve is moved by line pressure coming through the 3 4 shift valve The timing valve holds the 2 3 shift valve in an upshift position The purpose is to prevent the 2 3 valve from up or down shifting before the 3 4 valve The 3 4 accumulator is mounted on the overdrive housing and performs the same function as the 2 3 accumulator it is used to smooth engagement during a 3 4 shift The switch valve directs fluid apply pressure to the converter clutch in one position and releases it in the opposite position It also directs oil to the cooling and lube circuits The switch valve regulates oil pressure to the torque converter by limiting maximum oil pressure to 130 psi OVERDRIVE OFF SWITCH The overdrive OFF control switch is located in the instrument panel The switch is a momentary contact device that signals the PCM to toggle current status of the overdrive function At key on overdrive operation is allowed Pressing the switch once causes the overdrive OFF mode to be entered and the over drive OFF switch lamp to be illuminated Pressing the switch a second time causes normal overdrive operation to be restored and the overdrive lamp to be turned off The overdrive OFF mode defaults to ON after the ignition switch is cycled OFF and ON The normal position for the control switch is the ON posi tion The switch must be in this position to energize the solenoid and allow a 3 4 upshift The control
218. e 12 N m 100 in Ibs Sensor trans speed 27 N m 20 ft Ibs Screw solenoid wiring connector 4 N m 35 in Ibs Screw solenoid to transfer plate 4 N m 35 Ibs 2 TRANSMISSION AND TRANSFER CASE 21 113 SPECIFICATIONS Continued THRUST WASHER SPACER SNAP RING DIMENSIONS component we m Front clutch thrust washer reaction shaft 1 55 mm 0 061 in support hub Rear clutch thrust washer clutch retainer 0 061 in Intermediate shaft thrust plate shaft hub pilot 1 5 1 6 mm 0 060 0 063 in Output shaft thrust washer rear clutch hub Select fit to set end play Rear clutch pack snap ring 0 060 in 0 076 in 0 098 in Planetary geartrain snap ring at front of output shaft Select fit three thicknesses available Overdrive piston thrust plate Thrust plate and spacer are select fit Refer to size charts and selection procedures in Intermediate shaft spacer Overdrive Unit D amp A procedures PRESSURE TEST Overdrive clutch Fourth gear only Pressure should be 469 496 kPa 68 72 psi with closed throttle and increase to 620 896 kPa 90 130 psi at 1 2 to 3 4 throttle Line pressure at Closed throttle 372 414 kPa 54 60 psi accumulator Third gear only No more than 21 kPa 3 psi lower than line pressure Rear servo 1 range No more than 21 kPa 3 psi lower than line pressure R range 1103 kPa 160 psi at idle builds to 1862 kPa 270 psi at 1600 rpm Gove
219. e Inspect all the valve and plug bores in the valve body Use a penlight to view the bore interiors Replace the valve body if any bores are distorted or scored Inspect all of the valve body springs The springs must be free of distortion warpage or broken coils Check the two separator plates for distortion or damage of any kind Inspec the upper housing lower housing 3 4 accumulator housing and transfer plate carefully Be sure all fluid passages are dean and dear Check condition of the upper housing and transfer plate check balls as well The check balls and ball seats must not be worn or damaged Trial fit each valve and plug in its bore to check freedom of operation When dean and dry the valves and plugs should drop freely into the bores Valve body bores do not change dimensionally with use If the valve body functioned correctly when new it will continue to operate properly after cleaning and inspection It should not be necessary to replace a valve body assembly unless it is damaged in handling The only serviceable valve body components are listed below The remaining valve body components are serviced only as part of a complete valve body assembly Serviceable parts are e dual solenoid and harness assembly solenoid gasket solenoid case connector O rings and shoulder bolt switch valve and spring pressure adjusting screw and bracket assembly throttle lever manual lever and shaft seal throttle lever shaft seal washer a
220. e Worn 6 Disassemble overdrive Replace worn or damaged parts 7 Front Clutch Burnt 7 Remove and disassemble transmission Replace worn damaged clutch parts as required HAS FIRST REVERSE ONLY NO 1 Governor Circuit Electrical Fault 1 Test using DRB scan tool and repair 1 2 OR 2 3 UPSHIFT as required 2 Valve Body Malfunction 2 Repair stuck 1 2 shift valve or governor plug 3 Front Servo Kickdown Band 3 Repair replace Damaged Burned 2 5 5 AND TRANSFER CASE 21 137 DIAGNOSIS AND TESTING Continued CONDITION POSSIBLE CAUSES CORRECTION MOVES IN 2ND OR 3RD GEAR 1 Valve Body Malfunction 1 Remove clean and inspect Look ABRUPTLY DOWNSHIFTS TO LOW for stuck 1 2 valve or governor plug 2 Governor Valve Sticking 2 Remove clean and inspect Replace faulty parts NO LOW GEAR MOVES IN 2ND 1 Governor Valve Sticking 1 Remove governor clean inspect OR 3RD GEAR ONLY and repair as required 2 Governor Circuit Electrical Fault 2 Test with DRB scan tool and repair as required 3 Valve Body Malfunction 3 Remove clean and inspect Look for sticking 1 2 shift valve 2 3 shift valve governor plug or broken springs 4 Front Servo Piston Cocked in Bore 4 Inspect servo and repair as required 5 Front Band Linkage Malfunction 5 Inspect linkage and look for bind in linkage NO KICKDOWN OR NORMAL 1 Throttle Linkage Misadjusted 1 Adjust linkage DOWNSHIFT 2 Acce
221. e front case Fig 83 The low range annulus gear is not a serviceable part Replace the gear and case as an assembly if the gear is loose worn or damaged The shift rail bushing is a serviceable part and can be replaced if necessary Check the bushing in the rear retainer Replace the bushing if worn or scored Examine the sealing surfaces of both case halves and retainers Small burrs or scratches on these sur faces can be reduced with crocus cloth or a fine tooth file Examine condition of the shift rail bushing in the front case If the bushing is worn or damaged it can be removed with a blind hole type puller A replace ment bushing can be installed with a suitable size 21 292 TRANSMISSION AND TRANSFER CASE CLEANING AND INSPECTION Continued LOW RANGE ANNULUS bm GEAR Q a 0 ZV 2 1 AR I SHIFT 19321 50 Fig 83 Low Range Annulus Gear Location driver Recess the bushing slightly below the edge of the bore but do not seat it all the into the case GEARTRAIN Inspect the mainshaft splines gear teeth and bear ing surfaces carefully for evidence of wear or dam age Replace the shaft if necessary do not attempt to salvage it if damaged The shift rail and range fork are an assembly Replace both parts if either is damaged However the 2 nylon pads in the fork be replaced if worn cracked Inspect the transfer case snap rings closely Do not attempt to salvage a distorted
222. e gear Fig 92 Minor nicks can be dressed off with an oilstone but replace the gear if any teeth are broken cracked or chipped The bearing surface on the gear can be smoothed with 300 400 grit emery cloth if necessary Examine the carrier body and pinion gears for wear or damage The carrier will have to be replaced as an assembly if the body pinion pins or pinion gears are damaged Check the lock ring and both thrust washers for wear or cracks Replace them if necessary Also replace the lock retaining ring if bent distorted or broken SHIFT FORKS HUBS SLEEVES Check condition of the shift forks and mode fork shift rail Fig 93 Minor nicks on the shift rail can be smoothed with 320 400 grit emery cloth Inspect the shift fork wear pads The mode fork pads are serviceable and can be replaced if necessary The range fork pads are also serviceable Check both of the sleeves for wear or damage especially on the interior teeth Replace the sleeves if wear or damage is evident REAR THRUST WASHER PLANETARY CARRIER 2 RANGE AND RAIL FORK MODE SPRING 80010948 Fig 93 Shift forks REAR RETAINER BEARING SEAL SLINGER BOOT Inspect the retainer components Fig 94 Replace the bearing if rough or noisy Check the retainer for cracks or wear in the bearing bore Clean the retainer sealing surfaces with a scraper and all pur pose deaner This will ensure proper adhesion of the sealer durin
223. e sure adjusting screw turns freely in case Apply lubricant to screw threads if necessary 3 Tighten band adjusting screw to 8 N m 72 in lbs torque with Inch Pound Torque Wrench C 3380 A a 3 in extension and 5 16 socket CAUTION If Adapter C 3705 is needed to reach the adjusting screw Fig 255 tighten the screw to only 5 N m 47 50 in Ibs torque 42RE TRANSMISSION e Back off front band adjusting screw 3 5 8 turns e Hold adjuster screw in position and tighten lock nut to 41 30 ft 165 torque 44RE TRANSMISSION e Back off front band adjusting screw 2 1 4 turns e Hold adjuster screw in position and tighten lock nut to 41 N m 30 ft 165 torque 4 Lower vehicle ADJUSTER KY LOCK NUT NS N N V AG D 80b1712d Fig 254 Front Band Adjustment Screw Location REAR BAND ADJ USTMENT The transmission oil pan must be removed for access to the rear band adjusting screw 1 Raise vehicle 2 Remove transmission oil pan and drain fluid 3 Loosen band adjusting screw locknut 5 6 turns Fig 256 Be sure adjusting screw turns freely in lever 2 5 16 5 INCH POUND WRENCH ADAPTER 3705 TIGHTEN ADJUSTING 4 SCREW ONLY 5 N m 50 IN LBS IF ADAPTER IS USED J9121 233 Fig 255 Band Adjustment Adapter Tool ADJUSTING REAR BAND LEVER LOCKNUT J9321 382 Fig 256 Rear Band Adjusting Screw Location
224. e sure the fluid level and con trol cable adjustments have been checked and adjusted if necessary Verify that diagnostic trouble codes have been resolved Observe engine performance during the road test A poorly tuned engine will not allow accurate analy sis of transmission operation Operate the transmission in all gear ranges Check for shift variations and engine flare which indicates slippage Note if shifts are harsh spongy delayed early or if part throttle downshifts are sensitive Slippage indicated by engine flare usually means dutch band or overrunning dutch problems If the condition is advanced an overhaul will be necessary to restore normal operation A slipping dutch or band can often be determined by comparing which internal units are applied in the various gear ranges The Clutch and Band Applica tion chart provides a basis for analyzing road test results ANALYZING ROAD TEST Refer to the Clutch and Band Application chart and note which elements are in use in the various gear ranges Note that the rear clutch is applied in all forward ranges D 2 1 The transmission overrunning clutch is applied in first gear D 2 and 1 ranges only The rear band is applied in 1 and R range only Note that the overdrive clutch is applied only in fourth gear and the overdrive direct dutch and over 21 128 TRANSMISSION AND TRANSFER CASE DIAGNOSIS AND TESTING Continued TRANSMISSION CLUTCHES AND BANDS SHIFT LEVER
225. e vehicle 2 Remove front propeller shaft Refer to Group 3 Differential and Driveline for proper procedure 3 Remove front output shaft yoke 4 Remove seal from front case with pry tool Fig 7 2 REMOVAL AND INSTALLATION Continued ITEM TORQUE 2 3 Nem 15 27 in lbs 10 12 Nem 90 110 in Ibs SENSOR SPEEDOMETER ADAPTER TRANSMISSION AND TRANSFER CASE 21 245 ADAPTER O RING SPEEDOMETER PINION ADAPTER Aa CLAMP 1 VEHICLE 2 SPEED A GP SENSOR J9321 385 Fig 5 Speedometer Components SPEEDOMETER INDEX NUMBER LOCATION OUTPUT SHAFT SEAL 227 29321 386 80211085 Fig 6 Location Of Index Numbers Speedometer Adapter INSTALLATION 1 Install new front output seal in front case with Installer Tool 6952 A as follows a Place new seal on tool Garter spring on seal goes toward interior of case b Start seal in bore with light taps from ham mer Fig 8 Once seal is started continue tapping seal into bore until installer tool seats against case Fig 7 Remove Front Output Shaft Seal DISASSEMBLY AND ASSEMBLY NV242 TRANSFER CASE DISASSEMBLY REAR RETAINER REMOVAL 1 Remove output shaft boot Spread band damp that secures boot on slinger with a suitable awl Then slide boot off shaft Fig 9 21 246 TRANSMISSION AND TRANSFER CASE 2 DISASSEMBLY AND ASSEMBLY Continued INSTALLER ey SNAP RING
226. ear bearing O D retaining ring with snap ring pliers Fig 88 Be sure retaining ring is fully seated in retainer groove 4 Apply bead of Sealer P N 82300234 or Loctite Ultra Gray to mating surface of rear retainer Sealer bead should be a maximum of 3 16 in 5 Install rear retainer on rear case Tighten retainer bolts to 20 27 15 20 ft Ibs torque 2 DISASSEMBLY AND ASSEMBLY Continued REAR SNAP BEARING O D RING RETAINING PLIERS RING 800bdfae Fig 88 Rear Bearing Retaining Ring Installation 6 Install rear bearing 1 0 retaining ring and spacer on output shaft 7 Apply liberal quantity of petroleum jelly to new rear seal and to output shaft Petroleum jelly is needed to protect seal lips during installation 8 Slide seal onto Seal Protector 6992 Fig 89 Slide seal protector and seal onto output shaft 9 Slide Installer C 4076 B onto seal protector with the recessed side of the tool toward the seal Drive seal into rear bearing retainer with installer C 4076 B and handle MD 998323 Fig 90 OUTPUT SHAFT SPECIAL TOOL 6992 TRANSFER CASE 80450355 Fig 89 Output Shaft Seal and Protector 10 Install rear slinger with installer C 4076 A and handle M D 998323 Fig 90 11 Install boot on output shaft slinger and crimp retaining clamp with tool C 4975 A Fig 91 FRONT YOKE AND SWITCH INSTALLATION 1 Install indicator switch in front case Tighten switch to
227. ear dutch Then install and engage assembly in front planetary and driving shell Fig 138 Turn clutch retainers back and forth until both clutches are seated 9 Position front band lever in case and over servo rod guide Then install front band lever pin in case and slide it through lever 10 Coat threads of front band pin access plug with sealer and install it in case Tighten plug to 17 N m 13 ft 165 torque 11 Slide front band over front clutch retainer and install front band strut and anchor Fig 139 2 REAR 223 CLUTCH ASSEMBLY REAR CLUTCH SPLINED FRONT HUB CLUTCH ASSEMBLY 19121 100 Fig 136 Assembling Front And Rear Clutches 12 Tighten front band adjusting screw until band is tight on clutch retainer This will hold clutches in place while oil pump is being installed Verify that front rear clutch assembly is still properly seated before tightening band SURE WASHER GROOVES FACE OU THRUST WASHER J9121 101 Fig 137 Intermediate Shaft Thrust Washer OIL PUMP 1 Install oil pump Pilot Studs C 3288 B in case Fig 140 2 DISASSEMBLY AND ASSEMBLY Continued FRONT AND REAR CLUTCH ASSEMBLIES J9121 20 Fig 138 Front Rear Clutch Assemblies LEVER STRUT J9121 18 Fig 139 Front Band And Linkage 2 Install new oil pump gasket on pilot studs and seat it in case Be sure gasket is properly aligned with fluid passages in case Fig 140
228. ecessary 5 Oil Pump Damaged 5 Perform pressure test to confirm low pressure Replace pump body assembly if necessary 6 Valve Body Malfunctioned 6 Check and inspect valve body Replace valve body as assembly if any valve or bore is damaged Clean and reassemble correctly if all parts are in good condition 21 18 TRANSMISSION AND TRANSFER CASE 2 DIAGNOSIS AND TESTING Continued CONDITION POSSIBLE CAUSES CORRECTION 7 Transmission Internal 7 Remove and disassemble transmission Component Damaged Repair or replace failed components as needed 8 Park Sprag not Releasing 8 Remove disassemble repair Check Stall Speed Worn Damaged Stuck 9 Torque Converter Damage 9 Inspect and replace as required SHIFTS DELAYED OR 1 Fluid Level Low High 1 Correct fluid level and check for leaks if ERRATIC SHIFTS ALSO low HARSH AT TIMES 2 Fluid Filter Clogged 2 Replace filter If filter and fluid contained clutch material or metal particles an overhaul may be necessary Perform lube flow test 3 Throttle Linkage Misadjusted 3 Adjust linkage as described in service section 4 Throttle Linkage Binding 4 Check cable for binding Check for return to closed throttle at transmission 5 Gearshift Linkage Cable 5 Adjust linkage cable as described in service Misadjusted section 6 Clutch or Servo Failure 6 Remove valve body and air test clutch and band servo operation Disassem
229. ected converter housing fluid leaks may not be leaks at all They may only be the result of residual fluid in the converter housing or excess fluid spilled during factory fill or fill after repair Converter housing leaks have several potential sources Through careful observation a leak source can be identified before removing the transmission for repair Pump seal leaks tend to move along the drive hub and onto the rear of the converter Pump O ring or pump body leaks follow the same path as a seal leak Fig 10 Pump vent or pump attaching bolt leaks are generally deposited on the inside of the converter housing and not on the converter itself Fig 10 Pump seal or gasket leaks usually travel down the inside of the converter housing Front band lever pin plug leaks are generally deposited on the housing and not on the converter TORQUE CONVERTER LEAK POINTS Possible sources of converter leaks are 1 Leaks at the weld joint around the outside diameter weld Fig 11 2 Leaks at the converter hub weld Fig 11 CONVERTER HOUSING AREA LEAK CORRECTION 1 Remove converter 2 Tighten front band adjusting screw until band is tight around front clutch retainer This prevents front rear clutches from coming out when oil pump is removed TRANSMISSION AND TRANSFER CASE 21 15 PUMP PUMP PUMP SEAL REAR MAIN CONVERTER SEAL HOUSING LEAK CONVERTER J9021 35 Fig 10 Converter Housing Leak Paths TORQUE
230. ed 8 isd 01 96 3unssaud dH31H3ANOO isd 001 06 IMYA JILLOYHL OL 563 ANIT isd 07 62 13IHS 8 1 isd 0 3unssaud ATLLOYHL Od isd 0 2 091 3unssaud 3SH3A3H NI 3SH3A3UH 43437 1 4135 N 110 nr NOUS 282 77 1 T J 5 JO im afl Ee m o admo i og 455 EE Cmm E ES d JAYA TVONVIN TE SATVA bE 4 T iu
231. ed Check condition of the seal rings on the input shaft and clutch retainer hub Replace the seal rings only if worn distorted or damaged The input shaft front seal ring is teflon with chamfered ends The rear ring is metal with interlocking ends Check the input shaft for wear or damage Replace the shaft if worn scored or damaged in any way PLANETARY GEARTRAIN Clean the planetary components in solvent and dry them with compressed air Check sun gear and driving shell condition Replace the gear if damaged or if the bushings are scored or worn The bushings are not serviceable Replace the driving shell if worn cracked or dam aged Replace planetary gear sets if gears pinion pins or carrier are damaged in any way Replace the annulus gears and supports if either component is worn or damaged Inspect the geartrain spacers thrust plates snap rings and thrust washers Replace any of these parts that are worn distorted or damaged Do not attempt to reuse these parts The planetary gear thrust washers are different sizes The large diameter washers go on the front planetary and the smaller washers go on the rear planetary All the washers have four locating tabs on them These tabs fit in the holes or slots provided in each planetary gear Inspect the output shaft carefully Pay particular attention to the machined bushing bearing surfaces on the shaft and the governor valve shaft bore at the shaft rear Replace the outp
232. ed for trailer towing or similar heavy load hauling check fluid level and condition weekly Fluid level is checked with the engine running at curb idle speed the transmission in NEUTRAL and the transmission fluid at normal operating temperature FLUID LEVEL CHECK PROCEDURE 1 Transmission fluid must be at normal operat ing temperature for accurate fluid level check Drive vehicle if necessary to bring fluid temperature up to normal hot operating temperature of 82 C 180 F 2 Position vehicle on level surface 3 Start and run engine at curb idle speed 4 Apply parking brakes 5 Shift transmission momentarily into all gear ranges Then shift transmission back to Neutral 6 Clean top of filler tube and dipstick to keep dirt from entering tube 7 Remove dipstick Fig 12 and check fluid level as follows a Correct acceptable level is in crosshatch area 0 Correct maximum level is to MAX arrow mark c Incorrect level is at or below MIN line d If fluid is low add only enough Mopar ATF Plus 3 to restore correct level Do not overfill CAUTION Do not overfill the transmission Over filling may cause leakage out the pump vent which be mistaken for a pump seal leak Overfilling will also cause fluid aeration and foaming as the excess fluid is picked up and churned by the gear train This will significantly reduce fluid life DIPSTICK Batre D 20 Coon MAXIMUM ACCEPTABLE CORRECT FL
233. ed or Bolts are 8 Replace bolts or gasket or tighten both Loose 9 Adapter Extension Gasket 9 Replace gasket Damaged Leaks Damaged 10 Neutral Switch Leaks Damaged 10 Replace switch and gasket 11 Converter Housing Area Leaks 11 Check for leaks at seal caused by worn seal or burr on converter hub cutting seal worn bushing missing oil return oil in front pump housing or hole plugged Check for leaks past O ring seal on pump or past pump to case bolts pump housing porous oil coming out vent due to overfill or leak past front band shaft access plug 12 Pump Seal Leaks Worn 12 Replace seal Damaged 14 Case Porosity Leaks 14 Replace case NOISY OPERATION IN 1 Overdrive Clutch Discs Plates or 1 Remove unit and rebuild clutch pack FOURTH GEAR ONLY Snap Rings Damaged 2 Overdrive Piston or Planetary 2 Remove and disassemble unit Replace Thrust Bearing Damaged either thrust bearing if damaged 3 Output Shaft Bearings Scored 3 Remove and disassemble unit Replace Damaged either bearing if damaged 4 Planetary Gears Worn Chipped 4 Remove and overhaul overdrive unit 5 Overdrive Unit Overrunning 5 Remove and overhaul overdrive unit Clutch Rollers Worn Scored 13 Torque Converter Weld 13 Replace converter Leak Cracked Hub 21 26 TRANSMISSION AND TRANSFER CASE SERVICE PROCEDURES FLUID LEVEL CHECK Transmission fluid level should be checked monthly under normal operation If the vehicle is us
234. ed sensor throttle position sensor and battery temperature sen sor GOVERNOR PRESSURE CURVES There are four governor pressure curves pro grammed into the transmission control module The different curves allow the control module to adjust governor pressure for varying conditions One curve is used for operation when fluid temperature is at or below 1 C 30 F A second curve is used when fluid temperature is at or above 10 C 50 F during nor mal city or highway driving A third curve is used during wide open throttle operation The fourth curve is used when driving with the transfer case in low range 21 124 TRANSMISSION AND TRANSFER CASE DESCRIPTION AND OPERATION Continued SHIFT VALVE OPERATION The shift valves are moved by a combination of throttle and governor pressure The governor pres sure is generated by electrical components The conditions under which a shift to fourth will not occur are e Overdrive switch is Off e Transmission fluid temperature is below 10 C 50 F or above 121 C 250 F e Shift to third not yet completed e Vehicle speed too low for 3 4 shift to occur Battery temperature below 5 HYDRAULIC CONTROL SYSTEM The hydraulic control system provides fully auto matic operation The system performs five basic func tions which are pressure supply pressure regulation flow control clutch band application and lubrication PRESSURE REGULATION The pressure regulator valve m
235. ed to guide seals into place if necessary CAUTION Never push the clutch piston straight in This will fold the seals over causing leakage and clutch slip In addition never use any type of metal tool to help ease the piston seals into place Metal tools will cut shave or score the seals 9 Install piston spring in retainer and on top of piston Fig 162 Concave side of spring faces down ward toward piston 10 Install wave spring in retainer Fig 162 Be sure spring is completely seated in retainer groove 11 Install bottom pressure plate Fig 157 Ridged side of plate faces downward toward piston and flat side toward dutch pack 12 Install first clutch disc in retainer on top of bottom pressure plate Then install a clutch plate fol lowed by a dutch disc until entire dutch pack is installed 4 discs and 3 plates are required Fig 157 13 Install top pressure plate 14 Install selective snap ring Be sure snap ring is fully seated in retainer groove 15 Using a suitable gauge bar and dial indicator measure clutch pack clearance Fig 163 a Position gauge bar across the clutch drum with the dial indicator pointer on the pressure plate Fig 163 b Using two small screw drivers lift the pres sure plate and release it c Zero the dial indicator d Lift the pressure plate until it contacts the snap ring and record the dial indicator reading Clearance should be 0 64 1 14 mm 0 025 0
236. eels locked and the transmission in D range This test checks the holding ability of the converter over running and transmission dutches WARNING NEVER ALLOW ANYONE TO STAND DIRECTLY IN LINE WITH THE VEHICLE FRONT OR REAR DURING A STALL TEST ALWAYS BLOCK THE WHEELS AND FULLY APPLY THE SERVICE AND PARKING BRAKES DURING THE TEST STALL TEST PROCEDURE 1 Connect tachometer to engine Position tachom eter so it can be viewed from driver s seat 2 Drive vehicle to bring transmission fluid up to normal operating temperature Vehicle can be driven on road or on chassis dynamometer if available 3 Check transmission fluid level Add fluid if nec essary 4 Block front wheels 5 Fully apply service and parking brakes 6 Open throttle completely and record maximum engine speed registered on tachometer It takes 4 10 seconds to reach max rpm Once max rpm has been achieved do not hold wide open throttle for more than 4 5 seconds CAUTION Stalling the converter causes a rapid increase in fluid temperature To avoid fluid over heating hold the engine at maximum rpm for no more than 5 seconds If engine exceeds 2500 rpm during the test release the accelerator pedal imme diately transmission clutch slippage is occurring 7 second stall test is required cool down fluid before proceeding Shift into NEUTRAL and run engine at 1000 rpm for 20 30 seconds to cool fluid STALL TEST ANALYSIS Stall Speed Too High I
237. emoval spring retainer on top of piston 21 194 TRANSMISSION AND TRANSFER CASE Z DISASSEMBLY AND ASSEMBLY Continued INNER CLUTCH CLUTCH PISTON CLUTCH CLUTCH PISTON SEAL PISTON SPRING RETAINER PLATES PACK SNAP RING WAVED CLUTCH FRONT PISTON OUTER RETAINER CLUTCH RETAINER PISTON SEAL SPRINGS 9 SNAPRING CLUTCHDISCS REACTION PLATE J9321 129 Fig 166 Front Clutch Components SPECIAL EM SPECIAL TOOL R TOOL amn SP 3629 9 SPRING S CLUTCH FRONT CLUTCH RETAINER SPECIAL SPECIAL TOOL TOOL 41 SP 5511 J9521 75 BUSHING Fig 168 Front Clutch Spring Position INSTALLATION ASSEMBLY 1 Lubricate the splines of the new shaft with petroleum jelly or Plus 3 type 7176 Then align the shaft in the piston retainer and care fully press it into place using suitable press tools to Fig 167 Front Cluich Retainer Bushing Replacement Tools 6 Remove seals from dutch piston Discard seals after removal If the input shaft must be replaced first remove the retaining ring that secures the shaft in the piston retainer hub Then press the old shaft out of the retainer with a shop press using suitable press tools to press on the shaft and to support the retainer hub as dose to the shaft as possible press the shaft and to support the retainer hub as close to the shaft as possible Do not allow the shaft to become cocked during installation The
238. er from lodging between the valves and plugs and the bore Inspect all the valve and plug bores in the valve body Use a penlight to view the bore interiors Replace the valve body if any bores are distorted or scored Inspect all of the valve body springs springs must be free of distortion warpage or broken coils Check the two separator plates for distortion or damage of any kind Inspect the upper housing lower housing 3 4 accumulator housing and transfer plate carefully Be sure all fluid passages are dean and dear Check condition of the upper housing and transfer plate check balls as well The check balls and ball seats must not be worn or damaged Trial fit each valve and plug in its bore to check freedom of operation When dean and dry the valves and plugs should drop freely into the bores Valve body bores do not change dimensionally with use If the valve body functioned correctly when new it will continue to operate properly after cleaning and inspection It should not be necessary to replace a valve body assembly unless it is damaged in han dling The only serviceable valve body components are listed below The remaining valve body components are serviced only as part of a complete valve body assembly Serviceable parts are 21 92 TRANSMISSION AND TRANSFER CASE CLEANING AND INSPECTION Continued e dual solenoid and harness assembly e Solenoid gasket e Solenoid case connector O rings and shoulder bolt e
239. er side of the transfer plate Fig 4 The transfer plate channels line pressure to the solenoid valve through the governor body It also channels governor pressure from the solenoid valve to the governor circuit It is the solenoid valve that develops the necessary gover nor pressure TRANSMISSION FLUID TEMPERATURE THERMISTOR Transmission fluid temperature readings are sup plied to the transmission control module by the ther mistor The temperature readings are used to control engagement of the fourth gear overdrive dutch the converter dutch and governor pressure Normal resistance value for the thermistor at room tempera ture is approximately 1000 ohms The PCM prevents engagement of the converter dutch and overdrive dutch when fluid temperature is below approximately 10 C 50 F If fluid temperature exceeds 126 C 260 F the PCM causes a 4 3 downshift and engage the con verter dutch Engagement is according to the third gear converter dutch engagement schedule The overdrive OFF lamp in the instrument panel illuminates when the shift back to third occurs The transmission will not allow fourth gear operation until fluid temperature decreases to approximately 110 C 230 F The thermistor is part of the governor pressure sensor assembly and is immersed in transmission fluid at all times 2 TRANSMISSION SPEED SENSOR The speed sensor Fig 5 is located in the over drive gear case The sensor is positioned over the
240. er dean ing Inspect condition of each clutch part after cleaning Replace the overrunning clutch roller and spring assembly if any rollers or springs are worn or dam aged or if the roller cage is distorted or damaged Replace the cam if worn cracked or damaged Replace the low reverse drum if the dutch race roller surface or inside diameter is scored worn or damaged Do not remove the clutch race from the low reverse drum under any circumstances Replace the drum and race as an assembly if either component is damaged Examine the overdrive piston retainer carefully for wear cracks scoring or other damage Be sure the retainer hub is a snug fit in the case and drum Replace the retainer if worn or damaged ACCUM ULATOR Inspect the accumulator piston and seal rings Fig 254 Replace the seal rings if worn or cut Replace the piston if chipped or cracked Check condition of the accumulator inner and outer springs Fig 254 Replace the springs if the coils are cracked distorted or collapsed CCG RINGS Fig 254 Accumulator Components FRONT SERVO Clean the servo piston components with solvent and dry them with compressed air Wipe the band clean with lint free shop towels 2 CLEANING AND INSPECTION Continued Replace the front band if distorted lining is burned flaking off or worn to the point where the grooves in the lining material are no longer visible Inspect the servo components Replace the sprin
241. er is in 4L position Then tighten trunnion lock bolt 6 Lower vehicle and check transfer case shift operation SPEEDOMETER REMOVAL 1 Raise vehicle 2 Disconnect wires from vehicle speed sensor 3 Remove adapter clamp and screw Fig 5 4 Remove speed sensor and speedometer adapter as an assembly 5 Remove speed sensor retaining screw and remove sensor from adapter 21 274 TRANSMISSION AND TRANSFER CASE REMOVAL AND INSTALLATION Continued RIVNUT 4 TORQUE 3 4 Nem 27 35 in Ibs B 11 14 Nem 97 123 in Ibs 8 14 Nem 72 120 in Ibs TORQUE SHAFT TRANSFER CASE BRACKET TRANSFER CASE SHIFT LEVER TORQUE SHAFT 2 SHIFT LEVER ASSEMBLY FLOORPAN TRUNNION LOCK BOLT 9 SELECTOR ROD AND TRUNNION SHIFT LEVER SHAFT 19321 185 Fig 4 Shift Linkage Remove speedometer pinion from adapter Replace pinion if chipped cracked or worn 7 Inspect sensor and adapter O rings Fig 5 Remove and discard O rings if worn or damaged 8 Inspect terminal pins in speed sensor Clean pins with Mopar electrical spray cleaner if dirty or oxidized Replace sensor if faulty or if pins are loose severely corroded or damaged INSTALLATION AND INDEXING 1 Thoroughly clean adapter flange and adapter mounting surface in housing Surfaces must be clean for proper adapter alignment and speedometer oper ation 2 Install new O rin
242. ernor pressure control system 5 Release brakes slowly increase engine speed and observe speedometer and pressure test gauge do not exceed 30 mph on speedometer Governor pres sure should increase in proportion to speed Or approximately 6 89 kPa 1 psi for every 1 mph 6 Governor pressure rise should be smooth and drop back to no more than 20 6 kPa 3 psi after engine returns to curb idle and brakes are applied to prevent wheels from rotating 7 Compare results of pressure test with analysis chart Test Six Transmission In Overdrive Fourth Gear NOTE This test checks line pressure at the over drive clutch in fourth gear range Use 300 psi Test Gauge C 3292 for this test The test should be per formed on the road or on a chassis dyno 1 Remove tachometer it is not needed for this test 2 Move 300 psi Gauge to overdrive clutch pres sure test port Then remove other gauge and reinstall test port plug TRANSMISSION AND TRANSFER CASE 21 13 3 Lower vehicle 4 Turn OD switch on 5 Secure test gauge so it can be viewed from drivers seat 6 Start engine and shift into D range 7 Increase vehide speed gradually until 3 4 shift occurs and nate gauge pressure 8 Pressure should be 469 496 kPa 68 72 psi with closed throttle and increase to 620 827 kPa 90 120 psi at 1 2 to 3 4 throttle Note that pressure can increase to around 896 kPa 130 psi at full throttle 9 Return to s
243. es TRANSMISSION AND TRANSFER CASE 21 81 PLANETARY PLANETARY CLUTCH GEAR THRUST SPRING BEARING PLATE SPRING PLATE SNAP RING SUN GEAR J9121 312 Fig 205 Removing Sun Gear Thrust Bearing And Planetary Gear OVERRUNNING CLUTCH NEEDLE BEARING 8921 248 Fig 206 Overrunning Clutch Assembly Removal Installation DIRECT PUNCH 8921 249 Fig 207 Marking Direct Clutch Drum And Annulus Gear For Assembly Alignment 21 82 TRANSMISSION AND TRANSFER CASE 2 DISASSEMBLY AND ASSEMBLY Continued DIRECT CLUTCH OUTPUT DRUM SHAFT ANNULUS GEAR 21 293 ANNULUS RETAINING RING GEAR 19021 288 Fig 209 Clutch Drum Outer Retaining Ring Removal Fig 212 Annulus Gear Removal OUTPUT SHAFT 4 OUTPUT 2 SHAFT Ct 53 oM 2 pus pt Si ia ES PUNCH J9221 46 Fig 210 Marking Annulus Gear And Output Shaft For Assembly Alignment Fig 213 Output Shaft Pilot Bushing 2 Install new pilot bushing and dutch hub bush 3 Install annulus gear on output shaft if ing in output shaft if necessary Fig 213 Lubricate removed Then install annulus gear retaining snap bushings with petroleum jelly or transmission fluid ring Fig 214 2 DISASSEMBLY AND ASSEMBLY Continued 4 Align and install dutch drum on annulus gear Fig 215 Be sure drum is engaged in annulus gear lugs 5 Install clutch drum outer retaining ring F
244. f rollers and springs for assembly reference 30 Remove rear band adjusting lever reaction lever and pin Fig 119 TRANSMISSION AND TRANSFER CASE 21 179 31 Remove strut from rear band Keep strut with levers and pin for deaning inspection and assembly reference 32 Remove rear band and link Fig 120 LOW REVERSE DRUM SPOTFACE FOR WASHER THRUST WASHER 19521 90 Fig 116 Low Reverse Drum Thrust Washer OVERRUNNING CLUTCH RACE LOW REVERSE DRUM J9221 8 Fig 117 Overrunning Clutch Race Position On Low Reverse Drum 33 Compress front servo rod guide with large C damp Tool C 4470 or Compressor Tool C 3422 B Fig 121 Compress guide only enough to permit snap ring removal about 1 8 in 34 Remove servo piston snap ring Fig 121 Unseat one end of ring Then carefully work removal tool around back of ring until free of ring groove Exercise caution when removing snap ring Servo bore can be scratched or nicked if care is not exercised 21 180 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued oo 0 ON CAM CLUTCH ASSEMBLY REAR BAND ADJUSTING LEVER REACTION LEVER Q REAR BAND 2 3 REACTION CS 19121 37 Fig 119 Rear Band Levers Pins 35 Remove tools and remove servo piston and spring 36 Compress rear servo piston with and Tool C 4470 or Valve Spring Compress
245. f the stall speed exceeds 2500 rpm transmission clutch slippage is indicated Stall Speed Low Low stall speed with a properly tuned engine indi cate a torque converter overrunning clutch problem The condition should be confirmed by road testing A stall speed 250 350 rpm below normal indicates the converter overrunning clutch is slipping The vehicle also exhibits poor acceleration but operates normally once highway cruise speeds are reached Torque con verter replacement will be necessary 2 Stall Speed Normal But Acceleration Poor If stall speeds are normal 1800 2300 rpm but abnormal throttle opening is required for accelera tion or to maintain cruise speed the converter over running clutch is seized The torque converter will have to be replaced Converter Noise During Test A whining noise caused by fluid flow is normal dur ing a stall test However loud metallic noises indi cate a damaged converter To confirm that the noise is originating from the converter operate the vehide at light throttle in DRIVE and NEUTRAL on a hoist and listen for noise coming from the converter hous ing AIR TESTING TRANSMISSION CLUTCH AND BAND OPERATION Air pressure testing can be used to check transmis sion front rear dutch and band operation The test can be conducted with the transmission either in the vehicle or on the work bench as a final check after overhaul Air pressure testing requires that the oil pan and valve
246. failure that generates debris overheat that generates sludge fluid break down failure to reverse flush cooler and lines after repair failure to replace contaminated converter after repair The use of non recommended fluids can result in transmission failure The usual results are erratic shifts slippage abnormal wear and eventual failure due to fluid breakdown and sludge formation Avoid this condition by using recommended fluids only The dipstick cap and fill tube should be wiped dean before checking fluid level Dirt grease and other foreign material on the cap and tube could fall into the tube if not removed beforehand Take the time to wipe the cap and tube clean before withdraw ing the dipstick Engine coolant in the transmission fluid is gener ally caused by a cooler malfunction The only remedy is to replace the radiator as the cooler in the radiator is not a serviceable part If coolant has circulated through the transmission for some time an overhaul may also be necessary especially if shift problems had developed The transmission cooler and lines should be reverse flushed whenever a malfunction generates sludge and or debris The torque converter should also be replaced at the same time Failure to flush the cooler and lines will result in recontamination Flushing applies to auxiliary cool ers as well The torque converter should also be replaced whenever a failure generates sludge and debris This is
247. for the NV249 transfer case Approximate fluid refill capacity is approximately 1 18 liters 2 50 pints The fill and drain plugs are both in the rear case Correct fill level is to the bottom edge of the fill plug DIAGNOSIS AND TESTING NV249 DIAGNOSIS Condition TRANSFER CASE DIFFICULT TO SHIFT OR WILL NOT SHIFT INTO DESIRED RANGE TRANSFER CASE NOISY IN ALL DRIVE MODES NOISY IN OR JUMPS OUT OF FOUR WHEEL DRIVE LOW RANGE LUBRICANT LEAKING FROM OUTPUT SHAFT SEALS OR FROM VENT ABNORMAL TIRE WEAR ib d b c b d Possible Cause Vehicle speed too great to permit shifting If vehicle was operated for extended period in 4H mode on dry paved surface driveline torque load may cause difficulty Transfer case external shift linkage binding Insufficient or incorrect lubricant Internal components binding worn or damaged Insufficient or incorrect lubricant Transfer case not completely engaged in 4L position Shift linkage loose or binding Range fork cracked inserts worn or fork is binding on shift rail Annulus gear or lockplate work or damaged Transfer case overfilled Vent closed or restricted Output shaft seals damaged or installed correctly Extended operation on dry hard surface paved roads in 4H range a b 9 le b 9
248. fts and engages 2 DIAGNOSIS AND TESTING Continued STEERING COLUMN ASSEMBLY SCREW ALIGNING PIN INTERLOCK CABLE TRANSMISSION AND TRANSFER CASE 21 9 DASH PANEL CLIP CABLE UNDER RIGHT STUD ACCELERATOR PEDAL CLIP ON TUNNEL INSULATION ADJUSTMENT J9519 66 Fig 6 Ignition Interlock Cable Routing SUDER RETURN LOCKED SPRING RUN ACC START SLIDER UNLOCKED INTERLOCK CAM J9319 47 Fig 7 Ignition Key Cylinder Actuation 5 Perform stall test if complaint is based on slug gish acceleration Or if abnormal throttle opening is needed to maintain normal speeds with a properly tuned engine 6 Perform hydraulic pressure test if shift prob lems were noted during road test 7 Perform air pressure test to check dutch band operation VEHICLE IS DISABLED 1 Check fluid level and condition 2 Check for broken or disconnected gearshift or throttle linkage 3 Check for cracked leaking cooler lines or loose or missing pressure port plugs 4 Raise and support vehide on safety stands start engine shift transmission into gear and note followi ng a If propeller shaft turns but wheels do not problem is with differential or axle shafts b If propeller shaft does not turn and transmis sion is noisy stop engine Remove oil pan and check for debris If pan is clear remove transmis sion and check for damaged drive plate converter
249. g 3ATVA TVONVIA ONIINLL t E 3ATVA TOH LNOO LAIHS 8 1 JAVA L3IHS 2 1 ond HONHJAOD JATA 3 LEOHS 2 3ATVA JAVA 141 8 6 2 JILLOYHL JILLOYHL HONH3AOD n v HOLN19 1 HOLN19 uvad 5 uvad 105 HONH3AOD 5 21 101 TRANSMISSION AND TRANSFER CASE SCHEMATICS AND DIAGRAMS Continued 2 TVYLNAN NI MO TH 41p49208 45019 j 1 141 ROU pi
250. g Tighten tool to bushing and remove bushing Fig 37 REMOVER 6957 EXTENSION HOUSING BUSHING 80411095 Fig 37 Bushing Removal Typical INSTALLATION 1 Align bushing oil hole with oil slot in overdrive housing 2 Tap bushing into place with Installer 6951 and Handle C 4171 3 Install new oil seal in housing using Seal Installer C 3995 A Fig 38 SPECIAL TOOL 3995 OR 3972 SPECIAL TOOL 4471 19521 58 Fig 38 Overdrive Housing Seal Installation 2 REMOVAL AND INSTALLATION Continued OUTPUT SHAFT REAR BEARING REMOVAL 1 Remove overdrive unit from the vehicle 2 Remove overdrive geartrain from housing 3 Remove snap ring holding output shaft rear bearing into overdrive housing Fig 39 4 Using a suitable driver inserted through the rear end of housing drive bearing from housing INSTALLATION 1 Place replacement bearing in position in hous ing 2 Using a suitable driver drive bearing into housing until the snap ring groove is visible 3 Install snap ring to hold bearing into housing Fig 39 4 Install overdrive geartrain into housing 5 Install overdrive unit in vehide OVERDRIVE HOUSING OUTPUT SHAFT REAR BEARING 80315860 Fig 39 Output Shaft Rear Bearing TRANSMISSION AND TRANSFER CASE 21 159 OUTPUT SHAFT FRONT BEARING REMOVAL 1 Remove overdrive unit from the vehicle 2 Remove overdrive geartrain from housing 3 Remo
251. g 198 2 DISASSEMBLY AND ASSEMBLY Continued TORX SCREWDRIVER T25 ACCESS COVER SCREWS J9321 357 Fig 195 Access Cover Screw Removal Installation ACCESS COVER AND GASKET J9321 358 Fig 196 Access Cover And Gasket Removal Installation EXPAND BEARING LOCATING RING WITH SNAP Q RING PLIERS 225 A SS a ACCESS PUSH OUTPUT SHAFT FORWARD TO FREE 2 BEARING FROM RING 39321359 Fig 197 Releasing Bearing From Locating Ring 7 Remove snap ring that retains rear bearing on output shaft 8 Remove rear bearing from output shaft Fig 199 DIRECT CLUTCH HUB AND SPRING DISASSEMBLY WARNING THE NEXT STEP IN DISASSEMBLY INVOLVES COMPRESSING THE DIRECT CLUTCH SPRING IT IS EXTREMELY IMPORTANT THAT PROPER EQUIPMENT BE USED TO COMPRESS THE SPRING AS SPRING FORCE 15 APPROXI TRANSMISSION AND TRANSFER CASE 21 79 GEARTRAIN ASSEMBLY J9321 360 Fig 198 Removing Gear Case From Geartrain Assembly OUTPUT J9321 362 Fig 199 Rear Bearing Removal MATELY 830 POUNDS USE SPRING COMPRESSOR TOOL 6227 1 AND A HYDRAULIC SHOP PRESS WITH A MINIMUM RAM TRAVEL OF 5 6 INCHES THE PRESS MUST ALSO HAVE A BED THAT CAN BE ADJUSTED UP OR DOWN AS REQUIRED RELEASE CLUTCH SPRING TENSION SLOWLY AND COMPLETELY TO AVOID PERSONAL INJURY 1 Mount geartrain assembly in shop press Fig 200 2 Position Compressor Tool 6227 1 on clutch hub Fig 200
252. g 66 Applying Sealer To Front Case Flange Fig 69 Rear Case Installation 2 DISASSEMBLY AND ASSEMBLY Continued 11 Verify that oil pickup tube is still seated in case notch and tube end is pointed toward mainshaft Fig 70 CORRECT PICKUP TUBE POSITION J9321 76 Fig 70 Checking Position Of Oil Pickup Tube 12 Install case attaching bolts Alignment bolts at each end of case are only ones requiring washers Fig 71 13 Tighten case bolts to 27 34 20 25 ft Ibs torque ALIGNMENT BOLT AND WASHER AT EACH END OF CASE Fig 71 Alignment Bolt Location YOKE AND RANGE LEVER INSTALLATION 1 Install indicator switch in front case Tighten switch to 20 34 N m 15 25 ft 165 torque 2 Install range lever washer and locknut on sec tor shaft Fig 72 Tighten locknut to 27 34 N m 20 25 ft 105 torque 3 Install new seal washer on front output shaft Fig 74 4 Lubricate yoke hub with transmission fluid and install yoke on front shaft 5 Install new seal washer on front shaft 6 Install yoke and new yoke nut on front output shaft Fig 73 7 Tighten yoke nut to 122 176 N m 90 130 ft Ibs torque Use Tool C 3281 or similar tool to hold yoke while tightening yoke nut VISCOUS COUPLER 1 Install coupling on mainshaft Fig 75 TRANSMISSION AND TRANSFER CASE 21 289 RANGE IM NOM M 7 WASHER J9321 30 Fig 72 Range Lever Installation Y
253. g may also be the problem cause This process of elimination can be used to identify a slipping unit and check operation Proper use of the Clutch and Band Application Chart is the key Although road test analysis will help determine the slipping unit the actual cause of a malfunction usu ally cannot be determined until hydraulic and air pressure tests are performed Practically any condi tion can be caused by leaking hydraulic circuits or sticking valves Unless a malfunction is obvious such as no drive in D range first gear do not disassemble the trans mission Perform the hydraulic and air pressure tests to help determine the probable cause HYDRAULIC PRESSURE TEST Hydraulic test pressures range from a low of one psi 6 895 kPa governor pressure to 300 psi 2068 kPa at the rear servo pressure port in reverse An accurate tachometer and pressure test gauges are required Test Gauge C 3292 has a 100 psi range and is used at the accumulator governor and front servo ports Test Gauge C 3293 SP has a 300 psi range and is used at the rear servo and overdrive ports where pressures exceed 100 psi Pressure Test Port Locations Test ports are located at both sides of the transmis sion case Fig 8 Line pressure is checked at the accumulator port on the right side of the case The front servo pressure port is at the right side of the case just behind the filler tube opening The rear servo and governor pressure ports are at
254. g column 2 Remove two screws retaining the interlock mechanism to the column Fig 23 Unsnap the mechanism from column MOUNTING STEERING SCREWS COLUMN X INTERLOCK MECHANISM J9319 28 Fig 23 Interlock Mechanism on Column 3 Remove the center console and related trim Refer to Group 23 Body for proper procedures 4 Disconnect and remove the cable from the shift bracket 5 Remove the wire connector at the solenoid on the cable 6 Remove the accelerator pedal the cable routes under the pedal Refer to Group 14 Fuel Systems for proper procedures 7 Release the cable from the accelerator pedal clip 8 Remove the carpet as necessary to remove the cable INSTALLATION NOTE The gearshift cable must be secured into position and properly adjusted before the installa tion of the Brake Transmission Interlock Cable BTSI 1 Snap the cable base assembly into the large square opening in the steering column 2 Secure the plastic base with two 2 self tap ping screws tighten upper screw first 21 154 TRANSMISSION AND TRANSFER CASE REMOVAL AND INSTALLATION Continued 3 Snap BTSI cable solenoid tie strap into hole in steering column tube 4 Route BTSI cable into two dips on carpet pad 5 Snap electrical connector from brake light switch into BTSI cable solenoid housing 6 Snap BTSI cable adjuster ears into floor shifter bracket and attach cable end fitting onto fl
255. g reassembly Replace the slinger and seal outright do not reuse either part Inspect the retaining rings and washers Replace any part if distorted bent or broken Reuse is not recommended Also replace the boot if cut or torn Replace the boot band damps do not reuse them FRONT THRUST CARRIER WASHER LOCK CARRIER RING LOCK RETAINING RING 8001b75f Fig 92 Input Gear And Carrier Components 2 CLEANING AND INSPECTION Continued REAR REAR SEAL RETAINER BEARING RETAINING SLINGER LOCATING REAR WASHER TRANSMISSION AND TRANSFER CASE 21 267 REAR BAND CLAMPS REAR REAR SLINGER SLINGER LOCATING REAR RING BEARING O D REAR RETAINING BEARING RING 80010949 Fig 94 Rear Retainer Components Check condition of the seal contact surfaces of the PART OF YOKE SURFACE MUST yoke slinger Fig 95 This surface must be clean and BE CLEAN AND smooth to ensure proper seal life Replace the yoke SMOOTH nut and seal washer as neither part should be reused Inspect the shaft threads sprocket teeth and bear ing surfaces Minor nicks on the teeth can be smoothed with an oilstone Use 320 400 grit emery to smooth minor scratches on the shaft bearing sur faces Rough threads on the shaft can be chased if necessary Replace the shaft if the threads are dam aged bearing surfaces are scored or if any sprocket teeth are cracked or broken Examine the drive chain and shaft bearings Replace the chain
256. ge third gear should be within 3 psi 21 kPa of line pressure up to kickdown point Test Four Transmission Reverse NOTE This test checks pump output pressure reg ulation and the front clutch and rear servo circuits Use 300 psi Test Gauge C 3293 SP for this test 1 Leave vehicle on hoist and leave gauge C3292 in place at accumulator port 2 Move 300 psi Gauge C 3293 SP back to rear servo port 3 Have helper start and run engine at 1600 rpm for test 21 130 TRANSMISSION AND TRANSFER CASE DIAGNOSIS AND TESTING Continued 4 Move transmission shift lever four detents rearward from full forward position This is Reverse range 5 Move transmission throttle lever fully forward then fully rearward and note reading at Gauge C 3293 SP 6 Pressure should be 145 175 psi 1000 1207 kPa with throttle lever forward and increase to 230 280 psi 1586 1931 kPa as lever is gradually moved rearward Test Five Governor Pressure NOTE This test checks governor operation by measuring governor pressure response to changes in vehicle speed It is usually not necessary to check governor operation unless shift speeds are incorrect or if the transmission will not downshift The test should be performed on the road or on a hoist that will allow the rear wheels to rotate freely 1 Move 100 psi Test Gauge C 3292 to governor pressure port 2 Move transmission shift lever two detents rear ward from full forward po
257. gs if collapsed distorted or broken Replace the guide rod and piston if cracked bent or worn Discard the servo snap ring if distorted or warped Check the servo piston bore for wear If the bore is severely scored or damaged it will be necessary to replace the case Replace any servo component if doubt exists about condition Do not reuse suspect parts REAR SERVO Remove and discard the servo piston seal ring Fig 255 Then dean the servo components with solvent and dry with compressed air Replace either spring if collapsed distorted or broken Replace the plug and piston if cracked bent or worn Discard the servo snap rings and use a new ones at assembly SNAP PISTON PISTON SPRING SNAP RING SEAL PLUG RETAINER RING 5 e 3 CUSHION PISTON PISTON SPRING SPRING 19121 64 Fig 255 Rear Servo Components OIL PUMP AND REACTION SHAFT SUPPORT Clean pump and support components with solvent and dry them with compressed air Check condition of the seal rings and thrust washer on the reaction shaft support The seal rings do not need to be replaced unless cracked broken or severely worn Inspect the pump and support components Replace the pump or support if the seal ring grooves or machined surfaces are worn scored pitted or dam aged Replace the pump gears if pitted worn chipped or damaged Check the pump vent The vent must be secure Replace the pump body if the vent is cracked broken or loose
258. gs on speed sensor and speed ometer adapter Fig 5 if necessary 3 Lubricate sensor and adapter O rings with transmission fluid 4 Install vehicle speed sensor in speedometer adapter Tighten sensor attaching screw to 2 3 N m 15 27 in lbs torque 5 Install speedometer pinion in adapter 6 Count number of teeth on speedometer pinion Do this before installing assembly in housing Then lubricate pinion teeth with transmission fluid 7 Note index numbers on adapter body Fig 6 These numbers will correspond to number of teeth on pinion 8 Install speedometer assembly in housing 9 Rotate adapter until required range numbers are at 6 o dock position Be sure range index num bers correspond to number of teeth on pinion gear 10 Install speedometer adapter clamp and retain ing screw Tighten clamp screw to 10 12 N m 90 110 165 torque 11 Connect wires to vehicle speed sensor 12 Lower vehicle and top off transmission fluid level if necessary FRONT OUTPUT SHAFT SEAL REMOVAL 1 Raise vehicle 2 Remove front propeller shaft Refer to Group 3 Differential and Driveline for proper procedure 3 Remove front output shaft yoke 4 Remove seal from front case with pry tool Fig 7 INSTALLATION 1 Install new front output seal in front case with Installer Tool 6952 A as follows 2 REMOVAL AND INSTALLATION Continued ITEM TORQUE 2 3 Nem 15 27 in lbs 10 12 Nem 90 110 in
259. gth bolts be used to attach the converter to the driveplate Bolts that are too long will damage the clutch sur face inside the converter 22 Install torque converter to driveplate bolts Tighten bolts to 31 N m 270 in Ibs 23 Install converter housing access cover 24 Install starter motor and cooler line bracket 25 Connect cooler lines to transmission 26 Install transmission fill tube Install new seal on tube before installation 27 Install exhaust components 28 Install transfer case 29 Align and connect propeller shaft s 30 Adjust gearshift linkage and throttle valve cable if necessary 31 Lower vehicle 32 Fill transmission with Mopar ATF Plus 3 Type 7176 fluid TORQUE CONVERTER REMOVAL 1 Remove transmission and torque converter from vehicle 2 Place a suitable drain pan under the converter housing end of the transmission CAUTION Verify that transmission is secure on the lifting device or work surface the center of gravity of the transmission will shift when the torque con verter is removed creating an unstable condition The torque converter is a heavy unit Use caution when separating the torque converter from the transmission 3 Pull the torque converter forward until the cen ter hub clears the oil pump seal 4 Separate the torque converter from the trans mission INSTALLATION Check converter hub and drive notches for sharp edges burrs scratches or nicks
260. h plates and clutch discs 2 Compress clutch piston retainer and piston springs with Compressor Tool C 3863 A Fig 165 3 Remove retainer snap ring and remove pressor tool 2 DISASSEMBLY AND ASSEMBLY Continued SPECIAL TOOL C 3860 A PUMP PUMP BODY SEAL 9321 179 Fig 164 Oil Pump Seal 4 Remove dutch piston springs Fig 166 Note position of piston springs for assembly refer ence 5 Remove dutch piston from retainer with a twisting motion 6 Remove and discard clutch piston inner and outer seals SPECIAL TOOL SNAP RING Exc Fig 165 Removing Front Clutch Spring Retainer Snap Ring 7 Assemble Tool Handle C 4171 Bushing Remover SP 3629 Fig 167 8 Insert remover tool in bushing and drive bush ing straight out of dutch retainer TRANSMISSION AND TRANSFER CASE 21 193 ASSEMBLY 1 Mount Bushing Installer SP 5511 on tool han dle Fig 167 2 Slide new bushing onto installer tool and start bushing into retainer 3 Tap new bushing into place until installer tool bottoms against dutch retainer 4 Remove installer tools and clean retainer thor oughly 5 Soak dutch discs in transmission fluid 6 Install new inner and outer seals on clutch pis ton Be sure seal lips face interior of retainer 7 Lubricate new inner and outer piston seals with Ru Glyde or Mopar Door Ease 8 Install dutch piston in retainer Use twisting motion to seat p
261. haft bearings when installing differential 10 Install differential snap ring Fig 73 11 Install intermediate dutch shaft Fig 74 INTERMEDIATE CLUTCH DIFFERENTIAL J8921 260 Fig 74 Installing Intermediate Clutch Shaft 14 Inspect mode fork assembly Fig 77 Replace pads and bushing if necessary Replace fork tube if bushings inside tube are worn or damaged Also Fig 72 Differential Installation check springs and slider bracket Fig 77 Replace worn damaged components J8921 283 DIFFERENTIAL SNAP CLUTCH SHAFT THRUST RING J8921 261 J8921 259 Fig 73 Installing Differential Snap Ring 12 Install dutch shaft thrust washer Fig 75 Fig 75 Installing Clutch Shaft Thrust Washer 13 Install dutch shaft snap ring Fig 76 21 262 TRANSMISSION AND TRANSFER CASE 2 DISASSEMBLY AND ASSEMBLY Continued iib SHAFT MODE SLEEVE FORK ASSEMBLY SLIDER J8921 257 Fig 78 Installing Mode Fork And Sleeve em i 7 pj 18921 284 MODE FORK 2 Fig 77 Mode Fork Assembly Inspection a mi BUTT Co LLL 15 Install mode sleeve in mode fork Fig 78 Then install assembled sleeve and fork on mainshaft Be sure mode sleeve splines are engaged in differen Me tial splines 2 1 16 Install mode fork and mainshaft assembly TEC
262. he thrust washers if worn or damaged Replace the mainshaft and sprocket gears if the teeth or gear bores are worn or damaged Replace the mainshaft bearings if worn flat spot ted brinelled or damaged in any way Replace the mainshaft if it exhibits wear or dam age to the bearing surfaces splines or gear teeth INPUT AND LOW RANGE GEARS Inspect the low range gear pinions and pinion pins Replace the low range gear if any of the pins or pin ions are worn or damaged Inspect the thrust washers retainer snap ring Replace the snap ring if bent or distorted Replace the thrust washers and retainer if worn cracked or damaged in any way Examine the input gear carefully Be sure the gear teeth and bearing surfaces are in good condition Replace the gear if wear or damage is evident Check the input gear pilot bearing Rotate the bearing and check for roughness or noise Also check bearing position in the bore The bearing should be recessed approximately 2 5 mm 0 100 in below the top edge of the bore The bearing should not be seated at the bottom of the bore Replace the bearing if worn or roughness is evident Replace both the gear and bearing if the bearing is a loose fit in the bore GEAR CASE AND RETAINERS Examine both case halves and retainers carefully Replace any retainer or case half if wear cracks or other damage is evident Check condition of the low range annulus gear and the shift rail bushing in th
263. hifts The valve temporarily bypasses the clutch piston feed orifice at the start of a 3 4 upshift This exposes a larger pas sage into the piston retainer resulting in a much faster clutch fill and apply sequence The quick fill valve does not bypass the regular clutch feed orifice throughout the 3 4 upshift Instead once a predeter mined pressure develops within the clutch the valve closes the bypass Clutch fill is then completed through the regular feed orifice CONVERTER DRAINBACK VALVE The drainback valve is located in the transmission cooler outlet pressure line The valve prevents fluid from draining from the converter into the cooler and 2 lines when the vehide is shut down for lengthy ods Production valves have a hose nipple at one end while the opposite end is threaded for a flare fitting All valves have an arrow or similar mark to indi cate direction of flow through the valve BRAKE TRANSMISSION SHIFT INTERLOCK MECHANISM The Brake Transmission Shifter Ignition Interlock BTSI is a cable and solenoid operated system It interconnects the automatic transmission floor mounted shifter to the steering column ignition switch Fig 6 The system locks the shifter into the PARK position The Interlock system is engaged whenever the ignition switch is in the LOCK or ACCESSORY position An additional electrically acti vated feature will prevent shifting out of the PARK position unless the brake pedal is dep
264. hop or move vehide off chassis dyno PRESSURE TEST ANALYSIS CHART TEST CONDITION INDICATION Line pressure OK during Pump and regulator valve any one test OK Line pressure OK in R Leakage in rear clutch but low in D 2 1 area seal rings clutch seals Overdrive clutch piston seal or check ball problem Pressure OK in 1 2 but Leakage in front clutch low and R area Pressure OK in 2 but low Leakage in rear servo in R and 1 Front servo pressure low Leakage in servo broken in 2 servo ring or cracked Servo piston Pressure low in D Fourth Gear Range Pressure low in all positions Clogged filter stuck regulator valve worn or faulty pump low oil level Governor pressure too high at idle speed Governor pressure solenoid valve system fault Refer to diagnostic book Faulty governor pressure solenoid transmission control module or governor pressure sensor Clogged fluid cooler or lines seal rings leaking worn pump bushings pump clutch retainer or clogged filter Line pressure high Output shaft plugged Sticky regulator valve Line pressure low Sticky regulator valve clogged filter worn pump Governor pressure low at all mph figures Lubrication pressure low at all throttle positions 21 14 TRANSMISSION AND TRANSFER CASE DIAGNOSIS AND TESTING Continued CONVERTER STALL TEST Stall testing involves determining maximum engine speed obtainable at full throttle with the rear wh
265. hrust washer in hub of rear clutch retainer controls end play Washer is a select fit part and can be changed to adjust end play If end play turns out to be incorrect remove oil pump and clutches Then install thinner thicker thrust washer as necessary TRANSMISSION VE NT DIAL INDICATOR Fig 126 Measuring Input Shaft End Play 30 Install accumulator piston and inner and outer springs Fig 127 31 Verify that valve body solenoid harness is secured in 3 4 accumulator housing cover plate 32 Install valve body as follows a Align and carefully insert park rod into pawl Rod will make click noise as it enters pawl Move rod slightly to check engagement b Align and seat valve body on case Be sure manual lever shaft and overdrive connector are 2 PRESSURE 5 5 GOVERNOR BODY PRESSURE SOLENOID E ES ACCUMULATOR PISTON J9321 384 Fig 127 Accumulator Piston And Springs fully seated in case Also be sure valve body wiring is not pinched or kinked c Install and start all valve body attaching bolts by hand Then tighten bolts evenly in a diag onal pattern to 12 N m 105 in Ibs torque Do not overtighten valve body bolts This could result in distortion and cross leakage after installation CAUTION t is possible for the park rod to dis place into a cavity just above the pawl sprag during installation Make sure the rod i
266. hten support to pump bolts to required torque as follows a Reverse pump assembly and install it in transmission case Position pump so bolts are fac ing out and are accessible b Secure pump assembly in case with 2 or 3 bolts or with pilot studs Tighten support to pump bolts to 20 N m 15 ft Ibs d Remove pump assembly from transmission case 12 Install new oil seal in pump with Special Tool C 4193 and Tool Handle C 4171 Fig 151 Be sure seal lip faces inward 13 Install new seal ring around pump housing Be sure seal is properly seated in groove 14 Lubricate lip of pump oil seal and O ring seal with transmission fluid FRONT CLUTCH NOTE The 42RE transmission uses four plates and discs for the front clutch The 44RE uses five plates and discs for the front clutch The front clutch retainer is not interchangeable between these transmissions 2 SPECIAL TOOL C 4193 PUMP BODY PUMP SEAL J9321 183 Fig 151 Pump Oil Seal Installation DISASSEMBLY 1 Remove waved snap ring and remove pressure plate clutch plates and clutch discs Fig 152 2 Compress dutch piston spring with Compressor Tool C 3575 A Fig 153 Be sure legs of tool are seated squarely on spring retainer before compress ing spring 3 Remove retainer snap ring and remove com pressor tool 4 Remove spring retainer and dutch spring Note position of retainer on spring for assembly reference 5 Remove
267. ick fill valve 3 4 accumulator and ultimately to the overdrive piston Line pressure through the timing valve moves the overdrive piston into contact with the overdrive clutch The direct clutch is disengaged before the overdrive clutch is engaged The boost valve provides increased fluid apply pressure to the overdrive clutch during 3 4 upshifts and when accel erating in fourth gear The 3 4 accumulator cushions overdrive clutch engagement to smooth 3 4 upshifts The accumulator is charged at the same time as apply pressure acts against the overdrive piston CONVERTER CLUTCH ENGAGEMENT Converter clutch engagement in third or fourth gear range is controlled by sensor inputs to the pow ertrain control module Inputs that determine clutch engagement are coolant temperature engine rpm vehicle speed throttle position and manifold vac uum The torque converter clutch is engaged by the clutch solenoid on the valve body The clutch can be engaged in third and fourth gear ranges depending on overdrive control switch position If the overdrive control switch is in the normal ON position the clutch will engage after the shift to fourth gear and above approximately 72 km h 45 mph If the control switch is in the OFF position the clutch will engage after the shift to third gear at approximately 56 km h 35 mph at light throttle QUICK FILL VALVE The 3 4 quick fill valve provides faster engagement of the overdrive clutch during 3 4 ups
268. idle speed the gear selector in NEUTRAL and the parking brake applied check the transmission fluid level CAUTION Do not overfill transmission fluid foam ing and shifting problems can result 9 Add fluid to bring level up to MAX arrow mark When fluid level is correct shut engine off release park brake remove funnel and install dipstick in fill tube CONVERTER DRAINBACK CHECK VALVE SERVICE The converter drainback check valve is located in the cooler outlet pressure line near the radiator lower tank The valve prevents fluid drainback when the vehicle is parked for lengthy periods The valve check ball is spring loaded and has an opening pres sure of approximately 2 psi The valve is serviced as an assembly it is not repairable Do not dean the valve if restricted or contaminated by sludge or debris If the valve fails or if a transmission malfunction occurs that gener ates sludge and or clutch particles and metal shav ings the valve must be replaced The valve must be removed whenever the cooler and lines are reverse flushed The valve can be flow tested when necessary The procedure is exactly the same as for flow testing a cooler If the valve is restricted installed backwards or in the wrong line it will cause an overheating condition and possible transmission failure CAUTION The drainback valve is a one way flow device It must be properly oriented in terms of flow direction for the cooler to function
269. ig 215 SNAP OUTPUT SHAFT RING FRONT BEARING 19021 89 Fig 214 Annulus Gear Installation ANNULUS GEAR CLUTCH DRUM J9321 393 Fig 215 Clutch Drum And Outer Retaining Ring Installation 6 Slide dutch drum forward and install inner retaining ring Fig 216 7 Install rear bearing and snap ring on output shaft Fig 217 Be sure locating ring groove in bear ing is toward rear 8 Install overrunning clutch on hub Fig 218 Note that clutch only fits one way Shoulder on clutch should seat in small recess at edge of hub 9 Install thrust bearing on overrunning dutch hub Use generous amount of petroleum jelly to hold bearing in place for installation Bearing fits one way only Be sure bearing is seated squarely against hub Reinstall bearing if it does not seat squarely TRANSMISSION AND TRANSFER CASE 21 83 ANNULUS INNER GEAR SNAP RING CLUTCH DRUM J9321 394 Fig 216 Clutch Drum Inner Retaining Ring Installation REAR BEARING J9321 370 Fig 217 Rear Bearing And Snap Ring Installation CLUTCH HUB gt OVERRUNNING CLUTCH J9121 322 Fig 218 Assembling Overrunning Clutch And Hub 10 Install overrunning clutch in output shaft Fig 219 Insert snap ring pliers in hub splines Expand pliers to grip hub Then install assembly with counterclockwise twisting motion 21 84 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued 11 Install planet
270. ig 233 Reaction Plug And Snap Ring Installation CASE TAB ENDS ANAS ABS Fig 234 Correct Hear Bearing Locating Ring Position NOTE The 42RE transmission has overdrive clutch discs and 2 plates The 44RE transmission has 4 overdrive clutch discs and 3 plates 3 Assemble overdrive clutch pack Fig 240 4 Install overdrive dutch reaction plate first 2 GEARTRAIN ASSEMBLY J9321 360 Fig 235 Overdrive Gear Case Installation EXPAND BEARING LOCATING f RING WITH SNAP RING PLIERS PUSH OUTPUT SHAFT FORWARD TO FREE ROM RING Fig 236 Seating Locating Ring In Rear Bearing TORX SCREWDRIVER T25 ACCESS COVER SCREWS J9321 357 Fig 237 Locating Ring Access Cover And Gasket Installation 5 Install first clutch disc followed by first clutch plate Then install remaining dutch discs and plates in same order Install clutch pack pressure plate 7 Install dutch pack wiretype retaining ring Fig 241 2 3RANSMISSION AND TRANSFER CASE 21 89 DISASSEMBLY AND ASSEMBLY Continued REACTION OVERDRIVE CLUTCH CLUTCH PACK HUB RETAINING J9321 356 Fig 238 Overdrive Clutch Reaction Ring Installation 19321 352 Fig 241 Overdrive Clutch Retaining Ring Installation 2 Determine correct thickness intermediate shaft spacer as follows a Insert Special Tool 6312 through sun gear 19
271. ilds to 1862 kPa 270 psi at 1600 rpm Governor D range closed throttle Pressure should respond smoothly to changes in mph and return to 0 7 kPa 0 1 5 psi when stopped with transmission in D 1 2 Pressure above 7 kPa 1 5 psi at stand still will prevent transmission from downshifting SPECIAL TOOLS RE TRANSMISSION Cu Remover 6957 Oil Cooler Flusher 6906 TRANSMISSION AND TRANSFER CASE 21 237 SPECIAL TOOLS Continued 0 Installer 6951 Retainer Detent Ball and Spring 6583 Gauge Block 6312 Spring Compressor and Alignment Shaft 6227 IN Gauge Bar 6311 Fixture Engine Support C 3487 A 21 238 TRANSMISSION AND TRANSFER CASE 7 SPECIAL TOOLS Continued Extension Housing Pilot 3288 Spring Compressor C 3422 B SERM Puller Slide Hammer C 3752 Gauge Throttle Setting C 3763 ES 80114420 Dial Indicator C 3339 Seal Installer C 3860 A 2 5 5 AND TRANSFER CASE 21 239 SPECIAL TOOLS Continued Seal Remover C 3985 B Remover Installer C 4470 d e Overdrive Piston Seal Installer 8114 Dial Caliper C 4962 Installer C 3995 A Nut Bushing Remover SP 1191 From kit C 3887 J Universal Handle C 4171 21 240 TRANSMISSION AND TRANSFER CASE 2 SPECIAL TOOLS Continued Remover Front Clutch Bushing SP 3629 From kit I
272. in And Sprocket Installation OIL PUMP AND REAR CASE INSTALLATION 1 Insert oil pickup tube in oil pump and attach oil screen and connector hose to pickup tube Then 21 264 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued OY AP DRIVE SPROCKET SNAP RING Y J8921 251 Fig 84 Drive Sprocket Snap Ring Installation install assembled pump tube and screen in rear case Fig 85 Be sure screen is seated in case slot as shown 2 Install magne in front case pocket Fig 86 OIL PUMP J8921 287 Fig 85 Oil Screen And Pickup Tube Installation 3 Apply 3 mm 1 8 in wide bead of Mopar gas ket maker or silicone adhesive sealer to seal surface of front case 4 Align and install rear case on front case Be sure case locating dowels are in place and that main shaft splines are engaged in oil pump inner gear 2 18921 288 Fig 86 Installing Case Magnet 5 Install and tighten front case to rear case bolts to 41 30 ft Ibs torque Be sure to install washer under each bolt used at case dowel locations REAR RETAINER INSTALLATION 1 Remove rear bearing in retainer using Installer 8128 and Handle C 4171 2 Install rear bearing in retainer with Tools C 4171 and 5064 Fig 87 SPECIAL TOOL C 4171 SPECIAL TOOL 5064 REAR RETAINER 800bdfa9 Fig 87 Installing Rear Bearing In Retainer 3 Install r
273. in the adjustment A correctly adjusted throttle valve cable will cause the throttle lever on the transmission to move simul taneously with the throttle body lever from the idle position Proper adjustment will allow simultaneous movement without causing the transmission throttle lever to either move ahead of or lag behind the lever on the throttle body TRANSMISSION THROTTLE VALVE CABLE ACCELERATOR CABLE AN 5 CABLE ENGINE BRACKET Fig 251 Throttle Cable Attachment At Engine Checking Throttle Valve Cable Adjustment 1 Turn ignition key to OFF position 2 Remove air cleaner 3 Verify that lever on throttle body is at curb idle position Then verify that transmission throttle lever Fig 252 is also at idle fully forward position 4 Slide cable off attachment stud on throttle body lever 5 Compare position of cable end to attachment stud on throttle body lever 2 USTMENTS Continued THROTTLE VALVE CABLE THROTTLE VALVE LEVER BRACKET 5 CABLE BRACKET J9321 414 Fig 252 Throttle Cable Attachment At Transmission Cable end and attachment stud should be aligned or centered on one another to within 1mm 0 039 in in either direction f cable end and attachment stud are misaligned off center cable will have to be adjusted as described in Throttle Valve Cable Adjustment proce dure 6 Reconnect cable end to attachment stud Then with aid of a helper
274. inated with excessive amounts or debris refer to the diagnosis section of this group Check the adjustment of the front and rear bands adjust if necessary CLEANING 1 Using a suitable solvent dean pan and mag net 2 Using a suitable gasket scraper dean gasket material from gasket surface of transmission case and the gasket flange around the pan INSTALLATION 1 Place replacement filter in position on valve body 2 Install screws to hold filter to valve body Fig 14 Tighten screws to 4 35 in Ibs torque 3 Place new gasket in position on pan and install pan on transmission 4 Place pan in position on transmission 5 Install screws to hold pan to transmission Fig 13 Tighten bolts to 17 N m 150 in Ibs torque Lower vehicle fill transmission with Mopar ATF Plus 3 type 7176 fluid TRANSMISSION FILL PROCEDURE To avoid overfilling transmission after a fluid change or overhaul perform the following procedure 1 Remove dipstick and insert dean funnel in transmission fill tube 2 Add following initial quantity of Mopar ATF Plus 3 to transmission a If only fluid and filter were changed add 3 pints 1 1 2 quarts of ATF Plus 3 to transmis sion b If transmission was completely overhauled torque converter was replaced or drained and cooler was flushed add 12 pints 6 quarts of ATF Plus 3 to transmission 3 Apply parking brakes 4 Start and run engine at nor
275. ing Pump And Installing Outer Gear INNER GEAR J9321 465 Fig 148 Pump Inner Gear Installation 6 Install new thrust washer on hub of reaction shaft support Lubricate washer with transmission fluid or petroleum jelly 7 17 reaction shaft seal rings are being replaced install new seal rings on support hub Fig 149 Lubricate seal rings with transmission fluid or petro leum jelly after installation Squeeze each ring until ring ends are securely hooked together CAUTION reaction shaft support seal rings will break if overspread or twisted If new rings are being installed spread them only enough for instal lation Also be very sure the ring ends are securely hooked together after installation Otherwise the rings will either prevent pump installation or break during installation 8 Install reaction shaft support on pump housing Fig 150 9 Align reaction support on pump housing Use alignment marks made at disassembly Or rotate 21 68 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued SUPPORT HUB 1 J9321 218 Fig 149 Hub Seal Ring Position REACTION SHAFT SUPPORT PUMP HOUSING Fig 150 Assembling Reaction Shaft Support And Pump Housing support until bolt holes in support and pump housing are all aligned holes are offset for one way fit 10 Install all bolts that attach support to pump housing Then tighten bolts finger tight 11 Tig
276. ing in detent housing with Retainer Tool 6583 Fig 86 4 Install throttle lever in upper housing Then install manual lever over throttle lever and start manual lever into housing 5 Align manual lever with detent ball and man ual valve Hold throttle lever upward Then press down on manual lever until fully seated Remove detent ball retainer tool after lever is seated 6 Then install manual lever seal washer and E dip 21 52 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued RIGHT SIDE SCREW CONVERTER CLUTCH VALVE SPRING 3 4 SHIFT VALVE SPRING 3 4 ACCUMULATOR J9321 160 Fig 84 Converter Clutch And 3 4 Shift Valve Springs CONVERTER CLUTCH VALVE PLUG ACCUMULATOR BOX 9521 180 Fig 85 Seating 3 4 Accumulator On Lower Housing 7 Verify that throttle lever is aligned with end of kickdown valve stem and that manual lever arm is engaged in manual valve Fig 87 8 Position line pressure adjusting screw in adjusting screw bracket 9 Install spring on end of line pressure regulator valve 10 Install switch valve spring on tang at end of adjusting screw bracket 11 Install manual valve 12 Install throttle valve and spring 13 Install kickdown valve and detent 14 Install pressure regulator valve 15 Install switch valve 16 Position adjusting screw bracket on valve body Align valve springs and press bracket into place Install short uppe
277. ining ring Fig 208 8 Remove direct dutch drum outer retaining ring Fig 209 2 SPECIAL TOOL CLUTCH 922741 HUB DIRECT CLUTCH PACK RES Y SNAP RING CLUTCH DRUM J9321 364 Fig 201 Direct Clutch Pack Snap Ring Removal SPECIAL TOOL J9321 363 Fig 202 Direct Clutch Hub Retaining Ring Removal 9 Mark annulus gear and output shaft for assem bly alignment reference Fig 210 Use punch or scriber to mark gear and shaft 10 Remove snap ring that secures annulus gear on output shaft Fig 211 Use two screwdrivers to unseat and work snap ring out of groove as shown 11 Remove annulus gear from output shaft Fig 212 Use rawhide or plastic mallet to tap gear off shaft 2 DISASSEMBLY AND ASSEMBLY Continued SPECIAL TOOL DIRECT CLUTCH HUB DIRECT CLUTCH PACK J9321 365 Fig 203 Direct Clutch Pack Removal DIRECT DIRECT CLUTCH CLUTCH SPRING HUB N JE 19121 311 Fig 204 Direct Clutch Hub And Spring Removal GEAR CASE AND PARK LOCK DISASSEMBLY 1 Remove locating ring from gear case 2 Remove park pawl shaft retaining bolt and remove shaft pawl and spring 3 Remove reaction plug snap ring and remove reaction plug 4 Remove output shaft seal ASSEMBLY GEARTRAIN AND DIRECT CLUTCH ASSEMBLY 1 Soak direc dutch and overdrive dutch discs in Mopar ATF Plus 3 type 7176 transmission fluid Allow discs to soak for 10 20 minut
278. inkage 5 Rear Clutch Worn 5 Inspect and replace as needed 6 Low Hydraulic Pressure Due to 6 Perform hydraulic and air pressure tests to Worn Pump Incorrect Control determine cause Pressure Adjustments Valve Body Warpage or Malfunction Sticking Leaking Seal Rings Clutch Seals Leaking Servo Leaks Clogged Filter or Cooler Lines 7 Rear Clutch Malfunction Leaking 7 Air pressure check clutch servo operation Seals or Worn Plates and repair as required 8 Overrunning Clutch Worn Not 8 Replace Clutch Holding Slips in 1 Only SLIPS IN LOW GEAR D Overrunning Clutch Faulty Replace overrunning clutch ONLY BUT NO IN 1 POSITION GROWLING GRATING 1 Drive Plate Broken 1 Replace OR SCRAPING NOISES 2 Torque Converter Bolts Hitting 2 Dust shield bent Replace or repair Dust Shield 3 Planetary Gear Set Broken 3 Check for debris in oil pan and repair as Seized required 4 Overrunning Clutch Worn 4 Inspect and check for debris in oil pan Broken Repair as required 5 Oil Pump Components 5 Remove inspect and repair as required Scored Binding 6 Output Shaft Bearing or Bushing 6 Remove inspect and repair as required Damaged 8 Front and Rear Bands 8 Adjust bands Misadjusted DRAGS OR LOCKS UP 1 Fluid Level Low 1 Check and adjust level 3 Front or Rear Band Misadjusted 3 Adjust bands 4 Case Leaks Internally 4 Check for leakage between passages in case 5 Servo Band or Linkage
279. install plate on shaft pilot hub Fig 134 4 Check input shaft front seal rings fiber thrust washer and rear seal ring Fig 135 Be ends of rear seal ring are hooked together and diagonal cut ends of front seal rings are firmly seated against each other as shown Lubricate seal rings with petroleum jelly after checking them TRANSMISSION AND TRANSFER CASE 21 183 ADJUSTING ADJUSTING SCREW LEVER AND NUT REACTION LEVER 9121 92 Fig 132 Rear Levers Strut 5 Assemble front and rear clutches Fig 136 Align lugs on front clutch discs Mount front clutch on rear dutch Turn front clutch retainer back and forth until front clutch discs are fully seated on rear dutch splined hub INTERMEDIATE SHAFT AND PLANETARY GEAR TRAIN ASSEMBLY J9121 508 Fig 133 Intermediate Shaft And Planetary Geartrain 6 Install intermediate shaft thrust washer in hub of rear dutch retainer Fig 137 Use petroleum jelly to hold washer in place Position washer so grooves are fading outward Washer only fits one way in clutch retainer hub 7 Place transmission case in upright position or place blocks under front end of transmission repair 21 184 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued INTERMEDIATE SHAFT PILOT SR Fig 135 Input Shaft Seal Ring And Thrust Washer stand to tilt case rearward This makes it easier to install front rear dutch assembly 8 Align discs in r
280. ion key allowed in park position only 2 When the shift lever is in park and the shift handle push button is in the out position the igni tion key cylinder should rotate freely from off to lock When the shifter is in any other position the ignition key should not rotate from off to lock 3 Shifting out of park should be possible when the ignition key cylinder is in the off position 4 Shifting out of park should not be possible while applying 25 Ib max handle push button force and ignition key cylinder is in the run or start posi tions unless the foot brake pedal is depressed approximately 1 2 inch 12mm 5 Shifting out of park should not be possible when the ignition key cylinder is in the accessory or lock position 6 Shifting between any gears neutral or park may be done without depressing foot brake with igni tion switch in run or start positions and vehicle sta tionary or in motion 21 220 TRANSMISSION AND TRANSFER CASE ADJ USTMENTS Continued 7 The floorshifter lever and gate positions should be in alignment with all transmission detent posi tions 8 Engine starts must be possible with floorshift lever in park or neutral gate positions only Engine starts must not be possible in any other gate posi tions other than park or neutral 9 With floorshift lever handle push button not depressed and lever detent in e PARK POSITION apply forward force on center of handle and remove pressure Engine st
281. is overfilled the gears churn the fluid into foam This aerates the fluid and causing the same conditions occurring with a low level In either case air bubbles cause fluid overheating oxi dation and varnish buildup which interferes with valve clutch and servo operation Foaming also causes fluid expansion which can result in fluid over flow from the transmission vent or fill tube Fluid overflow can easily be mistaken for a leak if inspec tion is not careful CAUSES OF BURNT FLUID Burnt discolored fluid is a result of overheating which has two primary causes 1 A result of restricted fluid flow through the main and or auxiliary cooler This condition is usu ally the result of a faulty or improperly installed drainback valve a damaged main cooler or severe restrictions in the coolers and lines caused by debris or kinked lines 2 2 Heavy duty operation with a vehicle not prop erly equipped for this type of operation Trailer tow ing or similar high load operation will overheat the transmission fluid if the vehicle is improperly equipped Such vehides should have an auxiliary transmission fluid cooler a heavy duty cooling sys tem and the engine axle ratio combination needed to handle heavy loads FLUID CONTAMINATION Transmission fluid contamination is generally a result of e adding incorrect fluid failure to clean dipstick and fill tube when checking level e engine coolant entering the fluid internal
282. ise and support vehide on safety stands start engine shift transmission into gear and note followi ng a If propeller shaft turns but wheels do not problem is with differential or axle shafts b If propeller shaft does not turn and transmis sion is noisy stop engine Remove oil pan and check for debris If pan is clear remove transmis sion and check for damaged drive plate converter oil pump or input shaft c If propeller shaft does not turn and transmis sion is not noisy perform hydraulic pressure test to determine if problem is hydraulic or mechanical PARK NEUTRAL POSITION SWITCH The center terminal of the park neutral position switch is the starter circuit terminal It provides the ground for the starter solenoid circuit through the selector lever in PARK and NEUTRAL positions only The outer terminals on the switch are for the backup lamp circuit SWITCH TEST To test the switch remove the wiring connector Test for continuity between the center terminal and 2 DIAGNOSIS AND TESTING Continued the transmission case Continuity should exist only when the transmission is in PARK or NEUTRAL Shift the transmission into REVERSE and test continuity at the switch outer terminals Continuity should exist only when the transmission is in REVERSE Continuity should not exist between the outer terminals and the case Check gearshift linkage adjustment before replac ing a switch that tests faulty OVERDRIVE ELE
283. ise vehicle 3 Remove gearshift and throttle levers from shaft of valve body manual lever 4 Disconnect wires at solenoid case connector Fig 29 5 Position drain pan under transmission oil pan 6 Remove transmission oil pan and gasket 7 Remove fluid filter from valve body 8 Remove bolts attaching valve body to transmis sion case 9 Lower valve body enough to remove accumula tor piston and springs 10 Work manual lever shaft and electrical con nector out of transmission case 11 Lower valve body rotate valve body away from case pull park rod out of sprag and remove valve body Fig 30 SOLENOID CASE CONNECTOR Seve a PARK NEUTRA POSITION SWITCH CONNECTOR TERMINAL 19321 387 Fig 29 Transmission Case Connector INSTALLATION 1 Check condition of O ring seals on valve body harness connector Fig 31 Replace seals on tor body if cut or worn 2 Check condition of manual lever shaft seal in transmission case Replace seal if lip is cut or worn Install new seal with 15 16 deep well socket Fig 32 3 Check condition of seals on accumulator piston Fig 33 Install new piston seals if necessary 21 36 5 15510 AND TRANSFER CASE REMOVAL AND INSTALLATION Continued VALVE BODY WIRE HARNESS GOVERNOR PRESSURE SOLENOID GOVERNOR PRESSURE SENSOR J9321 388 Fig 30 Valve Body 4 Place valve body manual leve
284. ission Fig 13 Tighten bolts to 17 N m 150 in Ibs torque Lower vehicle fill transmission with Mopar ATF Plus 3 type 7176 fluid TRANSMISSION FILL PROCEDURE To avoid overfilling transmission after a fluid change or overhaul perform the following procedure 1 Remove dipstick and insert dean funnel in transmission fill tube 2 Add following initial quantity of Mopar ATF Plus 3 to transmission a If only fluid and filter were changed add 3 pints 1 1 2 quarts of ATF Plus 3 to transmis sion b If transmission was completely overhauled torque converter was replaced or drained and cooler was flushed add 12 pints 6 quarts of ATF Plus 3 to transmission 3 Apply parking brakes 4 Start and run engine at normal curb idle speed 5 Apply service brakes shift transmission through all gear ranges then back to NEUTRAL set parking brake and leave engine running at curb idle speed 6 Remove funnel insert dipstick and check fluid level If level is low add fluid to bring level to MIN mark on dipstick Check to see if the oil level is equal on both sides of the dipstick If one side is noticably higher than the other the dipstick has TRANSMISSION AND TRANSFER CASE 21 147 picked up some oil from the dipstick tube Allow the oil to drain down the dipstick tube and re check 7 Drive vehicle until transmission fluid is at nor mal operating temperature 8 With the engine running at curb
285. ission manual valve lever 15 Disconnect throttle valve cable from transmis sion bracket and throttle valve lever 16 On 4 x 4 models disconnect shift rod from transfer case shift lever or remove shift lever from transfer case 17 Disconnect transmission fluid cooler lines at transmission fittings and clips 18 Support rear of engine with safety stand or jack 19 Raise transmission slightly with service jack to relieve load on crossmember and supports 20 Remove bolts securing rear support and cush ion to transmission and crossmember Raise trans mission slightly slide exhaust hanger arm from bracket and remove rear support 21 Remove bolts attaching crossmember to frame and remove crossmember 22 On 4 x 4 models remove transfer case 23 Remove all converter housing bolts 24 Carefully work transmission and torque con verter assembly rearward off engine block dowels 25 Hold torque converter in place during trans mission removal 26 Lower transmission and remove assembly from under the vehicle 27 To remove torque converter carefully slide torque converter out of the transmission INSTALLATION 1 Check torque converter hub and hub drive notches for sharp edges burrs scratches or nicks Polish the hub and notches with 320 400 grit paper and crocus cloth if necessary The hub must be smooth to avoid damaging pump seal at installation 2 Lubricate converter drive hub and oil pump seal li
286. iston in bottom of retainer A thin strip of plastic about 0 015 0 020 in thick can be used to guide seals into place if necessary CAUTION Never push the clutch piston straight in This will fold the seals over causing leakage and clutch slip In addition never use any type of metal tool to help ease the piston seals into place Metal tools will cut shave or score the seals 9 Install and position nine dutch piston springs Fig 168 10 Install springs 11 Compress spring retainer and piston springs with Tool C 3863 A 12 Install spring retainer snap ring and remove compressor tool 13 Install clutch plates and discs Fig 166 Three dutch discs three steel plates and one reac tion plate are required 14 Install reaction plate followed by waved snap ring 15 Check dutch pack dearance with feeler gauge Fig 169 Clearance between waved spring and pres sure plate should 1 78 3 28 mm 0 070 0 129 in If dearance is incorrect dutch plates dutch discs snap ring or pressure plate may have to be changed REAR CLUTCH DISASSEMBLY 1 Remove dutch pack select fit snap ring 2 Remove reaction plate and remove clutch plates and discs Fig 170 3 Remove pressure plate wave spring spacer ring and piston spring from dutch retainer 4 Remove clutch piston from piston retainer with a twisting motion 5 Remove input shaft thrust washer if washer remained in piston retainer hub during r
287. ke sure all valves operate freely in bores and do not bind or stick Make sure valve body screws are correctly tightened and separator plates are properly positioned 6 Disassemble overdrive unit and replace thrust bearing NO 1 thrust bearing is between overdrive piston and clutch hub NO 2 thrust bearing is between the planetary gear and the direct clutch spring plate NO 3 thrust bearing is between overrunning clutch hub and output shaft 7 O D Check Valve Bleed Orifice 7 Check for function secure orifice Failure insert in O D piston retainer DELAYED 3 4 UPSHIFT SLOW TO ENGAGE 1 Fluid Level Low 1 Add fluid and check for leaks 2 Throttle Valve Cable Misadjusted 2 Adjust throttle valve cable 3 Overdrive Clutch Pack Worn 3 Remove unit and rebuild clutch Burnt pack 4 TPS Faulty 4 Test with DRB scan tool and replace TPS 5 Overdrive Clutch Bleed Orifice 5 Disassemble transmission and Plugged replace orifice 6 Overdrive Solenoid or Wiring Shorted Open 6 Test solenoid and check wiring for loose corroded connections or shorts grounds Replace solenoid if faulty and repair wiring if necessary 7 Overdrive Excess Clearance 7 Remove unit Measure end play and select proper spacer 8 O D Check Valve Missing or Stuck Lockup Solenoid Relay or Wiring Shorted Open TORQUE CONVERTER LOCKS UP IN SECOND AND OR THIRD GEAR 8 Check for presence of check valve Repair or replace as re
288. ken cracked or no longer securely hooked together Inspect the input shaft splines and machined sur faces Very minor nicks or scratches can be smoothed off with crocus cloth replace the shaft if the splines are damaged or any of the machined surfaces are severely scored Replace the clutch discs if warped worn scored burned charred the lugs are damaged or if the fac ing is flaking off Replace the steel plates and the pressure plate if heavily scored warped or broken Be sure the driv ing lugs on the discs and plates are also in good con dition The lugs must not be bent cracked or damaged in any way Replace the piston spring and wave spring if either part is distorted warped or broken Check the lug grooves in the clutch retainer The steel plates should slide freely in the slots Replace the retainer if the grooves are worn or damaged Also check action of the retainer check ball The ball must move freely and not stick Inspect the piston and retainer seal surfaces for nicks or scratches Minor scratches can be removed with crocus cloth However replace the piston and or retainer if the seal surfaces are seriously damaged Check thrust washer condition Washer thickness should be 1 55 to 1 60 mm 0 061 to 0 063 in Replace the washer if worn or damaged Check condition of the two seal rings on the input shaft and the single seal ring on the piston retainer hub Replace the seal rings only if severely worn cracke
289. l 5 Remove oil pickup tube from rear case Fig REAR HOUSING OUTPUT SHAFT 27 6 Remove drive gear snap ring Fig 28 7 Disengage drive gear Fig 28 Pry gear upward and off mainshaft as shown 8 Remove front output shaft drive chain and drive gear as assembly Fig 28 MAINSHAFT SPROCKET 80315896 Fig 28 Front Output Shaft Drive Gear And Chain Removal 21 280 TRANSMISSION AND TRANSFER CASE 2 DISASSEMBLY AND ASSEMBLY Continued SHIFT FORKS AND MAINSHAFT REMOVAL 1 Remove detent plug O ring detent spring and detent plunger Fig 29 2 Remove mainshaft from dutch sleeve and input gear pilot bearing CLUTCH SLEEVE DETENT PLUNGER J9321 25 Fig 31 Range Fork And Clutch Sleeve Removal 19321 22 Fig 29 Detent Plug Spring And Plunger Removal 3 Rotate shift sector so sector teeth face upward Fig 30 4 Remove range fork rail and dutch sleeve as assembly Fig 31 Lift shift rail upward rotate fork out of shift sector and remove assembly SHIFT SECTOR ROTATE SO TEETH FACE UPWARD 19321 24 Fig 30 Rotating Shift Sector SHIFT 5 Remove shift sector Rotate and tilt sector as SECTOR BUSHING needed to remove it Fig 32 y fe 6 Remove shift sector bushing and O ring Fig 33 INPUT GEAR LOW RANGE ASSEMBLY REMOVAL 1 Turn front case on side so front bearing retainer is accessible 2 Rem
290. l press plates as shown and center assembly under press ram 3 Apply press pressure slowly Compress hub and spring far enough to expose clutch hub retaining ring and relieve spring pressure on clutch pack snap ring 1 Mount geartrain assembly in shop press Fig Fig 208 GEARTRAIN Social ASSEMBLY GEAR PRESS TOOL CASE RAM OR SIMILAR TOOL J9321 360 SPECIAL TOOL Fig 206 Removing Gear Case From Geartrain Assembly 7 Remove snap ring that retains rear bearing on output shaft CLUTCH 8 Remove rear bearing from output shaft Fig 207 nup DIRECT CLUTCH HUB AND SPRING WARNING THE NEXT STEP IN DISASSEMBLY INVOLVES COMPRESSING THE DIRECT CLUTCH PLATES SPRING IT IS EXTREMELY IMPORTANT THAT PROPER EQUIPMENT BE USED TO COMPRESS THE SPRING AS SPRING FORCE IS APPROXIMATELY 830 POUNDS USE SPRING COMPRESSOR TOOL 6227 1 AND A HYDRAU LIC SHOP PRESS WITH A MINIMUM RAM TRAVEL OF 5 6 INCHES THE PRESS MUST ALSO HAVE A BED __ LIC 9321 398 THAT CAN BE ADJUSTED UP OR DOWN AS REQUIRED Fig 208 Geartrain Mounted In Shop Press 21 204 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued 4 Remove direct dutch pack snap ring Fig 209 5 Remove direct clutch hub retaining ring Fig 210 6 Release press load slowly and completely Fig 211 7 Remove Spedal Tool 6227 1 Then remove dutch pack from hub Fig 211 SPECIAL TOOL CLUTCH 6227 HUB DIRECT CLUTCH PACK SNAP RING
291. l pump and reaction shaft support by bumping slide hammers outward alternately to pull pump from case Fig 106 15 Remove oil pump gasket Fig 107 Note gas ket position in case for assembly reference 16 Loosen front band adjusting screw until band is completely loose 17 Remove front band strut and anchor Fig 108 18 Squeeze front band together slightly and slide band over front dutch retainer and out of case Fig 109 PUMP HOUSING Fig 107 Oil Pump Gasket LEVER STRUT SLIDE HAMMER TOOLS HOUSING 19121 14 Fig 105 Oil Pump Removal Tools FRONT 23 19121 18 Fig 108 Front Band Linkage OIL PUMP AND REACTION SHAFT SUPPORT 19121 15 Fig 106 Oil Pump Removal 21 178 TRANSMISSION AND TRANSFER CASE 2 DISASSEMBLY AND ASSEMBLY Continued prevent misalignment of the overdrive clutches dur ing service of main transmission components Fig 109 Front Band 19 Remove front and rear clutch assemblies as a unit Fig 110 20 Remove front band reaction pin and lever Start pin through lever and out of case bore with drift or punch Then use pencil magnet to withdraw pin completely Fig 111 21 Remove intermediate shaft thrust washer Tri angular shaped washer will either be on shaft pilot hub or in rear clutch retainer Fig 112 22 Remove thrust plate from intermediate shaft hub Fig 113 23 Remove inter
292. le must be secured into position and properly adjusted before the installa tion of the Brake Transmission Interlock Cable BTSI 1 Snap the cable base assembly into the large square opening in the steering column 2 Secure the plastic base with two 2 self tap ping screws tighten upper screw first 21 34 TRANSMISSION AND TRANSFER CASE REMOVAL AND INSTALLATION Continued 3 Snap BTSI cable solenoid tie strap into hole in steering column tube 4 Route BTSI cable into two dips on carpet pad 5 Snap electrical connector from brake light switch into BTSI cable solenoid housing 6 Snap BTSI cable adjuster ears into floor shifter bracket and attach cable end fitting onto floor shifter interlock lever stud 7 Remove shipping pin from plastic base Then place floor shifter in Park position 8 Place the ignition key cylinder in the ACCES SORY position 9 Push the cable adjuster lock damp downward to lock it 10 Remove and discard the BTSI cable nail head lockpin at steering column 11 Install the center console and related trim Refer to Group 23 Body for proper procedures 12 Test the BTSI cable operation GOVERNOR SOLENOID AND PRESSURE SENSOR REMOVAL 1 Hoist and support vehicle on safety stands 2 Remove transmission fluid pan and filter 3 Disengage wire connectors from pressure sen sor and solenoid Fig 24 4 Remove screws holding pressure solenoid retainer to governor body
293. learance should be 0 63 to 1 14 mm 0 025 to 0 045 in 18 If dutch pack clearance is incorrect clutch pack snap ring may have to be replaced 19 Install thrust washer on piston retainer hub Use petroleum jelly to hold thrust washer in place CLUTCH RETAINER SEAL RING J9121 366 ns Fig 171 Input Shaft Seal Ring Locations FEELER GAUGE CLUTCH PACK SNAP RING 29321 167 Fig 172 Measuring Rear Clutch Pack Clearance 2 PLANETARY GEARTRAIN OUTPUT SHAFT DISASSEMBLY 1 Remove planetary snap ring from intermediate shaft Fig 173 Discard snap ring as it is not reus able 2 Remove front planetary gear and front annulus gear as assembly Fig 174 3 Remove front planetary gear and thrust washer from front annulus gear Fig 175 Note thrust washer position for assembly reference 4 Remove tabbed thrust washer from driving shell Fig 176 Note washer position for assembly reference 5 Remove sun gear and driving shell as assembly Fig 177 PLANETARY ERES SNAP RING X DRIVING SHELL FRONT ANNULUS GEAR PLANETARY GEAR J9321 169 Fig 174 Removing Front Planetary And Annulus Gears 2 DISASSEMBLY AND ASSEMBLY Continued FRONT PLANETARY GEAR TABBED THRUST WASHER FRONT ANNULUS J9121 27 Fig 175 Disassembling Front Planetary And Annulus Gears DRIVING SHELL TABBED THRUST SUN GEAR J9
294. lerator Pedal Travel Restricted 2 Verify floor mat is not under pedal repair worn accelerator cable or bent brackets 3 Valve Body Hydraulic Pressures 3 Perform hydraulic pressure tests to Too High or Too Low Due to Valve determine cause and repair as Body Malfunction or Incorrect required Correct valve body pressure Hydraulic Control Pressure adjustments as required Adjustments 4 Governor Circuit Electrical Fault 4 Test with DRB scan tool and repair as required 5 Valve Body Malfunction 5 Perform hydraulic pressure tests to determine cause and repair as required Correct valve body pressure adjustments as required 6 TPS Malfunction 6 Replace sensor check with DRB scan tool 7 PCM Malfunction 7 Check with DRB scan tool and replace if required 8 Valve Body Malfunction 8 Repair sticking 1 2 2 3 shift valves governor plugs 3 4 solenoid 3 4 shift valve 3 4 timing valve STUCK IN LOW GEAR WILL NOT 1 Throttle Linkage Misadjusted Stuck 1 Adjust linkage and repair linkage if UPSHIFT worn or damaged Check for binding cable or missing return spring 2 Gearshift Linkage Misadjusted 2 Adjust linkage and repair linkage if worn or damaged 3 Governor Component Electrical 3 Check operating pressures and test Fault with DRB scan tool repair faulty component 4 Front Band Out of Adjustment 4 Adjust Band 5 Clutch or Servo Malfunction 5 Air pressure check operation of clutches and bands
295. lever 9 Snap shift cable adjuster into mounting bracket on transmission 10 Lock shift cable by pressing cable adjuster damp down until it snaps into place 11 Lower vehide and check engine starting Engine should start only in Park and Neutral FRONT BAND ADJUSTMENT The front kickdown band adjusting screw is located on the left side of the transmission case above the manual valve and throttle valve levers 1 Raise vehide 2 Loosen band adjusting screw locknut Fig 261 Then back locknut off 3 5 turns Be sure adjusting screw turns freely in case Apply lubricant to screw threads if necessary 3 Tighten band adjusting screw to 8 N m 72 in lbs torque with Inch Pound Torque Wrench C 3380 A a 3 in extension and 5 16 socket CAUTION If Adapter 3705 is needed to reach the adjusting screw Fig 262 tighten the screw to only 5 N m 47 50 in Ibs torque TRANSMISSION AND TRANSFER CASE 21 221 THROTTLE VALVE CABLE BRACKET INT SHIFT TRANSMISSION CABLE SHIFT LEVER J9321 417 Fig 260 Shift Cable Attachment At Transmission Typical 4 Back off front band adjusting screw 2 7 8 turns 5 Hold adjuster screw in position and tighten locknut to 41 N m 30 ft Ibs torque 6 Lower vehicle FRONT BAND ADJUSTER KY LOCK NUT NS N V AG D 80b1712d Fig 261 Front Band Adjustment Screw Location 5 16 SOCKET INCH POUND WRENCH ADAPTER 3705 TIGHTEN ADJUS
296. lt The charts neutral third fourth and reverse gear ranges Nor provide general information on a variety of transmis Mal working pressures are also supplied for each of sion overdrive unit and converter dutch fault condi the gear ranges tions DIAGNOSIS CHARTS CONDITION POSSIBLE CAUSES CORRECTION HARSH ENGAGEMENT 1 Fluid Level Low 1 Add Fluid FROM NEUTRAL TO 2 Throttle Linkage Misadjusted 2 Adjust linkage setting may be too long DRIVE OR REVERSE 3 Mount and Driveline Bolts Loose 3 Check engine mount transmission mount propeller shaft rear spring to body bolts rear control arms crossmember and axle bolt torque Tighten loose bolts and replace missing bolts 4 U Joint Worn Broken 4 Remove propeller shaft and replace U Joint 5 Axle Backlash Incorrect 5 Check per Service Manual Correct as needed 6 Hydraulic Pressure Incorrect 6 Check pressure Remove overhaul or adjust valve body as needed 7 Band Misadjusted 7 Adjust rear band 8 Valve Body Check Balls Missing 8 Inspect valve body for proper check ball installation 9 Axle Pinion Flange Loose 9 Replace nut and check pinion threads before installing new nut Replace pinion gear if threads are damaged 10 Clutch band or planetary 10 Remove disassemble and repair component damaged transmission as necessary 11 Converter Clutch Faulty 11 Replace converter and flush cooler and line before installing new converter DELAYED ENG
297. ly to hold washer in place and be sure all four washer tabs are seated 14 Install front planetary gear on output shaft and in driving shell Fig 179 15 Install front thrust washer on front planetary gear Use enough petroleum jelly to hold washer in place and be sure all four washer tabs are seated 16 Assemble front annulus gear and support if necessary Be sure support snap ring is seated 17 Install front annulus on front planetary Fig 179 18 Position thrust plate on front annulus gear support Fig 180 Note that plate has two tabs on it These tabs fit in notches of annulus hub PLANETARY GEAR J9121 158 Fig 171 Installing Rear Planetary Front Thrust Washer 2 DISASSEMBLY AND ASSEMBLY Continued SUN GEAR DRIVING SHELL REAR THRUST PLATE J9121 162 Fig 174 Installing Driving Shell Rear Thrust Plate SUN WOOD BLOCK DRIVING SHELL DRIVING SHELL 39121164 Fig 176 Installing Sun Gear Lock Ring 19 Install thrust washer in front annulus Fig 181 Align flat on washer with flat on planetary hub Also be sure washer tab is facing up TRANSMISSION AND TRANSFER CASE 21 75 SUN GEAR DRIVING SHELL ASSEMBLY OUTPUT SHAFT 7 5 J9121 165 Fig 177 Installing Assembled Sun Gear And Driving Shell On Output Shaft FRONT PLANETARY THRUST WASHER J9121 166 Fig 178 Installing Rear Thrust Washer On Front Planetary Gear 20 Ins
298. mage or wear Lubricate the front band adjusting screw threads with petroleum jelly and thread the screw part way into the case Be sure the screw turns freely OVERRUNNING CLUTCH LOW REVERSE DRUM OVERDRIVE PISTON RETAINER Clean the overrunning dutch assembly dutch cam low reverse drum and overdrive piston retainer in solvent Dry them with compressed air after clean ing Inspect condition of each clutch part after cleaning Replace the overrunning clutch roller and spring assembly if any rollers or springs are worn or dam aged or if the roller cage is distorted or damaged Replace the cam if worn cracked or damaged Replace the low reverse drum if the dutch race roller surface or inside diameter is scored worn or damaged Do not remove the clutch race from the low reverse drum under any circumstances Replace the drum and race as an assembly if either component is damaged Examine the overdrive piston retainer carefully for wear cracks scoring or other damage Be sure the retainer hub is a snug fit in the case and drum Replace the retainer if worn or damaged ACCUM ULATOR Inspect the accumulator piston and seal rings Fig 246 Replace the seal rings if worn or cut Replace the piston if chipped or cracked Check condition of the accumulator inner and outer springs Fig 246 Replace the springs if the coils are cracked distorted or collapsed 2 CLEANING AND INSPECTION Continued CT Fig 246 Accumulato
299. mal curb idle speed 5 Apply service brakes shift transmission through all gear ranges then back to NEUTRAL set parking brake and leave engine running at curb idle speed 6 Remove funnel insert dipstick and check fluid level If level is low add fluid to bring level to MIN mark on dipstick Check to see if the oil level is equal on both sides of the dipstick If one side is noticably higher than the other the dipstick has TRANSMISSION AND TRANSFER CASE 21 27 picked up some oil from the dipstick tube Allow the oil to drain down the dipstick tube and re check 7 Drive vehicle until transmission fluid is at nor mal operating temperature 8 With the engine running at curb idle speed the gear selector in NEUTRAL and the parking brake applied check the transmission fluid level CAUTION Do not overfill transmission fluid foam ing and shifting problems can result 9 Add fluid to bring level up to MAX arrow mark When fluid level is correct shut engine off release park brake remove funnel and install dipstick in fill tube CONVERTER DRAINBACK CHECK VALVE SERVICE The converter drainback check valve is located in the cooler outlet pressure line near the radiator lower tank The valve prevents fluid drainback when the vehicle is parked for lengthy periods The valve check ball is spring loaded and has an opening pres sure of approximately 2 psi The valve is serviced as an assembly it is not repairable Do
300. mediate shaft planetary gear train assembly Fig 114 24 If overdrive unit is not to be serviced install Alignment Shaft 6227 2 into the overdrive unit to Fig 110 Removing Front Rear Clutch Assemblies FRONT AND REAR CLUTCH ASSEMBLIES 19121 20 Fig 111 Front Band Lever Pin LE INTERMEDIATE SHAFT PILOT HUB J9121 506 Fig 112 Intermediate Shaft Thrust Washer SHAFT INTERMEDIATE THRUST 609 E Sx SHAFT PLATE Se PILOT HUB N Fig 113 Intermediate Shaft Thrust Plate 2 DISASSEMBLY AND ASSEMBLY Continued 25 Loosen rear band locknut and loosen adjust ing screw 3 4 turns 26 Remove snap ring that retains low reverse drum on overdrive piston retainer hub Fig 115 INTERMEDIATE SHAFT AND PLANETARY GEAR TRAIN ASSEMBLY J9121 508 Fig 114 Intermediate Shaft And Planetary Geartrain ce C 5 2 SO LOW REVERSE DRUM TABBED WASHER 7 19521 89 Fig 115 Low Reverse Drum Snap Ring 27 Slide low reverse drum and thrust washer off piston retainer hub and out of rear band Fig 116 28 Note that overrunning dutch race will remain on splines of low reverse drum after removal Fig 117 The race is a permanent press fit on the hub splines Do not attempt to remove the race 29 Remove overrunning clutch assembly Fig 118 Assembly be removed without displacing rollers and springs if care is exercised Note position o
301. moval and installation proce dures CAUTION The transmission and torque converter must be removed as an assembly to avoid compo nent damage The converter drive plate pump bushing or oil seal can be damaged if the con verter is left attached to the driveplate during removal Be sure to remove the transmission and converter as an assembly REMOVAL 1 Disconnec battery negative cable 2 Disconnect and lower or remove necessary exhaust components 3 Remove engine to transmission bending braces 4 Disconnect fluid cooler lines at transmission 5 Remove starter motor 6 Disconnect and remove crankshaft position sen sor Retain sensor attaching bolts CAUTION The crankshaft position sensor will be damaged if the transmission is removed or installed while the sensor is still bolted to the engine block or transmission 4 0L only To avoid damage be sure to remove the sensor before removing the transmission 7 Remove torque converter access cover 8 If transmission is being removed for overhaul remove transmission oil pan drain fluid and reinstall pan 9 Remove fill tube bracket bolts and pull tube out of transmission Retain fill tube seal On 4 x 4 models it will also be necessary to remove bolt attaching transfer case vent tube to converter hous ing Fig 15 TRANSFER CASE VENT TUBE FILL EN TUBE V8 AR FILL TUBE V6 TUBE SEAL 80b170f3 Fig 15 Fill Tube Attachment
302. n saxle case and valve body can be repaired by the use of Heli Coils or equivalent This repair consists of drilling out the worn out damaged threads Then tap the hole with a special Heli Coil tap or equivalent and installing a Heli Coil insert or equivalent into the hole This brings the hole back to its original thread size Heli Coil or equivalent tools and inserts are readily available from most automotive parts suppli ers REMOVAL AND INSTALLATION TRANSMISSION The overdrive unit can be removed and serviced separately It is not necessary to remove the entire transmission assembly to perform overdrive unit repairs 2 REMOVAL AND INSTALLATION Continued If only the overdrive unit requires service refer to the overdrive unit removal and installation proce dures CAUTION The transmission and torque converter must be removed as an assembly to avoid compo nent damage The converter drive plate pump bushing or oil seal can be damaged if the con verter is left attached to the driveplate during removal Be sure to remove the transmission and converter as an assembly REMOVAL 1 Disconnec battery negative cable 2 Disconnect and lower or remove necessary exhaust components 3 Remove engine to transmission bending braces 4 Disconnect fluid cooler lines at transmission 5 Remove starter motor 6 Disconnect and remove crankshaft position sen sor Retain sensor attaching bolts CAUTION The c
303. n 106 torque SPRING B RETAINER Be BOOST TRANSMISSION AND TRANSFER CASE 21 49 3 Install 1 2 and 2 3 shift valves and springs 4 Install 1 2 shift control valve and spring 5 Install retainer spring limit valve and 2 3 throttle plug from limit valve housing 6 Install limit valve housing and cover plate Tighten screws to 4 N m 35 in Ibs 7 Install shuttle valve as follows a Insert plastic guides in shuttle valve second ary spring and install spring on end of valve b Install shuttle valve into housing c Hold shuttle valve in place d Compress secondary spring and install E dip in groove at end of shuttle valve e Verify that spring and E dip are properly seated before proceeding 8 Install shuttle valve cover plate Tighten cover plate screws to 4 N m 35 in Ibs torque 9 Install 1 2 and 2 3 valve governor plugs in valve body 10 Install throttle plug 11 Align and install governor plug cover Tighten cover screws to 4 N m 35 in 105 torque shuttle valve primary spring and BOOST VALVE E CLIP SPRING GUIDES SHUTTLE e VALVE SECONDARY SPRING SHUTTLE VALVE P d COVER UPP R HOUSING 76 7 THROTTLE L9 PLUG SHUTTLE VALVE PRIMARY 3 SPRING GOVERNOR PLUG e SS COVER e 9421 217 Fig 78 Shuttle And Boost Valve Components 21 50 TRANSMISSION AND TRANSFER CASE 2 DISASSEMBLY AND ASSEMBLY Continued UPPER
304. n In Manual Low NOTE This test checks pump output pressure reg ulation and condition of the rear clutch and servo circuit Both test gauges are required for this test 1 Connect tachometer to engine Position tachom eter so it can be observed from driver seat if helper will be operating engine Raise vehicle on hoist that will allow rear wheels to rotate freely 2 Connect 100 psi Gauge C 3292 to accumulator port Then connect 300 psi Gauge C 3293 SP to rear servo port 3 Disconnect throttle and gearshift cables from levers on transmission valve body manual shaft 4 Have helper start and run engine at 1000 rpm 5 Move transmission shift lever fully forward into 1 range 6 Gradually move transmission throttle lever from full forward to full rearward position and note pressures on both gauges e Line pressure at accumulator port should be 54 60 psi 372 414 kPa with throttle lever forward and gradually increase to 90 96 psi 621 662 kPa as throttle lever is moved rearward e Rear servo pressure should be same as line pres sure within 3 psi 20 68 kPa 2 Test Two Transmission In 2 Range NOTE This test checks pump output line pressure and pressure regulation Use 100 psi Test Gauge C 3292 for this test 1 Leave vehicle in place on hoist and leave Test Gauge C 3292 connected to accumulator port 2 Have helper start and run engine at 1000 rpm 3 Move transmission shift lever one detent rear ward
305. n also be used to lubricate and hold thrust washers and plates in position during assembly Do not use chassis grease bearing grease white grease or similar lubricants on any part These types of lubricants can eventually block or restrict fluid passages and valve operation Use petroleum jelly only Do not force parts into place The transmission components and sub assemblies are easily installed by hand when properly aligned If a part seems dif ficult to install it is either misaligned or incorrectly assembled Verify that thrust washers thrust plates and seal rings are correctly positioned The planetary geartrain front rear clutch assem blies and oil pump are all much easier to install when the transmission case is upright Either tilt the case upward with wood blocks or cut a hole in the bench large enough for the intermediate shaft and rear support Then lower the shaft and support into the hole and support the rear of the case directly on the bench FRONT REAR SERVO 1 Lubricate rear servo piston seal with Mopar Door Ease or ATF Plus 3 Lubricate servo bore in case with ATF Plus 3 2 Install rear servo piston in case Position piston at slight angle to bore and insert piston with twisting motion Fig 123 3 Install rear servo spring and retainer in case bore Fig 124 Be sure spring is seated on piston 4 Compress rear servo piston with C damp or Valve Spring Compressor C 3422 B and install servo piston sn
306. n control module PCM GOVERNOR PRESSURE SOLENOID VALVE The solenoid valve is a duty cyde solenoid which regulates the governor pressure needed for upshifts and downshifts It is an electro hydraulic device located in the governor body on the valve body trans fer plate Fig 3 The inlet side of the solenoid valve is exposed to normal transmission line pressure The outlet side of the valve leads to the valve body governor circuit The solenoid valve regulates line pressure to pro duce governor pressure The average current sup plied to the solenoid controls governor pressure One amp current produces zero kPa psi governor pres sure Zero amps sets the maximum governor pres sure The powertrain control module PCM turns on the trans control relay which supplies electrical power to the solenoid valve Operating voltage is 12 volts DC The PCM controls the ground side of the sole noid using the governor pressure solenoid control cir cuit SOLENOID FILTER GOVERNOR PRESSURE SOLENOID J9321 408A Fig 3 Governor Pressure Solenoid Valve GOVERNOR PRESSURE SENSOR The governor pressure sensor measures output pressure of the governor pressure solenoid valve Fig 4 The sensor output signal provides the necessary feedback to the PCM This feedback is needed to ade quately control governor pressure 2 DESCRIPTION AND OPERATION Continued RETAINING CLIP GOVERNOR BODY GOVERNOR PRESSURE SENSOR TRANSMI
307. n or damaged 8 Inspect terminal pins in speed sensor Clean pins with Mopar electrical spray cleaner if dirty or oxidized Replace sensor if faulty or if pins are loose severely corroded or damaged INSTALLATION AND INDEXING 1 Thoroughly clean adapter flange and adapter mounting surface in housing Surfaces must be clean for proper adapter alignment and speedometer oper ation 2 Install new O rings on speed sensor and speed ometer adapter Fig 5 if necessary 3 Lubricate sensor and adapter O rings with transmission fluid 4 Install vehicle speed sensor in speedometer adapter Tighten sensor attaching screw to 2 3 N m 15 27 in lbs torque 5 Install speedometer pinion in adapter 6 Count number of teeth on speedometer pinion Do this before installing assembly in housing Then lubricate pinion teeth with transmission fluid 7 Note index numbers on adapter body Fig 6 These numbers will correspond to number of teeth on pinion 8 Install speedometer assembly in housing 9 Rotate adapter until required range numbers are at 6 o dock position Be sure range index num bers correspond to number of teeth on pinion gear 10 Install speedometer adapter clamp and retain ing screw Tighten damp screw to 10 12 N m 90 110 165 torque 11 Connect wires to vehicle speed sensor 12 Lower vehicle and top off transmission fluid level if necessary FRONT OUTPUT SHAFT SEAL REMOVAL 1 Rais
308. n transfer case under vehide 4 Align transfer case and transmission shafts and install transfer case on transmission 5 Install and tighten transfer case attaching nuts to 35 N m 26 ft Ibs torque Fig 3 6 Connec vehide speed sensor wires and vent hose 7 Connect indicator switch harness to transfer case switch if necessary Secure wire harness to clips on transfer case TRANSMISSION AND TRANSFER CASE 21 243 8 Align and connect propeller shafts Refer to Group 3 Differential and Driveline for proper proce dures and specifications 9 Fill transfer case with correct fluid Check transmission fluid level Correct as necessary 10 Install rear crossmember or skid plate Tighten crossmember bolts to 41 N m 30 ft Ibs torque 11 Remove transmission jack and support stand 12 Connect shift rod to transfer case range lever 13 Adjust transfer case shift linkage 14 Lower vehicle and verify transfer case shift operation SHIFT LEVER REMOVAL 1 Shift transfer case into 4L 2 Raise vehicle 3 Loosen adjusting trunnion locknut and slide shift rod out of trunnion Fig 4 If rod lacks enough travel to come out of trunnion push trunnion out of torque shaft 4 Lower vehicle 5 Remove console Refer to Group 23 Body for proper procedures 6 Remove screws attaching lever assembly to floorpan and remove assembly and shift rod if left attached INSTALLATION 1 If shift rod
309. nVHGAH 3SH3A3U NI 43437 HOLO3 T3S N Har 110 nr NOUS 282 77 1 T J 5 ausos PIE Fo BH Lr 008 2 4 455 EE Cmm i AHOHSAO E ES mmm d TYNNYN TE SATVA bE 4 T iu HolviniNn2ov 7 6 3AIHOHSAO 5 LNOHJ f OAH3S uvau
310. nd E dip fluid filter and screws detent ball and spring valve body screws governor pressure solenoid governor pressure sensor and retaining dip park lock rod and E dip 21 215 TRANSMISSION AND TRANSFER CASE 2 CLEANING AND INSPECTION Continued sjayoeig Puy seA BA saddn esz big 21 1961 ANAS Mads LaDvua YIAOD AN382S AN382S JAVA ONILSNfav JAVA JAIVA 34056344 FRCS NIILSRhIOv 15009 HOLIMS 31 JINN 143130 4 31 gt divid onid AJAO ONId ee 4 ANY 3AIVA N AOQODI JATVA a 15009 ONINdS ONIddS ANY 3AIVA 31LLOSWHL 92 00 16008 ONINdS 214 3AIVA 1 5 DAT INVA 21 JILLNHS 31 14 83 3 4 116 YOLVUVdAS Ond 34155344 3ATVA 3ATIVA l4lHS 6 2 QNY JAVA JILLNHS Q9 vans 34155334 v IMYA No1vino3u ONIMNdS ANY 3ATVA M TOYLNOD 14 6 21 1 IMYA 1 5 AQO8 3A1VA ONIUdS 3AIVA 14IHS 2 1 7 sadino 9 5 45 ANVONOD3S ANY 3AIVA YIAOD 3AIVA 31LL0HS HIHS EZ 14IHS 21 216 TRANSMISSION AND TRANSFER CASE CLEANING AND INSPECTION Continued TRANSMISSION GENERAL INFORMATION Inspec
311. nd lower vehicle 5b Top off transmission fluid level GEARSHIFT CABLE REMOVAL 1 Shift transmission into Park 2 Remove shift lever bezel and necessary console parts for access to shift lever assembly 3 Disconnect cable at shift lever and feed cable through dash panel opening to underside of vehide 4 Raise vehide 5 Disengage cable eyelet at transmission shift lever and pull cable adjuster out of mounting bracket Then remove old cable from vehicle INSTALLATION 1 Route cable through hole in dash panel Fully seat cable grommet into dash panel 2 Place the auto transmission manual shift con trol lever in Park detent rearmost position and rotate prop shaft to ensure transmission is in park 3 Connect shift cable to shifter mechanism by snapping cable retaining ears into shifter bracket and press cable end fitting onto lever ball stud 4 Place the floor shifter lever in park position Ensure that the pawl is seated within the confines of the adjustment gauge clip 5 Snap the cable into the transmission bracket so the retaining ears are engaged and connect cable end fitting onto the manual control lever ball stud 6 Lock shift cable into position by pushing upward on the adjusting lock button 7 Remove and discard the shift cable adjustment gauge clip from the park gate of the shifter TRANSMISSION AND TRANSFER CASE 21 153 BRAKE TRANSMISSION SHIFT INTERLOCK REMOVAL 1 Lower the steerin
312. nd sensor 3 Lubricate solenoid and sensor O rings with dean transmission fluid 4 Install governor pressure sensor in governor body Then secure sensor with M shaped retaining dip 5 Install governor pressure solenoid in governor body Push solenoid in until it snaps into place in body 2 3RANSMISSION AND TRANSFER CASE 21 53 DISASSEMBLY AND ASSEMBLY Continued 6 Position governor body gasket on transfer plate 7 Install retainer plate on governor body and around solenoid Be sure solenoid connector is posi tioned in retainer cutout 8 Align screw holes in governor body and trans fer plate Then install and tighten governor body screws to 4 N m 35 in 165 torque 9 Connect harness wires to governor pressure a AW solenoid and governor pressure sensor KICKDOWN M X THROTILE 10 Perform Line Pressure and Throttle Pressure VALVE e adjustments Refer to adjustment section of this MANUAL group for proper procedures AME 11 Install fluid filter and pan ARM 9121 54 12 Lower vehicle 13 Fill transmission with recommended fluid and Fig 87 Manual And Throttle Lever Alignment road test vehicle to verify repair SOLENOID TRANSMISSION HARNESS CASE DISASSEMBLY 1 Clean transmission exterior with steam gun or with solvent Wear eye protection during deaning operations 2 Place transmission in a vertical position 3 Measure and record input shaft end play reading
313. ng and wave spring Fig 157 5 Remove clutch piston with rotating motion 6 Remove and discard piston seals 7 Remove input shaft snap ring Fig 158 It may be necessary to press the input shaft in slightly to relieve tension on the snap ring 8 Press input shaft out of retainer with shop press and suitable size press tool Use a suitably sized press tool to support the retainer as dose to the input shaft as possible ASSEMBLY 1 Soak dutch discs in transmission fluid while assembling other dutch parts 2 Install new seal rings on dutch retainer hub and input shaft if necessary Fig 159 a Be sure dutch hub seal ring is fully seated in groove and is not twisted 3 Lubricate splined end of input shaft and dutch retainer with transmission fluid Then press input 2 shaft into retainer Use a suitably sized press tool to support retainer as dose to input shaft as possible 4 Install input shaft snap ring Fig 158 5 Invert retainer and press input shaft in oppo site direction until snap ring is seated 6 Install new seals on dutch piston Be sure lip of each seal faces interior of clutch retainer 7 Lubricate lip of piston seals with generous quantity of Mopar Door Ease Then lubricate retainer hub and bore with light coat of transmission fluid 8 Install dutch piston in retainer Use twisting motion to seat piston in bottom of retainer A thin strip of plastic about 0 020 thick can be us
314. ng the screw dockwise decreases pressure WRENCH Fig 257 Line Pressure Adjustment TRANSMISSION AND TRANSFER CASE 21 99 THROTTLE PRESSURE ADJUSTMENT Insert Gauge Tool C 3763 between the throttle lever cam and the kickdown valve stem Fig 258 Push the gauge tool inward to compress the kick down valve against the spring and bottom the throt tle valve Maintain pressure against kickdown valve spring Turn throttle lever stop screw until the screw head touches throttle lever tang and the throttle lever cam touches gauge tool NOTE The kickdown valve spring must be fully compressed and the kickdown valve completely bottomed to obtain correct adjustment SPECIAL TOOL C 3763 POSITIONED HEX BETWEEN WRENCH THROTTLE IN THROTTLE LEVER AND LEVER KICKDOWN VALVE ADJUSTING SCREW 19521 109 Fig 258 Throttle Pressure Adjustment 2 TRANSMISSION AND TRANSFER CASE SCHEMATICS AND DIAGRAMS HYDRAULIC SCHEMATICS 21 100 0 NOILONS 3unssa3ud A amp HVd Ol TOnVHGAH JILLOYHL 938012 dyd H3A31 HOLO3 3S uaria 10 NOLLVOIHB TI 1 19 OL U31H3ANOO ANDYOL FATWA d 174001 JAVA HOLIMS 1 Naduos 0 45008 df 15201 4105 105 AHQUSAO 3ATVA LJIHS t
315. ng them CASE SLOTS J8921 271 Fig 45 Separating Differential Case Halves 2 THRUST WASHERS 12 GEARS 6 J8921 272 Fig 46 Planet Gears And Thrust Washer Removal MAINSHAFT GEAR SPROCKET GEAR J8921 273 Fig 47 Mainshaft And Sprocket Gear Removal ASSEMBLY Lubricate transfer case components with automatic transmission fluid or petroleum jelly where indi cated during assembly CAUTION The bearing bores in various transfer case components contain oil feed holes Make sure replacement bearings do not block the holes 2 DISASSEMBLY AND ASSEMBLY Continued BEARING AND SEAL INSTALLATION 1 Remove snap ring that retains front output shaft front bearing in case Fig 48 Then remove bearing Use hammer handle or hammer and brass punch to tap bearing out of 2 Install new front output shaft front bearing with Tool Handle C 4171 and Installer 8033A with the tapered cone upward Fig 49 J8921 274 Fig 48 Front Output Shaft Front Bearing Snap Ring Removal SPECIAL TOOL SPECIAL 4171 TOOL 8033A 27 10521 45 Fig 49 Front Output Shaft Front Bearing Installation TRANSMISSION AND TRANSFER CASE 21 255 3 Install front bearing snap ring Fig 48 4 Remove front output shaft seal using an appro priate pry tool Fig 50 or slide hammer mounted screw 5 Install new front output shaft oil seal with Installer 6952 A Fig 51 i OUT
316. ngine will not start at all the park neutral position switch may be faulty Gearshift Adjustment Procedure 1 Shift transmission into Park 2 Raise vehicle 3 Release cable adjuster clamp at transmission end of cable to unlock cable 4 Unsnap cable from cable mounting bracket on transmission Fig 253 5 Slide cable eyelet off transmission shift lever 6 Verify transmission shift lever is in Park detent by moving lever fully rearward Last rearward detent is Park position 7 Verify positive engagement of transmission park lock by attempting to rotate propeller shaft Shaft will not rotate when park lock is engaged 8 Slide cable eyelt onto transmission shift lever 9 Snap shift cable adjuster into mounting bracket on transmission 10 Lock shift cable by pressing cable adjuster damp down until it snaps into place 11 Lower vehicle and check engine starting Engine should start only in Park and Neutral THROTTLE VALVE CABLE BRACKET SHIFT TRANSMISSION CABLE SHIFT LEVER J9321 417 Fig 253 Shift Cable Attachment At Transmission Typical 21 98 TRANSMISSION AND TRANSFER CASE ADJ USTMENTS Continued BAND ADJUSTMENTS FRONT BAND ADJ USTMENT The front kickdown band adjusting screw is located on the left side of the transmission case above the manual valve and throttle valve levers 1 Raise vehide 2 Loosen band adjusting screw locknut Fig 254 Then back locknut off 3 5 turns B
317. not dean the valve if restricted or contaminated by sludge or debris If the valve fails or if a transmission malfunction occurs that gener ates sludge and or clutch particles and metal shav ings the valve must be replaced The valve must be removed whenever the cooler and lines are reverse flushed The valve can be flow tested when necessary The procedure is exactly the same as for flow testing a cooler If the valve is restricted installed backwards or in the wrong line it will cause an overheating condition and possible transmission failure CAUTION The drainback valve is a one way flow device It must be properly oriented in terms of flow direction for the cooler to function properly The valve must be installed in the pressure line Other wise flow will be blocked and would cause an over heating condition and eventual transmission failure OIL PUMP VOLUME CHECK After the new or repaired transmission has been installed fill to the proper level with Mopar ATF PLUS 3 Type 7176 automatic transmission fluid The volume should be checked using the following procedure 1 Disconnec the From cooler line at the trans mission and place a collecting container under the disconnected line 21 28 TRANSMISSION AND TRANSFER CASE SERVICE PROCEDURES Continued CAUTION With the fluid set at the proper level fluid collection should not exceed 1 quart or inter nal damage to the transmission may occur 2 Run the engine a
318. ns mission Fig 1 with an electronic governor First through third gear ranges are provided by the clutches bands overrunning clutch and planetary gear sets in the transmission Fourth gear range is provided by the overdrive unit that contains an over drive dutch direct clutch planetary gear set and overrunning clutch The overdrive clutch is applied in fourth gear only The direct clutch is applied in all ranges except fourth gear The torque converter clutch is controlled by the Powertrain Control ule PCM The torque converter clutch is hydrauli cally applied and is released when fluid is vented from the hydraulic circuit by the torque converter control TCC solenoid on the valve body The torque converter clutch engages in fourth gear and in third gear when the O D switch is OFF Engagement occurs when the vehicle is moving at a steady speed after the vehicle has warmed up The torque con verter dutch disengages when the accelerator is applied The 42 44 RE transmission is cooled by an integral fluid cooler inside the radiator 21 3 TRANSMISSION AND TRANSFER CASE GENERAL INFORMATION Continued 2 01551 5 41 3H tt Zb L O14 40 1656 108 nome ava XSVLINV 1d EM 3AhIQU3AO ANVI3NV Id NOISSIWSNVUL 1NOM AI8W3SSv 3AIVA HOLNTD uvas 35 Y F
319. nsfer plate Fig 66 The ECE check ball is approximately 4 8 mm 3 16 in in diameter 33 Remove transfer plate from upper housing Fig 67 34 Turn transfer plate over so upper housing sep arator plate is facing upward 35 Remove upper housing separator plate from transfer plate Fig 68 Note position of filter in sep arator plate for assembly reference 36 Remove rear clutch and rear servo check balls from transfer plate Note check ball location for assembly reference Fig 69 LOWER HOUSING DISENGAGE UPPER THIS END OF HOUSING TUBE FIRST J9321 147 Fig 64 Boost Valve Tube TRANSMISSION AND TRANSFER CASE 21 165 LOWER OVERDRIVE TRANSFER PLATE HOUSING SEPARATOR AND UPPER 80017018 CHECK BALL UPPER HOUSING 80b170f9 Fig 67 Transfer Plate 21 166 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued TRANSFER UPPER PLATE HOUSING SEPARATOR PLATE FILTER SCREEN BRACE 19321 151 Fig 68 Upper Housing Separator Plate REAR REAR CLUTCH SERVO CHECK CHECK BALL BALL TRANSFER J9321 437 Fig 69 Rear Clutch And Rear Servo Check Ball Locations VALVE BODY UPPER HOUSING 1 Note location of check balls in valve body upper housing Fig 70 Then remove the one large diame ter and the six smaller diameter check balls 2 Remove governor plug and shuttle valve covers Fig 72 3
320. nstaller Reaction Shaft Bushing SP 5302 From C 3887 J kit C 3887 J Cup Bushing Remover SP 3633 From kit C 3887 J Installer Front Clutch Bushing SP 5511 From kit C 3887 J Installer Oil Pump Bushing SP 5118 From kit Remover Bushing SP 3550 From kit C 3887 J C 3887 J Adapter Adjuster C 3705 Remover Reaction Shaft Bushing SP 5301 From kit C 3887 J 2 TRANSMISSION AND TRANSFER CASE 21 241 NV242 TRANSFER CASE INDEX page page GENERAL INFORMATION IBANSEER CASH 243 TT 241 DISASSEMBLY AND ASSEMBLY RECOMMENDED LUBRICANT AND dea 242 REMOVAL AND INSTALLATION 244 DO Baten as gem mbna ae ah 243 CEU PT 243 GENERAL INFORMATION NV242 TRANSFER CASE The NV242 is a full and part time transfer case Fig 1 It provides full time 2 wheel 4 wheel drive operation A differential in the transfer case is used to control torque transfer to the front and rear axles A low range gear provides increased low speed torque capa bility for off road operation The low range provides a 2 72 1 reduction ratio J8921 243 Fig 1 NV242 Transfer Case The input gear is splined to the transmission out put shaft It drives the mainshaft through the plan etary gear and range hub The front output shaft is ADJUSTMENTS 268 SPECIFICATIONS 268 SPECIAL TOOLS T 269
321. observe movement of transmis sion throttle lever and lever on throttle body e f both levers move simultaneously from idle to half throttle and back to idle position adjustment is correct f transmission throttle lever moves ahead of or lags behind throttle body lever cable adjustment will be necessary Or if throttle body lever prevents transmission lever from returning to closed position cable adjustment will be necessary Throttle Valve Cable Adjustment Procedure 1 Turn ignition switch to OFF position 2 Remove air cleaner if necessary 3 Disconnect cable end from attachment stud Carefully slide cable off stud Do not pry or pull cable off 4 Verify that transmission throttle lever is in fully dosed position Then be sure lever on throttle body is at curb idle position 5 Insert a small screwdriver under edge of retaining clip and remove retaining clip 6 Center cable end on attachment stud to within 1 mm 0 039 in 7 Install retaining dip onto cable housing 8 Check cable adjustment Verify transmission throttle lever and lever on throttle body move simul taneously TRANSMISSION AND TRANSFER CASE 21 97 GEARSHIFT CABLE Check adjustment by starting the engine in Park and Neutral Adjustment is OK if the engine starts only in these positions Adjustment is incorrect if the engine starts in one but not both positions If the engine starts in any position other than Park or Neu tral or if the e
322. ocated in same groove as wave spring 3 Remove Torx head screws that attach access cover and gasket to overdrive case Fig 203 4 Remove access cover and gasket Fig 204 lt 2 19321 355 Fig 201 Overdrive Clutch Wave Spring Removal Installation 2 REACTION RING CLUTCH HUB 7 19321 356 Fig 202 Overdrive Clutch Reaction Snap Ring Removal Installation TORX SCREWDRIVER T25 ACCESS COVER SCREWS J9321 357 Fig 203 Access Cover Screw Removal installation ACCESS COVER AND GASKET J9321 358 Fig 204 Access Cover And Gasket Removal Installation 2 5 55 AND TRANSFER CASE 21 203 DISASSEMBLY AND ASSEMBLY Continued 5 Expand output shaft bearing snap ring with expanding type snap ring pliers Then push output OUTPUT shaft forward to release shaft bearing from locating ring Fig 205 6 Lift gear case up and off geartrain assembly REAR Fig 206 BEARING EXPAND BEARING LOCATING RING NN WITH SNAP 9 RING PLIERS NSS Wf 2 2 SNAP AH RING SE 19321 362 1 Fig 207 Rear Bearing Removal RELEASE CLUTCH SPRING TENSION SLOWLY AND COMPLETELY TO AVOID PERSONAL INJURY PUSH OUTPUT SHAFT FORWARD TO FREE 208 BEARING FROM RING E 2 Position Compressor Tool 6227 1 on dutch hub Fig 205 Releasing Bearing From Locating Ring Fig 208 Support output shaft flange with stee
323. ock ring that retains sun gear in driving shell Then remove sun gear spacer and thrust plates FRONT ANNULUS DRIVING AND PLANETARY SHELL ASSEMBLY PLANETARY SNAP RING 19421 175 Fig 165 Front Annulus And Planetary Assembly Removal PLANETARY SNAP J9421 176 Fig 166 Front Planetary Snap Ring Removal ASSEMBLY 1 Lubricate output shaft and planetary compo nents with transmission fluid Use petroleum jelly to lubricate and hold thrust washers and plates in posi tion 2 Assemble rear annulus gear and support if dis assembled Be sure support snap ring is seated and that shoulder side of support faces rearward Fig 169 3 Install rear thrust washer on rear planetary gear Use enough petroleum jelly to hold washer in place Also be sure all four washer tabs are properly engaged in gear slots 4 Install rear annulus over and onto rear plane tary gear Fig 169 5 Install assembled rear planetary and annulus gear on output shaft Fig 170 Verify that assembly is fully seated on shaft TRANSMISSION AND TRANSFER CASE 21 73 FRONT ANNULUS THRUST WASHER THRUST FRONT FRONT THRUST PLATE WASHER PLANETARY 19421 177 Fig 167 Front Planetary Annulus Gear Disassembly REAR REAR PLANETARY ANNULUS DRIVING SHELL OUTPUT SHAFT J9421 178 Fig 168 Removing Driving Shell Rear Planetary And Rear Annulus 6 Install front thrust washer on rear planetary gear
324. ocks in bearing groove and release snap ring 10 Install locating ring access cover and gasket in overdrive unit case Fig 244 Fig 243 Seating Locating Ring In Rear Bearing 21 212 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued TORX SCREWDRIVER T25 ACCESS COVER SCREWS J9321 357 Fig 244 Locating Ring Access Cover And Gasket Installation OVERDRIVE CLUTCH 1 Install overdrive clutch reaction ring first Reaction ring is flat with notched ends Fig 245 2 Install wave spring on top of reaction ring Fig 246 Reaction ring and wave ring both fit in same ring groove Use screwdriver to seat each ring securely in groove Also ensure that the ends of the two rings are offset from each other 3 Assemble overdrive clutch pack Fig 247 REACTION J9321 356 Fig 245 Overdrive Clutch Reaction Ring Installation 9321 355 Fig 246 Overdrive Clutch Wave Spring Installation 4 Install overdrive dutch reaction plate first 5 Install first dutch disc followed by first dutch plate Then install remaining clutch discs and plates in same order 6 Install dutch pack pressure plate 7 Install clutch pack wire type retaining ring Fig 248 2 REACTION PLATE PRESSURE CLUTCH DISCS 4 J9321 227 Fig 247 46RE Overdrive Clutch Components OVERDRIVE CLUTCH PACK RETAINING M 19321 352 Fig 248 Overdrive Clutch Retaining Ring
325. ok overdrive converter solenoid harness from 3 4 accumulator cover plate Fig 42 10 Turn valve body over and remove screws that attach overdrive converter solenoid assembly to valve body Fig 43 11 Remove solenoid and harness assembly from valve body Fig 44 12 Remove boost valve cover Fig 45 13 Remove boost valve retainer valve spring and boost valve Fig 46 SOLENOID HARNESS CASE CONNECTOR 3 4 ACCUMULATOR HOUSING Fig 41 Solenoid Harness Case Connector Shoulder Bolt 21 40 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued OVERDRIVE CONVERTER 34 SOLENOID ACCUMULATOR WIRE 2 HARNESS 4 ve PLATE X J9321 458 Fig 42 Unhooking Solenoid Harness From Accumulator Cover Plate OVERDRIVE CONVERTER CLUTCH SOLENOID ASSEMBLY 9521 176 Fig 43 Solenoid Assembly Screws HARNESS GOVERNOR SOLENOID WIRES GOVERNOR SENSOR WIRES CONVERTER CLUTCH OVERDRIVE SOLENOID SOLENOID SOLENOID SCREWS J9521 177 Fig 44 Solenoid Assembly HARNESS 2 5 VALVE HOUSING AND COVER TUBE 19321 467 Fig 45 Boost Valve Cover Location COVER BOOST SCREWS VALVE SPRING COVER AND WU RETAINER BOOST VALVE PLUG BOOST VALVE SPRING VALVE 19321 468 Fig 46 Boost Valve Components 14 Secure detent ball and spring with Retainer Tool 6583 Fig 47 15 Remove park rod E clip and
326. oleum jelly to hold bearing in place for installation Bearing fits one way only Be sure bearing is seated squarely against hub Reinstall bearing if it does not seat squarely CLUTCH HUB OVERRUNNING CLUTCH J9121 322 Fig 226 Assembling Overrunning Clutch And Hub 10 Install overrunning dutch in output shaft Fig 227 Insert snap ring pliers in hub splines Expand pliers to grip hub Then install assembly with counterclockwise twisting motion 11 Install planetary gear in annulus gear Fig 228 Be sure planetary pinions are fully seated in annulus gear before proceeding 12 Coat planetary thrust bearing and bearing contact surface of spring plate with generous amount of petroleum jelly This will help hold bearing in place during installation 13 Install planetary thrust bearing on sun gear Fig 229 Slide bearing onto gear and seat it against spring plate as shown Bearing fits one way only If it does not seat squarely against spring plate remove and reposition bearing 14 Install assembled sun gear spring plate and thrust bearing Fig 230 Be sure sun gear and thrust bearing are fully seated before proceeding 15 Mount assembled output shaft annulus gear and dutch drum in shop press Direct clutch spring hub and dutch pack are easier to install with assem bly mounted in press 16 Align splines in hubs of planetary gear and overrunning dutch with Alignment tool 6227 2 Fig 231 Insert tool
327. on Then verify that transmission throttle lever Fig 259 is also at idle fully forward position THROTTLE VALVE CABLE GEAR THROTTLE BRACKET VALVE SELECTOR LEVER 5 CABLE LEVER 9321 414 BRACKET Fig 259 Throttle Cable Attachment At Transmission 4 Slide cable off attachment stud on throttle body lever 5 Compare position of cable end to attachment stud on throttle body lever e Cable end and attachment stud should be aligned or centered on one another to within 1 mm 0 039 in in either direction cable end and attachment stud are misaligned off center cable will have to be adjusted as described in Throttle Valve Cable Adjustment proce dure 6 Reconnect cable end to attachment stud Then with aid of a helper observe movement of transmis sion throttle lever and lever on throttle body e both levers move simultaneously from idle to half throttle and back to idle position adjustment is correct f transmission throttle lever moves ahead of or lags behind throttle body lever cable adjustment will be necessary Or if throttle body lever prevents transmission lever from returning to closed position cable adjustment will be necessary Throttle Valve Cable Adjustment Procedure 1 Turn ignition switch to OFF position 2 Remove air cleaner if necessary 3 Disconnect cable end from attachment stud Carefully slide cable off stud Do not pry or pull cable off 4 Verify tha
328. on can be caused by leaking hydraulic circuits or sticking valves Unless a malfunction is obvious such as no drive in D range first gear do not disassemble the trans mission Perform the hydraulic and air pressure tests to help determine the probable cause HYDRAULIC PRESSURE TEST Hydraulic test pressures range from a low of one psi 6 895 kPa governor pressure to 300 psi 2068 kPa at the rear servo pressure port in reverse An accurate tachometer and pressure test gauges are required Test Gauge C 3292 has a 100 psi range and is used at the accumulator governor and front servo ports Test Gauge C 3293 SP has a 300 psi range and is used at the rear servo and overdrive ports where pressures exceed 100 psi Pressure Test Port Locations Test ports are located at both sides of the transmis sion case Fig 8 Line pressure is checked at the accumulator port on the right side of the case The front servo pressure port is at the right side of the case just behind the filler tube opening The rear servo and governor pressure ports are at the right rear of the transmission case The overdrive dutch pressure port is at the left rear of the case 21 12 TRANSMISSION AND TRANSFER CASE DIAGNOSIS AND TESTING Continued OVERDRIVE CLUTCH TEST PORT GOVERNOR ACCUMULATOR TEST PORT TEST PORT 7 FRONT SERVO TEST PORT TEST PORT 80b170e6 Fig 8 Pressure Test Port Locations Test One Transmissio
329. on plug at same time Avoid tilting overdrive during installation as this could cause planetary gear and overrunning dutch splines to rotate out of alignment If this occurs it will be nec essary to remove and disassemble overdrive unit to realign splines 11 Work overdrive unit forward on intermediate shaft until seated against transmission case 12 Install bolts attaching overdrive unit to trans mission unit Tighten bolts in diagonal pattern to 34 25 ft Ibs 13 Install speed sensor and speedometer adapter Be sure to index adapter 14 Connect speed sensor and overdrive wires 15 Align and install propeller shaft OVERDRIVE HOUSING BUSHING REMOVAL 1 Remove overdrive housing yoke seal 2 Insert Remover 6957 into overdrive housing Tighten tool to bushing and remove bushing Fig 37 REMOVER 6957 EXTENSION HOUSING BUSHING 80411095 Fig 37 Bushing Removal Typical 2 INSTALLATION 1 Align bushing oil hole with oil slot in overdrive housing 2 Tap bushing into place with Installer 6951 and Handle C 4171 3 Install new oil seal in housing using Seal Installer C 3995 A Fig 38 SPECIAL TOOL 3995 3972 SPECIAL TOOL 4471 19521 58 Fig 38 Overdrive Housing Seal Installation OUTPUT SHAFT REAR BEARING REMOVAL 1 Remove overdrive unit from the vehicle 2 Remove overdrive geartrain from housing 3 Remove snap ring holding output shaft rear
330. on the output shaft These surfaces should clean and smooth Very minor nicks or scratches can be smoothed with crocus cloth Replace the shaft if worn scored or damaged in any way Inspect the output shaft bushings The small bush ing is the intermediate shaft pilot bushing The large bushing is the overrunning clutch hub bushing Replace either bushing if scored pitted cracked or worn ADJ USTMENTS BRAKE TRANSMISSION SHIFT INTERLOCK The park interlock cable is part of the brake shift lever interlock system Correct cable adjustment is important to proper interlock operation The gear shift and park lock cables must both be correctly adjusted in order to shift out of Park Park Interlock Cable Adjustment Procedure 1 Shift into Park position TRANSMISSION AND TRANSFER CASE 21 219 2 Turn ignition switch to Accessory position Be sure ignition key cylinder is in Accessory posi tion Cable will not adjust correctly in any other position 3 Remove shift lever bezel and console screws Raise bezel and console for access to park interlock cable 4 Pull cable lock button up to release cable Fig 257 5 Pull cable forward Then release cable and press lock button down until it snaps in place PARK INTERLOCK CABLE INTERLOCK CABLE LOCK BUTTON SHIFT LEVER AND HOUSING ASSEMBLY HOUSING MOUNTING J9321 416 Fig 257 Shift And Park Lock Cables BTSI FUNCTION CHECK 1 Verify removal of ignit
331. oor shifter interlock lever stud 7 Remove shipping pin from plastic base Then place floor shifter in Park position 8 Place the ignition key cylinder in the ACCES SORY position 9 Push the cable adjuster lock damp downward to lock it 10 Remove and discard the BTSI cable nail head lockpin at steering column 11 Install the center console and related trim Refer to Group 23 Body for proper procedures 12 Test the BTSI cable operation GOVERNOR SOLENOID AND PRESSURE SENSOR REMOVAL 1 Hoist and support vehicle on safety stands 2 Remove transmission fluid pan and filter 3 Disengage wire connectors from pressure sen sor and solenoid Fig 24 4 Remove screws holding pressure solenoid retainer to governor body 5 Separate solenoid retainer from governor Fig 25 6 Pull solenoid from governor body Fig 26 7 Remove bolts holding governor body to valve body 8 Separate governor body from valve body Fig 27 9 Remove governor body gasket 10 Remove retainer holding pressure sensor to governor body 11 Pull pressure sensor from governor body Fig 28 INSTALLATION Before installing the pressure sensor and solenoid in the governor body replace O ring seals clean the gasket surfaces and replace gasket 1 Lubricate O ring on pressure sensor with transmission fluid 2 Align pressure sensor to bore in governor body Fig 28 3 Push pressure sensor into governor body
332. operated by a drive chain that connects the shaft to a drive sprocket on the mainshaft The drive sprocket is engaged disengaged by the mode fork which oper ates the mode sleeve and hub The sleeve and hub are not equipped with a synchro mechanism for shift ing The geartrain is mounted in two aluminum case halves attached with bolts The mainshaft front and rear bearings are mounted in aluminum retainer housings bolted to the case halves OPERATING RANGES NV242 operating ranges are 2WD 2 wheel drive 4x4 part time 4x4 full time and 4 Lo The 2WD and 4x4 full time ranges can be used at any time and on any road surface The 4x4 part time and 4 Lo ranges are for off road use only The only time these ranges can be used on hard surface roads is when the surface is covered with snow and ice SHIFT MECHANISM Operating ranges are selected with a floor mounted shift lever The shift lever is connected to the trans fer case range lever by an adjustable linkage rod A straight line shift pattern is used Range positions are marked on the shifter bezel cover plate or on the shift knob TRANSFER CASE IDENTIFICATION A circular ID tag is attached to the rear case of each transfer case Fig 2 The ID tag provides the transfer case model number assembly number serial number and low range ratio The transfer case serial number also represents the date of build 21 242 TRANSMISSION AND TRANSFER CASE 2 G
333. or C 3422 B Fig 122 Compress servo spring retainer only enough to permit snap ring removal 37 Remove servo piston snap ring Fig 122 Start one end of ring out of bore Then carefully work removal tool around back of snap ring until free of ring groove Exercise caution when removing snap ring Servo bore can be scratched or nicked if care is not exercised 38 Remove tools and remove rear servo retainer spring and piston assembly FRONT SERVO ROD GUIDE gt dis Fig 121 Front Servo Retaining Snap Ring REAR SERVO SPRING A 5 RETAINER RETAINER SN SNAP RING 4 J9121 40 Fig 122 Rear Servo Retaining Snap Ring ASSEMBLY Do not allow dirt grease or foreign material to enter the case or transmission components during 2 DISASSEMBLY AND ASSEMBLY Continued assembly Keep the transmission case and compo nents clean Also make sure the tools and workbench area used for reassembly operations are equally dean Shop towels used for wiping off tools and your hands must be made from lint free materials Lint will stick to transmission parts and could interfere with valve operation or even restrict fluid passages Lubricate transmission clutch and gear compo nents with Mopar ATF Plus 3 type 7176 during reassembly Soak dutch discs in transmission fluid before installation Use Mopar Door Ease or Ru Glyde on piston seals and O rings to ease installation Petroleum jelly ca
334. or in motion GEARSHIFT CABLE 1 The floor shifter lever and gate positions should be in alignment with all transmission PARK NEUTRAL and gear detent positions 2 Engine starts must be possible with floor shift lever in PARK or NEUTRAL gate positions only Engine starts must not be possible in any other gear position 3 With floor shift lever handle push button not depressed and lever in TRANSMISSION AND TRANSFER CASE 21 127 a PARK position Apply forward force on cen ter of handle and remove pressure Engine starts must be possible b PARK position Apply rearward force on cen ter of handle and remove pressure Engine starts must be possible NEUTRAL position Normal position Engine starts must be possible d NEUTRAL position Engine running and brakes applied apply forward force on center of shift handle Transmission shall not be able to shift from neutral to reverse THROTTLE VALVE CABLE Transmission throttle valve cable adjustment is extremely important to proper operation This adjust ment positions the throttle valve which controls shift speed quality and part throttle downshift sensitivity If cable setting is too loose early shifts and slip page between shifts may occur If the setting is too tight shifts may be delayed and part throttle down shifts may be very sensitive Refer to the Adjust ments section for the proper adjustment procedure ROAD TESTING Before road testing b
335. ould be reverse flushed whenever a malfunction generates sludge and or debris The torque converter should also be replaced at the same time Failure to flush the cooler and lines will result in recontamination Flushing applies to auxiliary cool ers as well The torque converter should also be replaced whenever a failure generates sludge and debris This is necessary because normal converter flushing procedures will not remove all contami nants ELECTRONIC LOCK UP TORQUE CONVERTER The torque converter is a hydraulic device that couples the engine crankshaft to the transmission 21 122 TRANSMISSION AND TRANSFER CASE GENERAL INFORMATION Continued The torque converter consists of an outer shell with an internal turbine a stator an overrunning clutch an impeller and an electronically applied converter dutch Torque multiplication is created when the sta tor directs the hydraulic flow from the turbine to rotate the impeller in the direction the engine crank shaft is turning The turbine transfers power to the planetary gear sets in the transmission The transfer of power into the impeller assists torque multiplica tion At low vehide speed the overrunning dutch holds the stator stationary during torque multiplica tion and allows the stator to freewheel at high vehi de speed The converter dutch engagement reduces engine speed Clutch engagement also provides reduced transmission fluid temperatures The torque converter hub dri
336. ould be checked whenever the transmission fails to shift into fourth gear range BRAKE TRANSMISSION SHIFT INTERLOCK 1 Verify that the key can only be removed in the PARK position 2 When the shift lever is in PARK And the shift handle pushbutton is in the OUT position the igni tion key cylinder should rotate freely from OFF to LOCK When the shifter is in any other gear or neu tral position the ignition key cylinder should not rotate to the LOCK position 3 Shifting out of PARK should be possible when the ignition key cylinder is in the OFF position 4 Shifting out of PARK should not be possible while applying 25 10 maximum handle pushbutton force and ignition key cylinder is in the RUN or START positions unless the foot brake pedal is depressed approximately 1 2 inch 12mm 5 Shifting out of PARK should not be possible when the ignition key cylinder is in the ACCESSORY or LOCK positions 6 Shifting between any gears NEUTRAL or into PARK may be done without depressing foot brake pedal with ignition switch in RUN or START posi tions and vehicle stationary or in motion GEARSHIFT CABLE 1 The floor shifter lever and gate positions should be in alignment with all transmission PARK NEUTRAL and gear detent positions 2 Engine starts must be possible with floor shift lever in PARK or NEUTRAL gate positions only Engine starts must not be possible in any other gear position 3 With floor shift lever handle pu
337. ove front bearing retainer bolts Fig 34 l i 18921 207 3 Remove front bearing retainer as follows Fig 33 Sector Bushing And O Ring Removal 2 DISASSEMBLY AND ASSEMBLY Continued a Loosen retainer with flat blade screwdriver to break sealer bead To avoid damaging case and retainer position screwdriver blade only in slots provided in retainer Fig 35 b Then remove retainer from case and gear Fig 34 Front Bearing Retainer Bolt Removal FRONT BEARING RETAINER RETAINER NOTCH 27 6 gt 1 3 4 9 BLADE pe SCREWDRIVER 19321 27 Fig 35 Front Bearing Retainer Removal 4 Remove snap ring that retains input gear shaft in front bearing Fig 36 5 Remove input and low range gear assembly Fig 37 6 Remove oil seals from following components e front bearing retainer e rear retainer e case halves INPUT AND LOW RANGE GEAR DISASSEMBLY 1 Remove snap ring that retains input gear in low range gear Fig 38 2 Remove retainer Fig 39 3 Remove front tabbed thrust washer Fig 40 4 Remove input gear Fig 41 TRANSMISSION AND TRANSFER CASE 21 281 INPUT GEAR 19321 28 ASSEMBLY J9321 29 Fig 37 Input And Low Range Gear Assembly Removal 5 Remove rear tabbed thrust washer from low range gear Fig 42 J9321 32 Fig 38 Input Gear Snap Ring Removal 21 282 TRANSMISSION AND TRANSFER CASE
338. p with transmission fluid 3 Lubricate converter pilot hub with transmis sion fluid 4 Align converter and oil pump 21 150 TRANSMISSION AND TRANSFER CASE REMOVAL AND INSTALLATION Continued 5 Carefully insert converter in oil pump Then rotate converter back and forth until fully seated in pump gears 6 Check converter seating with steel scale and straightedge Fig 16 Surface of converter lugs should be 1 2 in to rear of straightedge when con verter is fully seated 7 Temporarily secure converter with C clamp STRAIGHTEDGE Fig 16 Typical Method Of Checking Converter Seating 8 Position transmission on jack and secure it with chains 9 Check condition of converter driveplate Replace the plate if cracked distorted or damaged Also be sure transmission dowel pins are seated in engine block and protrude far enough to hold transmission in alignment 10 Raise transmission and align converter with drive plate and converter housing with engine block 11 Move transmission forward Then raise lower or tilt transmission to align converter housing with engine block dowels 12 Rotate converter so alignment marks scribed on converter are aligned with mark on driveplate 13 Carefully work transmission forward and over engine block dowels until converter hub is seated in crankshaft 14 Install bolts attaching converter housing to engine 15 Install rear support Then lower transmission onto cros
339. pan bolts to 17 13 ft Ibs torque 17 Lower vehicle and fill transmission with Mopar ATF Plus 3 type 7176 fluid 18 Check and adjust gearshift and throttle valve cables if necessary VALVE BODY CONNECTOR HARNESS O RINGS CONNECTOR J9321 389 Fig 31 Valve Body Harness Connector O Ring Seal 15 16 SOCKET Fig 32 Manual Lever Shaft Seal CG RINGS Fig 33 Accumulator Piston Components 2 REMOVAL AND INSTALLATION Continued OVERDRIVE UNIT REMOVAL 1 Shift transmission into Park 2 Raise vehide 3 Mark propeller shaft universal joint s and axle pinion yoke for alignment reference at installation 4 Disconnect and remove propeller shaft s 5 Remove transmission oil pan remove gasket drain oil and reinstall pan If overdrive unit had malfunctioned or if fluid is contaminated remove entire transmission If diag nosis indicated overdrive problems only remove just the overdrive unit 7 Support transmission with transmission jack 8 Remove vehide speed sensor and speedometer adapter if necessary 9 Remove bolts attaching overdrive unit to trans mission Fig 34 CAUTION Support the overdrive unit with a jack before moving it rearward This is necessary to pre vent damaging the intermediate shaft Do not allow the shaft to support the entire weight of the over drive unit OVERDRIVE UNIT ATTACHING BOLTS 7 US p 2 San ELS 522 IRS N S
340. per housing Fig 80 Be sure filter screen is seated in proper housing recess 3 Install the ECE check ball into the transfer plate Fig 66 The ECE check ball is approximately 4 8 mm 3 16 in in diameter 4 Position lower housing separator transfer plate Fig 81 5 Install lower housing on assembled transfer plate and upper housing Fig 82 6 Install and start all valve body screws by hand except for the screws to hold the boost valve tube brace Save those screws for later installation Then tighten screws evenly to 4 N m 35 in 165 torque Start at center and work out to sides when tighten ing screws Fig 82 plate on TRANSFER PLATE SEPARATOR FILTER SCREEN J9321 439 Fig 80 Installing Transfer Plate On Upper Housing BE SURE TO ALIGN TRANSFER La PLATE LOWER HOUSING OVERDRIVE SEPARATOR PLATE J9321 441 Fig 81 Lower Housing Separator Plate UPPER HOUSING VALVE AND PLUG Refer to Fig 83 Fig 84 and Fig 85 to perform the following steps 2 VALVE BODY SCREWS 13 LOWER HOUSING TRANSFER PLATE J9321 442 Fig 82 Installing Lower Housing On Transfer Plate And Upper Housing 1 Lubricate valves plugs springs with dean transmission fluid 2 Assemble regulator valve line pressure plug sleeve throttle plug and spring Insert assembly in upper housing and install cover plate Tighten cover plate screws to 4 N m 35 in Ibs torque 3 Ins
341. planetary gear and into pilot bushing in output 19321 355 shaft Be sure tool bottoms against planetary shoulder Fig 239 Overdrive Clutch Wave Spring Installation REACTION OVERDRIVE PRESSURE PLATE CLUTCH DISCS 3 PLATE CLUTCH PLATES 2 J9321 369 Fig 240 42RE Overdrive Clutch Components INTERMEDIATE SHAFT SPACER SELECTION b Position Gauge Tool 6311 across face of over 1 Place overdrive unit in vertical position Mount drive case Fig 242 Then position Dial Caliper it on blocks or in workbench with appropriate size C 4962 over gauge tool mounting hole cut into it Be sure unit is facing c Extend sliding scale of dial caliper downward upward for access to direct clutch hub Also be sure through gauge tool slot until scale contacts end of output shaft is not loaded and internal components Gauge Alignment Tool 6312 Lock scale in place are moved rearward for accurate measurement 21 90 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued Remove dial caliper tool and note distance mea sured Fig 242 d Select proper thickness end play spacer from spacer chart based on distance measured Fig 243 e Remove Gauge Alignment Tool 6312 SPECIAL TOOL C 4962 7 SPECIAL TOOL 6311 SPECIAL TOOL 6312 J9221 47 Fig 242 Shaft End Play Measurement Measurement Inches Spacer Thickness Inches 336 7505 7506 7675 676 7855 7856 8011 158 159 175
342. properly The valve must be installed in the pressure line Other wise flow will be blocked and would cause an over heating condition and eventual transmission failure OIL PUMP VOLUME CHECK After the new or repaired transmission has been installed fill to the proper level with Mopar ATF PLUS 3 Type 7176 automatic transmission fluid The volume should be checked using the following procedure 1 Disconnec the From cooler line at the trans mission and place a collecting container under the disconnected line 21 148 TRANSMISSION AND TRANSFER CASE SERVICE PROCEDURES Continued CAUTION With the fluid set at the proper level fluid collection should not exceed 1 quart or inter nal damage to the transmission may occur 2 Run the engine at curb idle speed with the shift selector in neutral 3 If fluid flow is intermittent or it takes more than 20 seconds to collect one quart of ATF PLUS 3 disconnect the To Cooler line at the transaxle 4 Refill the transaxle to proper level and recheck pump volume 5 If flow is found to be within acceptable limits replace the cooler Then fill transmission to the proper level using Mopar ATF PLUS 3 Type 7176 automatic transmission fluid 6 If fluid flow is still found to be inadequate check the line pressure using the Transaxle H ydrau lic Pressure Test procedure FLUSHING COOLERS AND TUBES When a transmission failure has contaminated the fluid the oil cooler s must
343. quired Test solenoid relay and wiring for continuity shorts or grounds Replace solenoid and relay if faulty Repair wiring and connectors as necessary 21 144 TRANSMISSION AND TRANSFER CASE 2 DIAGNOSIS AND TESTING Continued CONDITION POSSIBLE CAUSES CORRECTION HARSH 1 2 2 3 3 4 OR 3 2 Lockup Solenoid Malfunction Remove valve body and replace SHIFTS solenoid assembly NO START IN PARK OR 1 Gearshift Linkage Cable 1 Adjust linkage cable NEUTRAL Misadjusted 2 Neutral Switch Wire Open Cut 2 Check continuity with test lamp Repair as required 3 Neutral Switch Faulty 3 Refer to service section for test and replacement procedure 4 Neutral Switch Connect Faulty 4 Connectors spread open Repair 5 Valve Body Manual Lever 5 Inspect lever assembly and Assembly Bent Worn Broken replace if damaged NO REVERSE OR SLIPS IN 1 Direct Clutch Pack front clutch 1 Disassemble unit and rebuild REVERSE Worn clutch pack 2 Rear Band Misadjusted 2 Adjust band 3 Front Clutch Malfunctioned 3 Air pressure test clutch operation Burned Remove and rebuild if necessary 4 Overdrive Thrust Bearing Failure 4 Disassemble geartrain and replace bearings 5 Direct Clutch Spring Collapsed 5 Remove and disassemble unit Broken Check clutch position and replace spring 2 5 55 AND TRANSFER CASE 21 145 DIAGNOSIS AND TESTING Continued CONDITIO
344. r Components FRONT SERVO Clean the servo piston components with solvent and dry them with compressed air Wipe the band dean with lint free shop towels Replace the front band if distorted lining is burned flaking off or worn to the point where the grooves in the lining material are no longer visible Inspect the servo components Replace the springs if collapsed distorted or broken Replace the guide rod and piston if cracked bent or worn Discard the servo snap ring if distorted or warped Check the servo piston bore for wear If the bore is severely scored or damaged it will be necessary to replace the case Replace any servo component if doubt exists about condition Do not reuse suspect parts REAR SERVO Remove and discard the servo piston seal ring Fig 247 Then dean the servo components with solvent and dry with compressed air Replace either spring if collapsed distorted or broken Replace the plug and piston if cracked bent or worn Discard the servo snap rings and use a new ones at assembly SNAP PISTON PISTON SPRING SNAP RING SEAL PLUG RETAINER RING 5 3 CUSHION PISTON PISTON SPRING SPRING 19121 64 Fig 247 Rear Servo Components OIL PUMP AND REACTION SHAFT SUPPORT 1 Clean pump and support components with sol vent and dry them with compressed air 2 Check condition of the seal rings and thrust washer on the reaction shaft support The seal rings TRANSMISSION AND TRANSFER CASE 2
345. r bracket screws first and long bottom screw last Verify that valve springs and 2 bracket are properly aligned Then tighten all three bracket screws to 4 35 in Ibs torque 17 Lubricate solenoid case connector O rings and shaft of manual lever with light coat of petroleum jelly 18 Obtain new fluid filter for valve body but do not install filter at this time 19 If line pressure and or throttle pressure adjustment screw settings were not disturbed con tinue with overhaul or reassembly However if adjustment screw settings were moved or changed readjust as described in Valve Body Control Pressure Adjustment procedure 20 Attach solenoid case connector to 3 4 accumu lator with shoulder type screw Connector has small locating tang that fits in dimple at top of accumula tor housing Fig 88 Seat tang in dimple before tightening connector screw 21 Install solenoid assembly and gasket Tighten solenoid attaching screws to 8 72 in lbs torque 22 Verify that solenoid wire harness is properly routed Fig 89 Solenoid harness must be clear of manual lever and park rod and not be pinched between accumulator housing and cover SPECIAL TOOL 6583 POSITIONED ON DETENT J9521 178 Fig 86 Detent Ball Spring GOVERNOR BODY SENSOR AND SOLENOID 1 Turn valve body assembly over so accumulator side of transfer plate is facing down 2 Install new O rings on governor pressure sole noid a
346. r connector removal 10 Unhook overdrive converter solenoid harness from 3 4 accumulator cover plate Fig 47 11 Turn valve body over and remove screws that attach overdrive converter solenoid assembly to valve body Fig 48 12 Remove solenoid and harness assembly from valve body Fig 49 13 Remove boost valve cover Fig 50 14 Remove boost valve retainer valve spring and boost valve Fig 51 SOLENOID HARNESS CASE CONNECTOR 3 4 ACCUMULATOR HOUSING J9321 427 _ SS Fig 46 Solenoid Harness Case Connector Shoulder Bolt TRANSMISSION AND TRANSFER CASE 21 161 OVERDRIVE CONVERTER 34 SOLENOID 2 ACCUMULATOR WIRE 55 Fig 47 Unhooking Solenoid Harness From Accumulator Cover Plate HARNESS OVERDRIVE CONVERTER CLUTCH SOLENOID NS ASSEMBLY 19521 176 Fig 48 Solenoid Assembly Screws HARNESS GOVERNOR SOLENOID WIRES GOVERNOR SENSOR WIRES e 994 CONVERTER CLUTCH OVERDRIVE SOLENOID SOLENOID SOLENOID SCREWS J9521 177 Fig 49 Solenoid Assembly 21 162 TRANSMISSION AND TRANSFER CASE 2 DISASSEMBLY AND ASSEMBLY Continued remove Retainer Tool 6583 and remove detent ball and spring Fig 56 20 Remove screws attaching pressure adjusting screw bracket to valve body and transfer plate Fig 57 Hold bracket firmly against spring tension while removing last screw MANUAL LE
347. r in low 1 posi tion so ball on park lock rod will be easier to install in sprag 5 Lubricate shaft of manual lever with petroleum jelly This will ease inserting shaft through seal in case 6 Lubricate seal rings on valve body harness con nector with petroleum jelly 7 Position valve body in case and work end of park lock rod into and through sprag Turn pro peller shaft to align sprag and park lock teeth if nec essary The rod will click as it enters pawl Move rod to check engagement CAUTION It is possible for the park rod to dis place into a cavity just above the pawl sprag during installation Make sure the rod is actually engaged in the pawl and has not displaced into this cavity 8 Install accumulator springs and piston into case Then swing valve body over piston and outer spring to hold it in place 9 Align accumulator piston and outer spring manual lever shaft and electrical connector in case 10 Then seat valve body in case and install one or two bolts to hold valve body in place 11 Tighten valve body bolts alternately and evenly to 11 N m 100 in Ibs torque 12 Install new fluid filter on valve body Tighten filter screws to 4 N m 35 in 15 torque 13 Install throttle and gearshift levers on valve body manual lever shaft 2 14 Check and adjust front and rear bands if nec essary 15 Connect solenoid case connector wires 16 Install oil pan and new gasket Tighten
348. rankshaft position sensor will be damaged if the transmission is removed or installed while the sensor is still bolted to the engine block or transmission 4 0L only To avoid damage be sure to remove the sensor before removing the transmission 7 Remove torque converter access cover 8 If transmission is being removed for overhaul remove transmission oil pan drain fluid and reinstall pan 9 Remove fill tube bracket bolts and pull tube out of transmission Retain fill tube seal On 4 x 4 models it will also be necessary to remove bolt attaching transfer case vent tube to converter hous ing Fig 15 TRANSFER CASE VENT TUBE FILL EN TUBE V8 AR FILL TUBE V6 TUBE SEAL 80b170f3 Fig 15 Fill Tube Attachment TRANSMISSION AND TRANSFER CASE 21 149 10 Mark torque converter and drive plate for assembly alignment Note that bolt holes in crank shaft flange drive plate and torque converter all have one offset hole 11 Rotate crankshaft in clockwise direction until converter bolts are accessible Then remove bolts one at a time Rotate crankshaft with socket wrench on dampener bolt 12 Mark propeller shaft and axle yokes for assembly alignment Then disconnect and remove propeller shaft On 4 4 models remove both propel ler shafts 13 Disconnect wires from park neutral position switch transmission solenoid and vehicle speed sen sor 14 Disconnect gearshift cable from transm
349. red or cracked Check the lugs on the clutch plates for wear The plates should slide freely in the drum Replace the plates or drum if binding occurs Check condition of the annulus gear direct dutch hub clutch drum and clutch spring Replace the gear hub and drum if worn or damaged Replace the spring if collapsed distorted or cracked Be sure the splines and lugs on the gear drum and hub are in good condition The dutch plates and discs should slide freely in these components Inspect the thrust bearings and spring plate Replace the plate if worn or scored Replace the bear ings if rough noisy brinnelled or worn Inspect the planetary gear assembly and the sun gear and bushings If either the sun gear or the bushings are damaged replace the gear and bush ings as an assembly The gear and bushings are not serviced separately The planetary carrier and pinions must be in good condition Also be sure the pinion pins are secure and in good condition Replace the carrier if worn or dam aged Inspect the overrunning dutch and race The race surface should be smooth and free of scores Replace the overrunning clutch assembly or the race if either assembly is worn or damaged in any way Inspect the output shaft and governor components Replace the shaft pilot bushing and inner bushing if damaged Replace either shaft bearing if rough or noisy Replace the bearing snap rings if distorted or cracked Check the machined surfaces
350. remove remaining bolt hold ing pan to transmission 7 While holding pan level lower pan away from transmission 8 Pour remaining fluid in pan into drain pan 9 Remove screws holding filter to valve body Fig 14 10 Separate filter from valve body and pour fluid in filter into drain pan 11 Dispose of used trans fluid and filter properly 80b17180 TRANSMISSION FILTER 80b170e8 Fig 14 Transmission Filter 2 SERVICE PROCEDURES Continued INSPECTION Inspect bottom of pan and magnet for excessive amounts of metal or fiber contamination A light coating of clutch or band material on the bottom of the pan does not indicate a problem unless accompa nied by slipping condition or shift lag If fluid and pan are contaminated with excessive amounts or debris refer to the diagnosis section of this group Check the adjustment of the front and rear bands adjust if necessary CLEANING 1 Using a suitable solvent dean pan and mag net 2 Using a suitable gasket scraper dean gasket material from gasket surface of transmission case and the gasket flange around the pan INSTALLATION 1 Place replacement filter in position on valve body 2 Install screws to hold filter to valve body Fig 14 Tighten screws to 4 35 in Ibs torque 3 Place new gasket in position on pan and install pan on transmission 4 Place pan in position on transmission 5 Install screws to hold pan to transm
351. ressed at least one half an inch A magnetic holding device in line with the park lock cable is enegized when the igni tion is in the RUN position When the key is in the RUN position and the brake pedal is depressed the shifter is unlocked and will move into any position The interlock system also prevents the ignition switch from being turned to the LOCK or ACCES SORY position Fig 7 unless the shifter is fully locked into the PARK position DIAGNOSIS AND TESTING AUTOMATIC TRANSMISSION DIAGNOSIS Automatic transmission problems can be a result of poor engine performance incorrect fluid level incor rect linkage or cable adjustment band or hydraulic control pressure adjustments hydraulic system mal functions or electrical mechanical component mal functions Begin diagnosis by checking the easily accessible items such as fluid level and condition linkage adjustments and electrical connections A road test will determine if further diagnosis is neces sary PRELIMINARY DIAGNOSIS Two basic procedures are required One procedure for vehicles that are drivable and an alternate proce dure for disabled vehicles will not back up or move forward VEHICLE IS DRIVEABLE 1 Check for transmission fault codes using DRB scan tool 2 Check fluid level and condition 3 Adjust throttle and gearshift linkage if com plaint was based on delayed erratic or harsh shifts 4 Road test and note how transmission upshifts downshi
352. retainer can be cracked if misalignment occurs 2 Install the shaft retaining ring after pressing the shaft into place Be sure the ring is fully seated before proceeding with dutch assembly 3 Invert the input shaft in the press and using the same tools as in removal press on shaft enough to seat the snap ring into the retainer 4 Soak dutch discs in transmission fluid before assembly 2 TRANSMISSION AND TRANSFER CASE 21 195 DISASSEMBLY AND ASSEMBLY Continued FEELER GAUGE WAVED SNAP RING CK A FEELER GAUGE RH288 Fig 169 Typical Method Of Measuring Front Clutch Pack Clearance 5 Install new seals on dutch piston Lubricate piston seals with Mopar Door Ease or Ru Glyde to ease installation Be sure seal lips face input shaft 6 Install dutch piston in retainer Use twisting motion to seat piston in bottom of retainer A thin OUTPUT SHAFT UN PISTON SPRING WASHER PISTON SEAL INNER PISTON RETAINER strip of plastic about 0 020 thick can be used to guide seals into place if necessary CAUTION Never push the clutch piston straight in This will fold the seals over causing leakage and clutch slip In addition never use any type of metal tool to help ease the piston seals into place Metal tools will cut shave or score the seals 7 Assemble piston retainer and dutch retainer 8 Support dutch retainer with wood blocks or insert input
353. retainer into place on rear case Fig 81 11 Install and tighten rear retainer bolts to 27 34 N m 20 25 ft Ibs 12 Install locating ring access cover and gasket Fig 82 Tighten plate attaching screws to 10 N m 85 in 165 torque REAR REAR CASE RETAINER J9321 7 Fig 80 Rear Retainer Installation 2 DISASSEMBLY AND ASSEMBLY Continued PARALLEL JAW SNAP RING PLIERS BEARING LOCATING RING ACCESS COVER AND GASKET 19321 4 Fig 82 Installing Locating Ring Access Cover Gasket FINAL ASSEMBLY 1 Install drain plug Tighten plug to 41 54 N m 30 40 ft 165 torque 2 Level transfer case and fill it with Mopar Dexron automatic transmission fluid Correct fill level is to bottom edge of fill plug hole 3 Install and tighten fill plug to 41 54 N m 30 40 ft 105 torque CLEANING AND INSPECTION NV249 COMPONENTS GENERAL Clean the transfer case components with parts deaning solvent Flush the oil passages in the cases and drivetrain components with solvent This will help remove dirt and particles from these passages Dry the transfer case components with compressed air or allow them to air dry on clean shop towels TRANSMISSION AND TRANSFER CASE 21 291 Apply compressed air through all oil passages in the cases and gear components to dear them of any residue MAINSHAFT Examine the mainshaft components carefully for evidence of wear or damage Replace t
354. rive chain drive sprocket and front output shaft Fig 64 3 Start drive sprocket on mainshaft FRONT DRIVE OUTPUT CHAIN SHAFT 1 l MAINSHAFT tx aum Bg CS DRIVE SPROCKET J9321 72 Fig 64 Installing Drive Chain Front Output Shaft And Drive Sprocket 21 288 TRANSMISSION AND TRANSFER CASE 2 DISASSEMBLY AND ASSEMBLY Continued 4 Guide front shaft into bearing and drive LX CASE NOTCH sprocket onto mainshaft drive gear Fig 64 M Ol 5 Install drive sprocket snap ring Fig 65 SNAP RING PLIERS DRIVE SPROCKET MAINSHAFT SNAP RING DRIVE SPROCKET 9 iE c OIL PICKUP ASSEMBLY CASE SLOT o J9321 73 Fig 67 Oil Pickup Tube Installation 19321 19 Fig 65 Installing Drive Sprocket Snap Ring 6 Clean sealing flanges of front case and rear case with a wax and grease remover 7 Apply 3 mm 1 8 in wide bead of Mopar gas ket maker or silicone adhesive sealer to mounting flange of front case Work sealer bead around bolt holes as shown Fig 66 8 Install oil pickup tube in rear case Be sure tube is seated in case notch as shown Fig 67 9 Install magnet in front case pocket Fig 68 10 Align and install rear case on front case Fig 69 MAGNET J8921 288 Fig 68 Installing Case Magnet FLANGE 19321 74 Fi
355. rned MOVES IN 2ND OR 3RD 1 Valve Body Malfunction 1 Remove clean and inspect Look for stuck GEAR ABRUPTLY 1 2 valve or governor plug DOWNSHIFTS TO LOW 2 Governor Valve Sticking 2 Remove clean and inspect Replace faulty parts NO LOW GEAR MOVES 1 Governor Valve Sticking 1 Remove governor clean inspect and IN 2ND OR 3RD GEAR repair as required ONLY 2 Governor Circuit Electrical Fault 2 Test with DRB scan tool and repair as required 3 Valve Body Malfunction 3 Remove clean and inspect Look for sticking 1 2 shift valve 2 3 shift valve governor plug or broken springs 4 Front Servo Piston Cocked in 4 Inspect servo and repair as required Bore 5 Front Band Linkage Malfunction 5 Inspect linkage and look for bind in linkage NO KICKDOWN OR 1 Throttle Linkage Misadjusted 1 Adjust linkage NORMAL DOWNSHIFT 2 Accelerator Pedal Travel 2 Verify floor mat is not under pedal repair Restricted worn accelerator cable or bent brackets 3 Valve Body Hydraulic Pressures 3 Perform hydraulic pressure tests to Too High or Too Low Due to Valve determine cause and repair as required Body Malfunction or Incorrect Correct valve body pressure adjustments as Hydraulic Control Pressure required Adjustments 4 Governor Circuit Electrical Fault 4 Test with DRB scan tool and repair as required 5 Valve Body Malfunction 5 Perform hydraulic pressure tests to determine cause and repair as required
356. rnor D range closed throttle Pressure should respond smoothly to changes in mph and return to 0 7 kPa 0 1 5 psi when stopped with transmission in D 1 2 Pressure above 7 kPa 1 5 psi at stand still will prevent transmission from downshifting 21 114 TRANSMISSION AND TRANSFER CASE 2 SPECIAL TOOLS RE TRANSMISSIONS Spring Compressor and Alignment Shaft 6227 Gauge Bar 6311 8011d42b Dial Indicator C 3339 Extension Housing Pilot C 3288 B Spring Compressor C 3422 B 2 5 55 AND TRANSFER CASE 21 115 SPECIAL TOOLS Continued Puller Slide Hammer C 3752 Installer C 3995 A Gauge Throttle Setting C 3763 c Universal Handle C 4171 Seal Installer C 3860 A Seal Installer C 4193 A Seal Remover C 3985 B d Dial Caliper C 4962 Ye 21 116 TRANSMISSION AND TRANSFER CASE 2 SPECIAL TOOLS Continued Installer Bushing SP 5117 Remover Bushing SP 5324 Nut Bushing Remover SP 1191 From kit C 3887 J M Installer Bushing SP 5325 Cup Bushing Remover SP 3633 From kit C 3887 J Compressor Spring C 3575 A Remover Bushing SP 3551 2 SPECIAL TOOLS Continued Gauge 6312 Tu Adapter C 3705 Flusher 6906 d Installer 8114 TRANSMISSION AND TRANSFER CASE Remover 6957 2 Installer 6951 Retainer 6
357. round front dutch retainer This prevents BODY BOLTS X NY front rear clutches from coming out with pump and gt possibly damaging clutch or pump components 55 14 Remove pump bolts 15 Thread bolts of Slide Hammer Tools C 3752 into threaded holes in pump body flange Fig 94 16 Bump slide hammer weights outward to remove pump and reaction shaft support assembly from case Fig 94 OIL PUMP AND REACTION SHAFT SUPPORT ASSEMBLY 80b17127 Fig 91 Valve Body Bolt Locations GOVERNOR VANE PRESSURE BODY SLIDE HAMMER SENSOR GOVERNOR TOOLS C 3752 PRESSURE Fig 94 Removing Oil Pump And Reaction Shaft Support Assembly 17 Loosen front band adjusting screw until band is completely loose 18 Squeeze front band together and remove band strut Fig 95 19 Remove front band lever Fig 96 20 Remove front band lever shaft plug if neces ACCUMULATOR sary from converter housing PISTON mo 21 Remove front band lever shaft 22 Remove front and rear dutch units as assem bly Grasp input shaft hold clutch units together and remove them from case Fig 97 23 Lift front dutch off rear dutch Fig 98 Set dutch units aside for overhaul Fig 92 Valve Body Removal 2 DISASSEMBLY AND ASSEMBLY Continued BAND Ser BAND LEVER E STRUT Wem A P CMT FRONT BAND 9121 121 Fig 95 Removing Installing Front Band Strut Fig
358. round piston retainer with razor knife Fig 35 4 Use old gasket as template and trim new gas ket to fit 5 Position new gasket over piston retainer and on transmission case Use petroleum jelly to hold gasket in place if necessary Do not use any type of sealer to secure gasket Use petroleum jelly only SHARP KNIFE GASKET A 8921 269 Fig 35 Trimming Overdrive Case Gasket 6 Install selective spacer on intermediate shaft if removed Spacer goes in groove just rearward of shaft rear splines Fig 36 N SPACER SELECTIVE SPACER INTERMEDIATE SHAFT 19021 96 Fig 36 Intermediate Shaft Selective Spacer Location 21 38 TRANSMISSION AND TRANSFER CASE REMOVAL AND INSTALLATION Continued 7 Install thrust bearing in overdrive unit sliding hub Use petroleum jelly to hold bearing in position CAUTION Be sure the shoulder on the inside diameter of the bearing is facing forward 8 Verify that splines in overdrive planetary gear and overrunning dutch hub are aligned with Align ment Tool 6227 2 Overdrive unit cannot be installed if splines are not aligned If splines have rotated out of alignment unit will have to be disassembled to realign splines 9 Carefully slide Alignment Tool 6227 2 out of overdrive planetary gear and overrunning dutch splines 10 Raise overdrive unit and carefully slide it straight onto intermediate shaft Insert park rod into park lock reacti
359. ry or lock position 6 Shifting between any gears neutral or park may be done without depressing foot brake with igni tion switch in run or start positions and vehide sta tionary or in motion 7 The floorshifter lever and gate positions should be in alignment with all transmission detent posi tions 8 Engine starts must be possible with floorshift lever in park or neutral gate positions only Engine starts must not be possible in any other gate posi tions other than park or neutral 9 With floorshift lever handle push button not depressed and lever detent in 2 PARK POSITION apply forward force on center of handle and remove pressure Engine start must be possi ble e PARK POSITION apply rearward force on cen ter of handle and remove pressure Engine start must be possible e NEUTRAL POSITION engine start must be possi ble e NEUTRAL POSITION ENGINE RUNNING AND BRAKES APPLIED Apply forward force on center of shift handle Transmission should not be able to shift into reverse detent TRANSMISSION THROTTLE VALVE CABLE ADJUSTM ENT The transmission throttle valve is operated by a cam on the throttle lever The throttle lever is oper ated by an adjustable cable Fig 251 The cable is attached to an arm mounted on the throttle lever shaft A retaining dip at the engine end of the cable is removed to provide for cable adjustment The retaining dip is then installed back onto the throttle valve cable to lock
360. s 2 Install new pilot bushing and clutch hub bush ing in output shaft if necessary Fig 221 Lubricate bushings with petroleum jelly or transmission fluid OUTPUT SHAFT HUB OVERRUNNING CLUTCH HUB J9121 321 Fig 221 Output Shaft Pilot Bushing 3 Install annulus gear on output shaft if removed Then install annulus gear retaining snap ring Fig 222 4 Align and install clutch drum on annulus gear Fig 223 Be sure drum is engaged in annulus gear lugs 5 Install dutch drum outer retaining ring Fig 223 Slide clutch drum forward and install inner retaining ring Fig 224 SNAP OUTPUT SHAFT RING FRONT BEARING J9021 89 Fig 222 Annulus Gear Installation 2 DISASSEMBLY AND ASSEMBLY Continued ANNULUS CLUTCH DRUM J9321 393 Fig 223 Clutch Drum And Outer Retaining Ring Installation 7 Install rear bearing and snap ring on output shaft Fig 225 Be sure locating ring groove in bear ing is toward rear ANNULUS GEAR CLUTCH DRUM J9321 394 Fig 224 Clutch Drum Inner Retaining Ring Installation REAR BEARING J9321 370 Fig 225 Rear Bearing And Snap Ring Installation TRANSMISSION AND TRANSFER CASE 21 207 8 Install overrunning dutch on hub Fig 226 Note that clutch only fits one way Shoulder on clutch should seat in small recess at edge of hub 9 Install thrust bearing on overrunning clutch hub Use generous amount of petr
361. s 4 Remove shift and throttle levers from valve body manual lever shaft 5 Place transmission in horizontal position 22 6 Remove transmission oil pan and gasket mz 7 Remove filter from valve body Fig 90 Keep fil A ter screws separate from other valve body screws Filter screws are longer and should be kept with filter CONNECTOR ACCUMULATOR HOUSING J9321 427 _ Fig 88 Solenoid Harness Case Connector Shoulder Bolt OVERDRIVE CONVERTER 34 SOLENOID ACCUMULATOR WIRE COVER HARNESS PLATE 80b17126 Fig 90 Oil Filter Removal 8 Remove park neutral position switch 9 Remove hex head bolts attaching valve body to transmission case Fig 91 A total of 10 bolts are used J XL 9321 458 Note different bolt lengths for assembly reference Fig 89 Solenoid Harness Routing 21 54 TRANSMISSION AND TRANSFER CASE 2 DISASSEMBLY AND ASSEMBLY Continued 10 Remove valve body assembly Push valve body ACCUMULATOR OUTER harness connector out of case Then work park rod PISTON and valve body out of case Fig 92 11 Remove accumulator piston and inner and outer springs Fig 93 12 Remove pump oil seal with suitable pry tool slide hammer mounted screw I Sa te J9121 208 Fig 93 Accumulator Piston And Springs 13 Loosen front band adjusting screw locknut 4 5 turns Then tighten band adjusting screw until band is tight a
362. s DRB scan tool 9 Solenoid Feed Orifice in Valve 9 Remove disassemble and clean Body Blocked valve body thoroughly Check feed orifice 10 Overdrive Clutch Failed 10 Disassemble overdrive and repair as needed 11 Hydraulic Pressure Low 11 Pressure test transmission to determine cause 12 Valve Body Valve Stuck 12 Repair stuck 3 4 shift valve 3 4 timing valve 13 O D Piston Incorrect Spacer 13 Remove unit check end play and install correct spacer 14 Overdrive Piston Seal Failure 14 Replace both seals 15 O D Check Valve Orifice Failed 15 Check for free movement and secure assembly in piston retainer Check ball bleed orifice 2 DIAGNOSIS AND TESTING Continued TRANSMISSION AND TRANSFER CASE 21 143 CONDITION POSSIBLE CAUSES CORRECTION SLIPS IN OVERDRIVE FOURTH GEAR 1 Fluid Level Low 1 Add fluid and check for leaks 2 Overdrive Clutch Pack Worn 2 Remove overdrive unit and rebuild clutch pack 3 Overdrive Piston Retainer Bleed 3 Disassemble transmission Orifice Blown Out remove retainer and replace orifice 4 Overdrive Piston or Seal Malfunction 5 3 4 Shift Valve Timing Valve or Accumulator Malfunction 6 Overdrive Unit Thrust Bearing Failure 4 Remove overdrive unit Replace seals if worn Replace piston if damaged If piston retainer is damaged remove and disassemble the transmission 5 Remove and overhaul valve body Replace accumulator seals Ma
363. s 3 Type 7176 fluid TORQUE CONVERTER REMOVAL 1 Remove transmission and torque converter from vehicle 2 Place a suitable drain pan under the converter housing end of the transmission CAUTION Verify that transmission is secure on the lifting device or work surface the center of gravity of the transmission will shift when the torque con verter is removed creating an unstable condition The torque converter is a heavy unit Use caution when separating the torque converter from the transmission 3 Pull the torque converter forward until the cen ter hub clears the oil pump seal 4 Separate the torque converter from the trans mission INSTALLATION Check converter hub and drive notches for sharp edges burrs scratches or nicks Polish the hub and 2 REMOVAL AND INSTALLATION Continued notches with 320 400 grit paper or crocus cloth if nec essary The hub must be smooth to avoid damaging the pump seal at installation 1 Lubricate converter hub and oil pump seal lip with transmission fluid 2 Place torque converter in position on transmis sion CAUTION Do not damage oil pump seal or bushing while inserting torque converter into the front of the transmission 3 Align torque converter to oil pump seal open ing 4 Insert torque converter hub into oil pump 5 While pushing torque converter inward rotate converter until converter is fully seated in the oil pump gears 6 Check converter se
364. s actually engaged in the pawl and has not displaced into the cavity 33 Install new filter on valve body Tighten filter screws to 4 N m 35 in 165 34 Adjust front and rear bands 35 Install seal on park neutral position switch Fig 128 Then install and tighten switch to 34 N m 25 ft Ibs NEUTRAL SWITCH J9121 106 Fig 128 Park Neutral Position Switch Seal Position 36 Install magnet in oil pan Magnet goes on small protrusion at corner of pan 2 DISASSEMBLY AND ASSEMBLY Continued 37 Position new oil pan gasket on case and install oil pan Tighten pan bolts to 17 N m 13 ft Ibs 38 Install new valve body manual shaft seal in case Fig 129 Lubricate seal lip and manual shaft with petroleum jelly Start seal over shaft and into case Seat seal with 15 16 inch deep well socket 15 16 SOCKET Fig 129 Installing Manual Lever Shaft Seal 39 Install throttle valve and shift selector levers on valve body manual lever shaft OVERRUNNING CLUTCH CAM OVERDRIVE PISTON RETAINER DISASSEMBLY NOTE TO SERVICE THE OVERRUNNING CLUTCH CAM AND THE OVERDRIVE PISTON RETAINER THE TRANSMISSION GEARTRAIN AND OVERDRIVE UNIT MUST BE REMOVED FROM THE TRANSMISSION 1 Remove the overdrive piston Fig 130 2 Remove the overdrive piston retainer bolts 3 Remove overdrive piston retainer 4 Remove case gasket 5 Mark the position of the overrunning dutch cam in the case Fig 131 6
365. s and the overdrive case Replace the case if cracked scored or damaged Replace the park lock pawl plug or spring if worn or damaged Be sure the bullet at the end of the park lock rod is in good condition Replace the rod if the bullet is worn or the rod itself is bent or distorted Do not attempt to straighten the rod Check the bushings in the overdrive case Replace the bushings if severely scored or worn Also replace the case seal if loose distorted or damaged Examine the overdrive and direct clutch discs and plates Replace the discs if the facing is worn severely scored or burned and flaking off Replace the clutch plates if worn heavily scored or cracked Check the lugs on the clutch plates for wear The plates should slide freely in the drum Replace the plates or drum if binding occurs Check condition of the annulus gear direct clutch hub clutch drum and clutch spring Replace the gear hub and drum if worn or damaged Replace the spring if collapsed distorted or cracked Be sure the splines and lugs on the gear drum and hub are in good condition The clutch plates and discs should slide freely in these components TRANSMISSION AND TRANSFER CASE 21 95 Inspect the thrust bearings and spring plate Replace the plate if worn or scored Replace the bear ings if rough noisy brinnelled or worn Inspect the planetary gear assembly and the sun gear and bushings If either the sun gear or the bushings are damage
366. s pump output line pressure and pressure regulation Use 100 psi Test Gauge C 3292 for this test 1 Leave vehicle in place on hoist and leave Test Gauge C 3292 connected to accumulator port 2 Have helper start and run engine at 1000 rpm 3 Move transmission shift lever one detent rear ward from full forward position This is 2 range 4 Move transmission throttle lever from full for ward to full rearward position and read pressure on gauge 5 Line pressure should be 54 60 psi 372 414 kPa with throttle lever forward and gradually increase to 90 96 psi 621 662 kPa as lever is moved rearward Test Three Transmission In D Range Third Gear NOTE This test checks pressure regulation and condition of the clutch circuits Both test gauges are required for this test 1 Turn OD switch off 2 Leave vehicle on hoist and leave Gauge C 3292 in place at accumulator port 3 Move Gauge C 3293 SP over to front servo port for this test 4 Have helper start and run engine at 1600 rpm for this test 5 Move transmission shift lever two detents rear ward from full forward position This is D range 6 Read pressures on both gauges as transmission throttle lever is gradually moved from full forward to full rearward position Line pressure at accumulator D range third gear should be 54 60 psi 372 414 kPa with throttle lever forward and increase as lever is moved rear ward e Front servo pressure in D ran
367. se failure can plug cooler NO DRIVE RANGE 1 Fluid Level Low 1 Add fluid and check for leaks if drive is REVERSE OK restored 2 Gearshift Linkage Cable 2 Repair or replace linkage components Loose Misadjusted 3 Rear Clutch Burnt 3 Remove and disassemble transmission and rear clutch and seals Repair replace worn or damaged parts as needed 4 Valve Body Malfunction 4 Remove and disassemble valve body Replace assembly if any valves or bores are damaged 5 Transmission Overrunning Clutch 5 Remove and disassemble transmission Broken Replace overrunning clutch 6 Input Shaft Seal Rings 6 Remove and disassemble transmission Worn Damaged Replace seal rings and any other worn or damaged parts 7 Front Planetary Failed Broken 7 Remove and repair NO DRIVE OR REVERSE 1 Fluid Level Low 1 Add fluid and check for leaks if drive is VEHICLE WILL NOT restored MOVE 2 Gearshift Linkage Cable 2 Inspect adjust and reassemble linkage as Loose Misadjusted needed Replace worn damaged parts 3 U Joint Axle Transfer Case 3 Perform preliminary inspection procedure Broken for vehicle that will not move Refer to procedure in diagnosis section 4 Filter Plugged 4 Remove and disassemble transmission Repair or replace failed components as needed Replace filter If filter and fluid contained clutch material or metal particles an overhaul may be necessary Perform lube flow test Flush oil Replace cooler as n
368. sh button not depressed and lever in 2 PARK position Apply forward force on cen ter of handle and remove pressure Engine starts must be possible b PARK position Apply rearward force on cen ter of handle and remove pressure Engine starts must be possible NEUTRAL position Normal position Engine starts must be possible d NEUTRAL position Engine running and brakes applied apply forward force on center of shift handle Transmission shall not be able to shift from neutral to reverse THROTTLE VALVE CABLE Transmission throttle valve cable adjustment is extremely important to proper operation This adjust ment positions the throttle valve which controls shift speed quality and part throttle downshift sensitivity If cable setting is too loose early shifts and slip page between shifts may occur If the setting is too tight shifts may be delayed and part throttle down shifts may be very sensitive Refer to the Adjust ments section for the proper adjustment procedure ROAD TESTING Before road testing be sure the fluid level and con trol cable adjustments have been checked and adjusted if necessary Verify that diagnostic trouble codes have been resolved Observe engine performance during the road test A poorly tuned engine will not allow accurate analy sis of transmission operation Operate the transmission in all gear ranges Check for shift variations and engine flare which indicates slipp
369. shaft through pre drilled hole in work bench Clutch pack components are easier to install if retainers are properly supported 9 Install piston spring in dutch retainer Concave side of spring faces upward and away from clutch piston 10 Install spacer ring on top of piston spring 11 Install wave spring on top of spacer ring Then seat wave spring in retainer groove If wave spring will not seat properly spacer ring has probably shifted over and into wave spring groove in retainer Use small screwdriver to realign spacer ring if necessary 12 Install inner pressure plate in dutch retainer 13 Install first dutch disc followed by steel plate until all discs and plates are installed 4 clutch discs and steel plates are required Fig 170 14 Install reaction plate on top of last clutch disc 15 Install selective snap ring to secure clutch pack in retainer SNAP RING SELECTIVE CLUTCH DISCS REACTION INPUT SHAFT PLATE CLUTCH RETAINER CLUTCH FRONT PLATES SEAL RINGS WAVE SPRING SPACER RING PISTON PISTON SEAL REAR OUTER SEAL THRUST RING WASHER SNAP RING FIBER J9121 66 Fig 170 Rear Clutch Components 21 196 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued 16 Install new seal rings on input shaft if neces sary Fig 171 Be very sure ring ends are all securely hooked together before proceeding 17 Check clutch pack clearance with feeler gauge Fig 172 C
370. sing TRANSFER PLATE 1 Install rear dutch and rear servo check balls in transfer plate Fig 76 2 Install filter screen in upper housing separator plate Fig 77 3 Align and position upper housing separator plate on transfer plate Fig 78 4 Install brace plate Fig 78 Tighten brace attaching screws to 4 N m 35 in 165 torque 5 Install remaining separator plate attaching screws Tighten screws to 4 N m 35 in Ibs torque REAR REAR CLUTCH SERVO CHECK CHECK BALL BALL TRANSFER J9321 437 Fig 76 Rear Clutch And Rear Servo Check Ball Locations UPPER AND LOWER HOUSING 1 Position upper housing so internal passages and check ball seats are facing upward Then install check balls in housing Fig 79 Eight check balls are used The single large check ball is approximately 8 7 mm 11 32 in diameter The single small check ball TRANSMISSION AND TRANSFER CASE 21 169 UPPER FILTER HOUSING SEPARATOR SCREEN PLATE SEPARATOR TRANSFER PLATE PLATE J9321 150 Fig 78 Brace Plate is approximately 4 8 mm 3 16 in in diameter The remaining 6 check balls are approximately 6 3 mm 1 4 in in diameter SMALL DIAMETER CHECK BALLS 6 LARGE DIAMETER CHECK BALL 1 J9321 154 Fig 79 Check Ball Locations In Upper Housing 21 170 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued 2 Position assembled transfer plate and upper housing separator plate on up
371. sion will not allow fourth gear operation until fluid temperature decreases to approximately 110 C 230 F The thermistor is part of the governor pressure sensor assembly and is immersed in transmission fluid at all times TRANSMISSION AND TRANSFER CASE 21 123 TRANSMISSION SPEED SENSOR The speed sensor Fig 5 is located in the over drive gear case The sensor is positioned over the park gear and monitors transmission output shaft rotating speed Speed sensor signals are triggered by the park gear lugs as they rotate past the sensor pickup face Input signals from the sensor are sent to the transmission control module for processing The vehicle speed sensor also serves as a backup for the transmission speed sensor Signals from this sensor are shared with the powertrain control module TRANSMISSION OUTPUT SHAFT SPEED SENSOR SEAL J9321 411 Fig 5 Transmission Output Speed Sensor THROTTLE POSITION SENSOR TPS The TPS provides throttle position input signals to the PCM This input signal is used to determine overdrive and converter dutch shift schedule and to select the proper governor curve POWERTRAIN CONTROL MODULE PCM The PCM controls operation of the converter dutch overdrive dutch and governor pressure sole noid The control module determines transmission shift points based on input signals from the transmission thermistor transmission output shaft speed sensor crankshaft position sensor vehide spe
372. sition This is D range 3 Have helper start and run engine at curb idle speed Then firmly apply service brakes so wheels will not rotate 4 Note governor pressure e Governor pressure should be no more than 20 6 kPa 3 psi at curb idle speed and wheels not rotat ing e f pressure exceeds 20 6 kPa 3 psi a fault exists in governor pressure control system 5 Release brakes slowly increase engine speed and observe speedometer and pressure test gauge do not exceed 30 mph on speedometer Governor pres sure should increase in proportion to speed Or approximately 6 89 kPa 1 psi for every 1 mph 6 Governor pressure rise should be smooth and drop back to no more than 20 6 kPa 3 psi after engine returns to curb idle and brakes are applied to prevent wheels from rotating 7 Compare results of pressure test with analysis chart Test Six Transmission In Overdrive Fourth Gear NOTE This test checks line pressure at the over drive clutch in fourth gear range Use 300 psi Test Gauge C 3292 for this test The test should be per formed on the road or on a chassis dyno 1 Remove tachometer it is not needed for this test 2 Move 300 psi Gauge to overdrive clutch pres sure test port Then remove other gauge and reinstall test port plug 2 3 Lower vehicle 4 Turn OD switch on 5 Secure test gauge so it can be viewed from drivers seat 6 Start engine and shift into D range 7
373. smember and install bolts attaching trans mission mount to crossmember 16 Remove engine support fixture 17 Install crankshaft position sensor 18 Install vehicle speed sensor and speedometer adapter 2 19 Install new plastic retainer grommet on shift linkage rod or lever that was disconnected Grommets should not be reused Use pry tool to remove rod from grommet and cut away old grom met Use pliers to snap new grommet into lever and to snap rod into grommet at assembly 20 Connect gearshift and throttle valve cable to transmission 21 Connect wires to park neutral position switch transmission solenoid s and oxygen sensor Be sure transmission harnesses are properly routed CAUTION It is essential that correct length bolts be used to attach the converter to the driveplate Bolts that are too long will damage the clutch sur face inside the converter 22 Install torque converter to driveplate bolts Tighten bolts to 31 N m 270 in Ibs 23 Install converter housing access cover 24 Install starter motor and cooler line bracket 25 Connect cooler lines to transmission 26 Install transmission fill tube Install new seal on tube before installation 27 Install exhaust components 28 Install transfer case 29 Align and connect propeller shaft s 30 Adjust gearshift linkage and throttle valve cable if necessary 31 Lower vehicle 32 Fill transmission with Mopar ATF Plu
374. snap ring by straight ening or reshaping it Replace any snap ring that is distorted or worn Inspect the low range gear input gear and the gear thrust washers retainer and snap ring The low range gear is serviced as an assembly only Replace the gear if the case or pinions are damaged During inspection also make sure the seal surface of the input gear is in good condition Minor nicks on this surface can be reduced with crocus cloth How ever replace the gear if the seal surface is severely scored or worn The speedometer gear should be replaced if worn cracked or if the small spline teeth are worn OIL PUMP AND VISCOUS COUPLING The oil pump and viscous coupling are not service able components Replace the coupling as an assem bly if it is leaking or damaged Replace the oil pump as an assembly if the gear teeth are worn or if the pump has become damaged BEARINGS AND SEALS The transfer case seals should be replaced during overhaul Use new seals in the input gear bearing retainer front case and rear retainer Also replace the yoke seal washer and the detent plug O ring Check condition of each transfer case bearing Replace any bearing exhibiting signs of roughness wear or damage 2 USTMENTS SHIFT LINKAGE ADJUSTM ENT 1 Shift transfer case into Neutral position 2 Raise vehicle on hoist that will allow all four wheels to rotate freely 3 Loosen trunnion lock bolt Fig 84 Loosen bolt enough
375. solenoid 5 Valve Body Malfunction 5 Remove disassemble clean and inspect valve body components Make sure all valves and plugs slide freely in bores Polish valves with crocus cloth if needed WHINE NOISE RELATED TO 1 Fluid Level Low 1 Add fluid and check for leaks ENGINE SPEED 2 Shift Cable Incorrect Routing 2 Check shift cable for correct routing Should not touch engine or bell housing 21 142 TRANSMISSION AND TRANSFER CASE 2 DIAGNOSIS AND TESTING Continued CONDITION POSSIBLE CAUSES CORRECTION NO 3 4 UPSHIFT 1 Dash O D Switch In OFF 1 Turn control switch to ON position Position 2 Overdrive Circuit Fuse Blown 2 Replace fuse Determine why fuse failed and repair as necessary i e shorts or grounds in circuit 3 O D Switch Wire Shorted Open 3 Check wires connections with 12V Cut test lamp and voltmeter Repair damaged or loose wire connection as necessary 4 Distance or Coolant Sensor 4 Test both sensors with test lamp Malfunction or volt ohmmeter and replace faulty sensor 5 TPS Malfunction 5 Check with DRB scan tool and replace if necessary 6 Neutral Switch to PCM Wire 6 Test switch as described in Shorted Cut service section and replace if necessary Engine no start 7 PCM Malfunction 7 Check with DRB scan tool and replace if necessary 8 Overdrive Solenoid Shorted 8 Replace solenoid if shorted or Open open and repair loose or damaged wire
376. ssadud YONYSAOD isd 061 66 3unss3ud INIT 0311997 LON H LNT H3183ANOO HV39 04 3AIHG Q35120 IND 9 1 HV3O 3AIHQH3AO SAI NI H3 31 HO12313S JAWA ONIIALL d 154001 3ATVA aioNanos 108 SATVA 5 1 6 ONIIALL 4 6 AANO bE 3 7 6 HOLfTIO S3AIHQH3AO uou1viniNwnoov NOLIVOIHB TI HOL TIO 150089 SANA NAOCDIODI S FATWA 141 5 2 1 Q JATA JILLNHS ATLLOYHL LNOYS OAd3S LNOHH NOILVOIHSfY1 OL 984 oc p oe 1 OAu3S uvau U3lH3ANOO 3n0H0L N33uos 3ATVA TV INVIA FATWA LAIHS 2 1 ON 1d HONH3AOD DR SENG 5 L3IHS 6 2 Ord JILLOYHL 2 HOLMIO HV3H GION3 10S HONH3ACD 2 TRANSMISSION AND TRANSFER CASE SCHEMATICS AND DIAGRAMS Continued 21 108 28 NOILOnS isd 09 9 3 5539 39101 H31H3ANOO isd 001 0 3unssaud JILLOHYHL isd 09 0 3unssdud UONH3JAOD isd 01 96 3unss3ud INIT H LNT H3183ANOO HV39 3AIHG NI MOTA Q393201 O L uV39 3AIHQH3AO NI H3A31 HOLO3 13S JAYA d 14001
377. ssion case and align bolt holes in retainer gasket and case Fig 155 Then install and tighten retainer bolts to 17 13 ft Ibs torque 15 Install new seals on overdrive piston 16 Stand transmission case upright on bellhous ing 17 Position Guide Ring 8114 1 on outer edge of overdrive piston retainer 18 Position Seal Guide 8114 3 on inner edge of overdrive piston retainer 19 Install overdrive piston in overdrive piston retainer by aligning locating lugs on overdrive piston to the two mating holes in retainer TRANSMISSION AND TRANSFER CASE 21 189 GASKET BE SUR GOVERNOR TUBE FEED HOLES IN CASE AND GASKET ARE ALIGNED J9121 349 Fig 154 Installing Aligning Case Gasket gt S r gt PBION 2222 RETAINER mame gt O RETAINER BOLTS J9321 464 Fig 155 Aligning Overdrive Piston Retainer a Aligning locating lugs on overdrive piston to the two mating holes in retainer b Lubricate overdrive piston seals with Door Ease or equivalent c Install piston over Seal Guide 8114 3 and inside Guide Ring 8114 1 d Push overdrive piston retainer into position in 21 190 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued e Verify that the locating lugs entered the lug bores in the retainer NOTE INSTALL THE REMAINING TRANSMISSION COMPONENTS AND OVERDRIVE UNIT FRONT SER
378. stall tabbed thrust washer on front plane tary gear Fig 188 Seat washer tabs in matching slots in face of gear carrier Use extra petroleum jelly to hold washer in place if desired DRIVING SHELL OUTPUT REAR PLANETARY GEAR OUTPUT SHAFT SUN GEAR 19121 72 Fig 186 Installing Sun Gear Driving Shell TAB DRIVING SLOTS 3 SHELL TABBED THRUST WASHER J9121 73 Fig 187 Installing Driving Shell Thrust Washer 11 Install front annulus gear over and onto front planetary gear Fig 189 Be sure gears are fully meshed and seated TRANSMISSION AND TRANSFER CASE 21 199 TABBED THRUST WASHER PLANETARY GEAR 9121 74 Fig 188 Installing Thrust Washer On Front Planetary Gear FRONT PLANETARY GEAR 19121 75 Fig 189 Assembling Front Planetary And Annulus Gears 12 Install front planetary and annulus gear assembly Fig 190 Hold gears together and slide them onto shaft Be sure planetary pinions are seated on sun gear and that planetary carrier is seated on intermediate shaft 13 Place geartrain in upright position Rotate gears to be sure all components are seated and prop 21 200 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued erly assembled Snap ring groove at forward end of intermediate shaft will be completely exposed when components are assembled correctly 14 Install new planetary snap ring in groove at end of intermediate shaft
379. stall valve body as follows a Start park rod into park pawl If rod will not slide past park pawl pawl is engaged in park gear Rotate overdrive output shaft with suitable size 12 point socket this will free pawl and allow rod to engage 0 Align and seat valve body on case Be sure manual lever shaft and overdrive connector are fully seated in case c Install and start all valve body attaching bolts by hand Then tighten bolts evenly in a diag onal pattern to 12 N m 105 165 torque Do not overtighten valve body bolts This could result in distortion and cross leakage after installation 5 Install new filter on valve body Tighten filter screws to 4 N m 35 in 165 6 Install seal on park neutral position switch Then install and tighten switch to 34 N m 25 ft Ibs 2 DISASSEMBLY AND ASSEMBLY Continued ACCUMULATOR PISTON gt INNER SPRING J9121 208 Fig 145 Accumulator Piston And Springs 15 16 SOCKET Fig 146 Manual Lever Shaft Seal CAUTION If the condition of the transmission before the overhaul procedure caused excessive metallic or fiber contamination in the fluid replace the torque converter and reverse flush the cooler s and cooler lines Fluid contamination and transmis sion failure can result if not done 7 Install torque converter Use C damp or metal strap to hold converter in place for installation BAND ADJUSTMENT AND FINAL 1 Adjust front and rear
380. system It interconnects the automatic transmission floor mounted shifter to the steering column ignition switch Fig 6 The system locks the shifter into the PARK position The Interlock system is engaged whenever the ignition switch is in the LOCK or ACCESSORY position An additional electrically acti vated feature will prevent shifting out of the PARK position unless the brake pedal is depressed at least one half an inch A magnetic holding device in line with the park lock cable is enegized when the igni tion is in the RUN position When the key is in the RUN position and the brake pedal is depressed the shifter is unlocked and will move into any position The interlock system also prevents the ignition switch from being turned to the LOCK or ACCES SORY position Fig 7 unless the shifter is fully locked into the PARK position DIAGNOSIS AND TESTING AUTOMATIC TRANSMISSION DIAGNOSIS Automatic transmission problems can be a result of poor engine performance incorrect fluid level incor rect linkage or cable adjustment band or hydraulic control pressure adjustments hydraulic system mal functions or electrical mechanical component mal functions Begin diagnosis by checking the easily accessible items such as fluid level and condition linkage adjustments and electrical connections A road test will determine if further diagnosis is neces sary PRELIMINARY DIAGNOSIS Two basic procedures are required One procedure for vehi
381. t 5 ONIIALL 3 6 FATWA AANO HOLM uoivinwnoov NOLIVOIHSITI HOLN19 INVA 15 TOHLNOO 1 1 8 2 1 3ATVA 31LLOHS 31LLOHHL 1 5 1 NOLLvOIHS TI OL JAYA OAYAS H31HJANOD 3no0uol 5 JAVA 3ATVA TIVONVIA SATIVA L3IHS 2 1 HONH3AOD JAVA 1 1 5 6 2 ATLLOYWHL Orid HOLN19 GION31OS HONH3AOS 21 233 TRANSMISSION AND TRANSFER CASE 2 SCHEMATICS AND DIAGRAMS Continued 6 isd 6 0 5534 1114 3 NOILOnS isd 9 9 3unssaud 3901 d31H3ANOO isd 25 9 3unssaud isd 2 TOYULNOD LAIHS 2 1 isd 29 99 3unssaud 8019313S 245 IWNNVM AILLOYHL Q3SO 19 uv35 GNOOAS HOLMIO ru INOS FATWA UE nr nm NOIL JHANTI OL FATWA HOLIMS MJ dION310S 7 HALYAANOD 3nouor N33uos df4201 105 AHQH3AO mu
382. t and leave gauge C3292 in place at accumulator port 2 Move 300 psi Gauge C 3293 SP back to rear servo port 3 Have helper start and run engine at 1600 rpm for test 2 DIAGNOSIS AND TESTING Continued 4 Move transmission shift lever four detents rearward from full forward position This is Reverse range 5 Move transmission throttle lever fully forward then fully rearward and note reading at Gauge C 3293 SP 6 Pressure should be 145 175 psi 1000 1207 kPa with throttle lever forward and increase to 230 280 psi 1586 1931 kPa as lever is gradually moved rearward Test Five Governor Pressure NOTE This test checks governor operation by measuring governor pressure response to changes in vehicle speed It is usually not necessary to check governor operation unless shift speeds are incorrect or if the transmission will not downshift The test should be performed on the road or on a hoist that will allow the rear wheels to rotate freely 1 Move 100 psi Test Gauge C 3292 to governor pressure port 2 Move transmission shift lever two detents rear ward from full forward position This is D range 3 Have helper start and run engine at curb idle speed Then firmly apply service brakes so wheels will not rotate 4 Note governor pressure e Governor pressure should be no more than 20 6 kPa 3 psi at curb idle speed and wheels not rotat ing e f pressure exceeds 20 6 kPa 3 psi a fault exists in gov
383. t curb idle speed with the shift selector in neutral 3 If fluid flow is intermittent or it takes more than 20 seconds to collect one quart of ATF PLUS 3 disconnect the To Cooler line at the transaxle 4 Refill the transaxle to proper level and recheck pump volume 5 If flow is found to be within acceptable limits replace the cooler Then fill transmission to the proper level using Mopar ATF PLUS 3 Type 7176 automatic transmission fluid 6 If fluid flow is still found to be inadequate check the line pressure using the Transaxle H ydrau lic Pressure Test procedure FLUSHING COOLERS AND TUBES When a transmission failure has contaminated the fluid the oil cooler s must be flushed The cooler bypass valve in the transmission must be replaced also The torque converter must also be replaced This will insure that metal particles or sludged oil are not later transferred back into the reconditioned or replaced transmission The only recommended procedure for flushing cool ers and lines is to use Tool 6906 Cooler Flusher WARNING WEAR PROTECTIVE EYEWEAR THAT MEETS THE REQUIREMENTS OF OSHA AND ANSI 287 1 1968 WEAR STANDARD INDUSTRIAL RUB BER GLOVES KEEP LIGHTED CIGARETTES SPARKS FLAMES AND OTHER IGNITION SOURCES AWAY FROM THE AREA TO PREVENT THE IGNITION OF COMBUSTI BLE LIQUIDS AND GASES KEEP A CLASS B FIRE EXTINGUISHER IN THE AREA WHERE THE FLUSHER WILL BE USED KEEP THE AREA WELL VENTILATED DO NOT LET
384. t support hub Lubricate washer with petroleum jelly or trans mission fluid before installation 3 reaction shaft seal rings are being replaced install new seal rings on support hub Lubricate seal rings with transmission fluid or petroleum jelly after 2 SPECIAL SPECIAL TOOL TOOL SP 1191 SAMT SE SPECIAL SPECIAL TOOL TOOL SP 3633 SP 5302 SPECIAL TOOL SP 5301 ESS REACTION BUSHING REMOVAL BUSHING INSTALLATION J9221 245 Fig 163 Reaction Shaft Bushing installation Squeeze each ring until ring ends are securely hooked together CAUTION The reaction shaft support seal rings will break if overspread or twisted If new rings are being installed spread them only enough for instal lation Also be very sure the ring ends are securely hooked together after installation Otherwise the rings will either prevent pump installation or break during installation 4 Align and install reaction shaft support on pump body 5 Install bolts attaching reaction shaft support to pump Tighten bolts to 20 N m 175 in 15 torque 6 Install new pump seal with Installer Tool C 3860 A Fig 164 Use hammer or mallet to tap seal into place 7 Install new O ring on pump body Lubricate oil seal and O ring with petroleum jelly 8 Cover pump assembly to prevent dust entry and set aside for assembly installation FRONT CLUTCH DISASSEMBLY 1 Remove waved snap ring and remove reaction plate clutc
385. t the transmission bushings during overhaul Bushing condition is important as worn scored bush ings contribute to low pressures clutch slip and accelerated wear of other components However do not replace bushings as a matter of course Replace bushings only when they are actually worn or scored Use recommended tools to replace bushings The tools are sized and designed to remove install and seat bushings correctly The bushing replacement tools are included in Bushing Tool Set C 3887 B Presized service bushings are available for replacement purposes Only the sun gear bushings are not serviced Low cost of the sun gear assembly makes it easier to simply replace the gear and bush ings as an assembly Heli Coil inserts can be used to repair damaged stripped or worn threads in aluminum parts These inserts are available from most automotive parts suppliers Stainless steel inserts are recommended The use of crocus cloth is permissible where neces sary providing it is used carefully When used on shafts or valves use extreme care to avoid rounding off sharp edges Sharp edges are vital as they pre vent foreign matter from getting between the valve and valve bore Do not reuse oil seals gaskets seal rings or O rings during overhaul Replace these parts as a matter of course Also do not reuse snap rings or E clips that are bent or distorted Replace these parts as well Lubricate transmission parts with Mopar ATF Plus T
386. t transmission throttle lever is in fully closed position Then be sure lever on throttle body is at curb idle position 2 USTMENTS Continued 5 Insert small screwdriver under edge of retaining clip and remove retaining clip 6 Center cable end on attachment stud to within 1 mm 0 039 in 7 Install retaining dip onto cable housing 8 Check cable adjustment Verify transmission throttle lever and lever on throttle body move simul taneously GEARSHIFT CABLE Check adjustment by starting the engine in Park and Neutral Adjustment is OK if the engine starts only in these positions Adjustment is incorrect if the engine starts in one but not both positions If the engine starts in any position other than Park or Neu tral or if the engine will not start at all the park neutral position switch may be faulty Gearshift Adjustment Procedure 1 Shift transmission into Park 2 Raise vehide 3 Release cable adjuster damp at transmission end of cable to unlock cable 4 Unsnap cable from cable mounting bracket on transmission Fig 260 5 Slide cable eyelet off transmission shift lever 6 Verify transmission shift lever is in Park detent by moving lever fully rearward Last rearward detent is Park position 7 Verify positive engagement of transmission park lock by attempting to rotate propeller shaft Shaft will not rotate when park lock is engaged 8 Slide cable eyelt onto transmission shift
387. tall 1 2 and 2 3 shift valves and springs 4 Install 1 2 shift control valve and spring 5 Install retainer spring limit valve and 2 3 throttle plug from limit valve housing 6 Install limit valve housing and cover plate Tighten screws to 4 N m 35 in Ibs 7 Install shuttle valve as follows a Insert plastic guides in shuttle valve second ary spring and install spring on end of valve b Install shuttle valve into housing c Hold shuttle valve in place d Compress secondary spring and install E dip in groove at end of shuttle valve e Verify that spring and E dip are properly seated before proceeding 8 Install shuttle valve cover plate Tighten cover plate screws to 4 N m 35 in Ibs torque 9 Install 1 2 and 2 3 valve governor plugs in valve body 10 Install throttle plug 11 Align and install governor plug cover Tighten Cover screws to 4 35 in 105 torque shuttle valve primary spring and BOOST VALVE TUBE AND BRACE 1 Position valve body assembly so lower housing is facing upward Fig 86 2 Lubricate tube ends and housing ports with transmission fluid or petroleum jelly 2 5 5 AND TRANSFER CASE 21 171 DISASSEMBLY AND ASSEMBLY Continued SPRING B RETAINER amp E CLIP 67 091 VALVE SPRING BOOST GUIDES VALVE BOOST SHUTTLE VALVE VALVE COVER SECONDARY 7 SPRING SHUTTL
388. tall front annulus snap ring Fig 182 Use snap ring pliers to avoid distorting ring during installation Also be sure ring is fully seated 21 Install planetary selective snap ring with snap ring pliers Fig 183 Be sure ring is fully seated 22 Turn planetary geartrain assembly over so driving shell is facing workbench Then support geartrain on wood block positioned under forward end of output shaft This allows geartrain compo nents to move forward for accurate end play check 23 Check planetary geartrain end play with feeler gauge Fig 184 Gauge goes between shoulder on output shaft and end of rear annulus support 24 Geartrain end play should be 0 12 to 1 22 mm 0 005 to 0 048 in If end play is incorrect snap ring or thrust washers may have to be replaced Snap ring is available in three different thicknesses for adjustment purposes 21 76 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued ANNULUS GEAR J9121 167 Fig 179 Installing Front Planetary And Annulus Gears THRUST J9421 179 Fig 180 Positioning Thrust Plate On Front Annulus Support WASHER FRONT FLAT ANNULUS ALIGNS THRUST WITH FLAT WASHER ON PLANETARY 7 HUB J9121 168 Fig 181 Installing Front Annulus Thrust Washer OVERDRIVE UNIT DISASSEMBLY 1 Remove transmission speed sensor and O ring seal from overdrive case Fig 185 2 FRONT ANNULUS Fig 182 Installing Front Annulus
389. tch Fig 111 e Turn drum back and forth Drum should rotate freely in clockwise direction and lock 2 SPRING COMPRESSOR TOOL C 3422 B ROD QUIDE SNAP RING 9121 136 Fig 109 Compressing Front Rear Servo Springs J9121 348 Fig 110 Rear Band Installation counterclockwise direction as viewed from front of case 7 Install snap ring that secures low reverse drum to hub of overdrive piston retainer Fig 112 8 Install rear band lever and pivot pin Fig 113 Align lever with pin bores in case and push pivot pin into place 9 Install planetary geartrain assembly Fig 114 10 Install thrust plate on intermediate shaft hub Fig 115 Use petroleum jelly to hold thrust plate in place 2 3RANSMISSION AND TRANSFER CASE 21 59 DISASSEMBLY AND ASSEMBLY Continued REAR BAND _ GEARTRAIN AO AND INTERMEDIATE SHAFT ASSEMBLY 19121 217 Fig 114 Installing Planetary Geartrain 11 Check seal ring on rear dutch retainer hub and seal rings on input shaft Fig 116 Also verify that shaft seal rings are installed in sequence shown OVERDRIVE 12 Install rear dutch thrust washer Fig 117 a STON RETAINER Use additional petroleum jelly to hold washer in Y LOW REVERSE DRUM SNAP RING J9121 351 Fig 112 Installing Low Reverse Drum Retaining Snap Ring REAR BAND LEVER INTERMEDIATE
390. tick to keep dirt from entering tube 7 Remove dipstick Fig 12 and check fluid level as follows a Correct acceptable level is in crosshatch area b Correct maximum level is to MAX arrow mark c Incorrect level is at or below MIN line d If fluid is low add only enough ATF Plus 3 to restore correct level Do not overfill CAUTION not overfill the transmission Over filling may cause leakage out the pump vent which can be mistaken for a pump seal leak Overfilling will also cause fluid aeration and foaming as the excess fluid is picked up and churned by the gear train This will significantly reduce fluid life DIPSTICK D 20 MAXIMUM ACCEPTABLE CORRECT FLUID FLUID LEVEL LEVEL 804d8eae Fig 12 Dipstick Fluid Level Marks Typical FLUID AND FILTER REPLACEMENT Refer to the Maintenance Schedules in Group O Lubrication and Maintenance for proper service intervals The service fluid fill after a filter change is approximately 3 8 liters 4 0 quarts 2 1 Hoist and support vehicle safety stands 2 Place a large diameter shallow drain pan beneath the transmission pan 3 Remove bolts holding front and sides of pan to transmission Fig 13 4 Loosen bolts holding rear of pan to transmis sion 5 Slowly separate front of pan away from trans mission allowing the fluid to drain into drain pan 6 Hold up pan and
391. tion 12 Remove output shaft rear bearing with the screw and jaws from Remover L 4454 and Cup 8148 Fig 57 13 Install new bearing with Tool Handle C 4171 and Installer 5066 Fig 58 Lubricate bearing after installation 22 SPECIAL TOOL n O h L 4454 1 E L 4454 3 REAR CASE y SPECIAL TOOL 8148 e pos C N 80298366 Fig 57 Remove Front Output Shaft Rear Bearing TRANSMISSION AND TRANSFER CASE 21 257 O HANDLE Eo 4171 OUTPUT SHAFT INNER INSTALLER BEARING 5066 La 80a11094 Fig 58 Install Front Output Shaft Rear Bearing 14 Install new seal in oil pump feed housing with Special Tool 7888 Fig 59 Nl OIL PUMP FEED HOUSING SPECIAL TOOL 7888 7 HOUSING SEAL J9521 35 Fig 59 Oil Pump Seal Installation 21 258 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued 15 Install new pickup tube O ring oil pump Fig 60 PICKUP TUBE O RING J8921 286 Fig 60 Pickup Tube O Ring Installation DIFFERENTIAL ASSEMBLY 1 Lubricate differential components with auto matic transmission fluid 2 Install sprocket gear in differential bottom case Fig 61 J8921 279 Fig 61 Installing Differential Sprocket Gear 2 3 Install differential planet gears and new thrust washers Fig 62 Be sure thrust washers are installed at top and bottom of each planet gear
392. tion do not overtighten the transfer plate and valve body screws during reassembly Over tightening can distort the housings resulting in valve sticking cross leakage and unsatisfactory operation Tighten valve body screws to recom mended torque only Fig 75 Accumulator Housing Components LOWER HOUSING 3 4 ACCUMULATOR PISTON AND SPRING 3 4 ACCUMULATOR HOUSING ACCUMULATOR END PLATE PLUG 3 4 TIMING VALVE AND SPRING 3 4 SHIFT VALVE AND N SPRING SPRING TIMING VALVE esit CONVERTER RETAINER COVER CLUTCH VALVE AND SPRING OVERDRIVE CONVERTER CLUTCH SOLENOID 8 TIMING VALVE AND SPRING CONVERTER CLUTCH SOLENOID 3 SOLENOID GASKET CASE CONNECTOR OVERDRIVE SEPARATOR PLATE 80468d95 Fig 74 Lower Housing Shift Valves And Springs 2 DISASSEMBLY AND ASSEMBLY Continued LOWER HOUSING 1 Lubricate valves springs and the housing valve and plug bores with dean transmission fluid Fig 74 2 Install 3 4 timing valve spring and valve in lower housing 3 Install 3 4 quick fill valve in lower housing 4 Install 3 4 quick fill valve spring and plug in housing 5 Install timing valve end plate Tighten end plate screws to 4 35 in 165 torque 3 4 ACCUMULATOR 1 Lubricate accumulator piston seals and hous ing piston bore with clean transmission fluid Fig 75 2 Install new seal rings on accumulator piston 3 Install piston and spring in housing 4 Install end plate on hou
393. tion the clutch will engage after the shift to fourth gear and above approximately 72 km h 45 mph If the control switch is in the OFF position the clutch will engage after the shift to third gear at approximately 56 km h 35 mph at light throttle QUICK FILL VALVE The 3 4 quick fill valve provides faster engagement of the overdrive clutch during 3 4 upshifts The valve temporarily bypasses the clutch piston feed orifice at the start of a 3 4 upshift This exposes a larger pas sage into the piston retainer resulting in a much faster clutch fill and apply sequence The quick fill valve does not bypass the regular clutch feed orifice throughout the 3 4 upshift Instead once a predeter mined pressure develops within the clutch the valve closes the bypass Clutch fill is then completed through the regular feed orifice CONVERTER DRAINBACK VALVE The drainback valve is located in the transmission cooler outlet pressure line The valve prevents fluid from draining from the converter into the cooler and TRANSMISSION AND TRANSFER CASE 21 125 lines when the vehide is shut down for lengthy peri ods Production valves have a hose nipple at one end while the opposite end is threaded for a flare fitting All valves have an arrow or similar mark to indi cate direction of flow through the valve BRAKE TRANSMISSION SHIFT INTERLOCK MECHANISM The Brake Transmission Shifter Ignition Interlock BTSI is a cable and solenoid operated
394. tip 0 089 0 190 0 004 0 008 in clearance mm Planetary end play 0 150 1 22 mm 0 006 0 048 in Input shaft end play 0 86 2 13 mm 0 034 0 084 in Clutch pack 1 78 3 28mm 0 070 0 129 in clearance Front 3 disc Clutch pack 0 64 1 14 mm 0 025 0 045 clearance Rear 4 disc Overdrive clutch disc 4 discs usage Direct clutch disc 8 discs usage Front clutch spring 9 spring usage Band adjustment from 72 in lbs Front band Back off 2 7 8 turns Rear band Back off 2 turns Recommended fluid Mopar ATF Plus type 7176 TRANSMISSION AND TRANSFER CASE 21 235 TORQUE DESCRIPTION TORQUE Bolt torque convertor 31 N m 23 ft Ibs Bolt nut crossmember 68 N m 50 ft Ibs Bolt driveplate to crankshaft 75 N m 55 ft 165 Plug front band reaction 17 N m 13 ft Ibs Locknut front band adj 34 N m 25 ft Ibs Switch park neutral 34 N m 25 ft Ibs Bolt fluid 17 N m 13 ft Ibs Bolt oil pump 20 N m 15 ft Ibs Bolt overrunning clutch cam 17 N m 13 ft 165 Bolt O D totrans 34 25 ft Ibs Bolt O D piston retainer 17 N m 13 ft Ibs Plug pressure test port 14 N m 10 ft Ibs Bolt reaction shaft support 20 N m 15 ft Ibs Locknut rear 41 N m 30 ft Ibs Bolt speedometer adapter 11 N m 8 ft Ibs Screw fluid
395. to Park position 2 Turn ignition switch to Accessory position Be sure ignition key cylinder is in Accessory posi tion Cable will not adjust correctly in any other position 3 Remove shift lever bezel and console screws Raise bezel and console for access to park interlock cable 4 Pull cable lock button up to release cable Fig 250 5 Pull cable forward Then release cable and press lock button down until it snaps in place 21 96 TRANSMISSION AND TRANSFER CASE ADJ USTMENTS Continued PARK INTERLOCK CABLE INTERLOCK CABLE LOCK BUTTON SHIFT LEVER AND HOUSING ASSEMBLY HOUSING MOUNTING J9321 416 Fig 250 Shift And Park Lock Cables BTSI FUNCTION CHECK 1 Verify removal of ignition key allowed in park position only 2 When the shift lever is in park and the shift handle push button is in the out position the igni tion key cylinder should rotate freely from off to lock When the shifter is in any other position the ignition key should not rotate from off to lock 3 Shifting out of park should be possible when the ignition key cylinder is in the off position 4 Shifting out of park should not be possible while applying 25 10 max handle push button force and ignition key cylinder is in the run or start posi tions unless the foot brake pedal is depressed approximately 1 2 inch 12mm 5b Shifting out of park should not be possible when the ignition key cylinder is in the accesso
396. to straighten a bent shaft or correct a loose lever Replace these compo nents if worn bent loose or damaged in any way Inspect all of the valve body mating surfaces for scratches nicks burrs or distortion Use a straightedge to check surface flatness Minor scratches may be removed with crocus cloth using only very light pressure Minor distortion of a valve body mating surface may be corrected by smoothing the surface with a sheet of crocus cloth Position the crocus cloth on a surface plate sheet of plate glass or equally flat surface If distortion is severe or any surfaces are heavily scored the valve body will have to be replaced 2 CAUTION of the valves and plugs such the throttle valve shuttle valve plug 1 2 shift valve and 1 2 governor plug are made of coated alumi num Aluminum components are identified by the dark color of the special coating applied to the sur face or by testing with a magnet Do not sand alu minum valves or plugs under any circumstances This practice could damage the special coating causing the valves plugs to stick and bind Inspect the valves and plugs for scratches burrs nicks or scores Minor surface scratches on steel valves and plugs can be removed with crocus cloth but do not round off the edges of the valve or plug lands Maintaining sharpness of these edges is vitally important The edges prevent foreign matter from lodging between the valves and plugs and the bor
397. to this cavity 8 Install accumulator springs and piston into case Then swing valve body over piston and outer spring to hold it in place 9 Align accumulator piston and outer spring manual lever shaft and electrical connector in case 10 Then seat valve body in case and install one or two bolts to hold valve body in place 11 Tighten valve body bolts alternately and evenly to 11 N m 100 in Ibs torque 12 Install new fluid filter on valve body Tighten filter screws to 4 N m 35 in 15 torque 13 Install throttle and gearshift levers on valve body manual lever shaft 2 14 Check and adjust front and rear bands if nec essary 15 Connect solenoid case connector wires 16 Install oil pan and new gasket Tighten pan bolts to 17 13 ft Ibs torque 17 Lower vehicle and fill transmission with Mopar ATF Plus 3 type 7176 fluid 18 Check and adjust gearshift and throttle valve cables if necessary VALVE BODY CONNECTOR HARNESS O RINGS CONNECTOR J9321 389 Fig 31 Valve Body Harness Connector O Ring Seal 15 16 SOCKET Fig 32 Manual Lever Shaft Seal CG RINGS Fig 33 Accumulator Piston Components 2 REMOVAL AND INSTALLATION Continued OVERDRIVE UNIT REMOVAL 1 Shift transmission into Park 2 Raise vehide 3 Mark propeller shaft universal joint s and axle pinion yoke for alignment reference at installation 4 Disconnect and remove propeller shaft s
398. tput Shaft Bearing or Bushing 6 Remove inspect and repair as Damaged required 7 Clutch Operation Faulty 7 Perform air pressure check and repair as required 8 Front and Rear Bands Misadjusted 8 Adjust bands 21 140 TRANSMISSION AND TRANSFER CASE 2 DIAGNOSIS AND TESTING Continued CONDITION POSSIBLE CAUSES CORRECTION DRAGS OR LOCKS UP 1 Fluid Level Low 1 Check and adjust level 2 Clutch Dragging Failed 2 Air pressure check clutch operation and repair as required 3 Front or Rear Band Misadjusted 3 Adjust bands 4 Case Leaks Internally 4 Check for leakage between passages in case 5 Servo Band or Linkage Malfunction 5 Air pressure check servo operation and repair as required 6 Overrunning Clutch Worn 6 Remove and inspect clutch Repair as required 7 Planetary Gears Broken 7 Remove inspect and repair as required look for debris in oil pan 8 Converter Clutch Dragging 8 Check for plugged cooler Perform flow check Inspect pump for excessive side clearance Replace pump as required NO 4 3 DOWNSHIFT 1 Circuit Wiring and or Connectors 1 Test wiring and connectors with test Shorted lamp and volt ohmmeter Repair wiring as necessary Replace connectors and or harnesses as required 2 POM Malfunction 2 Check PCM operation with DRB scan tool Replace PCM only if faulty 3 TPS Malfunction 3 Check TPS with DRB scan tool at PCM 4 Lockup Solenoid Not
399. transmissions Dexron fluid IS NOT recommended Clutch chatter can result from the use of improper fluid EFFECTS OF INCORRECT FLUID LEVEL A low fluid level allows the pump to take in air along with the fluid Air in the fluid will cause fluid pressures to be low and develop slower than normal If the transmission is overfilled the gears churn the fluid into foam This aerates the fluid and causing the same conditions occurring with a low level In either case air bubbles cause fluid overheating oxi dation and varnish buildup which interferes with valve clutch and servo operation Foaming also causes fluid expansion which can result in fluid over flow from the transmission vent or fill tube Fluid overflow can easily be mistaken for a leak if inspec tion is not careful CAUSES OF BURNT FLUID Burnt discolored fluid is a result of overheating which has two primary causes 1 A result of restricted fluid flow through the main and or auxiliary cooler This condition is usu ally the result of a faulty or improperly installed drainback valve a damaged main cooler or severe restrictions in the coolers and lines caused by debris or kinked lines TRANSMISSION AND TRANSFER CASE 21 121 2 Heavy duty operation with a vehicle not prop erly equipped for this type of operation Trailer tow ing or similar high load operation will overheat the transmission fluid if the vehicle is improperly equipped Such vehides should have an
400. uid for clutch material or metal fragments If fluid contains these items overhaul will be necessary 16 If overdrive unit does not require any service leave alignment tool in position Tool will prevent accidental misalignment of planetary gear and over running clutch splines INSTALLATION 1 Be sure overdrive unit Alignment Tool 6227 2 is fully seated before moving unit If tool is not seated and gear splines rotate out of alignment over drive unit will have to be disassembled in order to realign splines 2 If overdrive piston retainer was not removed during service and original case gasket is no longer reusable prepare new gasket by trimming it 3 Cut out old case gasket around piston retainer with razor knife Fig 35 4 Use old gasket as template and trim new gas ket to fit 5 Position new gasket over piston retainer and on transmission case Use petroleum jelly to hold gasket in place if necessary Do not use any type of sealer to secure gasket Use petroleum jelly only GASKET SHARP KNIFE 8921 269 Fig 35 Trimming Overdrive Case Gasket 21 158 TRANSMISSION AND TRANSFER CASE REMOVAL AND INSTALLATION Continued 6 2I nstall selective spacer on intermediate shaft if removed Spacer goes in groove just rearward of shaft rear splines Fig 36 SPACER GROOVE SELECTIVE SPACER INTERMEDIATE SHAFT 19021 96 Fig 36 Intermediate Shaft Selective Spacer Location 7 Install thrust
401. ure O D piston retainer DELAYED 3 4 UPSHIFT 1 Fluid Level Low 1 Add fluid and check for leaks SLOW TO ENGAGE 2 Throttle Valve Cable Misadjusted 2 Adjust throttle valve cable 3 Overdrive Clutch Pack Worn 3 Remove unit and rebuild clutch pack Burnt 4 TPS Faulty 4 Test with DRB scan tool and replace TPS 5 Overdrive Clutch Bleed Orifice 5 Disassemble transmission and replace Plugged orifice 6 Overdrive Solenoid or Wiring 6 Test solenoid and check wiring for Shorted Open loose corroded connections or shorts grounds Replace solenoid if faulty and repair wiring if necessary 7 Overdrive Excess Clearance 7 Remove unit Measure end play and select proper spacer 8 O D Check Valve Missing or 8 Check for presence of check valve Repair Stuck or replace as required TORQUE CONVERTER Lockup Solenoid Relay or Wiring Test solenoid relay and wiring for continuity LOCKS UP IN SECOND Shorted Open shorts or grounds Replace solenoid and relay AND OR THIRD GEAR if faulty Repair wiring and connectors as necessary HARSH 1 2 2 3 3 4 OR Lockup Solenoid Malfunction Remove valve body and replace solenoid 3 2 SHIFTS assembly NO START IN PARK OR 1 Gearshift Linkage Cable 1 Adjust linkage cable NEUTRAL Misadjusted 2 Neutral Switch Wire Open Cut 2 Check continuity with test lamp Repair as required 3 Neutral Switch Faulty 3 Refer to service section for test and replacement procedure 4 Neutral Switch
402. uspect seal incorrectly Transfer case will not shift through Incomplete shift due to drivetrain 1 Momentarily release the 4X4 part time range light remains load accelerator pedal to complete the on shift 2 Incorrect tire pressure 2 Correct tire pressure as necessary 3 Excessive Tire wear 3 Correct tire condition as necessary 4 Excessive vehicle loading 4 Correct as necessary 2 REMOVAL AND INSTALLATION TRANSFER CASE REMOVAL 1 Shift transfer case into Neutral 2 Raise vehide 3 Drain transfer case lubricant 4 Mark front and rear propeller shaft yokes for alignment reference 5 Support transmission with jack stand 6 Remove rear crossmember or skid plate 7 Disconnec front rear propeller shafts at trans fer case 8 Disconnect vehicle speed sensor wires 9 Disconnect transfer case linkage rod from range lever 10 Disconnect transfer case vent hose Fig 3 and indicator switch harness if necessary 11 Support transfer case with transmission jack 12 Secure transfer case to jack with chains 13 Remove nuts attaching transfer case to trans mission 14 Pull transfer case and jack rearward to disen gage transfer case 15 Remove transfer case from under vehicle TRANSFER CASE 80b09a89 Fig 3 Transfer Case Mounting INSTALLATION 1 Mount transfer case on a transmission jack 2 Secure transfer case to jack with chains 3 Positio
403. ut shaft if the machined surfaces are scored pitted or damaged in any way Also replace the shaft if the splines are damaged or 2 CLEANING AND INSPECTION Continued exhibits cracks at any location especially at the gov ernor valve shaft bore The annulus gears can be removed from their sup ports if necessary J ust remove the snap rings and separate the two parts when replacement is neces sary In addition the annulus gear bushings can be replaced if severely worn or scored However it is not necessary to replace the bushings if they only exhibit normal wear Check bushing fit on the output shaft to be sure OVERDRIVE UNIT Clean the geartrain and case components with sol vent Dry all parts except the bearings with com pressed air Allow bearings to air dry Do not use shop towels for wiping parts dry unless the towels are made from a lint free material A suf fident quantity of lint from shop towels cloths rags etc could plug the transmission filter and fluid pas sages Discard the old case gasket and seals Do not attempt to salvage these parts They are not reus able Replace any of the overdrive unit snap rings if distorted or damaged Minor nicks or scratches on components can be smoothed with crocus cloth However do not attempt to reduce severe scoring on any components with abrasive materials Replace severely scored compo nents do not try to salvage them Check condition of the park lock component
404. valve cover 2 Remove 3 4 timing valve and spring SPRING RETAINER E CUP 2 5 VALVE SPRING BOOST GUIDES SHUTTLE VALVE UPPER HOUSING THROTTLE PLUG EN VALVE SHUTTLE VALVE PRIMARY S SPRING GOVERNOR PLUG IIIS e COVER 19421 217 Fig 67 Shuttle And Boost Valve Components 21 46 5 15510 AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued UPPER HOUSING PRESSURE 2 a VALVE PRESSURE PLUG AND SPRING 222275 2 1 2 SHIFT VALVE AND SPRING 2 3 SHIFT VALVE AND SPRING PLUG LIMIT VALVE HOUSING LIMIT PRESSURE VAIVE LIMIT PLUG RETAINER AND VALVE COVER SPRING COVER J9321 157 Fig 68 Upper Housing Shift Valve And Pressure Plug Locations 6 Remove converter dutch timing valve retainer and valve spring 3 4 ACCUMULATOR HOUSING 1 Remove end plate from housing 2 Remove piston spring 3 Remove piston Remove and discard piston seals Fig 70 ASSEMBLY CAUTION not force valves or plugs into place during reassembly If the valve body bores valves and plugs are free of distortion or burrs the valve body components should all slide into place easily In addition do not overtighten the transfer plate and valve body screws during reassembly Over tightening can distort the housings resulting in valve sticking cross leakage and unsatisfactory operation
405. ve battery post Connect black alligator clip to a good ground 4 Disconnect the cooler lines at the transmission NOTE When flushing transmission cooler and lines ALWAYS reverse flush 5 Connect the BLUE pressure line to the OUT LET From cooler line 6 Connect the CLEAR return line to the INLET To cooler line 7 Turn pump ON for two to three minutes to flush cooler s and lines Monitor pressure readings and clear return lines Pressure readings should sta bilize below 20 psi for vehicles equipped with a sin gle cooler and 30 psi for vehicles equipped with dual coolers If flow is intermittent or exceeds these pres sures replace cooler 8 Turn pump OFF 9 Disconnect CLEAR suction line from reservoir at cover plate Disconnect CLEAR return line at cover plate and place it in a drain pan 10 Turn pump ON for 30 seconds to purge flush ing solution from cooler and lines Turn pump OFF 11 Place CLEAR suction line into a one quart container of Mopar ATF Plus 3 type 7176 automatic transmission fluid 12 Turn pump ON until all transmission fluid is removed from the one quart container and lines This purges any residual cleaning solvent from the trans mission cooler and lines Turn pump OFF 13 Disconnect alligator clips from battery Recon nect flusher lines to cover plate and remove flushing adapters from cooler lines ALUMINUM THREAD REPAIR Damaged or worn threads in the aluminum tra
406. ve snap ring holding output shaft front bearing to overdrive geartrain Fig 40 4 Pull bearing from output shaft INSTALLATION 1 Place replacement bearing in position on geartrain with locating retainer groove toward the rear 2 Push bearing onto shaft until the snap ring groove is visible 3 Install snap ring to hold bearing onto output shaft Fig 40 4 Install overdrive geartrain into housing 5 Install overdrive unit in vehicle OUTPUT SHAFT FRONT BEARING SNAP RING OVERDRIVE GEARTRAIN GROOVE OUTPUT TO REAR SHAFT 80315861 Fig 40 Output Shaft Front Bearing 21 160 TRANSMISSION AND TRANSFER CASE DISASSEMBLY AND ASSEMBLY VALVE BODY Remove the valve body from the transmission refer to Removal and Installation procedures section in this group DISASSEMBLY CAUTION not clamp any valve body compo nent in a vise This practice can damage the com ponent resulting in unsatisfactory operation after assembly and installation Do not use pliers to remove any of the valves plugs or springs and do not force any of the components out or into place The valves and valve body housings will be dam aged if force is used Tag or mark the valve body springs for reference as they are removed Do not allow them to become intermixed 1 Remove fluid filter 2 Disconnect wires from governor pressure sen sor and solenoid Fig 41 3 Remove screws attaching governor body and retainer plate
407. vehicle 21 276 TRANSMISSION AND TRANSFER CASE REMOVAL AND INSTALLATION Continued V INSTALLER VA 6952 227 N t D TRANSFER CASE 80 98363 Fig 8 Front Output Seal Installation 5 X REMOVER 6957 RETAINER BUSHING 80498373 Fig 9 Rear Retainer Bushing Removal REAR RETAINER BUSHING INSTALLER 80a9836c Fig 10 Rear Retainer Bushing Install 2 SPECIAL SPECIAL TOOL TOOL C 4171 C 3995 A 80a983a7 Fig 11 Install Rear Retainer Seal DISASSEMBLY AND ASSEMBLY NV249 TRANSFER CASE DISASSEMBLY Position transfer case on shallow drain pan Remove drain plug and drain lubricant remaining in case REAR RETAINER AND OIL PUMP REMOVAL 1 Remove the speedometer adapter 2 Remove rear retainer bolts Fig 12 3 Remove rear bearing locating ring access cover Screws cover and gasket Fig 13 RETAINER J9321 3 Fig 12 Rear Retainer Bolt Removal 2 DISASSEMBLY AND ASSEMBLY Continued COVER AND GASKET J9321 4 Fig 13 Locating Ring Access Cover And Gasket Removal 4 Loosen rear retainer with pry tool to break sealer bead Pry only against retainer boss as shown Fig 14 5 Remove rear retainer as follows a Spread rear bearing locating ring with snap ring pliers Fig 15 b Then slide retainer off mainshaft and rear bearing Fig 16 Y 2 7 Tool s REAR SD SEALER BEAD
408. verrunning dutch is faulty Similarly if slippage occurs any two forward gears the rear clutch is slipping Applying the same method of analysis note that the front and rear clutches are applied simulta neously only in D range third and fourth gear If the transmission slips in third gear either the front dutch or the rear dutch is slipping If the transmission slips in fourth gear but not in third gear the overdrive dutch is slipping By select ing another gear which does not use these clutches the slipping unit can be determined For example if the transmission also slips in Reverse the front dutch is slipping If the transmission does not slip in Reverse the rear dutch is slipping If slippage occurs during the 3 4 shift or only in fourth gear the overdrive clutch is slipping Simi larly if the direct dutch were to fail the transmis sion would lose both reverse gear and overrun braking in 2 position manual second gear If the transmission will not shift to fourth gear the control switch overdrive solenoid or related wiring may also be the problem cause This process of elimination can be used to identify a slipping unit and check operation Proper use of the Clutch and Band Application Chart is the key Although road test analysis will help determine the slipping unit the actual cause of a malfunction usu ally cannot be determined until hydraulic and air pressure tests are performed Practically any condi ti
409. ves the transmission oil fluid pump The torque converter is a sealed welded unit that is not repairable and is serviced as an assembly CAUTION The torque converter must be replaced if a transmission failure results in large amounts of metal or fiber contamination in the fluid TRANSMISSION GEAR RATIOS 46RE gear ratios are 2 45 1 first gear 1 45 1 second gear 1 00 1 third gear 0 69 1 forth gear 2 21 reverse GEARSHIFT MECHANISM The shift mechanism is cable operated and pro vides six shift positions The shift positions are e Park P Reverse R Neutral N Drive D Manual Second 2 e Manual Low 1 Manual low 1 range provides first gear only Overrun braking is also provided in this range Man ual second 2 range provides first and second gear only Drive range provides first second third and overdrive fourth gear ranges The shift into overdrive fourth gear range occurs only after the transmission has completed the shift into D third gear range No further movement of the shift mechanism is required to complete the 3 4 shift 2 DESCRIPTION AND OPERATION ELECTRONIC GOVERNOR Governor pressure is controlled electronically Com ponents used for governor pressure control include e Governor body Valve body transfer plate Governor pressure solenoid valve Governor pressure sensor Fluid temperature thermistor Throttle position sensor TPS Transmission speed sensor Powertrai
410. ward as far as possible and support case with wood blocks F ront rear dutch and oil pump assemblies are easier to install if transmission is as close to upright position as possible 17 Slide front band into case 18 Install front and rear dutch units as assembly Fig 121 Align rear clutch with front annulus gear and install assembly in driving shell Be sure out put shaft thrust washer and thrust plate are not displaced during installation 19 Carefully work assembled clutches back and forth to engage and seat rear clutch discs on front annulus gear Also be sure front clutch drive lugs are fully engaged in slots of driving shell after installa tion 20 Assemble front band strut 21 Install front band adjuster strut and adjust ing screw Fig 122 22 Tighten band adjusting screw until band just grips clutch retainer Verify that front rear clutches are still seated before continuing 23 Check seal rings on reaction shaft support hub Verify that seal rings are hooked together and that front clutch thrust washer is properly positioned Fig 123 Use petroleum jelly to hold thrust washer in place if necessary 24 Lubricate oil pump body seal with petroleum jelly Lubricate pump shaft seal lip with petroleum jelly 2 DISASSEMBLY AND ASSEMBLY Continued EN SCREWDRIVER CLUTCH DISC TEETH Fig 120 Aligning Rear Clutch Disc Lugs FRONT CLUTCH REAR CLUTCH INPUT
411. wer housing and overdrive separa tor plate from transfer plate Fig 60 31 Remove the ECE check ball from the transfer plate Fig 61 The ECE check ball is approximately 4 8 mm 3 16 in in diameter LOWER OVERDRIVE TRANSFER PLATE HOUSING SEPARATOR AND UPPER PLATE HOUSING ORE AS RS Ly 255 5 rf 80b170f8 Fig 60 Lower Housing 21 44 TRANSMISSION AND TRANSFER CASE 2 DISASSEMBLY AND ASSEMBLY Continued 32 Remove transfer plate from upper housing TRANSFER UPPER Fig 62 PLATE HOUSING 33 Turn transfer plate over so upper housing sep d ao arator plate is facing upward FILTER 34 Remove upper housing separator plate from transfer plate Fig 63 Note position of filter in sep arator plate for assembly reference 35 Remove rear clutch and rear servo check balls from transfer plate Note check ball location for assembly reference Fig 64 VALVE BODY UPPER HOUSING 1 Note location of check balls in valve body upper housing Fig 65 Then remove the one large diame ter and the six smaller diameter check balls BRACE J9321 151 Fig 63 Upper Housing Separator Plate REAR REAR CLUTCH SERVO CHECK BALL BALL TRANSFER ECE CHECK BALL WS 2 9 321 437 Fig 64 Rear Clutch And Rear Servo Check Ball Locations SMALL DIAMETER CHECK BALLS 6 LARGE D
412. worn pump Governor pressure low at all mph figures Lubrication pressure low at all throttle positions 2 DIAGNOSIS AND 5 Continued CONVERTER STALL TEST Stall testing involves determining maximum engine speed obtainable at full throttle with the rear wheels locked and the transmission in D range This test checks the holding ability of the converter over running and transmission clutches WARNING NEVER ALLOW ANYONE TO STAND DIRECTLY IN LINE WITH THE VEHICLE FRONT OR REAR DURING A STALL TEST ALWAYS BLOCK THE WHEELS AND FULLY APPLY THE SERVICE AND PARKING BRAKES DURING THE TEST STALL TEST PROCEDURE 1 Connect tachometer to engine Position tachom eter so it can be viewed from driver s seat 2 Drive vehicle to bring transmission fluid up to normal operating temperature Vehicle can be driven on road or on chassis dynamometer if available 3 Check transmission fluid level Add fluid if nec essary 4 Block front wheels 5 Fully apply service and parking brakes 6 Open throttle completely and record maximum engine speed registered on tachometer It takes 4 10 seconds to reach max rpm Once max rpm has been achieved do not hold wide open throttle for more than 4 5 seconds CAUTION Stalling the converter causes a rapid increase in fluid temperature To avoid fluid over heating hold the engine at maximum rpm for no more than 5 seconds If engine exceeds 2500 rpm during the test release the
413. ype 7176 transmission fluid during overhaul and assembly Use petroleum jelly Mopar Door Ease or Ru Glyde to prelubricate seals O rings and thrust washers Petroleum jelly can also be used to hold parts in place during reassembly TRANSMISSION CASE CLEANING AND INSPECTION Clean the case in a solvent tank Flush the case bores and fluid passages thoroughly with solvent Dry the case and all fluid passages with compressed air Be sure all solvent is removed from the case and that all fluid passages are clear NOTE Do not use shop towels or rags to dry the case or any other transmission component unless they are made from lint free materials Lint will stick to case surfaces and transmission components and circulate throughout the transmission after assem bly A sufficient quantity of lint can block fluid pas sages and interfere with valve body operation 2 Inspect the case for cracks porous spots worn bores or damaged threads Damaged threads can be repaired with Helicoil thread inserts However the case will have to be replaced if it exhibits any type of damage or wear Lubricate the front band adjusting screw threads with petroleum jelly and thread the screw part way into the case Be sure the screw turns freely OVERRUNNING CLUTCH LOW REVERSE DRUM OVERDRIVE PISTON RETAINER Clean the overrunning dutch assembly dutch cam low reverse drum and overdrive piston retainer in solvent Dry them with compressed air aft

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