2014 Jeep Compass Limited

2014 AUTOMATIC TRANSMISSION 6F24 - Service Information - Compass & Patriot

2014 AUTOMATIC TRANSMISSION

6F24 - Service Information - Compass & Patriot

DIAGNOSIS AND TESTING

AIR TEST

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Fig. 1: Air Test Port Locations
Courtesy of CHRYSLER GROUP, LLC

1= 3-5-Reverse Clutch
2= Overdrive Clutch
3= 2-6 Brake
4= Underdrive Brake
5= Low-reverse Brake
6= To Cooler
7= From Cooler

Before the completion of the transaxle assembly procedure and before installing
the valve body, an air test should be performed to determine the condition of the
seals in the clutch and brake pistons. Using a rubber tip air nozzle, apply
regulated 482 kPa (70 psi) shop air into the ports shown for each clutch or brake.
ROAD TEST

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Prior to performing a road test, verify that the fluid level, fluid condition, and
linkage adjustment have been verified.

During the road test, the transaxle should be operated in each position to check
for slipping and any variation in shifting.

If the vehicle operates properly at highway speeds, but has poor acceleration, the
converter stator overrunning clutch may be slipping. If acceleration is normal,
but high throttle opening is needed to maintain highway speeds, the converter
stator clutch may have seized. Both of these stator defects require replacement of
the torque converter and thorough transaxle cleaning.
Slipping clutches can be isolated by comparing the "Elements in Use" chart with
clutch operation encountered on a road test. This chart identifies which clutches

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are applied at each position of the selector lever.

A slipping clutch may also set a DTC and can be determined by operating the
transaxle in all selector positions.

1.4 Liter And 2.0 Liter Engines

CLUTCH CLUTCH BRAKE BRAKE BRAKE
OD 35R 26 LR UD ONE
WAY
CLUTCH
GEAR 1 X X X
GEAR 2 X X
GEAR 3 X X
GEAR 4 X X
GEAR 5 X X
GEAR 6 X X
GEAR NEUTRAL/PARK X
GEAR R X X

2.4 Liter Engine

CLUTCH CLUTCH BRAKE BRAKE BRAKE
OD 35R 26 LR UD ONE
WAY
CLUTCH

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GEAR 1 X X X
GEAR 2 X X
GEAR 3 X X
GEAR 4 X X
GEAR 5 X X
GEAR 6 X X
GEAR NEUTRAL/PARK X
GEAR R X X
6F24 POWER FLOW

Hydraulic power flow is controlled by the TCM and the solenoids attached to the
valve body. The TCM toggles control voltage or ground on and off in a duty

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cycle to regulate the line pressure flowing through the valve body. The lower the
duty cycle percentage is the higher the line pressure. The pressure can be
measured with (special tool #10424, Adapter, Transmission Pressure) and
(special tool #C-3293-SP, Gauge, Pressure 0-300 P.S.I.).

Fig. 2: Valve Body Solenoids

Courtesy of CHRYSLER GROUP, LLC

1= Outer Valve Body

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2= VFS Solenoid Valve NH

3= On-Off Solenoid Valve
4= VFS Solenoid Valve NH
5= VFS Solenoid Valve NL
6= Over Drive Pressure Control Valve
7= Under Drive Pressure Control Valve
8= 2-6 Brake Pressure Control Valve
9= 3-5-R Pressure Control Valve
10= Adjust Screws
11= Reducing Valve
12= Regulator Valve
13= Regulator Sleeve

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Solenoid Clutch/Brake
Gear OD UD 2/6 3/5/R TCC
LPS SS-A SS-B OD 3/5/R 2/6
(LR (with
with SS-B)
SS-A)
Normal Normal Normal Normal Normal Normal Normal Normal
Open Open Closed Open Closed Open Closed Closed
P 7% 42% 7% 41% 7% 45% 82% OL
(13.6V)
R 7% 42% 7% 6.80% 7% 8% 82% 82% 230
(3V) psi
N 7% 42% 7% 42% 45% 82% OL

D1 7% 7% 13% 42% 45% @ 82% OL

idle
(min
pres.)
8% @
max
pres.
36% @
90 psi
AS1 40% 7% 13% 42% 82% 82%

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AS2 40% 7% 39% 42% OL OL 50

psi
AS3 40% 7% 7% 6.70% OL OL 50
psi
AS4 7% 7% 7% 40% OL OL 51
psi
AS5 7% 42% 7.60% 6.70% OL 82% 51 50
psi psi
AS6 7% 42% 39% 41% OL OL 51 50
psi psi

General Line Pressure Readings

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LPS Duty Cycle (%) Pressure
8% 230 psi
34% 97 psi
36% 90 psi
45% 47-50 psi

Solenoid Reduced Circuit Feeds

RED 1 (SS-A/SS-B) 73-75 psi max.
RED 2 (all other solenoids 79-81 psi max.

CLUTCHES/BRAKES
Gear OWC Holding Brake Driving Clutch
Range Low/Rev Underdrive 2/6 3/5/R Overdrive
P/N O
1st O X O
2nd O O
3rd O O
4th O O
5th O O
6th O O
Low O O
Rev O O

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O = Applied X = Applied under certain

conditions

ON/OFF Variable Force Solenoids

Gear SS/A- SS/B- UD-NO OD-NO 3/5/R- 2/6-NC LPS- TCC-
NC NC NO NO NC
P/N O O O X
1st X X O X
2nd O O O X X
3rd O O X X
4th O X X
5th O O X X

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6th O O O X X
Low O O X X
Rev O O O X X
O = Electric signal applied X = Electric signal may be applied
for certain conditions
NO = Normally hydraulically open NC = Normally hydraulically
closed
TRANS RANGE SENSOR (TRS)

The Trans Range Sensor (TRS) provides data to the Transmission Control
Module (TCM) and other ECUs about the gear range that has been selected by
the operator. The TRS also indicates from which direction the range selector was
moved to obtain the current gear position. The accompanying table provides an
overview of how the sensor sends Closed (1) or Open (0) signals to indicate the
range the gear selector just left and the current position the gear selector is in.
The TRS also functions as a neutral safety switch to inhibit the starter if the
transaxle is not in Park or Neutral. The TRS also functions as a reverse lamp
switch and will signal the Body Control Module (BCM) to turn on the back-up
lamps when the transaxle is shifted into reverse.

S4 S3 S2 S1
P 0 0 0 1
pr 0 0 1 1
R 0 0 1 0

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rn 0 1 1 0
N 0 1 0 0
nd 1 1 0 0
D 1 0 0 0
d3 1 1 1 1

Continuity Test
Using a suitable continuity tester or OHM meter test for continuity from pin 3 to
each of the signal Pins as the sensor is cycled to each shift position.

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Fig. 3: Transmission Range Sensor Connector Terminal Identification
Courtesy of CHRYSLER GROUP, LLC

1 = S5 (Signal, Pst, Nst)

2 = Power (12v, Pst, Nst)
3 = Power (12v)
4= S2 (Signal R)
5 = NC
6 = NC
7 = S3 (Signal N)
8= S1 (Signal P)
9 = S4 (Signal D)

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REMOVAL
FWD

1. Position vehicle on a suitable hoist with transaxle in neutral.

2. Release the hood latch and open the hood. Support the hood on the prop-rod
3. Release the fasteners holding the engine air-box to the front crossmember.
4. Separate the engine air-box from the vehicle.
5. Remove the battery form the vehicle. Refer to BATTERY, REMOVAL .
6. Remove the battery tray from the vehicle. Refer to TRAY, BATTERY,
REMOVAL .
7. Remove the air box lid and position it out of the way.
8. Loosen the engine inlet air tube clamp.

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9. Remove the lower air cleaner body. Refer to 2.0L BODY, AIR
CLEANER, REMOVAL , 2.2L BODY, AIR CLEANER, REMOVAL or
2.4L BODY, AIR CLEANER, REMOVAL .

Fig. 4: Air Cleaner Bracket Nuts & Bolts

Courtesy of CHRYSLER GROUP, LLC
10. Remove bolts and nuts (1) holding the lower air cleaner bracket to the left
frame rail.

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Fig. 5: Lower Air Cleaner Bracket

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Courtesy of CHRYSLER GROUP, LLC
11. Separate the lower air cleaner bracket (1) from the vehicle.

Fig. 6: Shift Cable End & Manual Lever

Courtesy of CHRYSLER GROUP, LLC
12. Using a suitable prying tool (2), lift upward on the shift cable end (1) at the
transaxle manual lever.
13. Separate the shift cable (1) from the manual lever.
14. Release the clips holding the shift cable to the bracket on the top of the
transaxle.

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15. Position the shaft cable (1) out of the way.

16. Release the lock on the transaxle solenoid connector (1).

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Fig. 7: Transaxle Wire Harness Connector
Courtesy of CHRYSLER GROUP, LLC
17. Separate the wire harness connector (1) from the transaxle.

Fig. 8: Transaxle TRS Connector

Courtesy of CHRYSLER GROUP, LLC
18. Release the lock (2) on the transaxle TRS connector.
19. Separate the wire harness connector from the transaxle (1).

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Fig. 9: Vent Tube & Bolt

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Courtesy of CHRYSLER GROUP, LLC
20. Remove the bolt (2) holding the vent tube (1) to the transaxle.
21. Position the vent tube (1) out of the way.

Fig. 10: Ground Cable & Transaxle Bellhousing Bolt

Courtesy of CHRYSLER GROUP, LLC
22. Remove the hidden bolt (1) holding the ground cable and transaxle
bellhousing to the engine block from under the engine coolant tubes.

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Fig. 11: Starter Motor Bolts

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Courtesy of CHRYSLER GROUP, LLC
23. Remove the hidden bolts (1, 2) holding the starter motor to the engine block
and bellhousing.

NOTE: The starter will stay in place after the transaxle is

removed.

24. Position a suitable floor jack under the left (driver) side of the transaxle to
add support.
25. Lift jack enough the support the transaxle but not raise it.

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Fig. 12: Transaxle Mount Bolts

Courtesy of CHRYSLER GROUP, LLC
26. Remove the through bolt (2) holding the transaxle mount rubber isolator to
the frame rail bracket.
27. Remove the bolts (1) holding the transaxle mount to the transaxle.
28. Lower the transaxle to gain clearance for the transaxle mount.
29. Separate the transaxle mount from the vehicle.

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Fig. 13: Transaxle Cooler Hose Clamps
Courtesy of CHRYSLER GROUP, LLC
30. Using a suitable clamp pliers (3), release the clamps (1) holding the
transaxle cooler hoses to the tubes (2) on the transaxle.

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Fig. 14: Cooler Tubes & Hoses

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Courtesy of CHRYSLER GROUP, LLC

CAUTION: Do not bend or crush the transaxle cooler

tubes when removing the cooler hoses. If the
tubes become damaged, they must be
replaced.

31. Using suitable hose/spark plug wire pliers, separate the hoses (1) from the
cooler tubes (2) on the transaxle.
32. Raise the vehicle.
33. Remove the belly pan. Refer to BELLY PAN, REMOVAL .
34. Place a suitable drain pan under the transaxle to catch fluid that may leak
when the halfshafts are removed.
35. Remove the left and right halfshafts. Refer to REMOVAL .

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Fig. 15: Torque Converter Bolt Access Plug

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Courtesy of CHRYSLER GROUP, LLC
36. Using a flat blade screw driver to release the locks (1), remove the torque
converter bolt access plug (2) from the bellhousing cover.

Fig. 16: Torque Converter Bolt

Courtesy of CHRYSLER GROUP, LLC
37. Remove the bolts (2) holding the flex plate to the torque converter.

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Fig. 17: Bellhousing Bolt

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Courtesy of CHRYSLER GROUP, LLC
38. Remove the hidden bolt (2) holding the engine block to the bellhousing from
behind the heat-shield (1) at the back of the engine.

Fig. 18: Bellhousing Bolt

Courtesy of CHRYSLER GROUP, LLC
39. Remove the bolt (1) holding the engine block (2) to the bellhousing next to
the starter motor.

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Fig. 19: Bellhousing Bolts

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Courtesy of CHRYSLER GROUP, LLC
40. Remove the bolts (1) holding the lower engine adapter to the bellhousing.

Fig. 20: Supporting Engine

Courtesy of CHRYSLER GROUP, LLC
41. Position a suitable high-stand (3) under the engine for support when the
front-to-rear support member is removed.

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Fig. 21: Front-To-Rear Support

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Courtesy of CHRYSLER GROUP, LLC
42. Remove the trough bolt (1) holding the front-to-rear support rubber isolator
to the front crossmember.
43. Remove the bolts (2) holding the front-to-rear support to the front and rear
crossmembers.
44. Separate the front-to-rear support from the vehicle.

Fig. 22: Supporting Engine

Courtesy of CHRYSLER GROUP, LLC
45. Position a suitable transmission jack (2) under the transaxle so the weight is

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evenly distributed across the jack cradle (2).

46. Install a safety chine (4) to hold the transaxle (1) to the jack cradle.
47. Lift the transaxle (1) so not all of the weight is bearing on the high-stand (3).

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Fig. 23: Rear Transaxle Mount
Courtesy of CHRYSLER GROUP, LLC
48. Remove the bolts (2) holding the rear transaxle mount (1) to the back of the
transaxle.

NOTE: The rear mount will flex out of the way during
transaxle removal.

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Fig. 24: Bellhousing Bolts

Courtesy of CHRYSLER GROUP, LLC
49. Remove the remaining bolts (1, 2) holding the engine block to the
bellhousing.

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Fig. 25: Bellhousing & Engine Block
Courtesy of CHRYSLER GROUP, LLC
Separate the bellhousing (1) from the engine block (2).

While guiding the transaxle past obstacles, lower the transaxle downward
until the transaxle is clear of the vehicle.
AWD

1. Position vehicle on a suitable hoist with transaxle in neutral.

2. Release the hood latch and open the hood. Support the hood on the prop-rod
3. Remove the engine cover. Refer to COVER, ENGINE, REMOVAL .
4. Release the fasteners holding the engine air-box to the front crossmember.
5. Separate the engine air-box from the vehicle.
6. Remove the battery form the vehicle. Refer to BATTERY, REMOVAL .
7. Remove the battery tray from the vehicle. Refer to TRAY, BATTERY,
REMOVAL .
8. Remove the air box lid and position it out of the way.

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9. Loosen the engine inlet air tube clamp.

10. Remove the lower air cleaner body. Refer to 2.0L BODY, AIR
CLEANER, REMOVAL , 2.2L BODY, AIR CLEANER, REMOVAL or
2.4L BODY, AIR CLEANER, REMOVAL .

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Fig. 26: Air Cleaner Bracket Nuts & Bolts
Courtesy of CHRYSLER GROUP, LLC
11. Remove bolts and nuts (1) holding the lower air cleaner bracket to the left
frame rail.

Fig. 27: Lower Air Cleaner Bracket

Courtesy of CHRYSLER GROUP, LLC

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12. Separate the lower air cleaner bracket (1) from the vehicle.

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Fig. 28: Shift Cable End & Manual Lever
Courtesy of CHRYSLER GROUP, LLC
13. Using a suitable prying tool (2), lift upward on the shift cable end (1) at the
transaxle manual lever.
14. Separate the shift cable (1) from the manual lever.
15. Release the clips holding the shift cable to the bracket on the top of the
transaxle.
16. Position the shaft cable (1) out of the way.
17. Release the lock on the transaxle solenoid connector (1).

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Fig. 29: Transaxle Wire Harness Connector

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Courtesy of CHRYSLER GROUP, LLC
18. Separate the wire harness connector (1) from the transaxle.

Fig. 30: Transaxle TRS Connector

Courtesy of CHRYSLER GROUP, LLC
19. Release the lock (2) on the transaxle TRS connector.
20. Separate the wire harness connector from the transaxle (1).

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Fig. 31: Vent Tube & Bolt

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Courtesy of CHRYSLER GROUP, LLC
21. Remove the bolt (2) holding the vent tube (1) to the transaxle.
22. Position the vent tube (1) out of the way.

Fig. 32: Ground Cable & Transaxle Bellhousing Bolt

Courtesy of CHRYSLER GROUP, LLC
23. Remove the hidden bolt (1) holding the ground cable and transaxle
bellhousing to the engine block from under the engine coolant tubes.

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Fig. 33: Starter Motor Bolts

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Courtesy of CHRYSLER GROUP, LLC
24. Remove the hidden bolts (1, 2) holding the starter motor to the engine block
and bellhousing.

NOTE: The starter will stay in place after the transaxle is

removed.

25. Remove the Maniverter. Refer to 2.0L MANIFOLD, EXHAUST,

REMOVAL , 2.2L MANIFOLD, EXHAUST, REMOVAL or 2.4L
MANIFOLD, EXHAUST, REMOVAL .
26. Position a suitable floor jack under the left (driver) side of the transaxle to
add support.
27. Lift jack enough the support the transaxle but not raise it.

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Fig. 34: Transaxle Mount Bolts

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Courtesy of CHRYSLER GROUP, LLC
28. Remove the through bolt (2) holding the transaxle mount rubber isolator to
the frame rail bracket.
29. Remove the bolts (1) holding the transaxle mount to the transaxle.
30. Lower the transaxle to gain clearance for the transaxle mount.
31. Separate the transaxle mount from the vehicle.

Fig. 35: Transaxle Cooler Hose Clamps

Courtesy of CHRYSLER GROUP, LLC
32. Using a suitable clamp pliers (3), release the clamps (1) holding the

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transaxle cooler hoses to the tubes (2) on the transaxle.

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Fig. 36: Cooler Tubes & Hoses
Courtesy of CHRYSLER GROUP, LLC

CAUTION: Do not bend or crush the transaxle cooler

tubes when removing the cooler hoses. If the
tubes become damaged, they must be
replaced.

33. Using suitable hose/spark plug wire pliers, separate the hoses (1) from the
cooler tubes (2) on the transaxle.
34. Raise the vehicle.
35. Remove the belly pan. Refer to BELLY PAN, REMOVAL .
36. Place a suitable drain pan under the transaxle to catch fluid that may leak
when the halfshafts are removed.
37. Remove the left and right halfshafts. Refer to REMOVAL .

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Fig. 37: Supporting Engine

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Courtesy of CHRYSLER GROUP, LLC
38. Position a suitable high-stand (3) under the engine for support when the
front-to-rear support member is removed.

Fig. 38: Front-To-Rear Support

Courtesy of CHRYSLER GROUP, LLC
39. Remove the trough bolt (1) holding the front-to-rear support rubber isolator
to the front crossmember.
40. Remove the bolts (2) holding the front-to-rear support to the front and rear
crossmembers.

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41. Separate the front-to-rear support from the vehicle.

42. Remove the power transfer unit (PTU). Refer to REMOVAL .

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Fig. 39: Torque Converter Bolt Access Plug
Courtesy of CHRYSLER GROUP, LLC
43. Using a flat blade screw driver to release the locks (1), remove the torque
converter bolt access plug (2) from the bellhousing cover.

Fig. 40: Torque Converter Bolt

Courtesy of CHRYSLER GROUP, LLC
44. Remove the bolts (2) holding the flex plate to the torque converter.

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Fig. 41: Bellhousing Bolts
Courtesy of CHRYSLER GROUP, LLC
45. Remove the bolts (1) holding the engine block to the bellhousing at the back
of the engine.

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Fig. 42: Bellhousing Bolt

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Courtesy of CHRYSLER GROUP, LLC
46. Remove the bolt (1) holding the engine block (2) to the bellhousing next to
the starter motor.

Fig. 43: Bellhousing Bolts

Courtesy of CHRYSLER GROUP, LLC
47. Remove the bolts (1) holding the lower engine adapter to the bellhousing.

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Fig. 44: Supporting Engine

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Courtesy of CHRYSLER GROUP, LLC
48. Position a suitable transmission jack (2) under the transaxle so the weight is
evenly distributed across the jack cradle (2).
49. Install a safety chine (4) to hold the transaxle (1) to the jack cradle.
50. Lift the transaxle (1) so not all of the weight is bearing on the high-stand (3).

Fig. 45: Rear Transaxle Mount

Courtesy of CHRYSLER GROUP, LLC
51. Remove the bolts (2) holding the rear transaxle mount (1) to the back of the
transaxle (typical).

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52. Remove the remaining bolts (1) holding the engine block to the bellhousing.

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Fig. 46: Bellhousing & Engine Block
Courtesy of CHRYSLER GROUP, LLC
53. Separate the bellhousing (1) from the engine block (2).
54. While guiding the transaxle past obstacles, lower the transaxle downward
until the transaxle is clear of the vehicle.
DISASSEMBLY
FWD

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

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Fig. 47: Pin Punch, Manual Lever & Transmission Range Sensor

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Courtesy of CHRYSLER GROUP, LLC
1. Insert a suitable pin punch (2) or equivalent through the manual lever into
the TRS switch (1) to hold lever in place.
2. Remove nut holding the manual lever to the manual shaft.

Fig. 48: Manual Lever & Manual Shaft

Courtesy of CHRYSLER GROUP, LLC
3. Separate the manual level (1) from the manual shaft.

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Fig. 49: Transmission Range Sensor

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Courtesy of CHRYSLER GROUP, LLC
4. Remove bolts holding the TRS (1) to the transaxle housing.

Fig. 50: Transmission Range Sensor Separated From Transaxle

Courtesy of CHRYSLER GROUP, LLC
5. Separate the TRS (1) from the transaxle.

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2014 AUTOMATIC TRANSMISSION 6F24 - Service Information - Compass & Patriot

Fig. 51: Vent Hose, Spring Clamp & Pliers

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
6. Using common pliers (3), compress the hose spring clamp (2) and slide it
down the vent hose (1) away from the nipple adaptor.

Fig. 52: Vent Hose End & Nipple Adapter

Courtesy of CHRYSLER GROUP, LLC
7. Pull the vent hose end (1) off of the nipple adaptor (2).

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Fig. 53: Vent Tube Bracket & Bolt

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
8. Remove bolt holding the vent tube bracket (2) to the transaxle housing.
9. Separate the vent tube (3) from the transaxle (1).

Fig. 54: Cooler Tubes & Banjo Bolts

Courtesy of CHRYSLER GROUP, LLC
10. Remove banjo bolts (2) holding the cooler tubes (1) to the transaxle.

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Fig. 55: Cooler Tubes & Transaxle

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
11. Remove bolt holding the cooler tube (2) bracket to the transaxle (1).
12. Separate the cooler tubes from the transaxle.

Fig. 56: Valve Body Cover

Courtesy of CHRYSLER GROUP, LLC
13. Position the transaxle over a suitable drain pan.
14. Remove bolts holding the valve body cover (2) to the transaxle (1).

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Fig. 57: Valve Body Cover Separated From Transaxle

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
15. Separate the cover (1) from the transaxle (2).

Fig. 58: Fluid Temperature Sensor, Valve Body & Bolt

Courtesy of CHRYSLER GROUP, LLC
16. Remove bolt holding fluid temperature sensor (1) to the valve body (2).
17. Pull temperature sensor (1) straight out of the port in the valve body (2).

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Fig. 59: Solenoid Valve Connector, Valve Body & Bolts

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
18. Remove bolts holding the solenoid valve connector (2) to the valve body
(1).

Fig. 60: Solenoids & Connector

Courtesy of CHRYSLER GROUP, LLC
19. Starting at the bottom solenoid valve, using a suitable prying tool, pry
outward at each solenoid (2) until the connector (3) is disengaged.

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Fig. 61: Manual Shaft Detent Spring & Valve Body

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
20. Remove the screw holding the manual shaft detent spring (1) to the valve
body (2).

Fig. 62: Detent Spring Separated From Valve Body

Courtesy of CHRYSLER GROUP, LLC
21. Separate the detent spring (2) from the valve body (1).

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Fig. 63: Valve Body Bolts

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
22. Remove bolts, 7 short (1) and 1 long (2) bolts, holding the valve body to the
transaxle.

The manual valve is loose after the valve body is removed and may fall
out during removal.

Fig. 64: Valve Body Separated From Transaxle

Courtesy of CHRYSLER GROUP, LLC
23. Separate the valve body (2) from the transaxle (1).

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Fig. 65: Transfer Port Seals

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
24. Remove the two seals from the transfer ports in transaxle housing.

Fig. 66: Speed Sensors, Main Wire Harness & Bolts

Courtesy of CHRYSLER GROUP, LLC
25. Remove bolts (1) holding the speed sensors and main wire harness to
transaxle.
26. Separate the speed sensors and main wire harness from the transaxle.

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Fig. 67: Hold Down Bracket, Wire Connector & Bolts

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
27. Remove bolt holding the wire connector (1) hold down bracket (2) to the top
of transaxle housing.

Fig. 68: Wire Connector & Hold Down Bracket Separated From
Transaxle
Courtesy of CHRYSLER GROUP, LLC
28. Separate the wire connector (1) hold down bracket (2) from the transaxle.

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Fig. 69: Pushing Wire Connector Into Housing

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
29. Push the wire connector (1) inward to the inside of the transaxle housing.

Fig. 70: Main Wire Harness & Sensors

Courtesy of CHRYSLER GROUP, LLC
30. Separate the main wire harness and sensors (1) from the transaxle.

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Fig. 71: Manual Shaft, Pin & Magnet

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
31. Using a suitable magnet (2), remove the pin (3) holding the manual shaft (1)
in the transaxle from the hole in the pan gasket flange.

Fig. 72: Manual Shaft, Park Rod & Key Hole Slot
Courtesy of CHRYSLER GROUP, LLC
32. Rotate manual shaft (1) counterclockwise to align the staked nub on the park
rod (2) with the key hole slot (3) in the manual shaft detent comb.
33. Push manual shaft (1) downward until park rod (2) disengages form the
detent comb.

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34. Push the manual shaft (1) inward to the inside of the transaxle.
35. Separate the manual shaft (1) from the transaxle.

cardiagn.com
Fig. 73: Park Rod & Park Rod Guide
Courtesy of CHRYSLER GROUP, LLC
36. Disengage the park rod (1) from the park rod guide (2) in the transaxle
housing.
37. Separate the park rod (1) from the transaxle.
38. Using a suitable tool, remove the lip seal from the manual shaft hole in the
transaxle housing.

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Fig. 74: Transaxle Housing & Bolts

Courtesy of CHRYSLER GROUP, LLC
39. Remove five bolts from the back (3) and five bolts from the top (2) of the
transaxle housing (1).

cardiagn.com
Fig. 75: Transaxle Housing & Bottom Bolts
Courtesy of CHRYSLER GROUP, LLC
40. Remove six bolts from the bottom (2) of the transaxle housing (1).

Fig. 76: Inside Bell Housing Bolts

Courtesy of CHRYSLER GROUP, LLC

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41. Remove five bolts (1) from inside bell housing (2).

cardiagn.com
Fig. 77: Notch Locations At Top Of Case For Prying Case Halves Apart
Courtesy of CHRYSLER GROUP, LLC
42. Using a suitable pry bar, pay the case halves apart in notch (2) location on
top of the housing (1).

Fig. 78: Notch Locations At Bottom Of Case For Prying Case Halves
Apart
Courtesy of CHRYSLER GROUP, LLC
43. Pry the case halves apart in notch location (2) on the bottom of the housing

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(1).

cardiagn.com
Fig. 79: Bell Housing Separated From Transaxle
Courtesy of CHRYSLER GROUP, LLC
44. Separate the bell housing (1) from the transaxle (2).
45. Remove bolts holding the fluid guide to the transaxle housing.
46. Separate the fluid guide from the transaxle.
47. Remove bolts holding the lubrication tube to the transaxle.
48. Separate the lubrication tube from the transaxle.

Fig. 80: Differential Assembly Separated From Transaxle Housing

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Courtesy of CHRYSLER GROUP, LLC

49. Separate the differential assembly (1) from the transaxle housing (2).

cardiagn.com
Fig. 81: Small Transfer Port Seals
Courtesy of CHRYSLER GROUP, LLC
50. Remove seals from four small transfer ports (2) in the transaxle housing (1).

Fig. 82: Large Transfer Port Seal

Courtesy of CHRYSLER GROUP, LLC
51. Remove seal from the large transfer port (1) in the axle housing (2).

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Fig. 83: Fluid Filter, Fluid Pump & Bolts

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
52. Remove bolts (1) holding the fluid filter to the fluid pump (3) housing.

Fig. 84: Fluid Filter Separated From Transaxle Housing

Courtesy of CHRYSLER GROUP, LLC
53. Separate the fluid filter (2) from the transaxle housing (1).

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Fig. 85: Fluid Pump Housing O-Ring Seal & Hook Tool

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
54. Using a suitable hook tool (1), remove o-ring seal (4) from the groove (3) in
the fluid pump housing (3).

Fig. 86: Fluid Pump & Bolts

Courtesy of CHRYSLER GROUP, LLC
55. Remove bolts (1) holding fluid pump (3) to the trans axle housing (2).

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Fig. 87: Fluid Pump Separated From Transaxle Housing

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
56. Separate the fluid pump (2) from the transaxle housing (1).

Fig. 88: Thrust Washer & Fluid Pump

Courtesy of CHRYSLER GROUP, LLC
57. Remove the plastic thrust washer (2) from the underside of the fluid pump
(1). There are three nubs that insert into holes in the fluid pump hub to
prevent the thrust washer from rotating.

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Fig. 89: Split Seal Rings & Fluid Pump Hub

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
58. Remove two split seal rings (3) from land-grooves (2) in fluid pump (1) hub.

Fig. 90: Split Ring Seals & Input Shaft

Courtesy of CHRYSLER GROUP, LLC
59. Remove two split ring seals (2) from the input shaft (1).

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Fig. 91: 2/6 Brake Wave Plate & Hub

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
60. Remove 2/6 brake wave plate (1) from 2/6 brake hub.

Fig. 92: 2/6 Brake Plates, Discs & Hub

Courtesy of CHRYSLER GROUP, LLC
61. Remove the 2/6 brake (1) plates (3) and discs (2) from the 2/6 brake hub.

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Fig. 93: 2/6 Brake Select Thickness Reaction Plate & Hub

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
62. Remove 2/6 brake select thickness reaction plate (1) from the 2/6 brake hub.

Fig. 94: 3/5/R Clutch Assembly, 3/5/R & 2/6 Brake Hub Assembly
Courtesy of CHRYSLER GROUP, LLC
63. Remove the 3/5/R clutch assembly (1) from the 3/5/R and 2/6 brake hub (2)
assembly.

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Fig. 95: 3/5/R Clutch & 2/6 Brake Hub, Thrust Bearing

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
64. Remove the thrust bearing (2) from the 3/5/R clutch and 2/6 brake hub.
Mark the side toward 3/5/R clutch and 2/6 brake hub on bearing for
installation orientation.

Fig. 96: 3/5/R Clutch & 2/6 Brake Hub Assembly

Courtesy of CHRYSLER GROUP, LLC
65. Remove the 3/5/R clutch and 2/6 brake hub (2) assembly from the
underdrive brake.

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Fig. 97: Underdrive Brake Hub & Thrust Washer

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
66. Remove thrust washer (2) from underdrive brake hub.

Fig. 98: Underdrive Brake Hub

Courtesy of CHRYSLER GROUP, LLC
67. Remove underdrive brake hub (1) assembly from transaxle.

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Fig. 99: Underdrive Brake, Underdrive Brake Drum, & Large Snap

cardiagn.com
Ring
Courtesy of CHRYSLER GROUP, LLC
68. Remove large snap ring (3) holding underdrive brake (1) into underdrive
brake drum.

Fig. 100: Underdrive Brake Plates, Discs & Drum

Courtesy of CHRYSLER GROUP, LLC
69. Separate underdrive brake plates and discs from underdrive brake drum.
70. Turn the transaxle over to gain access to the rear cover.

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Fig. 101: Transaxle Rear Cover & Bolts

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
71. Remove bolts holding the rear cover (1) to the transaxle.

Fig. 102: Prying Locations At Rear Cover

Courtesy of CHRYSLER GROUP, LLC
72. In three locations (1) on the rear cover, pry upward using a suitable pry bar
(3).

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Fig. 103: Rear Cover Separated From Transaxle

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
73. Separate the rear cover (1) from the transaxle.

Fig. 104: Selective Spacer, Bearing & Rear Cover

Courtesy of CHRYSLER GROUP, LLC
74. Remove the selective spacer (3) and bearing (1) from under rear cover (2).

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Fig. 105: Split Seal Rings & Rear Cover Hub

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
75. Remove the two split seal rings (2) from the lands in the rear cover (1) hub.

Fig. 106: Transfer Port Seals In Transaxle Housing

Courtesy of CHRYSLER GROUP, LLC
76. Using a suitable hook tool (1), Remove the four seals (2) from transfer ports
in transaxle housing.

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Fig. 107: Thrust Bearing & Overdrive Clutch Hub Assembly

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
77. Remove thrust bearing from the overdrive clutch hub assembly.

Fig. 108: Overdrive Clutch Assembly & One Way Clutch

Courtesy of CHRYSLER GROUP, LLC
78. Remove the overdrive clutch assembly (1) from the one way clutch (2).

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Fig. 109: Thrust Washer & Planetary Gear Assembly Hub

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
79. Remove the plastic thrust washer (1) from the planetary gear assembly hub.

Fig. 110: Thrust Bearing, Race Set & Middle/Rear Planetary Gear
Assembly
Courtesy of CHRYSLER GROUP, LLC
80. Using a suitable hook tool, lift the thrust bearing (1) and race set out of the
center of the middle/rear planetary gear assembly (2).
81. Turn transaxle over to gain access to the underdrive springs.

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Fig. 111: Tool 5058A & Tool 10426

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
82. Insert the bolt for tool 5058A through tool 10426.

Fig. 112: Tool Bolt & Tool Cross Bar

Courtesy of CHRYSLER GROUP, LLC
83. Insert the tool bolt with the spring compressor through the center of the
transaxle and out the back into the threaded center bore of the tool cross bar
spanning the back of the transaxle.

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Fig. 113: Special Tool #5058A-3

Courtesy of CHRYSLER GROUP, LLC
(special tool #5058A-3, Screw, Forcing)

cardiagn.com
Fig. 114: Special Tool #10426
Courtesy of CHRYSLER GROUP, LLC
(special tool #10426, Compressor, Underdrive Spring)

Compress the underdrive springs (3) to gain access to the snap ring.

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Fig. 115: Underdrive Spring Plate Snap Ring

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
84. Remove the snap ring holding the underdrive spring plate to the underdrive
brake hub.

Fig. 116: Underdrive Spring Retainer & Underdrive Brake Piston

Courtesy of CHRYSLER GROUP, LLC
85. Remove the spring compressor tool from the transaxle.
86. Separate the underdrive spring retainer (1) from the underdrive brake piston
(2).

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Fig. 117: Underdrive Brake Piston & Underdrive Brake Chamber

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
87. Using a suitable pick tool (2) lift the underdrive brake piston (3), in several
locations, from the underdrive brake chamber.

Fig. 118: Underdrive Brake Piston & Location Tabs

Courtesy of CHRYSLER GROUP, LLC
88. Remove the underdrive brake piston (1) from the underdrive brake piston
chamber.

NOTE: The location tabs (2) on the underdrive brake piston

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should be oriented toward the valve body opening in

the transaxle.

89. Remove the D-ring outer seal and the O-ring inner seal from the underdrive
piston.

cardiagn.com
Fig. 119: Underdrive Brake Chamber & Bolts
Courtesy of CHRYSLER GROUP, LLC
90. Remove bolts (1) holding the underdrive brake chamber (2) to the transaxle
housing.

Fig. 120: Underdrive Brake Chamber & Transaxle Housing

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Courtesy of CHRYSLER GROUP, LLC

91. Separate the underdrive brake chamber from the transaxle housing.

cardiagn.com
Fig. 121: Underdrive Brake Retainer & Bolts
Courtesy of CHRYSLER GROUP, LLC
92. Mark the location and direction of the underdrive brake retainer in relation
to the bolt holes in the transaxle housing to ensure proper installation.
93. Using an impact driver (1), loosen the bolts holding the underdrive brake
retainer (2) to the transaxle housing without damaging the Torx® drive
heads.

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Fig. 122: Underdrive Brake Retainer & Bolts

Courtesy of CHRYSLER GROUP, LLC
94. Remove bolts (2) holding the underdrive brake retainer (1) to the transaxle
housing.

cardiagn.com
Fig. 123: Underdrive Brake Retainer & Transaxle Housing
Courtesy of CHRYSLER GROUP, LLC
95. Separate the underdrive brake retainer (2) from the transaxle housing (1).

Fig. 124: Park Rod Guide & Bolts

Courtesy of CHRYSLER GROUP, LLC

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96. Remove bolts holding the park rod guide (1) from the transaxle housing.

cardiagn.com
Fig. 125: Park Sprag Spring & Park Sprag
Courtesy of CHRYSLER GROUP, LLC
97. Using a suitable hook tool (1), lift the park sprag spring (2) off the park
sprag.

Fig. 126: Park Sprag Spring, Shaft & Transaxle Housing

Courtesy of CHRYSLER GROUP, LLC
98. Remove the park sprag spring and shaft (1) from the transaxle housing.

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Fig. 127: Park Sprag & Transaxle Housing

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
99. Separate the park sprag (1) from the transaxle housing.

Fig. 128: Park Sprag Support Shaft & Transaxle Housing

Courtesy of CHRYSLER GROUP, LLC
100. Remove the park sprag support shaft (1) from the transaxle housing.

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Fig. 129: Transfer Driven Gear Assembly & Transaxle

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
101. Remove the transfer driven gear (1) assembly from the transaxle (2).
102. Turn the transaxle over to gain access to the One-way-clutch.

Fig. 130: One-Way-Clutch Snap Ring

Courtesy of CHRYSLER GROUP, LLC
103. Remove the snap ring (1) holding the OWC to the transaxle housing.

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Fig. 131: One-Way-Clutch

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
104. Separate the OWC (1) from the transaxle. Mark the one way clutch to aid
installation orientation.

Fig. 132: Low/Reverse Brake & Snap Ring

Courtesy of CHRYSLER GROUP, LLC
105. Remove the snap ring (2) holding low/reverse brake into transaxle.

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Fig. 133: One Way Clutch Race & Snap Ring

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
106. Separate the low & reverse brake pressure plate, cushion plate and discs and
plates, in order, from transaxle.
107. Compress snap ring (1) holding one way clutch race (2) into transaxle.

Fig. 134: One Way Clutch Inner Race

Courtesy of CHRYSLER GROUP, LLC
108. Separate the one way clutch inner race (1) from the transaxle.

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Fig. 135: Rear Annulus Gear & Snap Ring

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
109. Remove the snap ring (2) holding the rear annulus gear (1) into transaxle.

Fig. 136: Rear Annulus Gear

Courtesy of CHRYSLER GROUP, LLC
110. Separate the rear annulus gear (1) from the transaxle.

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Fig. 137: Middle/Rear Planetary Gear Assembly

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
111. Separate the middle/rear planetary gear assembly (1) and from the planetary
gear hub.

Fig. 138: Front Planetary Gear Hub Thrust Washer

Courtesy of CHRYSLER GROUP, LLC
112. Remove the thrust washer (1) from front planetary gear hub.

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Fig. 139: Middle Sun Gear & Planetary Gear Hub

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
113. Separate the middle sun gear (1) from the planetary gear hub (2).

Fig. 140: Planetary Gear Hub Bearing And Race Set

Courtesy of CHRYSLER GROUP, LLC
114. Remove the bearing (2) and race (1) set from the planetary gear hub.

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Fig. 141: Front Sun Gear

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
115. Separate the front sun gear (1) from front planetary gear assembly.

Fig. 142: Front Planetary Gear & Front Annulus Gear Assembly
Courtesy of CHRYSLER GROUP, LLC
116. Separate the front planetary gear (1) the front annulus gear assembly (2).

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Fig. 143: Front Annulus Gear Thrust Bearing And Race

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
117. Separate the front annulus gear thrust bearing and race from the front
annulus gear hub,

Fig. 144: Front Annulus Gear

Courtesy of CHRYSLER GROUP, LLC
118. Separate the front annulus gear (1) from the low/reverse brake assembly.

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Fig. 145: Special Tool #5058A-3

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
119. Insert (special tool #5058A-3, Screw, Forcing) through center hole in
(special tool #8621, Compressor, Spring).

Fig. 146: Special Tool #5058A-3

Courtesy of CHRYSLER GROUP, LLC

Fig. 147: Special Tool #8621

Courtesy of CHRYSLER GROUP, LLC
Insert the screw through the transfer gear and into the threaded cross bar
across the bell housing opening.

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Fig. 148: Compressing Low/Reverse Spring Retainer

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
120. Compress the low/reverse spring retainer.

Fig. 149: Low/Reverse Brake Spring Retainer Snap Ring

Courtesy of CHRYSLER GROUP, LLC
121. Remove snap ring holding low/reverse brake spring retainer to the
low/reverse brake piston.
122. Remove spring compressor tools from transaxle.

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Fig. 150: Low/Reverse Brake Piston Spring Retainer

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
123. Remove low & reverse brake piston spring retainer.

Fig. 151: Low/Reverse Brake Piston

Courtesy of CHRYSLER GROUP, LLC
124. Separate low & reverse brake piston (1) from the transaxle housing.
125. Remove inside and outside D-ring seals from the low & reverse brake piston
(1).

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Fig. 152: Transfer Drive Assembly & Bolts

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
126. Remove bolts (2) holding transfer drive assembly (1) to the transaxle
housing.

Fig. 153: Transfer Drive Assembly

Courtesy of CHRYSLER GROUP, LLC
127. Remove the transfer drive assembly (1) from the transaxle case
AWD

NOTE: If the transaxle has not been drained before removal, fluid

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will spill from the valve body pan as it is removed.

cardiagn.com
Fig. 154: Pin Punch, Manual Lever & Transmission Range Sensor
Courtesy of CHRYSLER GROUP, LLC
1. Insert a suitable pin punch (2) or equivalent through the manual lever into
the TRS switch (1) to hold lever in place.
2. Remove nut holding the manual lever to the manual shaft.

Fig. 155: Manual Lever & Manual Shaft

Courtesy of CHRYSLER GROUP, LLC
3. Separate the manual level (1) from the manual shaft.

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Fig. 156: Transmission Range Sensor

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
4. Remove bolts holding the TRS (1) to the transaxle housing.

Fig. 157: Transmission Range Sensor Separated From Transaxle

Courtesy of CHRYSLER GROUP, LLC
5. Separate the TRS (1) from the transaxle.

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Fig. 158: Vent Hose, Spring Clamp & Pliers

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
6. Using common pliers (3), compress the hose spring clamp (2) and slide it
down the vent hose (1) away from the nipple adaptor.

Fig. 159: Vent Hose End & Nipple Adapter

Courtesy of CHRYSLER GROUP, LLC
7. Pull the vent hose end (1) off of the nipple adaptor (2).

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Fig. 160: Vent Tube Bracket & Bolt

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
8. Remove bolt holding the vent tube bracket (2) to the transaxle housing.
9. Separate the vent tube (3) from the transaxle (1).

Fig. 161: Cooler Tubes & Banjo Bolts

Courtesy of CHRYSLER GROUP, LLC
10. Remove banjo bolts (2) holding the cooler tubes (1) to the transaxle.

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Fig. 162: Cooler Tubes & Transaxle

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
11. Remove bolt holding the cooler tube (2) bracket to the transaxle (1).
12. Separate the cooler tubes from the transaxle.

Fig. 163: Valve Body Cover

Courtesy of CHRYSLER GROUP, LLC
13. Position the transaxle over a suitable drain pan.
14. Remove bolts holding the valve body cover (2) to the transaxle (1).

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Fig. 164: Valve Body Cover Separated From Transaxle

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
15. Separate the cover (1) from the transaxle (2).

Fig. 165: Fluid Temperature Sensor, Valve Body & Bolt

Courtesy of CHRYSLER GROUP, LLC
16. Remove bolt holding fluid temperature sensor (1) to the valve body (2).
17. Pull temperature sensor (1) straight out of the port in the valve body (2).

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Fig. 166: Solenoid Valve Connector, Valve Body & Bolts

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
18. Remove bolts holding the solenoid valve connector (2) to the valve body
(1).

Fig. 167: Solenoids & Connector

Courtesy of CHRYSLER GROUP, LLC
19. Starting at the bottom solenoid valve, using a suitable prying tool, pry
outward at each solenoid (2) until the connector (3) is disengaged.

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Fig. 168: Manual Shaft Detent Spring & Valve Body

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
20. Remove the screw holding the manual shaft detent spring (1) to the valve
body (2).

Fig. 169: Detent Spring Separated From Valve Body

Courtesy of CHRYSLER GROUP, LLC
21. Separate the detent spring (2) from the valve body (1).

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Fig. 170: Valve Body Bolts

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
22. Remove bolts, 7 short (1) and 1 long (2) bolts, holding the valve body to the
transaxle.

The manual valve is loose after the valve body is removed and may fall
out during removal.

Fig. 171: Valve Body Separated From Transaxle

Courtesy of CHRYSLER GROUP, LLC
23. Separate the valve body (2) from the transaxle (1).

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Fig. 172: Transfer Port Seals

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
24. Remove the two seals from the transfer ports in transaxle housing.

Fig. 173: Speed Sensors, Main Wire Harness & Bolts

Courtesy of CHRYSLER GROUP, LLC
25. Remove bolts (1) holding the speed sensors and main wire harness to
transaxle.
26. Separate the speed sensors and main wire harness from the transaxle.

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Fig. 174: Hold Down Bracket, Wire Connector & Bolts

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
27. Remove bolt holding the wire connector (1) hold down bracket (2) to the top
of transaxle housing.

Fig. 175: Wire Connector & Hold Down Bracket Separated From
Transaxle
Courtesy of CHRYSLER GROUP, LLC
28. Separate the wire connector (1) hold down bracket (2) from the transaxle.

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Fig. 176: Pushing Wire Connector Into Housing

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
29. Push the wire connector (1) inward to the inside of the transaxle housing.

Fig. 177: Main Wire Harness & Sensors

Courtesy of CHRYSLER GROUP, LLC
30. Separate the main wire harness and sensors (1) from the transaxle.

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Fig. 178: Manual Shaft, Pin & Magnet

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
31. Using a suitable magnet (2), remove the pin (3) holding the manual shaft (1)
in the transaxle from the hole in the pan gasket flange.

Fig. 179: Manual Shaft, Park Rod & Key Hole Slot
Courtesy of CHRYSLER GROUP, LLC
32. Rotate manual shaft (1) counterclockwise to align the staked nub on the park
rod (2) with the key hole slot (3) in the manual shaft detent comb.
33. Push manual shaft (1) downward until park rod (2) disengages form the
detent comb.

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34. Push the manual shaft (1) inward to the inside of the transaxle.
35. Separate the manual shaft (1) from the transaxle.

cardiagn.com
Fig. 180: Park Rod & Park Rod Guide
Courtesy of CHRYSLER GROUP, LLC
36. Disengage the park rod (1) from the park rod guide (2) in the transaxle
housing.
37. Separate the park rod (1) from the transaxle.
38. Using a suitable tool, remove the lip seal from the manual shaft hole in the
transaxle housing.

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Fig. 181: Transaxle Housing Bolts

Courtesy of CHRYSLER GROUP, LLC
39. Remove five bolts from the back (2) and four bolts from the top (1) of the
transaxle housing.

cardiagn.com
Fig. 182: Transaxle Housing Bolts
Courtesy of CHRYSLER GROUP, LLC
40. Remove six bolts from the bottom (2) of the transaxle housing.
41. Remove five bolts (1) from inside bell housing.
42. Using a suitable pry bar, pay the case halves apart in notch location on top
of the housing.

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Fig. 183: Transaxle Housing Notch Locations

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
43. Pry the case halves apart in notch location (2) on the bottom of the housing
(1).

Fig. 184: Transaxle Housing Halves

Courtesy of CHRYSLER GROUP, LLC
44. Separate the bell housing (1) from the transaxle (2).
45. Remove bolts holding the fluid guide to the transaxle housing.
46. Separate the fluid guide from the transaxle.
47. Remove bolts holding the lubrication tube to the transaxle.

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48. Separate the lubrication tube from the transaxle.

cardiagn.com
Fig. 185: Differential Assembly Separated From Transaxle Housing
Courtesy of CHRYSLER GROUP, LLC
49. Separate the differential assembly (1) from the transaxle housing (2).

Fig. 186: Small Transfer Port Seals

Courtesy of CHRYSLER GROUP, LLC
50. Remove seals from four small transfer ports (2) in the transaxle housing (1).

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Fig. 187: Large Transfer Port Seal

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
51. Remove seal from the large transfer port (1) in the axle housing (2).

Fig. 188: Fluid Filter, Fluid Pump & Bolts

Courtesy of CHRYSLER GROUP, LLC
52. Remove bolts (1) holding the fluid filter to the fluid pump (3) housing.

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Fig. 189: Fluid Filter Separated From Transaxle Housing

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
53. Separate the fluid filter (2) from the transaxle housing (1).

Fig. 190: Fluid Pump Housing O-Ring Seal & Hook Tool
Courtesy of CHRYSLER GROUP, LLC
54. Using a suitable hook tool (1), remove o-ring seal (4) from the groove (3) in
the fluid pump housing (3).

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Fig. 191: Fluid Pump & Bolts

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
55. Remove bolts (1) holding fluid pump (3) to the trans axle housing (2).

Fig. 192: Fluid Pump Separated From Transaxle Housing

Courtesy of CHRYSLER GROUP, LLC
56. Separate the fluid pump (2) from the transaxle housing (1).

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Fig. 193: Thrust Washer & Fluid Pump

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
57. Remove the plastic thrust washer (2) from the underside of the fluid pump
(1). There are three nubs that insert into holes in the fluid pump hub to
prevent the thrust washer from rotating.

Fig. 194: Split Seal Rings & Fluid Pump Hub

Courtesy of CHRYSLER GROUP, LLC
58. Remove two split seal rings (3) from land-grooves (2) in fluid pump (1) hub.

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Fig. 195: Split Ring Seals & Input Shaft

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
59. Remove two split ring seals (2) from the input shaft (1).

Fig. 196: 2/6 Brake Wave Plate & Hub

Courtesy of CHRYSLER GROUP, LLC
60. Remove 2/6 brake wave plate (1) from 2/6 brake hub.

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Fig. 197: 2/6 Brake Plates, Discs & Hub

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
61. Remove the 2/6 brake (1) plates (3) and discs (2) from the 2/6 brake hub.

Fig. 198: 2/6 Brake Select Thickness Reaction Plate & Hub
Courtesy of CHRYSLER GROUP, LLC
62. Remove 2/6 brake select thickness reaction plate (1) from the 2/6 brake hub.

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Fig. 199: 3/5/R Clutch Assembly, 3/5/R & 2/6 Brake Hub Assembly

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
63. Remove the 3/5/R clutch assembly (1) from the 3/5/R and 2/6 brake hub (2)
assembly.

Fig. 200: 3/5/R Clutch & 2/6 Brake Hub, Thrust Bearing
Courtesy of CHRYSLER GROUP, LLC
64. Remove the thrust bearing (2) from the 3/5/R clutch and 2/6 brake hub.
Mark the side toward 3/5/R clutch and 2/6 brake hub on bearing for
installation orientation.

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Fig. 201: 3/5/R Clutch & 2/6 Brake Hub Assembly

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
65. Remove the 3/5/R clutch and 2/6 brake hub (2) assembly from the
underdrive brake.

Fig. 202: Underdrive Brake Hub & Thrust Washer

Courtesy of CHRYSLER GROUP, LLC
66. Remove thrust washer (2) from underdrive brake hub.

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Fig. 203: Underdrive Brake Hub

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
67. Remove underdrive brake hub (1) assembly from transaxle.

Fig. 204: Underdrive Brake, Underdrive Brake Drum, & Large Snap
Ring
Courtesy of CHRYSLER GROUP, LLC
68. Remove large snap ring (3) holding underdrive brake (1) into underdrive
brake drum.

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Fig. 205: Underdrive Brake Plates, Discs & Drum

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
69. Separate underdrive brake plates and discs from underdrive brake drum.
70. Turn the transaxle over to gain access to the rear cover.

Fig. 206: Transaxle Rear Cover & Bolts

Courtesy of CHRYSLER GROUP, LLC
71. Remove bolts holding the rear cover (1) to the transaxle.

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Fig. 207: Prying Locations At Rear Cover

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
72. In three locations (1) on the rear cover, pry upward using a suitable pry bar
(3).

Fig. 208: Rear Cover Separated From Transaxle

Courtesy of CHRYSLER GROUP, LLC
73. Separate the rear cover (1) from the transaxle.

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Fig. 209: Selective Spacer, Bearing & Rear Cover

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
74. Remove the selective spacer (3) and bearing (1) from under rear cover (2).

Fig. 210: Split Seal Rings & Rear Cover Hub

Courtesy of CHRYSLER GROUP, LLC
75. Remove the two split seal rings (2) from the lands in the rear cover (1) hub.

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Fig. 211: Transfer Port Seals In Transaxle Housing

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
76. Using a suitable hook tool (1), Remove the four seals (2) from transfer ports
in transaxle housing.

Fig. 212: Thrust Bearing & Overdrive Clutch Hub Assembly

Courtesy of CHRYSLER GROUP, LLC
77. Remove thrust bearing from the overdrive clutch hub assembly.

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Fig. 213: Overdrive Clutch Assembly & One Way Clutch

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
78. Remove the overdrive clutch assembly (1) from the one way clutch (2).

Fig. 214: Thrust Washer & Planetary Gear Assembly Hub

Courtesy of CHRYSLER GROUP, LLC
79. Remove the plastic thrust washer (1) from the planetary gear assembly hub.

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Fig. 215: Thrust Bearing, Race Set & Middle/Rear Planetary Gear

cardiagn.com
Assembly
Courtesy of CHRYSLER GROUP, LLC
80. Using a suitable hook tool, lift the thrust bearing (1) and race set out of the
center of the middle/rear planetary gear assembly (2).
81. Turn transaxle over to gain access to the underdrive springs.

Fig. 216: Tool 5058A & Tool 10426

Courtesy of CHRYSLER GROUP, LLC
82. Insert the bolt for tool (special tool #5058A, Compressor, Spring) through
tool (special tool #10426, Compressor, Underdrive Spring).

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Fig. 217: Special Tool #5058A-3

Courtesy of CHRYSLER GROUP, LLC

cardiagn.com
Fig. 218: Special Tool #10426
Courtesy of CHRYSLER GROUP, LLC
.

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Fig. 219: Tool Bolt & Tool Cross Bar

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
83. Insert the tool bolt with the spring compressor (special tool #5058A,
Compressor, Spring) through the center of the transaxle and out the back
into the threaded center bore of the tool cross bar spanning the back of the
transaxle. Compress the underdrive springs (3) to gain access to the snap
ring.

Fig. 220: Special Tool #5058A-3

Courtesy of CHRYSLER GROUP, LLC

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Fig. 221: Underdrive Spring Plate Snap Ring

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
84. Remove the snap ring holding the underdrive spring plate to the underdrive
brake hub.

Fig. 222: Underdrive Spring Retainer & Underdrive Brake Piston

Courtesy of CHRYSLER GROUP, LLC
85. Remove the spring compressor tool from the transaxle.
86. Separate the underdrive spring retainer (1) from the underdrive brake piston
(2).

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Fig. 223: Underdrive Brake Piston & Underdrive Brake Chamber

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
87. Using a suitable pick tool (2) lift the underdrive brake piston (3), in several
locations, from the underdrive brake chamber.

Fig. 224: Underdrive Brake Piston & Location Tabs

Courtesy of CHRYSLER GROUP, LLC
88. Remove the underdrive brake piston (1) from the underdrive brake piston
chamber.

NOTE: The location tabs (2) on the underdrive brake piston

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should be oriented toward the valve body opening in

the transaxle.

89. Remove the D-ring outer seal and the O-ring inner seal from the underdrive
piston.

cardiagn.com
Fig. 225: Underdrive Brake Chamber & Bolts
Courtesy of CHRYSLER GROUP, LLC
90. Remove bolts (1) holding the underdrive brake chamber (2) to the transaxle
housing.

Fig. 226: Underdrive Brake Chamber & Transaxle Housing

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Courtesy of CHRYSLER GROUP, LLC

91. Separate the underdrive brake chamber from the transaxle housing.

cardiagn.com
Fig. 227: Underdrive Brake Retainer & Bolts
Courtesy of CHRYSLER GROUP, LLC
92. Mark the location and direction of the underdrive brake retainer in relation
to the bolt holes in the transaxle housing to ensure proper installation.
93. Using an impact driver (1), loosen the bolts holding the underdrive brake
retainer (2) to the transaxle housing without damaging the Torx® drive
heads.

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Fig. 228: Underdrive Brake Retainer & Bolts

Courtesy of CHRYSLER GROUP, LLC
94. Remove bolts (2) holding the underdrive brake retainer (1) to the transaxle
housing.

cardiagn.com
Fig. 229: Underdrive Brake Retainer & Transaxle Housing
Courtesy of CHRYSLER GROUP, LLC
95. Separate the underdrive brake retainer (2) from the transaxle housing (1).

Fig. 230: Park Rod Guide & Bolts

Courtesy of CHRYSLER GROUP, LLC

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96. Remove bolts holding the park rod guide (1) from the transaxle housing.

cardiagn.com
Fig. 231: Park Sprag Spring & Park Sprag
Courtesy of CHRYSLER GROUP, LLC
97. Using a suitable hook tool (1), lift the park sprag spring (2) off the park
sprag.

Fig. 232: Park Sprag Spring, Shaft & Transaxle Housing

Courtesy of CHRYSLER GROUP, LLC
98. Remove the park sprag spring and shaft (1) from the transaxle housing.

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Fig. 233: Park Sprag & Transaxle Housing

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
99. Separate the park sprag (1) from the transaxle housing.

Fig. 234: Park Sprag Support Shaft & Transaxle Housing

Courtesy of CHRYSLER GROUP, LLC
100. Remove the park sprag support shaft (1) from the transaxle housing.

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Fig. 235: Transfer Driven Gear Assembly & Transaxle

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
101. Remove the transfer driven gear (1) assembly from the transaxle (2).
102. Turn the transaxle over to gain access to the One-way-clutch.

Fig. 236: One-Way-Clutch Snap Ring

Courtesy of CHRYSLER GROUP, LLC
103. Remove the snap ring (1) holding the OWC to the transaxle housing.

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Fig. 237: One-Way-Clutch

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
104. Separate the OWC (1) from the transaxle. Mark the one way clutch to aid
installation orientation.

Fig. 238: Low/Reverse Brake & Snap Ring

Courtesy of CHRYSLER GROUP, LLC
105. Remove the snap ring (2) holding low/reverse brake into transaxle.

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Fig. 239: One Way Clutch Race & Snap Ring

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
106. Separate the low & reverse brake pressure plate, cushion plate and discs and
plates, in order, from transaxle.
107. Compress snap ring (1) holding one way clutch race (2) into transaxle.

Fig. 240: One Way Clutch Inner Race

Courtesy of CHRYSLER GROUP, LLC
108. Separate the one way clutch inner race (1) from the transaxle.

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Fig. 241: Rear Annulus Gear & Snap Ring

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
109. Remove the snap ring (2) holding the rear annulus gear (1) into transaxle.

Fig. 242: Rear Annulus Gear

Courtesy of CHRYSLER GROUP, LLC
110. Separate the rear annulus gear (1) from the transaxle.

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Fig. 243: Middle/Rear Planetary Gear Assembly

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Courtesy of CHRYSLER GROUP, LLC
111. Separate the middle/rear planetary gear assembly (1) and from the planetary
gear hub.

Fig. 244: Front Planetary Gear Hub Thrust Washer

Courtesy of CHRYSLER GROUP, LLC
112. Remove the thrust washer (1) from front planetary gear hub.

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Fig. 245: Middle Sun Gear & Planetary Gear Hub

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Courtesy of CHRYSLER GROUP, LLC
113. Separate the middle sun gear (1) from the planetary gear hub (2).

Fig. 246: Planetary Gear Hub Bearing And Race Set

Courtesy of CHRYSLER GROUP, LLC
114. Remove the bearing (2) and race (1) set from the planetary gear hub.

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Fig. 247: Front Sun Gear

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
115. Separate the front sun gear (1) from front planetary gear assembly.

Fig. 248: Front Planetary Gear & Front Annulus Gear Assembly
Courtesy of CHRYSLER GROUP, LLC
116. Separate the front planetary gear (1) the front annulus gear assembly (2).

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Fig. 249: Front Annulus Gear Thrust Bearing And Race

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Courtesy of CHRYSLER GROUP, LLC
117. Separate the front annulus gear thrust bearing and race from the front
annulus gear hub,

Fig. 250: Front Annulus Gear

Courtesy of CHRYSLER GROUP, LLC
118. Separate the front annulus gear (1) from the low/reverse brake assembly.

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Fig. 251: Special Tool #5058A-3

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Courtesy of CHRYSLER GROUP, LLC
119. Insert (special tool #5058A-3, Screw, Forcing) through center hole in
(special tool #8621, Compressor, Spring)

Fig. 252: Special Tool #5058A-3

Courtesy of CHRYSLER GROUP, LLC

Fig. 253: Special Tool #8621

Courtesy of CHRYSLER GROUP, LLC
Insert the screw through the transfer gear and into the threaded cross bar
across the bell housing opening.

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Fig. 254: Compressing Low/Reverse Spring Retainer

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Courtesy of CHRYSLER GROUP, LLC
120. Compress the low/reverse spring retainer.

Fig. 255: Low/Reverse Brake Spring Retainer Snap Ring

Courtesy of CHRYSLER GROUP, LLC
121. Remove snap ring holding low/reverse brake spring retainer to the
low/reverse brake piston.
122. Remove spring compressor tools from transaxle.

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Fig. 256: Low/Reverse Brake Piston Spring Retainer

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
123. Remove low & reverse brake piston spring retainer.

Fig. 257: Low/Reverse Brake Piston

Courtesy of CHRYSLER GROUP, LLC
124. Separate low & reverse brake piston (1) from the transaxle housing.
125. Remove inside and outside D-ring seals from the low & reverse brake piston
(1).

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Fig. 258: Transfer Drive Assembly & Bolts

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
126. Remove bolts (2) holding transfer drive assembly (1) to the transaxle
housing.

Fig. 259: Transfer Drive Assembly

Courtesy of CHRYSLER GROUP, LLC
127. Remove the transfer drive assembly (1) from the transaxle case
ASSEMBLY
FWD

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NOTE: Thoroughly clean all components to remove metallic and

fibrous materials that may have contaminated the
transaxle during a component failure.

NOTE: Inspect all components for excessive ware, spalled

surfaces, or other obvious damage. Replace only
damaged components that are serviceable with genuine
Mopar Parts.

NOTE: Not before assembling the transaxle, measure the Low-

Reverse Brake and adjust if necessary. If the housing,
differential, or the driven transfer gear was replaced, it
will necessary to the establish proper bearing turning

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torque. If just the bearings are replaced it is not
necessary to measure turn to torque valves. Refer to
STANDARD PROCEDURES.

Fig. 260: Transfer Drive Assembly

Courtesy of CHRYSLER GROUP, LLC
1. Place the transfer drive assembly (1) into position in the transaxle case.

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Fig. 261: Transfer Drive Assembly & Bolts

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
2. Install three bolts (2) to hold transfer drive assembly (1) to the transaxle
housing. Refer to SPECIFICATIONS.
3. Install NEW inside and outside D-ring seals into the low & reverse brake
piston (1).
4. Using specified transaxle fluid, lubricate the low & reverse brake piston (1)
D-ring seals.

Fig. 262: Low/Reverse Brake Piston

Courtesy of CHRYSLER GROUP, LLC

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5. Place low & reverse brake piston (1) in position in transaxle housing.
6. Push low & reverse brake piston downward into cylinder bore in the
transaxle housing.

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Fig. 263: Low/Reverse Brake Piston Spring Retainer
Courtesy of CHRYSLER GROUP, LLC
7. Place low & reverse brake piston spring retainer in position on the lo-reverse
brake piston.

Fig. 264: Special Tool #5058A-3

Courtesy of CHRYSLER GROUP, LLC
(special tool #5058A-3, Screw, Forcing)

Fig. 265: Special Tool #8621

Courtesy of CHRYSLER GROUP, LLC
(special tool #8621, Compressor, Spring)

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Fig. 266: Special Tool #5058A-3

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
8. Install spring compressor tools in position on transaxle.
9. Insert screw through center hole in spring compressor 8621. Insert the screw
through the transfer gear and into the threaded cross bar across the bell
housing opening.

Fig. 267: Compressing Low/Reverse Spring Retainer

Courtesy of CHRYSLER GROUP, LLC
10. Compress the low/reverse spring retainer.

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Fig. 268: Low/Reverse Brake Spring Retainer Snap Ring

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Courtesy of CHRYSLER GROUP, LLC
11. Install the snap ring (1) to hold the low/reverse brake spring retainer to the
low/reverse brake piston.

Fig. 269: Front Annulus Gear

Courtesy of CHRYSLER GROUP, LLC
12. Place the front annulus gear (1) in position in the low/reverse brake
assembly.

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Fig. 270: Front Annulus Gear Thrust Bearing And Race

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Courtesy of CHRYSLER GROUP, LLC
13. Place the front annulus gear thrust bearing and race (1) in position on the
front annulus gear (2) hub.

Fig. 271: Front Planetary Gear & Front Annulus Gear Assembly
Courtesy of CHRYSLER GROUP, LLC
14. Place the front planetary gear (1) in position on the front annulus gear
assembly (2).

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Fig. 272: Front Sun Gear

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Courtesy of CHRYSLER GROUP, LLC
15. Insert the front sun gear (1) into front planetary gear assembly.

Fig. 273: Planetary Gear Hub Bearing And Race Set

Courtesy of CHRYSLER GROUP, LLC
16. Place the bearing (2) and race (1) set in position on the planetary gear hub.

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Fig. 274: Middle Sun Gear & Planetary Gear Hub

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Courtesy of CHRYSLER GROUP, LLC
17. Insert the middle sun gear (1) in position in the in position on the front sun
gear (2).

Fig. 275: Front Planetary Gear Hub Thrust Washer

Courtesy of CHRYSLER GROUP, LLC
18. Place the thrust washer (1) in position on the front planetary gear hub.

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Fig. 276: Middle/Rear Planetary Gear Assembly

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Courtesy of CHRYSLER GROUP, LLC
19. Place the middle/rear planetary gear assembly (1) in position in the
planetary gear hub.

Fig. 277: Rear Annulus Gear

Courtesy of CHRYSLER GROUP, LLC
20.
21. Place the rear annulus gear (1) in position on the middle/rear planetary gear
assembly.

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Fig. 278: Rear Annulus Gear & Snap Ring

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Courtesy of CHRYSLER GROUP, LLC
22. Install the snap ring (2) to hold the rear annulus gear (1) into the front
annulus gear hub.

Fig. 279: Middle/Rear Planetary Gear Snap Ring

Courtesy of CHRYSLER GROUP, LLC
23. Insert the snap ring into the groove in the middle/rear planetary gear.

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Fig. 280: One Way Clutch Inner Race

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Courtesy of CHRYSLER GROUP, LLC
24. Place the one way clutch inner race (1) in position on the middle/rear
planetary gear.

Fig. 281: One Way Clutch Race & Snap Ring

Courtesy of CHRYSLER GROUP, LLC
25. Using long nose pliers (3), compress snap ring (1) to hold the one way
clutch race (2) to the middle/rear planetary gear.

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cardiagn.com
Fig. 282: Low & Reverse Brake Pressure Plate, Cushion Plate, Plates,
Discs, & Reaction Plate
Courtesy of CHRYSLER GROUP, LLC
26. Install the low & reverse brake pressure plate (1), cushion plate (2), plates 3)
discs (4), and the reaction plate (5), in order, into the transaxle.

Fig. 283: Low/Reverse Brake & Snap Ring

Courtesy of CHRYSLER GROUP, LLC
27. Install the snap ring (1) to hold low/reverse brake into the lowest snap ring

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land (2) in the transaxle.

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Fig. 284: One-Way-Clutch
Courtesy of CHRYSLER GROUP, LLC
28. Lining up the two narrow lugs on the OWC to the two narrow slots on the
transaxle housing insert the OWC (1) into the transaxle. Press down until it
is seated. The OWC should rotate in a counterclockwise direction only.

Fig. 285: One-Way-Clutch Snap Ring

Courtesy of CHRYSLER GROUP, LLC
29. Install the snap ring (1) to hold the OWC to the transaxle housing

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30. Turn transaxle over to gain access to the front of the transaxle.

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Fig. 286: Transfer Driven Gear Assembly & Transaxle
Courtesy of CHRYSLER GROUP, LLC
31. Install the transfer driven gear (1) assembly in position in the transaxle (2).

Fig. 287: Park Sprag Support Shaft & Transaxle Housing

Courtesy of CHRYSLER GROUP, LLC
32. Install the park sprag support shaft (1) in position in the transaxle housing.

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Fig. 288: Park Sprag & Transaxle Housing

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Courtesy of CHRYSLER GROUP, LLC
33. Insert the park sprag (1) in position in the transaxle housing.

Fig. 289: Park Sprag Spring, Shaft & Transaxle Housing

Courtesy of CHRYSLER GROUP, LLC
34. Install the park sprag spring and shaft (1) in position in the transaxle
housing.

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Fig. 290: Park Sprag Spring & Park Sprag

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
35. Using a suitable hook tool (1), lift the park sprag spring (2) onto the park
sprag.

Fig. 291: Park Rod Guide & Bolts

Courtesy of CHRYSLER GROUP, LLC
36. Install bolts to hold the park rod guide (1) in position on the transaxle
housing.

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Fig. 292: Underdrive Brake Retainer & Transaxle Housing

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Courtesy of CHRYSLER GROUP, LLC
37. Place the underdrive brake retainer (2) in position on the transaxle housing
(1).

Fig. 293: Underdrive Brake Retainer & Bolts

Courtesy of CHRYSLER GROUP, LLC
38. Install bolts (2) to hold the underdrive brake retainer (1) to the transaxle
housing. Refer to SPECIFICATIONS.

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Fig. 294: Underdrive Brake Chamber & Transaxle Housing

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Courtesy of CHRYSLER GROUP, LLC
39. Place the underdrive brake chamber in position on the transaxle housing.

Fig. 295: Underdrive Brake Chamber & Bolts

Courtesy of CHRYSLER GROUP, LLC
40. Install bolts (1) to hold the underdrive brake chamber (2) to the transaxle
housing. Refer to SPECIFICATIONS.

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Fig. 296: Underdrive Brake Piston & Location Tabs

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Courtesy of CHRYSLER GROUP, LLC
41. Install

NEW
D-ring outer seal and the O-ring inner seal in the lands on the underdrive
piston.

42. Install the underdrive brake piston (1) in position on the underdrive brake
piston chamber.

NOTE: The location tabs (2) on the underdrive brake piston

should be oriented toward the valve body opening in
the transaxle.

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Fig. 297: Underdrive Spring Retainer & Underdrive Brake Piston

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Courtesy of CHRYSLER GROUP, LLC
43. Push underdrive brake piston (3) downward until it seats in the underdrive
brake chamber.
44. Place the underdrive spring retainer (1) in position on the underdrive brake
piston (2).

Fig. 298: Tool Bolt & Tool Cross Bar

Courtesy of CHRYSLER GROUP, LLC
45. Insert the bolt (3) for tool 5058A through tool 10426
46. Insert the tool bolt (3) with the spring compressor through the center of the

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transaxle (1) and out the back into the threaded center bore of the tool cross
bar (2) spanning the back of the transaxle.

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Fig. 299: Tool 5058A & Tool 10426
Courtesy of CHRYSLER GROUP, LLC
(special tool #5058A-3, Screw, Forcing)

Fig. 300: Special Tool #5058A-3

Courtesy of CHRYSLER GROUP, LLC
(special tool #10426, Compressor, Underdrive Spring)

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cardiagn.com
Fig. 301: Special Tool #10426
Courtesy of CHRYSLER GROUP, LLC
Compress the underdrive springs (3) to gain access to the snap ring land.

Fig. 302: Underdrive Spring Plate Snap Ring

Courtesy of CHRYSLER GROUP, LLC
47. Install the snap ring (1) to hold the underdrive spring plate to the underdrive
brake hub.

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48. Remove the spring compressor tool from the transaxle.

49. Turn the transaxle over to gain access to the rear cover.

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Fig. 303: Thrust Bearing, Race Set & Middle/Rear Planetary Gear
Assembly
Courtesy of CHRYSLER GROUP, LLC
50. Place the thrust bearing (1) and race set into of the center of the middle/rear
planetary gear assembly (2).

Fig. 304: Thrust Washer & Planetary Gear Assembly Hub

Courtesy of CHRYSLER GROUP, LLC

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51. Place the thrust washer (1) in position on the middle/rear planetary gear.

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Fig. 305: Overdrive Clutch Assembly & One Way Clutch
Courtesy of CHRYSLER GROUP, LLC
52. Install the overdrive clutch assembly (1) onto the one way clutch race (2).

Fig. 306: Thrust Bearing & Overdrive Clutch Hub Assembly

Courtesy of CHRYSLER GROUP, LLC
53. Install thrust bearing (1) onto the overdrive clutch hub (2) assembly with the
rollers facing upward.

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Fig. 307: Transfer Port Seals

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Courtesy of CHRYSLER GROUP, LLC
54. Install the four seals (2) into transfer ports in transaxle housing.

Fig. 308: Split Seal Rings & Rear Cover Hub

Courtesy of CHRYSLER GROUP, LLC
55. Install the two split seal ring seals (2) into the lands in the rear cover (1)
hub.

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Fig. 309: Selective Spacer, Bearing & Rear Cover

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Courtesy of CHRYSLER GROUP, LLC
56. Using assembly lube applied in the seat area of the rear cover (3), Install the
selective spacer (1) onto the rear cover (2).
57. Apply a 3 mm (0.120 in.) bead of Dupont® Loctite™ 5460 Pink Flange
Sealant or equivalent around the perimeter of the rear cover.

Fig. 310: Rear Cover Separated From Transaxle

Courtesy of CHRYSLER GROUP, LLC
58. Place the rear cover (1) in position on the transaxle.

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Fig. 311: Transaxle Rear Cover & Bolts

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Courtesy of CHRYSLER GROUP, LLC
59. Install bolts to hold the rear cover (1) to the transaxle. Refer to
SPECIFICATIONS.
60. Turn transaxle over to gain access to the underdrive brake.

Fig. 312: Underdrive Brake Plates, Discs & Drum

Courtesy of CHRYSLER GROUP, LLC
61. Place underdrive brake plates and discs in position in underdrive brake
drum.

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Fig. 313: Underdrive Brake, Underdrive Brake Drum, & Large Snap

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Ring
Courtesy of CHRYSLER GROUP, LLC
62. Install large snap ring (3) to hold underdrive brake (1) into the underdrive
brake drum.

Fig. 314: Underdrive Brake Hub

Courtesy of CHRYSLER GROUP, LLC
63. Install underdrive brake hub (1) assembly in position on transaxle.

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Fig. 315: Underdrive Brake Hub & Thrust Washer

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Courtesy of CHRYSLER GROUP, LLC
64. Install thrust washer (2) in position on the underdrive brake hub.

Fig. 316: 3/5/R Clutch & 2/6 Brake Hub Assembly

Courtesy of CHRYSLER GROUP, LLC
65. Install the 3/5/R clutch and 2/6 brake hub (1) assembly in position on the
underdrive clutch.

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Fig. 317: 3/5/R Clutch & 2/6 Brake Hub, Thrust Bearing

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
66. Install the thrust bearing (2) in position on the 3/5/R clutch and 2/6 brake
hub.

Fig. 318: 3/5/R Clutch Assembly, 3/5/R & 2/6 Brake Hub Assembly
Courtesy of CHRYSLER GROUP, LLC
67. Install the 3/5/R clutch assembly (1) in position in the 3/5/R and 2/6 brake
hub (2) assembly.

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Fig. 319: 2/6 Brake Select Thickness Reaction Plate & Hub

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Courtesy of CHRYSLER GROUP, LLC
68. Install 2/6 brake select thickness reaction plate (1) in position in the 2/6
brake hub.

Fig. 320: 2/6 Brake Plates, Discs & Hub

Courtesy of CHRYSLER GROUP, LLC
69. Install the 2/6 brake alternating the (1) plates (3) and discs (2) in position in
the 2/6 brake hub.

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Fig. 321: 2/6 Brake Wave Plate & Hub

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Courtesy of CHRYSLER GROUP, LLC
70. Install 2/6 brake wave plate (1) in position in the 2/6 brake hub.

Fig. 322: Split Ring Seals & Input Shaft

Courtesy of CHRYSLER GROUP, LLC
71. Install two split ring seals (2) in the seal lands (2) in the input shaft (1).

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Fig. 323: Split Seal Rings & Fluid Pump Hub

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Courtesy of CHRYSLER GROUP, LLC
72. Install two split seal rings (3) in the lands (2) in fluid pump (1) hub.

Fig. 324: Thrust Washer & Fluid Pump

Courtesy of CHRYSLER GROUP, LLC
73. Apply a 3 mm (0.120 in.) bead of Dupont® Loctite™ 5460 Pink Flange
Sealant or equivalent around the perimeter of the fluid pump sealing surface.
74. Using assembly lube, install the plastic thrust washer (2) in position on the
underside of the fluid pump (1). There are three nubs that insert into holes in
the fluid pump hub to prevent the thrust washer from rotating.

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Fig. 325: Fluid Pump Separated From Transaxle Housing

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Courtesy of CHRYSLER GROUP, LLC
75. Place the fluid pump (2) in position on the transaxle housing (1).

Fig. 326: Fluid Pump & Bolts

Courtesy of CHRYSLER GROUP, LLC
76. Install bolts (1) to hold fluid pump (3) to the trans axle housing (2). Refer to
SPECIFICATIONS.
77. Install NEW o-ring seal in position in the groove in the fluid pump housing.

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Fig. 327: Fluid Filter Separated From Transaxle Housing

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
78. Place the fluid filter (2) in position in the transaxle housing (1).

Fig. 328: Fluid Filter, Fluid Pump & Bolts

Courtesy of CHRYSLER GROUP, LLC
79. Install bolts (1) to hold the fluid filter to the fluid pump (3) housing. Refer to
SPECIFICATIONS.

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Fig. 329: Small Transfer Port Seals

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
80. Install seals in position in four small transfer ports (2) in the transaxle
housing (1).

Fig. 330: Large Transfer Port Seal

Courtesy of CHRYSLER GROUP, LLC
81. Install seal in position in the large transfer port (1) in the axle housing (2).

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Fig. 331: Differential Assembly Separated From Transaxle Housing

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
82. Place the differential assembly in position in the transaxle housing.
83. Apply a 3 mm (0.120 in.) bead of Dupont® Loctite™ 5460 Pink Flange
Sealant or equivalent around the perimeter of the transaxle housing.

Fig. 332: Bell Housing Separated From Transaxle

Courtesy of CHRYSLER GROUP, LLC
84. If fluid guides and tube were removed during cleaning, install related
components in the transaxle housing. Refer to SPECIFICATIONS.
85. Place the bell housing (1) in position on the transaxle (2).

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Fig. 333: Inside Bell Housing Bolts

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
86. Install five bolts (1) on inside of the bell housing (2). Refer to
SPECIFICATIONS.

Fig. 334: Transaxle Housing & Bottom Bolts

Courtesy of CHRYSLER GROUP, LLC
87. Install six bolts in the bottom (2) of the transaxle housing (1). Refer to
SPECIFICATIONS.

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Fig. 335: Transaxle Housing & Bolts

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
88. Install five bolts in the back (3) and five bolts in the top (2) of the transaxle
housing (1). Refer to SPECIFICATIONS.

Fig. 336: Park Rod & Park Rod Guide

Courtesy of CHRYSLER GROUP, LLC
89. If seal required replacement, install the

NEW
lip seal in the manual shaft hole in the transaxle housing.

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90. Insert the park rod (1) into the park rod guide.

cardiagn.com
Fig. 337: Manual Shaft, Park Rod & Key Hole Slot
Courtesy of CHRYSLER GROUP, LLC
91. Insert the manual shaft (1) into the bearing in the transaxle.
92. Push manual shaft (1) upward until park rod (2) engages the detent comb.
93. Rotate manual shaft (1) clockwise to lock the staked nub on the park rod (2)
in the key hole slot (3) in the manual shaft detent comb.

Fig. 338: Manual Shaft & Pin

Courtesy of CHRYSLER GROUP, LLC

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94. Install the pin (2) to hold the manual shaft (1) in the transaxle into the hole
in the pan gasket flange.

cardiagn.com
Fig. 339: Main Wire Harness & Sensors
Courtesy of CHRYSLER GROUP, LLC
95. Place the main wire harness and sensors (1) in position on the transaxle.
96. Push the wire connector outward through to hole in the transaxle housing.

Fig. 340: Wire Connector & Hold Down Bracket Separated From
Transaxle
Courtesy of CHRYSLER GROUP, LLC

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97. Place the wire connector (1) hold down bracket (2) in position on the
transaxle.

cardiagn.com
Fig. 341: Hold Down Bracket, Wire Connector & Bolts
Courtesy of CHRYSLER GROUP, LLC
98. Install bolt to hold the wire connector (1) hold down bracket (2) to the top of
transaxle housing. Refer to SPECIFICATIONS.
99. Insert the speed sensors in position in the transaxle housing.

Fig. 342: Speed Sensors, Main Wire Harness & Bolts

Courtesy of CHRYSLER GROUP, LLC

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100. Install bolts (1) to hold the speed sensors and main wire harness to transaxle.
Refer to SPECIFICATIONS.

cardiagn.com
Fig. 343: Transfer Port Seals
Courtesy of CHRYSLER GROUP, LLC
101. Install the two seals into the transfer ports in transaxle housing.

Fig. 344: Valve Body Separated From Transaxle

Courtesy of CHRYSLER GROUP, LLC
102. The manual valve is loose after the valve body is removed and may fall
out during installation.

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Place the valve body (2) in position on the transaxle (1). Guide the pin on
the manual valve into the slot in the manual shaft detent comb.

cardiagn.com
Fig. 345: Valve Body Bolts
Courtesy of CHRYSLER GROUP, LLC
103. Install bolts, 7 short (1) and 1 long (2) bolts, to hold the valve body to the
transaxle. Refer to SPECIFICATIONS.

Fig. 346: Detent Spring Separated From Valve Body

Courtesy of CHRYSLER GROUP, LLC
104. Place the detent spring (2) in position on the valve body (1).

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Fig. 347: Manual Shaft Detent Spring & Valve Body

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
105. Install the screw to hold the manual shaft detent spring (1) to the valve body
(2). Refer to SPECIFICATIONS.

Fig. 348: Solenoids & Connector

Courtesy of CHRYSLER GROUP, LLC
106. Starting at the top solenoid valve, push inward at each solenoid (2) until the
connector (3) is engaged.

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Fig. 349: Solenoid Valve Connector, Valve Body & Bolts

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Courtesy of CHRYSLER GROUP, LLC
107. Install bolts to hold the solenoid valve connector (2) to the valve body (1).
Refer to SPECIFICATIONS.

Fig. 350: Fluid Temperature Sensor, Valve Body & Bolt

Courtesy of CHRYSLER GROUP, LLC
108. Insert the temperature sensor (1) into port in the valve body (2).
109. Install bolt to hold fluid temperature sensor (1) to the valve body (2). Refer
to SPECIFICATIONS.

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Fig. 351: Valve Body Cover Separated From Transaxle

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
110. Install a NEW gasket on the pan and place the pan (1) in position on the
transaxle (2).

Fig. 352: Valve Body Cover

Courtesy of CHRYSLER GROUP, LLC
111. Install bolts to hold the valve body pan (2) to the transaxle (1). Refer to
SPECIFICATIONS.

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Fig. 353: Cooler Tubes & Transaxle

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
112. Place the cooler tubes (2) in position on the transaxle (1).
113. Install bolt to hold the cooler tube (2) bracket to the transaxle (1). Refer to
SPECIFICATIONS.

Fig. 354: Cooler Tubes & Banjo Bolts

Courtesy of CHRYSLER GROUP, LLC
114. Install banjo bolts (2) to hold the cooler tubes (1) to the transaxle. Refer to
SPECIFICATIONS.

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Fig. 355: Vent Tube Bracket & Bolt

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
115. Place the vent tube (3) in position on the transaxle (1).
116. Install bolt to hold the vent tube bracket (2) to the transaxle housing. Refer
to SPECIFICATIONS.

Fig. 356: Vent Hose End & Nipple Adapter

Courtesy of CHRYSLER GROUP, LLC
117. Push the vent hose end (1) onto of the nipple on the vent adaptor (2).

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Fig. 357: Vent Hose, Spring Clamp & Pliers

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
118. Using common pliers (3), compress the hose spring clamp (2) and slide it up
the vent hose (1) into position to hold the hose to the nipple.

Fig. 358: Transmission Range Sensor Separated From Transaxle

Courtesy of CHRYSLER GROUP, LLC
119. Place the TRS (1) in position on the transaxle.

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Fig. 359: Transmission Range Sensor

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
120. Install bolts to hold the TRS (1) to the transaxle housing. Refer to
SPECIFICATIONS.

Fig. 360: Manual Lever & Manual Shaft

Courtesy of CHRYSLER GROUP, LLC
121. Place the manual level (1) in position on the manual shaft.

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Fig. 361: Pin Punch, Manual Lever & Transmission Range Sensor

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
122. Insert a suitable pin punch (2) or equivalent through the manual lever into
the TRS switch (1) to hold lever in place.
123. Install the nut to hold the manual lever to the manual shaft. Refer to
SPECIFICATIONS.

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

INSTALLATION.
AWD

NOTE: Thoroughly clean all components to remove metallic and

fibrous materials that may have contaminated the
transaxle during a component failure.

NOTE: Inspect all components for excessive ware, spalled

surfaces, or other obvious damage. Replace only
damaged components that are serviceable with genuine
Mopar Parts.

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Fig. 362: Transfer Drive Assembly

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
1. Place the transfer drive assembly (1) into position in the transaxle case.

Fig. 363: Transfer Drive Assembly & Bolts

Courtesy of CHRYSLER GROUP, LLC
2. Install three bolts (2) to hold transfer drive assembly (1) to the transaxle
housing. Refer to SPECIFICATIONS.
3. Install NEW inside and outside D-ring seals into the low & reverse brake
piston (1).
4. Using specified transaxle fluid, lubricate the low & reverse brake piston (1)

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D-ring seals.

cardiagn.com
Fig. 364: Low/Reverse Brake Piston
Courtesy of CHRYSLER GROUP, LLC
5. Place low & reverse brake piston (1) in position in transaxle housing.
6. Push low & reverse brake piston downward into cylinder bore in the
transaxle housing.

Fig. 365: Low/Reverse Brake Piston Spring Retainer

Courtesy of CHRYSLER GROUP, LLC
7. Place low & reverse brake piston spring retainer in position on the lo-reverse

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brake piston.

cardiagn.com
Fig. 366: Special Tool #5058A-3
Courtesy of CHRYSLER GROUP, LLC
8. Install spring compressor tools (special tool #5058A-3, Screw, Forcing) in
position on transaxle.
9. Insert screw through center hole in spring compressor (special tool #8621,
Compressor, Spring).

Fig. 367: Special Tool #8621

Courtesy of CHRYSLER GROUP, LLC
Insert the screw through the transfer gear and into the threaded cross bar
across the bell housing opening.

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Fig. 368: Compressing Low/Reverse Spring Retainer

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
10. Compress the low/reverse spring retainer.

Fig. 369: Low/Reverse Brake Spring Retainer Snap Ring

Courtesy of CHRYSLER GROUP, LLC
11. Install the snap ring (1) to hold the low/reverse brake spring retainer to the
low/reverse brake piston.

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Fig. 370: Front Annulus Gear

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
12. Place the front annulus gear (1) in position in the low/reverse brake
assembly.

Fig. 371: Front Annulus Gear Thrust Bearing And Race

Courtesy of CHRYSLER GROUP, LLC
13. Place the front annulus gear thrust bearing and race (1) in position on the
front annulus gear (2) hub.

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Fig. 372: Front Planetary Gear & Front Annulus Gear Assembly

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
14. Place the front planetary gear (1) in position on the front annulus gear
assembly (2).

Fig. 373: Front Sun Gear

Courtesy of CHRYSLER GROUP, LLC
15. Insert the front sun gear (1) into front planetary gear assembly.

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Fig. 374: Planetary Gear Hub Bearing And Race Set

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
16. Place the bearing (2) and race (1) set in position on the planetary gear hub.

Fig. 375: Middle Sun Gear & Planetary Gear Hub

Courtesy of CHRYSLER GROUP, LLC
17. Insert the middle sun gear (1) in position in the in position on the front sun
gear (2).

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Fig. 376: Front Planetary Gear Hub Thrust Washer

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
18. Place the thrust washer (1) in position on the front planetary gear hub.

Fig. 377: Middle/Rear Planetary Gear Assembly

Courtesy of CHRYSLER GROUP, LLC
19. Place the middle/rear planetary gear assembly (1) in position in the
planetary gear hub.

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Fig. 378: Rear Annulus Gear

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
20.
21. Place the rear annulus gear (1) in position on the middle/rear planetary gear
assembly.

Fig. 379: Rear Annulus Gear & Snap Ring

Courtesy of CHRYSLER GROUP, LLC
22. Install the snap ring (2) to hold the rear annulus gear (1) into the front
annulus gear hub.

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Fig. 380: Middle/Rear Planetary Gear Snap Ring

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
23. Insert the snap ring into the groove in the middle/rear planetary gear.

Fig. 381: One Way Clutch Inner Race

Courtesy of CHRYSLER GROUP, LLC
24. Place the one way clutch inner race (1) in position on the middle/rear
planetary gear.

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Fig. 382: One Way Clutch Race & Snap Ring

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
25. Using long nose pliers (3), compress snap ring (1) to hold the one way
clutch race (2) to the middle/rear planetary gear.

Fig. 383: Low & Reverse Brake Pressure Plate, Cushion Plate, Plates,
Discs, & Reaction Plate
Courtesy of CHRYSLER GROUP, LLC
26. Install the low & reverse brake pressure plate (1), cushion plate (2), plates 3)

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discs (4), and the reaction plate (5), in order, into the transaxle.

cardiagn.com
Fig. 384: Low/Reverse Brake & Snap Ring
Courtesy of CHRYSLER GROUP, LLC
27. Install the snap ring (1) to hold low/reverse brake into the lowest snap ring
land (2) in the transaxle.

Fig. 385: One-Way-Clutch

Courtesy of CHRYSLER GROUP, LLC
28. Lining up the two narrow lugs on the OWC to the two narrow slots on the
transaxle housing insert the OWC (1) into the transaxle. Press down until it
is seated. The OWC should rotate in a counterclockwise direction only.
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Fig. 386: One-Way-Clutch Snap Ring

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
29. Install the snap ring (1) to hold the OWC to the transaxle housing
30. Turn transaxle over to gain access to the front of the transaxle.

Fig. 387: Transfer Driven Gear Assembly & Transaxle

Courtesy of CHRYSLER GROUP, LLC
31. Install the transfer driven gear (1) assembly in position in the transaxle (2).

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Fig. 388: Park Sprag Support Shaft & Transaxle Housing

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
32. Install the park sprag support shaft (1) in position in the transaxle housing.

Fig. 389: Park Sprag & Transaxle Housing

Courtesy of CHRYSLER GROUP, LLC
33. Insert the park sprag (1) in position in the transaxle housing.

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Fig. 390: Park Sprag Spring, Shaft & Transaxle Housing

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
34. Install the park sprag spring and shaft (1) in position in the transaxle
housing.

Fig. 391: Park Sprag Spring & Park Sprag

Courtesy of CHRYSLER GROUP, LLC
35. Using a suitable hook tool (1), lift the park sprag spring (2) onto the park
sprag.

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Fig. 392: Park Rod Guide & Bolts

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
36. Install bolts to hold the park rod guide (1) in position on the transaxle
housing.

Fig. 393: Underdrive Brake Retainer & Transaxle Housing

Courtesy of CHRYSLER GROUP, LLC
37. Place the underdrive brake retainer (2) in position on the transaxle housing
(1).

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Fig. 394: Underdrive Brake Retainer & Bolts

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
38. Install bolts (2) to hold the underdrive brake retainer (1) to the transaxle
housing. Refer to SPECIFICATIONS.

Fig. 395: Underdrive Brake Chamber & Transaxle Housing

Courtesy of CHRYSLER GROUP, LLC
39. Place the underdrive brake chamber in position on the transaxle housing.

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Fig. 396: Underdrive Brake Chamber & Bolts

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
40. Install bolts (1) to hold the underdrive brake chamber (2) to the transaxle
housing. Refer to SPECIFICATIONS.

Fig. 397: Underdrive Brake Piston & Location Tabs

Courtesy of CHRYSLER GROUP, LLC
41. Install NEW D-ring outer seal and the O-ring inner seal in the lands on the
underdrive piston.
42. Install the underdrive brake piston (1) in position on the underdrive brake
piston chamber.

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NOTE: The location tabs (2) on the underdrive brake piston

should be oriented toward the valve body opening in
the transaxle.

cardiagn.com
Fig. 398: Underdrive Spring Retainer & Underdrive Brake Piston
Courtesy of CHRYSLER GROUP, LLC
43. Push underdrive brake piston (3) downward until it seats in the underdrive
brake chamber.
44. Place the underdrive spring retainer (1) in position on the underdrive brake
piston (2).

Fig. 399: Tool Bolt & Tool Cross Bar

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Courtesy of CHRYSLER GROUP, LLC

45. Insert the bolt (3) for tool (special tool #5058A, Compressor, Spring)
through tool (special tool #10426, Compressor, Underdrive Spring).
46. Insert the tool (special tool #5058A-3, Screw, Forcing) bolt (3) with the
spring compressor through the center of the transaxle (1) and out the back
into the threaded center bore of the tool cross bar (2) spanning the back of
the transaxle.

Fig. 400: Special Tool #5058A-3

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC

Fig. 401: Tool 5058A & Tool 10426

Courtesy of CHRYSLER GROUP, LLC
Compress the underdrive springs (3) to gain access to the snap ring land.

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Fig. 402: Underdrive Spring Plate Snap Ring

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
47. Install the snap ring (1) to hold the underdrive spring plate to the underdrive
brake hub.
48. Remove the spring compressor tool from the transaxle.
49. Turn the transaxle over to gain access to the rear cover.

Fig. 403: Thrust Bearing, Race Set & Middle/Rear Planetary Gear
Assembly
Courtesy of CHRYSLER GROUP, LLC
50. Place the thrust bearing (1) and race set into of the center of the middle/rear

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planetary gear assembly (2).

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Fig. 404: Thrust Washer & Planetary Gear Assembly Hub
Courtesy of CHRYSLER GROUP, LLC
51. Place the thrust washer (1) in position on the middle/rear planetary gear.

Fig. 405: Overdrive Clutch Assembly & One Way Clutch

Courtesy of CHRYSLER GROUP, LLC
52. Install the overdrive clutch assembly (1) onto the one way clutch race (2).

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Fig. 406: Thrust Bearing & Overdrive Clutch Hub Assembly

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
53. Install thrust bearing (1) onto the overdrive clutch hub (2) assembly with the
rollers facing upward.

Fig. 407: Transfer Port Seals

Courtesy of CHRYSLER GROUP, LLC
54. Install the four seals (2) into transfer ports in transaxle housing.

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Fig. 408: Split Seal Rings & Rear Cover Hub

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
55. Install the two split seal ring seals (2) into the lands in the rear cover (1)
hub.

Fig. 409: Selective Spacer, Bearing & Rear Cover

Courtesy of CHRYSLER GROUP, LLC
56. Using assembly lube applied in the seat area of the rear cover (3), Install the
selective spacer (1) onto the rear cover (2).
57. Apply a 3 mm (0.120 in.) bead of Dupont® Loctite™ 5460 Pink Flange
Sealant or equivalent around the perimeter of the rear cover.

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Fig. 410: Rear Cover Separated From Transaxle

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
58. Place the rear cover (1) in position on the transaxle.

Fig. 411: Transaxle Rear Cover & Bolts

Courtesy of CHRYSLER GROUP, LLC
59. Install bolts to hold the rear cover (1) to the transaxle. Refer to
SPECIFICATIONS.
60. Turn transaxle over to gain access to the underdrive brake.

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Fig. 412: Underdrive Brake Plates, Discs & Drum

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
61. Place underdrive brake plates and discs in position in underdrive brake
drum.

Fig. 413: Underdrive Brake, Underdrive Brake Drum, & Large Snap
Ring
Courtesy of CHRYSLER GROUP, LLC
62. Install large snap ring (3) to hold underdrive brake (1) into the underdrive
brake drum.

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Fig. 414: Underdrive Brake Hub

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
63. Install underdrive brake hub (1) assembly in position on transaxle.

Fig. 415: Underdrive Brake Hub & Thrust Washer

Courtesy of CHRYSLER GROUP, LLC
64. Install thrust washer (2) in position on the underdrive brake hub.

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Fig. 416: 3/5/R Clutch & 2/6 Brake Hub Assembly

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
65. Install the 3/5/R clutch and 2/6 brake hub (1) assembly in position on the
underdrive clutch.

Fig. 417: 3/5/R Clutch & 2/6 Brake Hub, Thrust Bearing
Courtesy of CHRYSLER GROUP, LLC
66. Install the thrust bearing (2) in position on the 3/5/R clutch and 2/6 brake
hub.

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Fig. 418: 3/5/R Clutch Assembly, 3/5/R & 2/6 Brake Hub Assembly

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
67. Install the 3/5/R clutch assembly (1) in position in the 3/5/R and 2/6 brake
hub (2) assembly.

Fig. 419: 2/6 Brake Select Thickness Reaction Plate & Hub
Courtesy of CHRYSLER GROUP, LLC
68. Install 2/6 brake select thickness reaction plate (1) in position in the 2/6
brake hub.

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Fig. 420: 2/6 Brake Plates, Discs & Hub

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
69. Install the 2/6 brake alternating the (1) plates (3) and discs (2) in position in
the 2/6 brake hub.

Fig. 421: 2/6 Brake Wave Plate & Hub

Courtesy of CHRYSLER GROUP, LLC
70. Install 2/6 brake wave plate (1) in position in the 2/6 brake hub.

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Fig. 422: Split Ring Seals & Input Shaft

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
71. Install two split ring seals (2) in the seal lands (2) in the input shaft (1).

Fig. 423: Split Seal Rings & Fluid Pump Hub

Courtesy of CHRYSLER GROUP, LLC
72. Install two split seal rings (3) in the lands (2) in fluid pump (1) hub.

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Fig. 424: Thrust Washer & Fluid Pump

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
73. Apply a 3 mm (0.120 in.) bead of Dupont® Loctite™ 5460 Pink Flange
Sealant or equivalent around the perimeter of the fluid pump sealing surface.
74. Using assembly lube, install the plastic thrust washer (2) in position on the
underside of the fluid pump (1). There are three nubs that insert into holes in
the fluid pump hub to prevent the thrust washer from rotating.

Fig. 425: Fluid Pump Separated From Transaxle Housing

Courtesy of CHRYSLER GROUP, LLC
75. Place the fluid pump (2) in position on the transaxle housing (1).

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Fig. 426: Fluid Pump & Bolts

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
76. Install bolts (1) to hold fluid pump (3) to the trans axle housing (2). Refer to
SPECIFICATIONS.
77. Install NEW o-ring seal in position in the groove in the fluid pump housing.

Fig. 427: Fluid Filter Separated From Transaxle Housing

Courtesy of CHRYSLER GROUP, LLC
78. Place the fluid filter (2) in position in the transaxle housing (1).

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Fig. 428: Fluid Filter, Fluid Pump & Bolts

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
79. Install bolts (1) to hold the fluid filter to the fluid pump (3) housing. Refer to
SPECIFICATIONS.

Fig. 429: Small Transfer Port Seals

Courtesy of CHRYSLER GROUP, LLC
80. Install seals in position in four small transfer ports (2) in the transaxle
housing (1).

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Fig. 430: Large Transfer Port Seal

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
81. Install seal in position in the large transfer port (1) in the axle housing (2).

Fig. 431: Differential Assembly Separated From Transaxle Housing

Courtesy of CHRYSLER GROUP, LLC
82. Place the differential assembly in position in the transaxle housing.
83. Apply a 3 mm (0.120 in.) bead of Dupont® Loctite™ 5460 Pink Flange
Sealant or equivalent around the perimeter of the transaxle housing.

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Fig. 432: Transaxle Housing Halves

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
84. If fluid guides and tube were removed during cleaning, install related
components in the transaxle housing. Refer to SPECIFICATIONS.
85. Place the bell housing (1) in position on the transaxle (2).

Fig. 433: Transaxle Housing Bolts

Courtesy of CHRYSLER GROUP, LLC
86. Install five bolts (1) on inside of the bell housing. Refer to
SPECIFICATIONS.

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87. Install six bolts (2) in the bottom of the transaxle housing. Refer to
SPECIFICATIONS.

cardiagn.com
Fig. 434: Transaxle Housing Bolts
Courtesy of CHRYSLER GROUP, LLC
88. Install five bolts from the back (2) and four bolts from the top (1) of the
transaxle housing. Refer to SPECIFICATIONS.

Fig. 435: Park Rod & Park Rod Guide

Courtesy of CHRYSLER GROUP, LLC
89. If seal required replacement, install the NEW lip seal in the manual shaft

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hole in the transaxle housing.

90. Insert the park rod (1) into the park rod guide.

cardiagn.com
Fig. 436: Manual Shaft, Park Rod & Key Hole Slot
Courtesy of CHRYSLER GROUP, LLC
91. Insert the manual shaft (1) into the bearing in the transaxle.
92. Push manual shaft (1) upward until park rod (2) engages the detent comb.
93. Rotate manual shaft (1) clockwise to lock the staked nub on the park rod (2)
in the key hole slot (3) in the manual shaft detent comb.

Fig. 437: Manual Shaft & Pin

Courtesy of CHRYSLER GROUP, LLC

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94. Install the pin (2) to hold the manual shaft (1) in the transaxle into the hole
in the pan gasket flange.

cardiagn.com
Fig. 438: Main Wire Harness & Sensors
Courtesy of CHRYSLER GROUP, LLC
95. Place the main wire harness and sensors (1) in position on the transaxle.
96. Push the wire connector outward through to hole in the transaxle housing.

Fig. 439: Wire Connector & Hold Down Bracket Separated From
Transaxle
Courtesy of CHRYSLER GROUP, LLC

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97. Place the wire connector (1) hold down bracket (2) in position on the
transaxle.

cardiagn.com
Fig. 440: Hold Down Bracket, Wire Connector & Bolts
Courtesy of CHRYSLER GROUP, LLC
98. Install bolt to hold the wire connector (1) hold down bracket (2) to the top of
transaxle housing. Refer to SPECIFICATIONS.
99. Insert the speed sensors in position in the transaxle housing.

Fig. 441: Speed Sensors, Main Wire Harness & Bolts

Courtesy of CHRYSLER GROUP, LLC

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100. Install bolts (1) to hold the speed sensors and main wire harness to transaxle.
Refer to SPECIFICATIONS.

cardiagn.com
Fig. 442: Transfer Port Seals
Courtesy of CHRYSLER GROUP, LLC
101. Install the two seals into the transfer ports in transaxle housing.

Fig. 443: Valve Body Separated From Transaxle

Courtesy of CHRYSLER GROUP, LLC
102. The manual valve is loose after the valve body is removed and may fall
out during installation.

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Place the valve body (2) in position on the transaxle (1). Guide the pin on
the manual valve into the slot in the manual shaft detent comb.

cardiagn.com
Fig. 444: Valve Body Bolts
Courtesy of CHRYSLER GROUP, LLC
103. Install bolts, 7 short (1) and 1 long (2) bolts, to hold the valve body to the
transaxle. Refer to SPECIFICATIONS.

Fig. 445: Detent Spring Separated From Valve Body

Courtesy of CHRYSLER GROUP, LLC
104. Place the detent spring (2) in position on the valve body (1).

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Fig. 446: Manual Shaft Detent Spring & Valve Body

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
105. Install the screw to hold the manual shaft detent spring (1) to the valve body
(2). Refer to SPECIFICATIONS.

Fig. 447: Solenoids & Connector

Courtesy of CHRYSLER GROUP, LLC
106. Starting at the top solenoid valve, push inward at each solenoid (2) until the
connector (3) is engaged.

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Fig. 448: Solenoid Valve Connector, Valve Body & Bolts

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
107. Install bolts to hold the solenoid valve connector (2) to the valve body (1).
Refer to SPECIFICATIONS.

Fig. 449: Fluid Temperature Sensor, Valve Body & Bolt

Courtesy of CHRYSLER GROUP, LLC
108. Insert the temperature sensor (1) into port in the valve body (2).
109. Install bolt to hold fluid temperature sensor (1) to the valve body (2). Refer
to SPECIFICATIONS.

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Fig. 450: Valve Body Cover Separated From Transaxle

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
110. Install a NEW gasket on the pan and place the pan (1) in position on the
transaxle (2).

Fig. 451: Valve Body Cover

Courtesy of CHRYSLER GROUP, LLC
111. Install bolts to hold the valve body pan (2) to the transaxle (1). Refer to
SPECIFICATIONS.

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Fig. 452: Cooler Tubes & Transaxle

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
112. Place the cooler tubes (2) in position on the transaxle (1).
113. Install bolt to hold the cooler tube (2) bracket to the transaxle (1). Refer to
SPECIFICATIONS.

Fig. 453: Cooler Tubes & Banjo Bolts

Courtesy of CHRYSLER GROUP, LLC
114. Install banjo bolts (2) to hold the cooler tubes (1) to the transaxle. Refer to
SPECIFICATIONS.

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Fig. 454: Vent Tube Bracket & Bolt

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
115. Place the vent tube (3) in position on the transaxle (1).
116. Install bolt to hold the vent tube bracket (2) to the transaxle housing. Refer
to SPECIFICATIONS.

Fig. 455: Vent Hose End & Nipple Adapter

Courtesy of CHRYSLER GROUP, LLC
117. Push the vent hose end (1) onto of the nipple on the vent adaptor (2).

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Fig. 456: Vent Hose, Spring Clamp & Pliers

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
118. Using common pliers (3), compress the hose spring clamp (2) and slide it up
the vent hose (1) into position to hold the hose to the nipple.

Fig. 457: Transmission Range Sensor Separated From Transaxle

Courtesy of CHRYSLER GROUP, LLC
119. Place the TRS (1) in position on the transaxle.

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Fig. 458: Transmission Range Sensor

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
120. Install bolts to hold the TRS (1) to the transaxle housing. Refer to
SPECIFICATIONS.

Fig. 459: Manual Lever & Manual Shaft

Courtesy of CHRYSLER GROUP, LLC
121. Place the manual level (1) in position on the manual shaft.

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Fig. 460: Pin Punch, Manual Lever & Transmission Range Sensor

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
122. Insert a suitable pin punch (2) or equivalent through the manual lever into
the TRS switch (1) to hold lever in place.
123. Install the nut to hold the manual lever to the manual shaft. Refer to
SPECIFICATIONS.

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

INSTALLATION.

INSTALLATION
FWD

1. While guiding the transaxle past obstacles, raise the transaxle upward until
the transaxle is in line with the engine.

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Fig. 461: Bellhousing & Engine Block

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
2. Place the bellhousing (1) in position against the engine block (2).

Fig. 462: Bellhousing Bolts

Courtesy of CHRYSLER GROUP, LLC
3. Install the bolts (1, 2) to hold the front (1) and rear (2) of the engine block to
the bellhousing. Refer to SPECIFICATIONS.

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Fig. 463: Rear Transaxle Mount

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
4. Place the rear mount (1) in position and install the bolts (2) to hold the rear
transaxle mount (1) to the back of the transaxle. Refer to
SPECIFICATIONS.

Fig. 464: Supporting Engine

Courtesy of CHRYSLER GROUP, LLC
5. Lower the transaxle (1) so all of the weight is bearing on the high-stand (3).
6. Remove the safety chine (4) holding the transaxle (1) to the jack cradle.
7. Lower and remove the transmission jack (2) from under the transaxle.

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Fig. 465: Front-To-Rear Support

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
8. Place the front-to-rear support in position on the vehicle.
9. Install the bolts (2) to hold the front-to-rear support to the front and rear
crossmembers. Refer to SPECIFICATIONS.
10. Install the trough bolt (1) to hold the front-to-rear support rubber isolator to
the front crossmember. Refer to SPECIFICATIONS.
11. Remove the high-stand (3) from under the engine.

Fig. 466: Bellhousing Bolts

Courtesy of CHRYSLER GROUP, LLC

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12. Install the bolts (1) to hold the lower engine adapter to the bellhousing.
Refer to SPECIFICATIONS.

cardiagn.com
Fig. 467: Bellhousing Bolt
Courtesy of CHRYSLER GROUP, LLC
13. Install the bolt (1) to hold the engine block (2) to the bellhousing next to the
starter motor. Refer to SPECIFICATIONS.

Fig. 468: Bellhousing Bolt

Courtesy of CHRYSLER GROUP, LLC
14. Install the hidden bolt (2) to hold the engine block to the bellhousing behind

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the heat-shield (1) at the back of the engine. Refer to SPECIFICATIONS.

cardiagn.com
Fig. 469: Torque Converter Bolt
Courtesy of CHRYSLER GROUP, LLC
15. Install the bolts (2) to hold the flex plate to the torque converter. Refer to
SPECIFICATIONS.

Fig. 470: Torque Converter Bolt Access Plug

Courtesy of CHRYSLER GROUP, LLC
16. Install the torque converter bolt access plug (2) into the bellhousing cover.
17. Install the left and right halfshafts. Refer to INSTALLATION .

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18. Fill the transaxle to the proper level.

19. Install the belly pan. Refer to BELLY PAN, INSTALLATION .

cardiagn.com
Fig. 471: Cooler Tubes & Hoses
Courtesy of CHRYSLER GROUP, LLC
20. Push the hoses (1) onto the cooler tubes (2) on the transaxle.

Fig. 472: Transaxle Cooler Hose Clamps

Courtesy of CHRYSLER GROUP, LLC
21. Using a suitable clamp pliers (3), crimp the clamps (1) to hold the transaxle
cooler hoses to the tubes (2) on the transaxle.

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Fig. 473: Transaxle Mount Bolts

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
22. Place the transaxle mount in position on the vehicle.
23. Position a suitable floor jack under the left (driver) side of the transaxle to
add support.
24. Raise the transaxle until the bolt holes for the transaxle mount line up.
25. Install the bolts (1) to hold the transaxle mount to the transaxle. Refer to
SPECIFICATIONS.
26. Install the through bolt (2) to hold the transaxle mount rubber isolator to the
frame rail bracket. Refer to SPECIFICATIONS.

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Fig. 474: Starter Motor Bolts

Courtesy of CHRYSLER GROUP, LLC
27. Install the hidden bolts (1, 2) to hold the starter motor to the engine block
and bellhousing. Refer to SPECIFICATIONS.

cardiagn.com
Fig. 475: Ground Cable & Transaxle Bellhousing Bolt
Courtesy of CHRYSLER GROUP, LLC
28. Install the hidden bolt (1) to hold the ground cable and transaxle bellhousing
to the engine block under the engine coolant tubes. Refer to
SPECIFICATIONS.

Fig. 476: Vent Tube & Bolt

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Courtesy of CHRYSLER GROUP, LLC

29. Place the vent tube (1) in position on the transaxle.
30. Install the bolt (2) to hold the vent tube (1) to the transaxle. Refer to
SPECIFICATIONS.

cardiagn.com
Fig. 477: Transaxle TRS Connector
Courtesy of CHRYSLER GROUP, LLC
31. Engage the wire harness connector into the TRS (1).
32. Push inward until the lock (2) clicks into position.

Fig. 478: Transaxle Wire Harness Connector

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Courtesy of CHRYSLER GROUP, LLC

33. Engage the wire harness connector (1) into the solenoid connector on the
transaxle.
34. Set the lock on the transaxle solenoid connector (1).
35. Insert the shift cable into the bracket on the top of the transaxle and engage
the locking clips.
36. Place the shift cable (adjuster screw up) on the manual lever pin.
37. Push downward on the shift cable end until it locks on the manual lever pin.

cardiagn.com
Fig. 479: Lower Air Cleaner Bracket
Courtesy of CHRYSLER GROUP, LLC
38. Place the lower air cleaner bracket (1) in position on the vehicle.

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Fig. 480: Air Cleaner Bracket Nuts & Bolts

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
39. Install the bolts and nuts (1) to hold the lower air cleaner bracket to the left
frame rail. Refer to SPECIFICATIONS.
40. Install the lower air cleaner body. Refer to 2.0L BODY, AIR CLEANER,
INSTALLATION , 2.2L BODY, AIR CLEANER, INSTALLATION or
2.4L BODY, AIR CLEANER, INSTALLATION .
41. Install the air box lid.
42. Install the battery tray in the vehicle. Refer to TRAY, BATTERY,
INSTALLATION .
43. Install the battery in the vehicle. Refer to BATTERY, INSTALLATION .
44. Install the engine air-box in the vehicle.
45. Secure the fasteners to hold the engine air-box to the front crossmember.
46. Close the hood.
47. Road test the vehicle to verify the repair.
AWD

1. While guiding the transaxle past obstacles, raise the transaxle upward until
the transaxle is in line with the engine.

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Fig. 481: Bellhousing & Engine Block

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
2. Place the bellhousing (1) in position against the engine block (2).
3. Install the bolt (1) to hold the front of the engine block to the bellhousing.
Refer to SPECIFICATIONS.

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cardiagn.com
Fig. 482: Bellhousing Bolts
Courtesy of CHRYSLER GROUP, LLC
4. Install the bolts (1) to hold the rear of the engine block to the bellhousing.
Refer to SPECIFICATIONS.

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Fig. 483: Rear Transaxle Mount

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
5. Place the rear mount (1) in position (typical) and install the bolts (2) to hold
the rear transaxle mount (1) to the back of the transaxle. Refer to
SPECIFICATIONS.

Fig. 484: Supporting Engine

Courtesy of CHRYSLER GROUP, LLC
6. Lower the transaxle (1) so all of the weight is bearing on the high-stand (3).
7. Remove the safety chine (4) holding the transaxle (1) to the jack cradle.
8. Lower and remove the transmission jack (2) from under the transaxle.

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Fig. 485: Front-To-Rear Support

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
9. Place the front-to-rear support in position on the vehicle.
10. Install the bolts (2) to hold the front-to-rear support to the front and rear
crossmembers. Refer to SPECIFICATIONS.
11. Install the trough bolt (1) to hold the front-to-rear support rubber isolator to
the front crossmember. Refer to SPECIFICATIONS.
12. Remove the high-stand (3) from under the engine.

Fig. 486: Bellhousing Bolts

Courtesy of CHRYSLER GROUP, LLC

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13. Install the bolts (1) to hold the lower engine adapter to the bellhousing.
Refer to SPECIFICATIONS.

cardiagn.com
Fig. 487: Bellhousing Bolt
Courtesy of CHRYSLER GROUP, LLC
14. Install the bolt (1) to hold the engine block (2) to the bellhousing next to the
starter motor. Refer to SPECIFICATIONS.

Fig. 488: Torque Converter Bolt

Courtesy of CHRYSLER GROUP, LLC
15. Install the bolts (2) to hold the flex plate to the torque converter. Refer to

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SPECIFICATIONS.

cardiagn.com
Fig. 489: Torque Converter Bolt Access Plug
Courtesy of CHRYSLER GROUP, LLC
16. Install the torque converter bolt access plug (2) into the bellhousing cover.
17. Install the power transfer unit (PTU). Refer to INSTALLATION .
18. Install the left and right halfshafts. Refer to INSTALLATION .
19. Fill the transaxle to the proper level.
20. Install the belly pan. Refer to BELLY PAN, INSTALLATION .
21. Lower the vehicle.

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Fig. 490: Cooler Tubes & Hoses

Courtesy of CHRYSLER GROUP, LLC
22. Push the hoses (1) onto the cooler tubes (2) on the transaxle.

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Fig. 491: Transaxle Cooler Hose Clamps
Courtesy of CHRYSLER GROUP, LLC
23. Using a suitable clamp pliers (3), crimp the clamps (1) to hold the transaxle
cooler hoses to the tubes (2) on the transaxle.

Fig. 492: Transaxle Mount Bolts

Courtesy of CHRYSLER GROUP, LLC

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24. Place the transaxle mount in position on the vehicle.

25. Position a suitable floor jack under the left (driver) side of the transaxle to
add support.
26. Raise the transaxle until the bolt holes for the transaxle mount line up.
27. Install the bolts (1) to hold the transaxle mount to the transaxle. Refer to
SPECIFICATIONS.
28. Install the through bolt (2) to hold the transaxle mount rubber isolator to the
frame rail bracket. Refer to SPECIFICATIONS.

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Fig. 493: Starter Motor Bolts
Courtesy of CHRYSLER GROUP, LLC
29. Install the hidden bolts (1, 2) to hold the starter motor to the engine block
and bellhousing. Refer to SPECIFICATIONS.

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Fig. 494: Ground Cable & Transaxle Bellhousing Bolt

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Courtesy of CHRYSLER GROUP, LLC
30. Install the hidden bolt (1) to hold the ground cable and transaxle bellhousing
to the engine block under the engine coolant tubes. Refer to
SPECIFICATIONS.

Fig. 495: Vent Tube & Bolt

Courtesy of CHRYSLER GROUP, LLC
31. Place the vent tube (1) in position on the transaxle.
32. Install the bolt (2) to hold the vent tube (1) to the transaxle. Refer to
SPECIFICATIONS.

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Fig. 496: Transaxle TRS Connector

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
33. Engage the wire harness connector into the TRS (1).
34. Push inward until the lock (2) clicks into position.

Fig. 497: Transaxle Wire Harness Connector

Courtesy of CHRYSLER GROUP, LLC
35. Engage the wire harness connector (1) into the solenoid connector on the
transaxle.
36. Set the lock on the transaxle solenoid connector (1).
37. Insert the shift cable into the bracket on the top of the transaxle and engage

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the locking clips.

38. Place the shift cable (adjuster screw up) on the manual lever pin.
39. Push downward on the shift cable end until it locks on the manual lever pin.

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Fig. 498: Lower Air Cleaner Bracket
Courtesy of CHRYSLER GROUP, LLC
40. Place the lower air cleaner bracket (1) in position on the vehicle.

Fig. 499: Air Cleaner Bracket Nuts & Bolts

Courtesy of CHRYSLER GROUP, LLC
41. Install the bolts and nuts (1) to hold the lower air cleaner bracket to the left

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frame rail. Refer to SPECIFICATIONS.

42. Install the lower air cleaner body. Refer to 2.0L BODY, AIR CLEANER,
INSTALLATION , 2.2L BODY, AIR CLEANER, INSTALLATION or
2.4L BODY, AIR CLEANER, INSTALLATION .
43. Install the air box lid.
44. Install the battery tray in the vehicle. Refer to TRAY, BATTERY,
INSTALLATION .
45. Install the battery in the vehicle. Refer to BATTERY, INSTALLATION .
46. Install the engine air-box in the vehicle.
47. Secure the fasteners to hold the engine air-box to the front crossmember.
48. Close the hood.
49. Road test the vehicle to verify the repair.

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STANDARD PROCEDURES
2-6 BRAKE MEASUREMENT

Fig. 500: 2-6 Brake Discs & Plates

Courtesy of CHRYSLER GROUP, LLC
When the 2-6 brake is replaced, the proper select pressure plate must be install to
achieve specified clearance. Refer to SPECIFICATIONS.

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Measurement (special tool #10427, Compressor, Return Spring) (special tool

#10429, Gauge, Force)

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Fig. 501: 2-6 Brake Wave Plate, Arbor Press & Tools 10427 & 10429
Courtesy of CHRYSLER GROUP, LLC
1. Place the 2-6 brake, with the wave plate on top (4), on a suitable arbor press
(1).
2. Position tools 10427 (3) and 10429 (2) on top of the 2-6 brake wave plate
and under the press ram (1).

Fig. 502: 2-6 Brake & Linear Caliper

Courtesy of CHRYSLER GROUP, LLC

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2
3. Apply 48.4 kg/cm (688 lbf.) of downward force on the 2-6 brake to
compress the wave plate.
4. Using a suitable linear caliper (2), measure the thickness of the compressed
2-6 brake (1) to calculate the 2-6 brake clearance in order to determine the
correct select pressure plate (2) thickness.

Record the measurement as (A)

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Fig. 503: Straight Edge & Underdrive Brake Retainer
Courtesy of CHRYSLER GROUP, LLC
5. Place a suitable straight edge (1) across the sealing surface of the transaxle
housing.
6. Measure (3) the distance between the underdrive brake retainer (2) and the
bottom of the straight edge (1) to calculate the 2-6 brake clearance in order
to determine the correct select pressure plate thickness.

Record the measurement as (B)

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Fig. 504: Special Tool #8285

Courtesy of CHRYSLER GROUP, LLC
(special tool #8285, Compressor, Spring)

Fig. 505: 2-6 Brake Piston & Straight Edge

Courtesy of CHRYSLER GROUP, LLC
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7. Positing the fluid pump on tool 8285 with the 2-6 brake piston (3) facing up.
8. Place a straight edge (1) across the 2-6 brake piston (3).
9. Measure (2) distance between the fluid pump sealing surface and the bottom
of the straight edge to calculate the 2-6 brake clearance in order to determine
the correct select pressure plate thickness.

Record the measurement as (C)

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Calculation
Add measurement C to B and subtract A. The remainder is the clearance of the 2-
6 brake. Refer to SPECIFICATIONS. If the clearance is not within
specification, a thicker or thinner select pressure plate can be installed to achieve
proper clearance.
LOW-REVERSE BRAKE MEASUREMENT

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Fig. 506: Low & Reverse Brake Pressure Plate, Cushion Plate, Plates, Discs,
& Reaction Plate
Courtesy of CHRYSLER GROUP, LLC
When the low-reverse brake is replaced, the proper select pressure plate (1) must
be install to achieve specified end play Refer to SPECIFICATIONS.

1. Install the low-reverse brake pressure plate (1), wave plate (2), plates (3),
discs (4), reaction plate (5) and snap-ring (6) in the transaxle housing.
2. Place transaxle housing on a suitable arbor press.

Fig. 507: Special Tool #10427

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Courtesy of CHRYSLER GROUP, LLC

(special tool #10427, Compressor, Return Spring)

Fig. 508: Special Tool #10429

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
(special tool #10429, Gauge, Force)

Fig. 509: Tool 10427 On The Low-Reverse Clutch, Tool 10429 On

Compressor Tool
Courtesy of CHRYSLER GROUP, LLC
3. Place tool 10427 on the low-reverse clutch.
4. Place tool 10429 on compressor tool directly under the arbor press ram.

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2
5. Apply 28 kg/cm (400 lbf.) of force to compress the wave plate in the low-
reverse brake.

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Fig. 510: Measuring Gap Between The Low-Reverse Reaction Plate &
Snap Ring
Courtesy of CHRYSLER GROUP, LLC
6. Using a suitable feeler gauge set (3), measure the gap between the low-
reverse reaction plate and the snap ring. Refer to SPECIFICATIONS.
7. If the clearance is not within specification, install a thicker or thinner select
pressure plate to adjust the clearance.
REAR COVER BEARING SPACER MEASUREMENT

Refer to MIDDLE-REAR PLANETARY THRUST WASHER

MEASUREMENT to determine the proper thickness for the rear cover
spacer/race.

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Fig. 511: Rear Cover Spacer/Race
Courtesy of CHRYSLER GROUP, LLC
UNDERDRIVE BRAKE MEASUREMENT

Fig. 512: Underdrive Brake Discs, Plates, Reaction Plate & Snap-Ring
Courtesy of CHRYSLER GROUP, LLC
When the underdrive brake is replaced, the proper select snap ring (1) must be

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install to achieve specified end play Refer to SPECIFICATIONS.

1. Install the, discs (3), plates (4), reaction plate (2) and snap-ring (1) in the
transaxle housing.
2. Place transaxle housing on a suitable arbor press.

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Fig. 513: Special Tool #8621, special tool #10429 & Press
Courtesy of CHRYSLER GROUP, LLC
3. Place tool (special tool #8621, Compressor, Spring) (1) on the underdrive
clutch.
4. Place tool (special tool #10429, Gauge, Force) on compressor tool (2)
directly under the arbor press ram.
2
5. Apply 2.8 kg/cm (40 psi) of force to compress the underdrive brake.
6. Using a suitable feeler gauge set (3), measure the gap between the
underdrive reaction plate and the snap ring (4). Refer to
SPECIFICATIONS.
7. If the clearance is not within specification, install a thicker or thinner select
snap-ring (4) to adjust the clearance.
OVERDRIVE CLUTCH MEASUREMENT

The overdrive clutch should be measured before and after it is disassembled or

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assembled. The end play can be adjusted by installing a thicker or thinner snap
ring holding the reaction plate into the overdrive clutch retainer.

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Fig. 514: Overdrive Clutch & Special Tool #8285
Courtesy of CHRYSLER GROUP, LLC
1. Place the overdrive clutch (1) on tool (special tool #8285, Compressor,
Spring) 8285.
2. Attach a magnetic base dial indicator stand (special tool #C-3339A, Set,
Dial Indicator) (2) to the overdrive clutch retainer (1).
3. Attach a (special tool #C-3339A, Set, Dial Indicator) dial indicator (3) to the
stand (2) with the dial indicator plunger against the top of the overdrive
clutch (1) reaction plate (1).

Fig. 515: Special Tool #C-3339A

Courtesy of CHRYSLER GROUP, LLC

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Fig. 516: Reaction Plate & Dial Indicator
Courtesy of CHRYSLER GROUP, LLC
4. Press downward on the reaction plate (1) and "zero" the dial indicator (3).

Fig. 517: Reaction Plate, Pair Of Screw Drivers & Dial Indicator
Courtesy of CHRYSLER GROUP, LLC
5. Lift upward on the reaction plate (1) with a pair of screw drivers (2).

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6. Record the highest reading on the dial indicator (3). This is the amount of
free travel within the overdrive clutch. Refer to SPECIFICATIONS.
7. If the overdrive clutch is not within specifications, install a thicker or thinner
snap ring to hold the reaction plate in the clutch retainer.
MIDDLE-REAR PLANETARY THRUST WASHER MEASUREMENT

This procedure is used to determine the proper thickness for the thrust washer
located between the middle-rear planetary assembly and the overdrive clutch
assembly.

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Fig. 518: Rear Cover Spacer/Race
Courtesy of CHRYSLER GROUP, LLC
1. Place the rear cover on a clean work surface, inside up.
2. Place the rear bearing spacer/race (1) and bearing (2) in position on rear
cover (3).

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Fig. 519: Overdrive Clutch & Rear Cover
Courtesy of CHRYSLER GROUP, LLC
3. Place the overdrive clutch (1) in position on the rear cover (2).

Fig. 520: Gauge Blocks, Straight Edge, Overdrive Clutch Hub & Rear
Cover
Courtesy of CHRYSLER GROUP, LLC

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4. Place two 25 mm (1 in) gauge blocks (1) on opposite sides of the rear cover
(5) on the sealing surface.
5. Place a straight edge (2) across the gauge blocks (1).
6. Using a linear caliper, measure the distance from the top of the straight edge
(2) to the top of the trust race on the overdrive clutch hub (4).
7. Subtract the thickness of the gauge blocks and straight edge from the overall
measurement. This is the distance from the sealing surface to the thrust race
of the overdrive clutch hub.

Record this as measurement (A)

.

Fig. 521: Gauge Blocks, Straight Edge & Thrust Race

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
8. Place two 25 mm (1 in) gauge blocks (1) on opposite sides of the rear of the
transaxle housing (5).
9. Place a straight edge (2) across the gauge blocks (1).
10. Measure (3) the distance from the top of the straight edge (2) to the top of
the trust race (4) on the middle-rear planetary gear assembly.
11. Subtract the thickness of the gauge blocks (1) and straight edge (2) from the
overall measurement. This is the distance from the sealing surface to the

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thrust race of the middle-rear planetary gear assembly (4).

Record this as measurement (B)

.

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Fig. 522: Middle-Rear Planetary Gear Thrust Washer
Courtesy of CHRYSLER GROUP, LLC
12. Measure (1) the thickness of the middle-rear planetary gear thrust washer
(2).

Record this as measurement (C)

Calculation and Thrust Washer Selection
Subtract measurement A from B. Record the sum and subtract measurement C.
The remaining sum is the clearance between the middle-rear planetary gear and
the overdrive clutch. Refer to SPECIFICATIONS.

A thicker or thinner thrust washer can be install to achieve the specified end play.
If the service kit does not contain a suitable replacement thrust washer, the rear
cover thrust bearing spacer/race can be changed to a suitable thickness.
BEARING TURNING TORQUE MEASUREMENT

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To determine proper select shim thickness for the Differential and driven transfer
gear bearings, the turning torque must be measured.

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Fig. 523: Differential & Transfer Gear
Courtesy of CHRYSLER GROUP, LLC
If the bearings, differential, driven transfer gear or transaxle housings have been
replaced turning torque of the differential (1) and then turning torque with the
transfer gear (2) added must be performed. A good starting point to would be to
use the factory installed select shims behind the bearing races in the transaxle
housing and bell housing.

Verify that the bearings and races are NEW and properly installed on/in clean
components with the factory installed select shims behind the bearing races.
Lightly lubricate the bearings with transaxle fluid.

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Fig. 524: Special Tool #C-4995A
Courtesy of CHRYSLER GROUP, LLC
Tool (special tool #C-4995A, Tool, Differential Bearing Torque) must be
modified to be compatibly with the following operation. Two 3/8-24 nuts (1)
must be added to keep the center shaft from rotating in the cone and sleeve.

1. Remove the nylok™ nut and expander cone from the center shaft.
2. Remove the sleeve from the center shaft.
3. Install a nut on the center shaft and tighten it against the existing nut. Install
the sleeve.
4. Install the 2nd nut inside the sleeve just far enough to install the cone and
nut.
5. Install the cone and nut tight enough to keep the center shaft from rotating
inside the cone and sleeve.

MEASUREMENT PROCEDURE
1. Position the differential on a clean work surface.

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Fig. 525: Differential Pinion Gears & Lock Tool
Courtesy of CHRYSLER GROUP, LLC
2. Install the lock tool (special tool #10425, Tool, Pinion and Side Gear
Locking) (2) between the differential (1) pinion gears next to the link pin to
prevent the differential from rotating.
3. Position the transaxle and bell housings on a suitable clean work bench.
4. Install new bearing races with the original select shims.
5. Install the differential with new bearings lightly lubricated with transaxle
fluid in the transaxle housing.
6. Install the bell housing.
7. Install the bolts to hold the bell housing to the transaxle housing. Tighten
bolts to 50% on the specified torque value. Refer to SPECIFICATIONS.
8. Insert modified tool (special tool #C-4995A, Tool, Differential Bearing
Torque) into the differential until the sleeve (C-4995-1) enters the halfshaft
spline in the differential side gear.
9. Tighten the nut until the sleeve expands tightly in the side gear.
10. Tighten the jamb nut to prevent the center shaft from rotating in the sleeve.
11. Using a suitable wrench, rotate the differential 20 rotations clockwise and 20
rotations counterclockwise.

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Fig. 526: Torque Wrench & Differential
Courtesy of CHRYSLER GROUP, LLC
12. Using a torque wrench (1), measure the turning resistance of the differential
(2) after the initial break away. Refer to SPECIFICATIONS.
13. Adjust the turning torque by adding to or subtracting from the thickness of
the select shims behind the differential bearing races.
14. After achieving proper differential turning torque, separate the bell housing
from the transaxle housing.

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Fig. 527: Differential & Transfer Gear
Courtesy of CHRYSLER GROUP, LLC
15. Install the driven transfer gear (2) with new bearings into the transaxle
housing.
16. Install the bell housing.
17. Install the bolts to hold the bell housing to the transaxle housing. Tighten
bolts to 50% on the specified torque value. Refer to SPECIFICATIONS.

NOTE: The turning torque of the differential and the transfer

gear will be about 4 times higher than the differential
alone. The ring gear is driving a much smaller pinion
gear on the transfer shaft.

18. Using a suitable wrench, rotate the differential 20 rotations clockwise and 20
rotations counterclockwise.
19. Using a torque wrench (1), measure the turning resistance of the differential
(2) after the initial break away. Refer to SPECIFICATIONS.
20. Adjust the turning torque by adding to or subtracting from the thickness of
the select shims behind the driven transfer shaft bearing races.
21. Remove tool C-4995 from the differential.
22. Separate the bell housing from the transaxle housing.

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Fig. 528: Differential & Transfer Gear
Courtesy of CHRYSLER GROUP, LLC
23. Remove the differential (1) and driven transfer gear (2).

Fig. 529: Differential Pinion Gears & Lock Tool

Courtesy of CHRYSLER GROUP, LLC
24. Remove lock tool 10425 (2) from the differential (1).

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25. Prepare transaxle components for final assembly.

3/5/REVERSE CLUTCH MEASUREMENT

The 3-5-Reverse (3-5-R) clutch should be measured before and after it is

disassembled or assembled. The end play can be adjusted by installing a thicker
or thinner snap ring holding the reaction plate into the 3-5-R clutch retainer.

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Fig. 530: 3-5-R Clutch Measurement Set-Up
Courtesy of CHRYSLER GROUP, LLC
1. Place the 3-5-R clutch (2) on tool (special tool #8285, Compressor, Spring).
2. Attach a magnetic base dial indicator stand (3) (special tool #C-3339A, Set,
Dial Indicator) to the 3-5-R clutch retainer (2).
3. Attach a dial indicator (4) to the stand (3) with the dial indicator plunger
against the top of the 3-5-R clutch (2) reaction place (1).

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Fig. 531: Reaction Place & Dial Indicator
Courtesy of CHRYSLER GROUP, LLC
4. Press downward on the reaction plate and "zero" the dial indicator (1).

Fig. 532: Dial Indicator, Pair Of Screw Drivers & Reaction Plate
Courtesy of CHRYSLER GROUP, LLC
5. Lift upward on the reaction plate with a pair of screw drivers (2).

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6. Record the highest reading on the dial indicator (1). This is the amount of
free travel within the 3-5-R clutch. Refer to SPECIFICATIONS.
7. If the 3-5-R clutch is not within specifications, install a thicker or thinner
snap ring to hold the reaction plate in the clutch retainer.
SPECIFICATIONS
SPECIFICATIONS

TIGHTENING SPECIFICATIONS
DESCRIPTION N.m Ft. Lb. In. Lb.
Flexplate to Torque Converter 37 27 -
Flexplate to Crankshaft-M12X1.25X14.00 95 70 -
(Do Not Reuse Original Bolts)

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Engine to Transaxle-M12X1.25X65.00 93 69 -
Engine to Transaxle-M10X1.25X45.00 50 37 -
Trans to Engine-M12X1.25X80.0 95 70 -
Transaxle to Engine-M12X1.25X50.0 93 69 -
Trans to Engine-M10X1.25X45.00 50 37 -
Bracket to Transaxle-M6X1.0X20.0 8 - 71
Dust Shield to Transaxle-M6X1X9.5 10 - 88
Lever to Transaxle Shaft-M8X1.25 19 14 -
ATX Cable Adjust-M5X0.8X14.00 8 - 71
Shifter to Floor Pan-M6X1.00 9 - 80
Bracket to Front Crossmember- 95 70 -
M12X1.75X40.00
FEM to Lower Load Path-M10X1.25X83.0 45 33 -
FEM to Front Rail-M10X1.25X30.5 45 33 -
Isolator to Transaxle Bracket- 100 74 -
M12X1.75X70.00
Isolator to Rail LT-M12X1.75X50.00 87 64 -

6F24 INTERNAL TIGHTENING SPECIFICATIONS

DESCRIPTION N.m Ft. Lb. In. Lb.
Transfer Gear Driven 34 25 -
Transfer Gear Driven Spanner Nut 265 195 -

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Rear Cover 30 22 -
Under Driver Brake Retainer With 40HP 33 24 -
driver
Under Driver Brake Retainer With 45HP 39 28 -
driver
Under Drive Brake Chamber 11 - 97
Differential Ring Gear Bolts 120 88 -
Differential Case Screws 11 - 97
Parking Rod Guide 11 - 97
Fluid Pump Pipe 11 - 97
Fluid Pump to Transaxle 22.5 17 -
Fluid Pump Cover 22.5 17 -

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Fluid Filter 11 - 97
Bell Housing 32 23 -
Valve Body 11 - 97
Detent Spring 14 - 124
Valve Body Solenoid Retainer Screws 10 - 88
Valve Body Accumulator Plate Bolts 11 - 97
Valve Body Separator Plate Bolts 6 - 53
Valve Body Housing Bolts 15 - 97
Valve Body Cover Pan 13 - 132
Trans Range Sensor (Inhibitor Switch) 11 - 97
Wire Harness Retainer Screws 10 - 88
Wire Harness Connector Hold Down Bolt 10 - 88
Wire Harness Solenoid Connector Bolts 10 - 88
Vent Bracket Bolt 11 - 97
Cooler Line Bracket Bolt 11 - 97
Differential Fluid Shield Bolts 11 - 97
END PLAY TOLERANCE

ITEM TOLERANCE
Input shaft end play (Rear) 0.25 - 0.45 mm (0.0098 - 0.0177 in.)
2/6 brake pressure plate end play 2.05 - 2.35 mm (0.0807 - 0.0925 in.)
Low & reverse brake pressure plate 2.25 - 2.55 mm (0.0886 - 0.1004 in.)

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end play
Under drive brake snap ring end play 0.65 - 0.95 mm (0.0255 - 0.0374 in.)
Over drive clutch snap ring end play 1.05 - 1.35 mm (0.0413 - 0.0531 in.)
3-5-R clutch snap ring end play 0.85 - 1.15 mm (0.0335 - 0.0453 in.)
Middle & rear planetary gear end 0.1 - 0.4 mm (0.0039 - 0.0157 in.)
play
Input shaft end play (Front) 0.55 - 0.85 mm (0.0216 - 0.0334 in.)
Differential side gear & differential 0.025 - 0.150 mm (0.0009 - 0.0059
pinion gear backlash in.)
SHIM SELECTION-DIFFERENTIAL

The following list of shims are available in a complete kit supplied by Mopar®.

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Spacer 1.10 mm 0.043 in.
Spacer 1.01 mm 0.040 in.
Spacer 1.04 mm 0.041 in.
Spacer 1.07 mm 0.042 in.
Spacer 1.13 mm 0.044 in.
Spacer 1.16 mm 0.045 in.
Spacer 1.19 mm 0.047 in.
Spacer 1.22 mm 0.048 in.
Spacer 1.25 mm 0.049 in.
Spacer 1.28 mm 0.050 in.
Spacer 1.31 mm 0.051 in.
Spacer 1.34 mm 0.052 in.
Spacer 1.37 mm 0.054 in.
Spacer 0.77 mm 0.030 in.
Spacer 0.80 mm 0.031 in.
Spacer 0.83 mm 0.033 in.
Spacer 0.86 mm 0.034 in.
Spacer 0.89 mm 0.035 in.
Spacer 0.92 mm 0.036 in.
Spacer 0.95 mm 0.037 in.
Spacer 0.98 mm 0.038 in.

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SHIM SELECTION-DRIVEN TRANSFER GEAR

The following list of shims are available in a complete kit supplied by Mopar®.

Spacer Output 0.83 mm 0.033 in.

Spacer Output 0.86 mm 0.034 in.
Spacer Output 0.89 mm 0.035 in.
Spacer Output 0.92 mm 0.036 in.
Spacer Output 0.95 mm 0.037 in.
Spacer Output 0.98 mm 0.039 in.
Spacer Output 1.01 mm 0.040 in.
Spacer Output 1.04 mm 0.041 in.
Spacer Output 1.07 mm 0.042 in.

cardiagn.com
Spacer Output 1.10 mm 0.043 in.
Spacer Output 1.13 mm 0.044 in.
Spacer Output 1.16 mm 0.046 in.
Spacer Output 1.19 mm 0.047 in.
Spacer Output 1.22 mm 0.048 in.
Spacer Output 1.25 mm 0.049 in.
Spacer Output 1.28 mm 0.050 in.
Spacer Output 1.31 mm 0.051 in.
Spacer Output 1.34 mm 0.053 in.
THRUST RACE SELECTION

The following list of Thrust Races are a complete kit available from Mopar®.

Thrust Race (Input Shaft End Play-Rear) 1.4 mm 0.055 in.

Thrust Race (Input Shaft End Play-Rear) 1.5 mm 0.059 in.
Thrust Race (Input Shaft End Play-Rear) 1.6 mm 0.063 in.
Thrust Race (Input Shaft End Play-Rear) 1.7 mm 0.067 in.
Thrust Race (Input Shaft End Play-Rear) 1.8 mm 0.071 in.
Thrust Race (Input Shaft End Play-Rear) 1.9 mm 0.075 in.
Thrust Race (Input Shaft End Play-Rear) 2.0 mm 0.079 in.
Thrust Race (Input Shaft End Play-Rear) 2.1 mm 0.083 in.
Thrust Race (Input Shaft End Play-Rear) 2.2 mm 0.087 in.

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Thrust Race (Input Shaft End Play-Rear) 2.3 mm 0.091 in.

BEARING TURNING TORQUE SPECIFICATION

Turning Torque Measurement must be performed with NEW bearings.

After the NEW bearings have been installed, they should be lightly lubricated
with automatic transaxle fluid. The bearings must be lapped in by rotating the
bearings 20 rotations clockwise and 20 rotations counterclockwise before
measuring the turning torque. Due to the larger size of the differential ring gear
over the smaller transfer gear the turning torque of the transfer gear is increased
by about 3.45 times by the gear ratio.

BEARING SET N.m in. lb.

cardiagn.com
Differential Side Bearings 1.6 (+/-.22) 15 (+/- 2)
Transfer Gear (Driven) 6.77 (+/-.9 60 (+/- 8)
Transfer Gear (Output) 0.67 (+/- 0.22 6 (+/- 2)
CLUTCH, BRAKE, THRUST AND BEARING CLEARANCE

For transfer bearing and differential bearing shim selection refer to Bearing
Turning Torque Measurement. Refer to SPECIFICATIONS.

Element mm in.
3-5-Reverse Clutch 0.85 to 1.15 0.033 to
0.045
Overdrive Clutch 1.25 to 1.55 0, 049 to
0.061
2-6 Brake 2.05 to 2.35 0.080 to
0.092
Underdrive Brake 0.65 to 0.95 0.025 to
0.037
Low-Reverse Brake 2.25 to 2.55 0.088 to
0.100
Middle-rear Planetary Thrust Washer 0.1 to 0.4 0.003 to
0.015
Rear Cover Bearing Spacer 0.25 to 0.45 0.009 to
0.017

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SPECIAL TOOLS
SPECIAL TOOLS - FWD

5058A-3 - Screw, Forcing

(Originally Shipped In Kit
Number(s) 8853.)

cardiagn.com
8285 - Compressor, Spring
(Originally Shipped In Kit
Number(s) 8283, 8283CC,
8527, 8527CC, 8575, 8575CC,
9975.)

8621 - Compressor, Spring

(Originally Shipped In Kit
Number(s) 8705.)

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8680 - Installer, Damper
(Originally Shipped In Kit
Number(s).)

8866 - Installer, Bearing Cup

(Originally Shipped In Kit
Number(s) 8998, 8998CC.)

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9664 - Remover, Bearing Cup
(Originally Shipped In Kit
Number(s) 9675, 9685, 9695.)

9668 - Remover/Installer,
Bearing Cup
(Originally Shipped In Kit
Number(s) 9691.)

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10117 - Installer, Seal
(Originally Shipped In Kit
Number(s) 10075-CHRYSLER,
10075-DODGE.)

10304 - Installer, Input Shaft

Seal
(Originally Shipped In Kit
Number(s) 10366, 10366A.)

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10323A - Dipstick
(Originally Shipped In Kit

cardiagn.com
Number(s).)

10371 - Tool, Turning Torque

10422 - Wrench, Spanner

(Originally Shipped In Kit
Number(s) 10419.)

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10423 - Fixture, Transfer Gear
Holding
(Originally Shipped In Kit
Number(s) 10419.)

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10424 - Adapter, Transmission
Pressure
(Originally Shipped In Kit
Number(s) 10419.)

10425 - Tool, Pinion and Side

Gear Locking
(Originally Shipped In Kit
Number(s) 10419.)

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10426 - Compressor,
Underdrive Spring
(Originally Shipped In Kit
Number(s) 10419.)

10427 - Compressor, Return

Spring

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(Originally Shipped In Kit

Number(s) 10419.)

10429 - Gauge, Force

(Originally Shipped In Kit
Number(s) 10419.)

cardiagn.com

C-293-PA - Puller, Press

(Originally Shipped In Kit
Number(s) 8418, 8837, C-293-
M.)

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C-293-39 - Block Set, Puller

(Originally Shipped In Kit

cardiagn.com
Number(s) 8418, C-293-M,
DD-914-CLT-L.)

C-293-48 - Block Set, Puller

(Originally Shipped In Kit
Number(s) 8418, 8837, C-293-
M, DD-914-CLT-L.)

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C-637 - Slide Hammer,

Universal
(Originally Shipped In Kit
Number(s) 9202.)

C-3095-A - Installer, Bearing

cardiagn.com
C-3339A - Set, Dial Indicator
(Originally Shipped In Kit
Number(s) 9202.)

C-4171 - Driver Handle,

Universal
(Originally Shipped In Kit

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Number(s) 9202, 9202A-CAN,

9202CC, 9299, 9299CC,
9299CC, 9300A-CAN.)

C-4995A - Tool, Differential

Bearing Torque

cardiagn.com
C-4996 - Adapter, Plug
(Originally Shipped In Kit
Number(s) 6672.)

SPECIAL TOOLS - AWD

5058A-3 - Screw, Forcing

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(Originally Shipped In Kit

Number(s) 8853.)

6342 - Installer, Seal

(Originally Shipped In Kit
Number(s) 6672.)

cardiagn.com
8285 - Compressor, Spring
(Originally Shipped In Kit
Number(s) 8283, 8283CC,
8527, 8527CC, 8575, 8575CC,
9975.)

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cardiagn.com
8621 - Compressor, Spring
(Originally Shipped In Kit
Number(s) 8705.)

8680 - Installer, Damper

(Originally Shipped In Kit
Number(s).)

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8866 - Installer, Bearing Cup

cardiagn.com
(Originally Shipped In Kit
Number(s) 8998, 8998CC.)

9664 - Remover, Bearing Cup

(Originally Shipped In Kit
Number(s) 9675, 9685, 9695.)

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9668 - Remover/Installer,
Bearing Cup

cardiagn.com
(Originally Shipped In Kit
Number(s) 9691.)

9678 - Press Plug

(Originally Shipped In Kit
Number(s) 9675, 9685, 9695.)

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cardiagn.com
10117 - Installer, Seal
(Originally Shipped In Kit
Number(s) 10075-CHRYSLER,
10075-DODGE.)

10304 - Installer, Input Shaft

Seal
(Originally Shipped In Kit
Number(s) 10366, 10366A.)

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10323A - Dipstick
(Originally Shipped In Kit

cardiagn.com
Number(s).)

10371 - Tool, Turning Torque

10422 - Wrench, Spanner

(Originally Shipped In Kit
Number(s) 10419.)

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10423 - Fixture, Transfer Gear
Holding
(Originally Shipped In Kit
Number(s) 10419.)

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10424 - Adapter, Transmission
Pressure
(Originally Shipped In Kit
Number(s) 10419.)

10425 - Tool, Pinion and Side

Gear Locking
(Originally Shipped In Kit
Number(s) 10419.)

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10426 - Compressor,
Underdrive Spring
(Originally Shipped In Kit
Number(s) 10419.)

10427 - Compressor, Return

Spring

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(Originally Shipped In Kit

Number(s) 10419.)

10429 - Gauge, Force

(Originally Shipped In Kit
Number(s) 10419.)

cardiagn.com

C-293-PA - Puller, Press

(Originally Shipped In Kit
Number(s) 8418, 8837, C-293-
M.)

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C-293-3 - Adapter,
Bearing/Gear

cardiagn.com
(Originally Shipped In Kit
Number(s) 8418, 8837, C-293-
M, C-4246-AL, DD-914-CLT-
L.)

C-293-39 - Block Set, Puller

(Originally Shipped In Kit
Number(s) 8418, C-293-M,
DD-914-CLT-L.)

C-293-48 - Block Set, Puller

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(Originally Shipped In Kit

Number(s) 8418, 8837, C-293-
M, DD-914-CLT-L.)

cardiagn.com
C-293-62 - Block Set, Puller

C-637 - Slide Hammer,

Universal
(Originally Shipped In Kit
Number(s) 9202.)

C-3095-A - Installer, Bearing

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C-3339A - Set, Dial Indicator

cardiagn.com
(Originally Shipped In Kit
Number(s) 9202.)

C-3972-A - Installer, Seal

(Originally Shipped In Kit
Number(s) 9975.)

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C-4171 - Driver Handle,

Universal
(Originally Shipped In Kit
Number(s) 9202, 9202A-CAN,
9202CC, 9299, 9299CC,
9299CC, 9300A-CAN.)

C-4310 - Installer, Bearing

(Originally Shipped In Kit

cardiagn.com
Number(s) C-4306.)

C-4995A - Tool, Differential

Bearing Torque

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C-4996 - Adapter, Plug

(Originally Shipped In Kit

cardiagn.com
Number(s) 6672.)

L-4454A - Remover, Bearing

Cup
(Originally Shipped In Kit
Number(s) 9975.)

L-4518 - Remover, Bearing

Cup

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(Originally Shipped In Kit

Number(s) 6822.)

FLUID

cardiagn.com
STANDARD PROCEDURES

FLUID

Fluid Type, Capacity and Service Interval

NOTE: There is no service interval recommended for the 6F24

Automatic Transaxle when operated under normal
conditions.

The fluid used in the 6F24 Automatic Transaxle is clear liquid with red tint. It is
formulated for use only in the 6F24 automatic transaxle. The Mopar Part Number
(PN) is on Star Parts .
The factory fill fluid capacity of the 6F24 Automatic Transaxle is 7.1 L (7.5 qt.).
Service fill with full torque converter and fluid cooler is 4.7 L (5 qt.)
FLUID DRAIN

1. Raise the vehicle on a suitable hoist that will keep the vehicle in a level
position, front-to-rear and side-to-side. Refer to HOISTING, STANDARD
PROCEDURE .

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cardiagn.com
Fig. 533: Transaxle Fluid Drain Plug
Courtesy of CHRYSLER GROUP, LLC
2. Remove the belly pan to gain access to the transaxle fluid drain plug (1).
Refer to BELLY PAN, REMOVAL .

Fig. 534: Transaxle Fluid Drain Plug & Drain Pan

Courtesy of CHRYSLER GROUP, LLC

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3. Position a suitable drain pan (2) under the vehicle to drain the transaxle fluid
into.

cardiagn.com
Fig. 535: Drain Fluid From Transaxle
Courtesy of CHRYSLER GROUP, LLC
4. Remove the drain plug from the transaxle (1) and allow fluid the drain into
the drain pan.
5. After the fluid has ceased draining from the transaxle, Install the drain plug.
Tighten to specifications.
6. Remove the drain pan.
7. Perform repair procedures as necessary or proceed to Fluid Fill Procedure.
8. Install the belly pan. Refer to BELLY PAN, INSTALLATION .
FLUID FILL

NOTE: It is necessary to vent the transaxle by removing the plug

from the fluid level check port, located on top of the
transaxle housing above the differential, before
attempting to pour fluid into the transaxle.

The 6F24 Automatic Transaxle is filled through the vent pod located on top front
surface of the valve body pan.

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1. Raise the vehicle on a suitable hoist that will keep the vehicle in a level
position, front-to-rear and side-to-side. Refer to HOISTING, STANDARD
PROCEDURE .

cardiagn.com
Fig. 536: Fluid Level Check Port
Courtesy of CHRYSLER GROUP, LLC
2. Remove the belly pan to gain access to the fluid level check port (3) located
on top of the transaxle housing above the differential. Refer to BELLY
PAN, REMOVAL .
3. Remove the plug (1) from the fluid level check port (3).
4. Lower the vehicle until the tires are 2 cm (8 in.) off the floor.

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cardiagn.com
Fig. 537: Fluid Level Check Port Plug
Courtesy of CHRYSLER GROUP, LLC
5. Connect a Scan tool to the diagnostic connector under the instrument panel
on the driver side.
6. Navigate the scan tool to a screen to display the transaxle temperature.
7. Remove the fill plug from the vent pod located on the front of the valve
body pan.
8. Insert a suitable funnel into the vent pod on the front of the valve body pan.
9. Slowly pour 4 L (4.3 qt.) of specified fluid into the funnel while watching
the fill hole for spill over.
10. Start the engine and allow it to idle in park.
11. Pour 1 L (1.05 qt.) into the transaxle and install the fill plug. Tighten to
specification.
12. With engine still running in park, raise the vehicle and check the fluid level.
13. Add or siphon fluid to achieve the specified fluid level. Refer to FLUID,
STANDARD PROCEDURES.
14. Install the fluid check plug in the transaxle. Tighten to specification
15. Install the belly pan. Refer to BELLY PAN, INSTALLATION .
16. Lower the vehicle and disconnect the scan tool.
17. Road test the vehicle to verify the repair.

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FLUID FILTER

FLUID FILTER SERVICE

The fluid filter in the 6F24 automatic transaxle is not periodically serviced. To
replace the fluid filter the transaxle must be removed and the bell housing
separated from the transaxle housing. Refer to DISASSEMBLY.
FLUID LEVEL CHECK

NOTE: It is not necessary to check the fluid level in the 6F24

Automatic Transaxle unless there are shifting issues
and/or has evidence of a transaxle fluid leak.

Fig. 538: Fluid Level Indicator, Transaxle & Fluid Level

Courtesy of CHRYSLER GROUP, LLC
cardiagn.com
NOTE: Special Tool (special tool #10323A, Dipstick) Fluid level
Indicator (1) and a Scan-tool are required to accurately
measure the fluid level (4) in the 6F24 Automatic
Transaxle (2).

Checking the fluid level in the 6F24 Automatic Transaxle (2) is to measure the
distance from the upper lip of the fluid level check port, located on top of the
transaxle housing above the differential, down to the surface of the fluid (4).

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Tool 10323A fluid level indicator is marked in 5 mm increments with the base of
the handle at 140 mm and the lower tip at "0". The engine must be running at idle
with the transaxle in park and the vehicle hoisted in a level position.

1. Connect a Scan Tool to the Diagnostic Connector under the instrument

panel on the driver's side of the vehicle.
2. Navigate to a screen to display transaxle fluid temperature.
3. Start the engine and allow it to run at idle with the transaxle in Park.
4. Verify that the fluid temperature is above 50 °C.
5. Raise the vehicle on a suitable hoist that will keep the vehicle in a level
position, front-to-rear and side-to-side. Refer to HOISTING, STANDARD
PROCEDURE .

Fig. 539: Differential, Special Tool #10323A & Fluid Level Check Port
cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
6. Remove the belly pan to gain access to the fluid level check port (3) located
on top of the transaxle housing above the differential (1). Refer to BELLY
PAN, REMOVAL .
7. Remove the plug from the fluid level check port.
8. Insert tool (special tool #10323A, Dipstick) (2) into the fluid level check
port (3) and allow the handle of the tool to rest on the flat surface of the
transaxle housing (1) around the check port.

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9. Remove the tool from the check port, keeping the handle above the tip so
the level reading remains accurate.
10. Note the increment on the shaft of the tool where the fluid left a witness
mark.

cardiagn.com
Fig. 540: Fluid Level & Temperature Chart
Courtesy of CHRYSLER GROUP, LLC
11. Based on the temperature of the fluid and the measurement on the tool, refer
to the graph or the table to determine the proper level.
12. Install the plug into the fluid level check port. Tighten to specification.
13. Install the belly pan. Refer to BELLY PAN, INSTALLATION .
14. Lower vehicle.

6F24 AUTOMATIC TRANSAXLE FLUID LEVEL TABLE

TEMP in °C MIN LEVEL NOMINAL MAX LEVEL
(mm) LEVEL (mm) (mm)
50° 21 mm 26 mm 31.5 mm
55° 23 mm 27.5 mm 33 mm
60° 25 mm 30 mm 34 mm
65° 27 mm 31 mm 35.5 mm
70° 28.5 mm 33 mm 36.5 mm
75° 30 mm 35 mm 38 mm
80° 31.5 mm 36 mm 39 mm

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85° 32.5 mm 37 mm 40 mm
90° 34 mm 38 mm 41.5 mm
FLUID LEAK DETECTION - AWD

The following procedure is for detecting transaxle fluid leaks from the area
between the transaxle and the Power Transfer Unit (PTU). When transaxle fluid
is leaking form the weep hole in the area of the PTU, the seals around the
differential output shaft and the differential side gear is most likely faulty. The
large seal around the differential output shaft is serviceable without removing the
transaxle. The seal around the inner differential side gear is serviceable after the
differential unit is removed from the transaxle. The following procedure is
recommended to determine which seal is leaking.

cardiagn.com
1. Disconnect the transaxle vent tube from the adaptor nipple on the top of the
valve body pan.
2. Adapt a compressed shop air coupling and a length neoprene hose onto the
vent nipple.
3. Attach a 48 kPa (7 psi) regulated shop air source to the air coupling on the
vent nipple.
4. Raise the vehicle on a suitable hoist.
5. Remove the PTU from the vehicle. Refer to REMOVAL .
6. Apply a soapy solution to the seals inside and around the differential output
shaft.
7. Observe over several minutes to see if air bubbles form in the leak area.

Test Results
If bubbles are emanating from the inner differential side gear seal, remove
the differential unit and replace the inner seal.
If bubbles are emanating from the outer output shaft seal, replace the seal.
If bubbles are emanating from the transaxle housing casting, replace the
porous component.
KNOB, GEARSHIFT
REMOVAL

REMOVAL

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1. Pry PRND escutcheon upward and separate it from the shifter assembly.

cardiagn.com
Fig. 541: Wire Connector At PRND Display
Courtesy of CHRYSLER GROUP, LLC
2. Disconnect the wire connector from the PRND display.
3. Pull shift boot upward to expose the shift knob set screw.

Fig. 542: Shift Knob & Set Screw At Shift Lever

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Courtesy of CHRYSLER GROUP, LLC

4. Loosen the set screw holding the shift knob to the shift lever.
5. Depress and hold the lock button on the shift knob.

cardiagn.com
Fig. 543: Shift Knob And Shifter
Courtesy of CHRYSLER GROUP, LLC
6. Lift the shift knob upward and separate it from the shifter.
INSTALLATION

INSTALLATION

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cardiagn.com
Fig. 544: Lock Button On The Shift Knob
Courtesy of CHRYSLER GROUP, LLC
1. Depress and hold the lock button (3) on the shift knob.

Fig. 545: Shift Knob And Shifter

Courtesy of CHRYSLER GROUP, LLC
2. With the lock button facing forward, guide the shift knob (1) downward and

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onto the shifter (2) until it seats.

3. Release the lock button.

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Fig. 546: Shift Knob & Set Screw At Shift Lever
Courtesy of CHRYSLER GROUP, LLC
4. Tighten the set screw to hold the shift knob to the shift lever.

Fig. 547: Wire Connector At PRND Display

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5. Connect the wire connector onto the PRND display.
6. Press PRND escutcheon downward until the clips engage the shifter
assembly.
CABLE, SHIFT
REMOVAL

REMOVAL

1. Open hood and support it on the prop-rod.

2. Disconnect the battery negative cable.

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3. Remove the center floor console from the vehicle. Refer to CONSOLE,
FLOOR, REMOVAL .
4. Disconnect the shift cable from the shifter.

Fig. 548: Floor Grommet, Gear Shift Cable & Access Hole
Courtesy of CHRYSLER GROUP, LLC
5. Push gear shift cable (2) floor grommet (1) through the access hole (3) in the
floor.
6. Remove air cleaner/engine cover. Refer to 2.0L BODY, AIR CLEANER,

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REMOVAL , 2.2L BODY, AIR CLEANER, REMOVAL or 2.4L

BODY, AIR CLEANER, REMOVAL .
7. From under the battery tray, pry the shift cable end from the manual lever on
the transaxle.

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Fig. 549: Gear Shift Cable, Clips & Bracket
Courtesy of CHRYSLER GROUP, LLC
8. Release the clips (2) holding the gear shift cable (1) to the bracket (3) on the
transaxle.
9. Lift vehicle on a suitable hoist. Refer to HOISTING, STANDARD
PROCEDURE .
10. Remove the heat shield from above the steering rack to enable the cable
removal.
11. Guide the shift cable rearward over the steering gear and toward passenger
side of the vehicle.
12. Squeeze the cable housing lock hub through the widest point between the
floor and the steering rack.
13. Separate the shift cable from the vehicle.
ADJUSTMENTS

GEAR SHIFT CABLE ADJUSTMENT

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1. Remove the center floor console to gain access to the gear shift cable under
the gear shift assembly. Refer to CONSOLE, FLOOR, REMOVAL .
2. Set the parking brake.
3. Place the Powertech transmission and the shifter lever into NEUTRAL. This
can be done with the key in the "Run" position and viewing the PRND.
(Engine should not be running.)

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Fig. 550: Shift Cable Adjustment Screw
Courtesy of CHRYSLER GROUP, LLC
4. Loosen the cable adjustment screw, but don't remove it.
5. Push shift lever forward, without depressing the knob button, until it hits the
gate stop to ensure shifter is in N position.
6. The cable will settle into its natural position which should be near the center
of the adjustment slot.
7. Tighten the adjusting screw to 8 +/-1 N.m (70 in. lb.).
8. Verify the shift lever can place the transaxle into PARK and the other gears.
9. Install the floor console. Refer to CONSOLE, FLOOR,
INSTALLATION .
INSTALLATION

INSTALLATION

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1. Insert the shift cable end upward into hole through the floor pan.
2. With the shift cable coiled above the passenger side heat shield, squeeze the
cable housing lock hub through the widest point between the floor and the
steering rack.
3. Guide the shift cable forward over the steering gear and toward the
transaxle.
4. Install the heat shield above the steering rack.
5. Lower vehicle to the floor.

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Fig. 551: Gear Shift Cable, Clips & Bracket
Courtesy of CHRYSLER GROUP, LLC
6. Engage the clips (2) to hold the gear shift cable (1) to the bracket (3) on the
transaxle.
7. Under the battery tray, snap the shift cable end onto the manual lever on the
transaxle.
8. Install the air cleaner/engine cover. Refer to 2.0L BODY, AIR CLEANER,
INSTALLATION , 2.2L BODY, AIR CLEANER, INSTALLATION or
2.4L BODY, AIR CLEANER, INSTALLATION .

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Fig. 552: Floor Grommet, Gear Shift Cable & Access Hole
Courtesy of CHRYSLER GROUP, LLC
9. Engage the gear shift cable (2) floor grommet (1) into the access hole (3) in
the floor.
10. Connect the shift cable onto the shifter.
11. Install the center floor console onto the vehicle. Refer to CONSOLE,
FLOOR, INSTALLATION .
12. Connect the battery negative cable.
13. Close the hood.
SEAL, DIFFERENTIAL
REMOVAL

FWD

1. Remove the halfshaft from the vehicle. Refer to REMOVAL .

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Fig. 553: Punching Hole In Differential Seal

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Courtesy of CHRYSLER GROUP, LLC

NOTE: Keep the punch tool in the center of the seal to avoid
damage to the transaxle housing.

2. Using a suitable slide awl tool and hammer, punch a hole in the metal
armature inside the seal.

Fig. 554: Slide Hammer & Differential Seal

Courtesy of CHRYSLER GROUP, LLC
3. Use a suitable Slide Hammer Dent Puller, to remove the seal.

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4. Thread the sheet metal screw of the dent puller into the punched hole in the
seal.
5. Tap outward on the slide hammer until the seal comes out of the seal bore.
REMOVAL

1. Remove PTU unit from the vehicle. Refer to REMOVAL .

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Fig. 555: Punching Hole In Differential Seal
Courtesy of CHRYSLER GROUP, LLC

NOTE: Keep the punch tool in the center of the seal to avoid
damage to the transaxle housing.

2. Using a suitable slide awl tool and hammer, punch a hole in the metal
armature inside the seal.

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Fig. 556: Slide Hammer & Differential Seal

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
3. Use a suitable Slide Hammer Dent Puller, to remove the seal.
4. Thread the sheet metal screw of the dent puller into the punched hole in the
seal.
5. Tap outward on the slide hammer until the seal comes out of the seal bore.
INSTALLATION

INSTALLATION

Verify that the seal bore is smooth and undamaged. Use a clean shop towel to
wipe residue from the sealing surfaces.
1. Apply transmission assembly lube on the seal lip and inside the tension
spring cavity on the inside of the seal.

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Fig. 557: Special Tool #10117 & Differential Seal

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
2. Attach the new seal onto the installer (1) (special tool #10117, Installer,
Seal).
3. Insert the installer and seal (1) into the output shaft seal bore on the
transaxle.

Fig. 558: Installing Differential Seal

Courtesy of CHRYSLER GROUP, LLC
4. Using a suitable hammer, drive the seal (1) into the seal bore until the
installer seats on the transaxle housing.

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5. Install the halfshaft. Refer to INSTALLATION .

6. Road test vehicle to verify the repair.
INSTALLATION

Clean the seal bore with suitable shop towel. Inspect the seal bore for scratches
or other defects that may cause fluid leaks. If all sealing surfaces are smooth and
defect free, install a NEW seal.

1. Apply transmission assembly lube on the seal lip and inside the tension
spring cavity on the inside of the seal.
2. Insert the NEW seal into the into the bore in the transaxle housing around
the output shaft.

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Fig. 559: Installing Differential Seal
Courtesy of CHRYSLER GROUP, LLC
3. Using tool (special tool #C-3972-A, Installer, Seal) and (special tool #C-
4171, Driver Handle, Universal) drive the seal in the bore until it is fully
seated.
4. Install the PTU unit.
5. Verify that the transaxle and PTU is properly filled with specified fluid.
6. Road test vehicle to verify the repair.
VALVE BODY

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DESCRIPTION

DESCRIPTION AND INSPECTION

The valve body is the device that controls the hydraulic power flow to the
clutches and brakes within the 6F24 Automatic Transaxle. The valve body is
equipped with on-off and variable force solenoids the are electrically controlled
by the PCM. If the transaxle passes an air pressure test and is relatively clean, the
transaxle should be OK and the valve body is most likely at fault. All of the
valve body internal components must be a able to travel freely within there bores
and cylinders. Any dirt or debris within the valve body can cause a valve or
piston to bind and fail to function. The valve body valves are somewhat self
cleaning. The leading edges of the valve chambers are ground sharply to cut
through soft debris and allows the valve to function. The strainers and screen in

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the valve body are designed to filter out dirt and debris as the fluid circulates
through the hydraulic passages. If a valve or piston is deeply scratched and can
be felt with a fingernail the valve body or transaxle must be replaced depending
on parts availability.
REMOVAL

REMOVAL

1. Remove the engine cover/air cleaner from the vehicle. Refer to 2.0L AIR
CLEANER, REMOVAL , 2.2L AIR CLEANER, REMOVAL or AIR
CLEANER, REMOVAL .
2. Drain the fluid from the transaxle. Refer to FLUID, STANDARD
PROCEDURES.

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Fig. 560: Vent Hose, Spring Clamp & Pliers
Courtesy of CHRYSLER GROUP, LLC
3. Using common pliers (3), compress the hose spring clamp (2) and slide it
down the vent hose (1) away from the nipple adaptor.

Fig. 561: Vent Hose End & Nipple Adaptor

Courtesy of CHRYSLER GROUP, LLC

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4. Pull the vent hose end (1) off of the nipple adaptor (2).
5. Position suitable drain pan under the valve body cover to catch fluid that
may spill as the cover is removed.

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Fig. 562: Transaxle & Valve Body Cover
Courtesy of CHRYSLER GROUP, LLC
6. Remove bolts holding the valve body cover (2) to the transaxle (1).

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Fig. 563: Valve Body Cover Separated From Transaxle

Courtesy of CHRYSLER GROUP, LLC
7. Separate the valve body cover (1) from the transaxle (2).

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Fig. 564: Fluid Temperature Sensor & Valve Body
Courtesy of CHRYSLER GROUP, LLC
8. Remove bolt holding fluid temperature sensor (1) to the valve body (2).
9. Pull temperature sensor (1) straight out of the port in the valve body (2).

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Fig. 565: Valve Body & Solenoid Valve Connector
Courtesy of CHRYSLER GROUP, LLC
10. Remove bolts holding the solenoid valve connector (2) to the valve body
(1).

Fig. 566: Solenoids & Connector

Courtesy of CHRYSLER GROUP, LLC

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11. Starting at the bottom solenoid valve, using a suitable prying tool, pry
outward at each solenoid (2) until the connector (3) is disengaged.

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Fig. 567: Manual Shaft Detent Spring & Valve Body
Courtesy of CHRYSLER GROUP, LLC
12. Remove the screw holding the manual shaft detent spring (1) to the valve
body (2).

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Fig. 568: Detent Spring Separated From Valve Body

Courtesy of CHRYSLER GROUP, LLC
13. Separate the detent spring (2) from the valve body (1).

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Fig. 569: Valve Body Bolts
Courtesy of CHRYSLER GROUP, LLC
14. Remove bolts, 7 short (1) and 1 long (2) bolts, holding the valve body to the
transaxle.

The manual valve is loose after the valve body is removed and may fall
out during removal.

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Fig. 570: Valve Body & Transaxle
Courtesy of CHRYSLER GROUP, LLC
15. Separate the valve body (2) from the transaxle (1).

Fig. 571: Transfer Port Seals

Courtesy of CHRYSLER GROUP, LLC
16. Remove the two seals from the transfer ports in transaxle housing.

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DISASSEMBLY

DISASSEMBLY

Prepare a work area that is clean and large enough to organize the valve body
components as they are cleaned and inspected and set aside to be installed during
the assembly of the valve body. Arrange the valve components and solenoids in
the order and direction that they will be installed to assure proper function when
the job is completed.

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Fig. 572: Valve Body Solenoids
Courtesy of CHRYSLER GROUP, LLC

1= Outer Valve Body

2= VFS Solenoid Valve NH
3= On-Off Solenoid Valve
4= VFS Solenoid Valve NH
5= VFS Solenoid Valve NL
6= Over Drive Pressure Control Valve
7= Under Drive Pressure Control Valve
8= 2-6 Brake Pressure Control Valve
9= 3-5-R Pressure Control Valve
10= Adjust Screws

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11= Reducing Valve

12= Regulator Valve
13= Regulator Sleeve

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Fig. 573: Valve Body & Valves
Courtesy of CHRYSLER GROUP, LLC

1= Middle Valve Body

2= Stopper Plates
3= Manual Valve
4= Adjust Screw
5= Reducing Valve -2
6= Torque Converter Control Valve
7= Overdrive and Low-reverse Switch Valve
8= Over Drive Pressure Switch Valve
9= 3-5-R and 2-6 Brake Check Valve
10= Low-reverse Switch Valve
11= Torque Converter Pressure Control Sleeve
12= Torque Converter Control Plug
13= Torque Converter Pressure Control Valve
14= 3-5-R pressure Switch Valve

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15= 2-6 Brake Pressure Switch Valve

16= Under Drive Pressure Switch Valve

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Fig. 574: Inner Valve Body & Accumulator
Courtesy of CHRYSLER GROUP, LLC

1= Inner Valve Body

2= Accumulator Plate
3= Accumulator 2
4= Accumulator 1
5= Damping Valve (Red 2)
6= Accumulator 3
7= Accumulator 4
8= OD Fail Safe Valve
9= 3-5-R Switch Valve
10= Lock-up Switch Valve
11= Accumulator Piston

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Fig. 575: Middle Valve Body & Manual Valve
Courtesy of CHRYSLER GROUP, LLC
1. Remove the manual valve (2) from the middle valve body.

Fig. 576: Valve Body Sections & Bolts

Courtesy of CHRYSLER GROUP, LLC
2. Remove three long bolts (2) holding the outer (1) and middle (3) valve body

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sections to the inner valve body from next to the accumulators.

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Fig. 577: Valve Body Sections & Bolts
Courtesy of CHRYSLER GROUP, LLC
3. Remove twelve bolts (1) holding the outer (2) and middle valve body
sections to the inner valve body.

Fig. 578: Valve Body Sections & "black" Bolts

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Courtesy of CHRYSLER GROUP, LLC

4. Remove three "black" bolts (1) holding the outer (2) and middle valve body
sections to the inner valve body.

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Fig. 579: Valve Body & Clamps
Courtesy of CHRYSLER GROUP, LLC

NOTE: There are check valves and damping valves that can
fall out when the inner valve body is separated from
the separator plate.

5. Optionally, suitable clamps (2) can be installed to keep the inner valve body
and the separator plate from parting prematurely during the next set.

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Fig. 580: Separator Plate, Outer & Middle Valve Body
Courtesy of CHRYSLER GROUP, LLC
6. If clamping option is not used, pinch the separator plate (2) to the outer
valve body (1) and lift them away from the middle valve body (3).
7. Turn the outer valve body over and set it on a flat work surface.

Fig. 581: Separator Plate & Outer Valve Body

Courtesy of CHRYSLER GROUP, LLC

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8. Separate the separator plate (1) from the outer valve body (2).

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Fig. 582: Outer Valve Body, Damping Valve & Spring
Courtesy of CHRYSLER GROUP, LLC
9. Remove the damping valve and spring (1) from the outer valve body (2).

Fig. 583: Outer Valve Body, Check Valve & Spring

Courtesy of CHRYSLER GROUP, LLC

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10. Remove the check valve (1) and spring from the outer valve body (2).

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Fig. 584: Outer Valve Body & Five Strainers
Courtesy of CHRYSLER GROUP, LLC
11. Remove five strainers (2) from the outer valve body (1).
12. Turn the outer valve body over on the work surface.

Fig. 585: Outer Valve Body & Solenoid Retainer

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Courtesy of CHRYSLER GROUP, LLC

13. Remove screws holding the solenoid retainer (2) to the outer valve body (1).

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Fig. 586: Solenoid Retainer Separated From Outer Valve Body
Courtesy of CHRYSLER GROUP, LLC
14. Separate the solenoid retainer (2) from the outer valve body (1).

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Fig. 587: Outer Valve Body & Solenoids

Courtesy of CHRYSLER GROUP, LLC
15. Pull the solenoids (2) from the outer valve body (1). The solenoids must be
installed in the same locations that they are removed.

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Fig. 588: Outer Valve Body, Pressure Control Valves & Springs
Courtesy of CHRYSLER GROUP, LLC
16. Remove the pressure control valves (2) and springs from the outer valve
body (1).

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Fig. 589: Outer Valve Body, Stopper Plate & Regulator Valve Adjuster
Courtesy of CHRYSLER GROUP, LLC
17. Using a suitable magnet (2), remove the stopper plate (3) holding the
regulator valve adjuster (4) into the outer valve body (1).

Fig. 590: Outer Valve Body, Stopper Plate & Reducing Valve Adjuster
Courtesy of CHRYSLER GROUP, LLC

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18. Using a suitable magnet (1), remove the stopper plate (2) holding the
reducing valve adjuster (3) into the outer valve body.

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Fig. 591: Outer Valve Body, Regulator, Regulator Sleeve, Reducing
Valve & Springs
Courtesy of CHRYSLER GROUP, LLC
19. Remove the regulator (7), regulator sleeve (6) and reducing valve (2) and
springs (5) from the outer valve body (1).

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Fig. 592: Middle Valve Body & Fluid Strainer
Courtesy of CHRYSLER GROUP, LLC
20. Remove the fluid strainer (2) from the middle valve body (1).

Fig. 593: Middle Valve Body & Damping Valve

Courtesy of CHRYSLER GROUP, LLC
21. Remove the damping valve (2) and coil spring from the middle valve body

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(1).

NOTE: There a two check valves on the backside of the

middle valve body that will fall out if the middle valve
body is lifted away from the outer valve body.

22. While holding the middle valve body to the inner valve body, turn the two
sections over so the middle valve body is on the work surface.
23. Separate the outer valve away from the middle valve body the gain access to
the check valves and stopper plates.

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Fig. 594: Middle Valve Body, Check Valves & Springs
Courtesy of CHRYSLER GROUP, LLC
24. Remove the check valves and springs (2) from the middle valve body (1).

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Fig. 595: Middle Valve Body, Stopper Plates, Valve Plugs & Adjusters
Courtesy of CHRYSLER GROUP, LLC
25. One valve at a time, remove the stopper plates (1) holding the valve plugs
and adjusters into the middle valve body.

Fig. 596: Valve Body & Valves

Courtesy of CHRYSLER GROUP, LLC

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1= Middle Valve Body

2= Stopper Plates
3= Manual Valve
4= Adjust Screw
5= Reducing Valve -2
6= Torque Converter Control Valve
7= Overdrive and Low-reverse Switch Valve
8= Over Drive Pressure Switch Valve
9= 3-5-R and 2-6 Brake Check Valve
10= Low-reverse Switch Valve
11= Torque Converter Pressure Control Sleeve
12= Torque Converter Control Plug

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13= Torque Converter Pressure Control Valve
14= 3-5-R pressure Switch Valve
15= 2-6 Brake Pressure Switch Valve
16= Under Drive Pressure Switch Valve

26. Remove valve assemblies, one at a time, and place them on a clean surface
oriented, and in order of, the way they were removed.

Fig. 597: Inner Valve Body, Accumulator Plate & Bolts

Courtesy of CHRYSLER GROUP, LLC

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27. Remove bolts holding accumulator plate (2) to the inner valve body (1).

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Fig. 598: Inner Valve Body & Accumulator Plate
Courtesy of CHRYSLER GROUP, LLC
28. Separate the accumulator plate (2) from the inner valve body (1).

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Fig. 599: Inner Valve Body & Accumulator
Courtesy of CHRYSLER GROUP, LLC

1= Inner Valve Body

2= Accumulator Plate
3= Accumulator 2 (Green and Yellow Springs)
4= Accumulator 1 (Pink Spring)
5= Damping Valve (White and White springs)
6= Accumulator 3 (Pink Spring)
7= Accumulator 4 (Yellow and Yellow Spring)
8= OD Fail Safe Valve
9= 3-5-R Switch Valve
10= Lock-up Switch Valve
11= Accumulator Piston

29. Remove accumulators and valves and place them on a clean surface
oriented, and in order of, the way they were removed.

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Fig. 600: Inner Valve Body, Separator Plate & Bolts
Courtesy of CHRYSLER GROUP, LLC
30. Remove bolts (2) holding the separator plate (1) to the inner valve body (3).

Fig. 601: Inner Valve Body & Separator Plate

Courtesy of CHRYSLER GROUP, LLC
31. Separate the separator plate (1) from the inner valve body (2).

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Fig. 602: Inner Valve Body, Steel Check Ball & Spring
Courtesy of CHRYSLER GROUP, LLC
32. Using a suitable magnet (2), remove steel check ball and spring (3) from
inner valve body (1).

Fig. 603: Inner Valve Body, Damping Valves & Check Valves
Courtesy of CHRYSLER GROUP, LLC

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33. Remove three damping valves (2) and three check valves (3) from inner
valve body (1).

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Fig. 604: Inner Valve Body, Stopper Plates & Accumulator
Courtesy of CHRYSLER GROUP, LLC
34. Remove stopper plates holding valves (1) and accumulator (3) in the inner
valve body (2).

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Fig. 605: Inner Valve Body & Accumulator
Courtesy of CHRYSLER GROUP, LLC

1= Inner Valve Body

2= Accumulator Plate
3= Accumulator 2 (Green and Yellow Springs)
4= Accumulator 1 (Pink Spring)
5= Damping Valve (White and White springs)
6= Accumulator 3 (Pink Spring)
7= Accumulator 4 (Yellow and Yellow Spring)
8= OD Fail Safe Valve
9= 3-5-R Switch Valve
10= Lock-up Switch Valve
11= Accumulator Piston

35. Remove the valves assemblies (8, 9 and 10) and accumulator piston (11) and
place them on a clean surface oriented, and in order of, the way they were
removed.
ASSEMBLY

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ASSEMBLY

Clean all valve body components with a suitable solvent and blow them dry with
regulated 345 kPa (50 psi) compressed shop air. Inspect all valves, pistons,
accumulators, and there bores for damage. If any of the surfaces are scored or
show evidence of damage, the valve body must be replaced. As the valve body is
assembled, lubricate each component with specified transaxle fluid as they are
installed. Refer to SPECIFICATIONS.

1= Inner Valve Body

2= Accumulator Plate
3= Accumulator 2 (Green and Yellow Springs)
4= Accumulator 1 (Pink Spring)
5= Damping Valve (White and White springs)

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6= Accumulator 3 (Pink Spring)
7= Accumulator 4 (Yellow and Yellow Spring)
8= OD Fail Safe Valve
9= 3-5-R Switch Valve
10= Lock-up Switch Valve
11= Accumulator Piston

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Fig. 606: Inner Valve Body & Accumulator

Courtesy of CHRYSLER GROUP, LLC
1. Install the valve assemblies (8, 9, and 10) and accumulator piston (11) in the
inner valve body (1) removed.

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Fig. 607: Inner Valve Body, Stopper Plates & Accumulator
Courtesy of CHRYSLER GROUP, LLC
2. Install the stopper plates to hold the valve assemblies (1) and accumulator
piston (3) in the inner valve body (2).

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Fig. 608: Inner Valve Body, Damping Valves & Check Valves
Courtesy of CHRYSLER GROUP, LLC
3. Install three damping valves (2) and three check valves (3) in the inner valve
body (1).

Fig. 609: Inner Valve Body, Steel Check Ball & Spring
Courtesy of CHRYSLER GROUP, LLC

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4. Install the steel check ball and spring (3) into inner valve body (1).

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Fig. 610: Inner Valve Body & Separator Plate
Courtesy of CHRYSLER GROUP, LLC
5. Place the separator plate (1) in position on the inner valve body (2).

Fig. 611: Inner Valve Body, Separator Plate & Bolts

Courtesy of CHRYSLER GROUP, LLC

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6. Install bolts (2) to hold the separator plate (1) to the inner valve body (3).
Refer to SPECIFICATIONS.

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Fig. 612: Inner Valve Body & Accumulator
Courtesy of CHRYSLER GROUP, LLC

1= Inner Valve Body

2= Accumulator Plate
3= Accumulator 2 (Green and Yellow Springs)
4= Accumulator 1 (Pink Spring)
5= Damping Valve (White and White springs)
6= Accumulator 3 (Pink Spring)
7= Accumulator 4 (Yellow and Yellow Spring)
8= OD Fail Safe Valve
9= 3-5-R Switch Valve
10= Lock-up Switch Valve
11= Accumulator Piston

7. Install accumulators (2, 3, 4 and 6) and valves (5, 8, 9 and 10) in the inner
valve body (1).

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Fig. 613: Inner Valve Body & Accumulator Plate
Courtesy of CHRYSLER GROUP, LLC
8. Place the accumulator plate (2) in position on the inner valve body (1).

Fig. 614: Inner Valve Body, Accumulator Plate & Bolts

Courtesy of CHRYSLER GROUP, LLC
9. Install bolts to hold the accumulator plate (2) to the inner valve body (1).

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Refer to SPECIFICATIONS.

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Fig. 615: Valve Body & Valves
Courtesy of CHRYSLER GROUP, LLC

1= Middle Valve Body

2= Stopper Plates
3= Manual Valve
4= Adjust Screw
5= Reducing Valve -2
6= Torque Converter Control Valve
7= Overdrive and Low-reverse Switch Valve
8= Over Drive Pressure Switch Valve
9= 3-5-R and 2-6 Brake Check Valve
10= Low-reverse Switch Valve
11= Torque Converter Pressure Control Sleeve
12= Torque Converter Control Plug
13= Torque Converter Pressure Control Valve
14= 3-5-R pressure Switch Valve
15= 2-6 Brake Pressure Switch Valve
16= Under Drive Pressure Switch Valve

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10. Install valve assemblies (5 threw 16), one at a time, into the middle valve
body (1).

cardiagn.com
Fig. 616: Middle Valve Body, Stopper Plates, Valve Plugs & Adjusters
Courtesy of CHRYSLER GROUP, LLC
11. One valve at a time, install the stopper plates (1) to hold the valve plugs and
adjusters into the middle valve body.

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Fig. 617: Middle Valve Body, Check Valves & Springs

Courtesy of CHRYSLER GROUP, LLC
12. Install the check valves and springs (2) in the middle valve body (1).
13. Place the outer valve body on the middle valve body.
14. While holding the middle valve body to the inner valve body, turn the two
sections over so the inner valve body is on the work surface.

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Fig. 618: Middle Valve Body & Damping Valve
Courtesy of CHRYSLER GROUP, LLC
15. Install the damping valve (2) and coil spring into the middle valve body (1).

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Fig. 619: Middle Valve Body & Fluid Strainer
Courtesy of CHRYSLER GROUP, LLC
16. Install the oil strainer (2) into the middle valve body (1).

Fig. 620: Outer Valve Body, Regulator, Regulator Sleeve, Reducing

Valve & Springs
Courtesy of CHRYSLER GROUP, LLC

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17. Install the regulator (7), regulator sleeve (6) and reducing valve (2) and
springs (5) into the outer valve body (1).

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Fig. 621: Outer Valve Body, Stopper Plate & Reducing Valve Adjuster
Courtesy of CHRYSLER GROUP, LLC
18. Install the stopper plate (2) to hold the reducing valve adjuster (3) into the
outer valve body.

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Fig. 622: Outer Valve Body, Stopper Plate & Regulator Valve Adjuster
Courtesy of CHRYSLER GROUP, LLC
19. Install the stopper plate (3) to hold the regulator valve adjuster (4) into the
outer valve body (1).

cardiagn.com
Fig. 623: Outer Valve Body, Pressure Control Valves & Springs
Courtesy of CHRYSLER GROUP, LLC
20. Install the pressure control valves (2) and springs into the outer valve body
(1).

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Fig. 624: Outer Valve Body & Solenoids
Courtesy of CHRYSLER GROUP, LLC
21. Insert the solenoids (2) into the outer valve body (1). The solenoids (1) must
be installed in the same locations that they were removed from.

Fig. 625: Solenoid Retainer Separated From Outer Valve Body

Courtesy of CHRYSLER GROUP, LLC

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22. Place the solenoid retainer (2) in position on outer valve body (1).

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Fig. 626: Outer Valve Body & Solenoid Retainer
Courtesy of CHRYSLER GROUP, LLC
23. Install screws to hold the solenoid retainer (2) to the outer valve body (1).
Refer to SPECIFICATIONS.
24. Turn the outer valve body over on the work surface.

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Fig. 627: Outer Valve Body & Five Strainers

Courtesy of CHRYSLER GROUP, LLC
25. Install five strainers (2) into the outer valve body (1).

cardiagn.com
Fig. 628: Outer Valve Body, Check Valve & Spring
Courtesy of CHRYSLER GROUP, LLC
26. Install the check valve (1) and spring into the outer valve body (2).

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Fig. 629: Outer Valve Body, Damping Valve & Spring
Courtesy of CHRYSLER GROUP, LLC
27. Install the damping valve and spring (1) into the outer valve body (2).

Fig. 630: Separator Plate & Outer Valve Body

Courtesy of CHRYSLER GROUP, LLC
28. Place the separator plate (1) onto the outer valve body (2).

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Fig. 631: Valve Body & Clamps
Courtesy of CHRYSLER GROUP, LLC
29. Optionally, suitable clamps (2) can be installed to keep the inner valve body
and the separator plate from parting prematurely during the next set.

Fig. 632: Separator Plate, Outer & Middle Valve Body

Courtesy of CHRYSLER GROUP, LLC

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30. If clamping option is not used, pinch the separator plate (2) to the outer
valve body (1) and lower them onto the middle valve body (3).
31. Holding the Lower, middle, and inner valve body sections together, turn the
valve body over, set it on a flat work surface.

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Fig. 633: Valve Body Sections & "black" Bolts
Courtesy of CHRYSLER GROUP, LLC
32. Install three "black" bolts (1) to hold the outer (2) and middle valve body
sections to the inner valve body. Refer to SPECIFICATIONS.

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Fig. 634: Valve Body Sections & Bolts
Courtesy of CHRYSLER GROUP, LLC
33. Install twelve bolts (1) to hold the outer (2) and middle valve body sections
to the inner valve body. Refer to SPECIFICATIONS.

Fig. 635: Valve Body Sections & Bolts

Courtesy of CHRYSLER GROUP, LLC

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34. Install three bolts (2) to hold the outer (1) and middle (3) valve body
sections to the inner valve body next to the accumulators. Refer to
SPECIFICATIONS.

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Fig. 636: Middle Valve Body & Manual Valve
Courtesy of CHRYSLER GROUP, LLC
35. Install the manual valve (2) into the middle valve body.
36. Install the valve body into the transaxle. Refer to VALVE BODY,
INSTALLATION.
INSTALLATION

INSTALLATION

Verify that all of the valve body mating surfaces are clean and are undamaged on
the transaxle housing and the valve body. If the surfaces are damaged the
transaxle housing or valve body will require replacement.

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Fig. 637: Transfer Port Seals
Courtesy of CHRYSLER GROUP, LLC
1. Install the two seals into the transfer ports in transaxle housing.

Fig. 638: Valve Body & Transaxle

Courtesy of CHRYSLER GROUP, LLC

NOTE: The manual valve is loose after the valve body is

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installed and may fall out during removal.

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Fig. 639: Valve Body Bolts
Courtesy of CHRYSLER GROUP, LLC
2. Place the valve body (2) in position on the transaxle (1).
3. Install bolts, 7 short (1) and 1 long (2) bolts, to hold the valve body to the
transaxle. Refer to SPECIFICATIONS.

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Fig. 640: Detent Spring Separated From Valve Body

Courtesy of CHRYSLER GROUP, LLC
4. Place the detent spring (2) in position on the valve body (1).

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Fig. 641: Manual Shaft Detent Spring & Valve Body
Courtesy of CHRYSLER GROUP, LLC
5. Install the screw to hold the manual shaft detent spring (1) to the valve body
(2). Refer to SPECIFICATIONS.

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Fig. 642: Solenoids & Connector
Courtesy of CHRYSLER GROUP, LLC
6. Starting at the top solenoid valve, push the wire connector onto each
solenoid (2) until the connector (3) is engaged.

Fig. 643: Valve Body & Solenoid Valve Connector

Courtesy of CHRYSLER GROUP, LLC

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7. Install bolts to hold the solenoid valve connector (2) to the valve body (1).
Refer to SPECIFICATIONS.

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Fig. 644: Fluid Temperature Sensor & Valve Body
Courtesy of CHRYSLER GROUP, LLC
8. Push temperature sensor (1) straight into the port in the valve body (2).
9. Install bolt to hold fluid temperature sensor (1) to the valve body (2). Refer
to SPECIFICATIONS.

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Fig. 645: Valve Body Cover Separated From Transaxle
Courtesy of CHRYSLER GROUP, LLC
10. Install a NEW gasket on the cover and place the valve body cover (1) in
position on the transaxle (2).

Fig. 646: Transaxle & Valve Body Cover

Courtesy of CHRYSLER GROUP, LLC

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11. Install bolts to hold the valve body cover (2) to the transaxle (1). Refer to
SPECIFICATIONS.
12. Remove the drain pan from under transaxle.

cardiagn.com
Fig. 647: Vent Hose End & Nipple Adaptor
Courtesy of CHRYSLER GROUP, LLC
13. Push the vent hose end (1) onto the nipple adaptor (2).

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Fig. 648: Vent Hose, Spring Clamp & Pliers

Courtesy of CHRYSLER GROUP, LLC
14. Using common pliers (3), compress the hose spring clamp (2) and slide it up
the vent hose (1) onto nipple adaptor.
15. Fill the transaxle with specified fluid. Refer to FLUID, STANDARD
PROCEDURES.
16. Install the engine cover/air cleaner on the vehicle. Refer to 2.0L AIR
CLEANER, INSTALLATION , 2.2L AIR CLEANER,
INSTALLATION or 2.4L AIR CLEANER, INSTALLATION .
17. Road test the vehicle to verify the repair.
BRAKE AND PISTON, 2-6

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REMOVAL

REMOVAL

1. Remove the transaxle from the vehicle

2. Disassemble the transaxle to remove the bell housing portion of the
transaxle housing.
3. Remove the fluid pump.

Fig. 649: Fluid Pump & 2-6 Brake Piston

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Courtesy of CHRYSLER GROUP, LLC

4. Position the fluid pump on a clean work surface with the 2-6 brake piston
facing upward.

NOTE: The 2-6 brake piston return spring and retainer will
self-eject when the snap-ring is removed.

5. Place one hand over the 2-6 brake piston assembly to prevent the piston
return spring and retainer from ejecting from the fluid pump housing when
the snap-ring is released.

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Fig. 650: Fluid Pump Housing, Snap-Ring & 2-6 Brake Piston Return
Spring & Retainer
Courtesy of CHRYSLER GROUP, LLC
6. Using a suitable snap-ring pliers, remove the snap-ring holding the 2-6 brake
piston return spring and retainer into the fluid pump housing.

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Fig. 651: Return Spring & Return Spring Retainer
Courtesy of CHRYSLER GROUP, LLC
7. Separate the return spring retainer from the return spring.

Fig. 652: Fluid Pump Housing & Return Spring

Courtesy of CHRYSLER GROUP, LLC
8. Separate the return spring from the fluid pump housing.

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Fig. 653: Fluid Pump Housing Assembly & 2-6 Brake Piston
Courtesy of CHRYSLER GROUP, LLC
9. Using two small pocket screw driver pry and lift the 2-6 brake piston out of
the groove in the fluid pump housing assembly.

Fig. 654: Removing 2-6 Brake Piston & Inner O-Ring Seal
Courtesy of CHRYSLER GROUP, LLC

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10. Using a suitable pick tool, remove the inner o-ring seal from the groove in
he center of the 2-6 brake piston.

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Fig. 655: Removing 2-6 Brake Piston & Outer O-Ring Seal
Courtesy of CHRYSLER GROUP, LLC
11. Using a suitable pick tool, remove the outer o-ring seal from the groove in
the circumference of the 2-6 brake piston.
INSTALLATION

INSTALLATION

NOTE: Do not wash the fluid pump housing in solvent prior to

assembling the 2-6 brake piston unless the fluid pump
itself required an overhaul.

NOTE: Wash the 2-6 brake piston components in suitable

solvent and dry them with regulated 344 kPa (50 psi)
shop air.

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Fig. 656: Installing 2-6 Brake Piston & Outer O-Ring Seal
Courtesy of CHRYSLER GROUP, LLC

1. Install the outer o-ring seal into the groove in the circumference of the 2-6
brake piston.

Fig. 657: Installing 2-6 Brake Piston & Inner O-Ring Seal
Courtesy of CHRYSLER GROUP, LLC

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2. Install the inner o-ring seal into the groove in the center of the 2-6 brake
piston.

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Fig. 658: Fluid Pump Housing Assembly & 2-6 Brake Piston
Courtesy of CHRYSLER GROUP, LLC
3. Coat the 2-5 brake piston and o-ring seals with Automatic Transmission
Fluid (ATF) to ease installation.
4. Place the 2-6 brake piston in position in the groove in the fluid pump
housing assembly.
5. Push the 2-6 brake piston downward until the piston reaches the bottom of
the groove in the fluid pump assembly.

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Fig. 659: Fluid Pump Housing & Return Spring
Courtesy of CHRYSLER GROUP, LLC
6. Place the return spring into the groove in the fluid pump housing.

Fig. 660: Return Spring & Return Spring Retainer

Courtesy of CHRYSLER GROUP, LLC
7. Place the return spring retainer on the return spring.

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8. Place Tool (special tool #10427, Compressor, Return Spring) over the 2-6
brake piston return spring retainer.

Fig. 661: Special Tool #10427

Courtesy of CHRYSLER GROUP, LLC

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Fig. 662: Tool Guide & Snap-Ring
Courtesy of CHRYSLER GROUP, LLC
9. Position the snap-ring over the circumference of the Tool guide.

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Fig. 663: Special Tool #10427 Installed Over Snap-Ring
Courtesy of CHRYSLER GROUP, LLC
10. Position Tool (special tool #10427, Compressor, Return Spring) Installer
over the snap-ring.

Fig. 664: Special Tool #10427

Courtesy of CHRYSLER GROUP, LLC

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Fig. 665: Pushing Installer Downward
Courtesy of CHRYSLER GROUP, LLC
11. Push the installer downward until the snap-ring locks in the groove in the
fluid pump hub.
12. Remove the tools from the fluid pump.
13. Install the fluid pump in the transaxle.
14. Assemble the transaxle to install the bell housing portion of the transaxle
housing.
15. Install the transaxle into the vehicle
16. Road test the vehicle the validate the repair
CLUTCH, 3-5 REVERSE
DISASSEMBLY

DISASSEMBLY

The 3-5-Reverse (3-5-R) Clutch is located under the fluid pump, in the center of
the input shaft, inside of the 2-6 brake discs and plates. The clutch includes a
retainer and shaft, selective snap-ring, five discs, five plates, reaction plate,
balance piston, bellville return spring, and a piston. The 3-5-R clutch balance
piston is equipped with a integral seal that cannot be replaced. If the seal is faulty
the balance piston must be replaced. The 3-5-R clutch piston is equipped with

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and inner and outer D-ring seals. The 3-5-R clutch has a series of alternating
steel plates separated by fiber discs. When applied it drives the 2-6 brake discs
and the overdrive clutch hub. The free play of the 3-5-R clutch is controlled by a
select snap-ring that the thickness can be changed to tighten or loosen the clutch.
Refer to SPECIFICATIONS.
1. Remove the transaxle. Refer to REMOVAL.
2. Disassemble the transaxle to gain access to the 3-5-R clutch. Refer to
DISASSEMBLY.
3. Remove the 3-5-R clutch from the transaxle.
4. Optionally, place the 3-5-R clutch on tool (special tool #8285, Compressor,
Spring).

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Fig. 666: Special Tool #8285
Courtesy of CHRYSLER GROUP, LLC

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Fig. 667: 3-5-R Clutch Retainer & Snap-Ring

Courtesy of CHRYSLER GROUP, LLC
5. Using a suitable screw driver, pry the snap-ring out (1) of the 3-5-R clutch
retainer (2).

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Fig. 668: 3-5-R Clutch Reaction Plate, Discs, Plates & Retainer
Courtesy of CHRYSLER GROUP, LLC
6. Remove the 3-5-R clutch reaction plate, discs, and plates (1) from the
retainer (2).

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Fig. 669: 3-5-R Clutch, Tool & Arbor Press
Courtesy of CHRYSLER GROUP, LLC
7. Place 3-5-R clutch (1) and tool on a suitable arbor press (3).

Fig. 670: 3-5-R Clutch, Special Tool #8680 & Arbor Press
Courtesy of CHRYSLER GROUP, LLC
8. Position tool (special tool #8680, Installer, Damper) over the shaft and onto

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the 3-5-R clutch balance piston.

Fig. 671: special tool #8680

Courtesy of CHRYSLER GROUP, LLC

cardiagn.com
Fig. 672: 3-5-R Clutch Balance Piston & Special Tool #10117
Courtesy of CHRYSLER GROUP, LLC
9. Position tool (special tool #10117, Installer, Seal) over the shaft and onto the
tool 8680.

Fig. 673: Special Tool #10117

Courtesy of CHRYSLER GROUP, LLC

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cardiagn.com
Fig. 674: 3-5-R Clutch, Balance Piston & Snap-Ring
Courtesy of CHRYSLER GROUP, LLC
10. Compress the 3-5-R clutch return spring until the snap-ring is free to be
removed.
11. Using a suitable snap-ring pliers, remove the snap-ring holding the balance
piston into the piston.
12. Remove the 3-5-R clutch from the arbor press.

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Fig. 675: 3-5-R Clutch Balance Piston & Piston

Courtesy of CHRYSLER GROUP, LLC
13. Using a suitable hook tool, remove the 3-5-R clutch balance piston (1) from
the piston.

cardiagn.com
Fig. 676: 3-5-R Clutch Return Spring & Piston
Courtesy of CHRYSLER GROUP, LLC
14. Remove the 3-5-R clutch return spring (1) from the piston.

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cardiagn.com
Fig. 677: 3-5-R Clutch Retainer & Piston
Courtesy of CHRYSLER GROUP, LLC
15. Through the holes in the back of the 3-5-R clutch retainer (1), Insert a screw
driver (2) and push the piston out of the retainer.

Fig. 678: 3-5-R Clutch Retainer & Piston

Courtesy of CHRYSLER GROUP, LLC

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16. Remove the 3-5-R clutch piston (1) from the retainer (2).

cardiagn.com
Fig. 679: Removing Inner D-Ring Seal
Courtesy of CHRYSLER GROUP, LLC
17. Using a suitable hook tool, remove the inner D-ring seal (1) from the groove
in the 3-5-R clutch hub (2).

Fig. 680: Removing Outer D-Ring Seal

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Courtesy of CHRYSLER GROUP, LLC

18. Using a suitable hook tool, remove the outer D-ring seal (1) from the groove
in the 3-5-R clutch retainer (2).
ASSEMBLY

ASSEMBLY

cardiagn.com
Fig. 681: 3-5-R Clutch Components
Courtesy of CHRYSLER GROUP, LLC
Wash the 3-5-Reverse (3-5-R) clutch components with suitable solvent and blow
them dry with 344 kPa (50 psi) regulated shop air. Inspect the steel side of the
plates for warping or excessive hot spots (blue) or other damage. Inspect the fiber
side of the discs for excessive ware or warping. If damage is evident, the clutch
assembly will require replacement.

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cardiagn.com
Fig. 682: Installing Outer D-Ring Seal
Courtesy of CHRYSLER GROUP, LLC
1. Install the outer D-ring seal (1) into the groove in the 3-5-R clutch retainer
(2).

Fig. 683: Installing Inner D-Ring Seal

Courtesy of CHRYSLER GROUP, LLC

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2. Install the D-ring seal (1) into the groove in the 3-5-R clutch hub (2).
3. Apply a light coat of transaxle fluid on the D-ring seals.

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Fig. 684: 3-5-R Clutch Retainer & Piston
Courtesy of CHRYSLER GROUP, LLC
4. Install the 3-5-R clutch piston (1) into the retainer (2).

Fig. 685: 3-5-R Clutch Return Spring & Piston

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Courtesy of CHRYSLER GROUP, LLC

5. Install the 3-5-R clutch return spring (1) into the piston.

cardiagn.com
Fig. 686: 3-5-R Clutch Balance Piston & Piston
Courtesy of CHRYSLER GROUP, LLC
6. Install the 3-5-R clutch balance piston (1) into the piston.
7. Place the 3-5-R clutch on a suitable arbor press.

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cardiagn.com
Fig. 687: 3-5-R Clutch, Special Tool #8680 & Arbor Press
Courtesy of CHRYSLER GROUP, LLC
8. Position tool (special tool #8680, Installer, Damper) over the shaft and onto
the 3-5-R clutch balance piston.

Fig. 688: special tool #8680

Courtesy of CHRYSLER GROUP, LLC

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cardiagn.com
Fig. 689: 3-5-R Clutch Balance Piston & Special Tool #10117
Courtesy of CHRYSLER GROUP, LLC
9. Position tool (special tool #10117, Installer, Seal) over the shaft and onto the
tool 8680.

Fig. 690: Special Tool #10117

Courtesy of CHRYSLER GROUP, LLC

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cardiagn.com
Fig. 691: 3-5-R Clutch, Balance Piston & Snap-Ring
Courtesy of CHRYSLER GROUP, LLC
10. Compress the 3-5-R clutch return spring until the snap-ring groove is open
to receive the snap-ring.
11. Using a suitable snap-ring pliers, install the snap-ring to hold the balance
piston into the piston.

Fig. 692: 3-5-R Clutch Components

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Courtesy of CHRYSLER GROUP, LLC

12. Starting with an outside lug disc, stack (in alternating order) four outside lug
plates (4) and four inside lug discs (3). Place the reaction plate (2) on top of
the stack, stepped side up.

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Fig. 693: 3-5-R Clutch Reaction Plate, Discs, Plates & Retainer
Courtesy of CHRYSLER GROUP, LLC
13. Install the 3-5-R clutch reaction plate, discs, and plates (1) into the retainer
(2).

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cardiagn.com
Fig. 694: 3-5-R Clutch Retainer & Snap-Ring
Courtesy of CHRYSLER GROUP, LLC
14. Install the snap-ring (1) to hold the reaction plate into 3-5-R clutch retainer
(2).

NOTE: Verify that end play is within specifications. Refer to

SPECIFICATIONS.

15. Install the 3-5-R clutch into the transaxle.

NOTE: Before installing the valve body, perform an air test to

determine that the seals were installed properly.
Refer to DIAGNOSIS AND TESTING.

16. Assemble the transaxle.

17. Install the transaxle in the vehicle.
CLUTCH, OVERDRIVE
DISASSEMBLY

DISASSEMBLY

The Overdrive Clutch is located under the rear cover, on top of the one way

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clutch (OWC) race. The overdrive clutch includes a retainer, selective snap-ring,
five discs, six plates, reaction plate, balance piston, helical return springs, and a
piston. The overdrive clutch balance piston is equipped with a integral seal that
cannot be replaced. If the seal is faulty the balance piston must be replaced. The
overdrive clutch piston is equipped with and inner and outer D-ring seals. The
overdrive clutch has a series of alternating steel plates separated by fiber discs.
When applied it drives the 2-6 brake discs and the 3-5-Reverse clutch hub shaft.
The free play of the overdrive clutch is controlled by a select snap-ring that the
thickness can be changed to tighten or loosen the clutch. Refer to
SPECIFICATIONS.
1. Remove the transaxle. Refer to REMOVAL.
2. Disassemble the transaxle to gain access to the overdrive clutch. Refer to

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DISASSEMBLY.
3. Remove the overdrive clutch from the transaxle.
4. Place the overdrive clutch on a clean work surface.

Fig. 695: Overdrive Clutch Retainer & Snap-Ring

Courtesy of CHRYSLER GROUP, LLC
5. Using a suitable screw driver, pry the snap-ring out (1) of the overdrive
clutch retainer (2).

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cardiagn.com
Fig. 696: Retainer, Overdrive Clutch Reaction Plate, Discs, & Plates
Courtesy of CHRYSLER GROUP, LLC
6. Remove the overdrive clutch reaction plate, discs, and plates (1) from the
retainer (2).
7. Place the overdrive clutch, balance piston up, on a suitable arbor press. (1)

Fig. 697: Overdrive Clutch, Special Tool #8285 & Balance Piston
Courtesy of CHRYSLER GROUP, LLC

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8. Position tool (special tool #8285, Compressor, Spring) (2) on the overdrive
clutch balance piston.
9. Compress the overdrive clutch return spring until the snap-ring is free to be
removed.

cardiagn.com
Fig. 698: Balance Piston, Piston & Snap-Ring
Courtesy of CHRYSLER GROUP, LLC
10. Using a suitable snap-ring pliers, remove the snap-ring (1) holding the
balance piston into the piston.
11. Remove the overdrive clutch from the arbor press.

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Fig. 699: Overdrive Clutch Balance Piston & Piston
Courtesy of CHRYSLER GROUP, LLC
12. Using a suitable hook tool, remove the overdrive clutch balance piston (1)
from the piston (2).

Fig. 700: Overdrive Clutch Return Spring & Piston

Courtesy of CHRYSLER GROUP, LLC

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13. Remove the overdrive clutch return spring (1) from the piston (2).

cardiagn.com
Fig. 701: Pushing Piston Out Of Retainer
Courtesy of CHRYSLER GROUP, LLC
14. Through the holes in the back of the overdrive clutch retainer (1), Insert a
screw driver (2) and push the piston out of the retainer.

Fig. 702: Overdrive Clutch Retainer & Piston

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Courtesy of CHRYSLER GROUP, LLC

15. Remove the overdrive clutch piston from the retainer.

cardiagn.com
Fig. 703: Removing Inner D-Ring Seal
Courtesy of CHRYSLER GROUP, LLC
16. Using a suitable hook tool, remove the inner D-ring seal (1) from the groove
in the overdrive clutch hub (2).

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cardiagn.com
Fig. 704: Removing Outer D-Ring Seal
Courtesy of CHRYSLER GROUP, LLC
17. Using a suitable hook tool, remove the outer D-ring seal (1) from the groove
in the overdrive clutch retainer (2).
ASSEMBLY

ASSEMBLY

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Fig. 705: Overdrive Clutch Components

Courtesy of CHRYSLER GROUP, LLC
Wash the Overdrive Clutch components with suitable solvent and blow them dry
with 344 kPa (50 psi) regulated shop air. Inspect the steel plates (2 and 4) for
warping or excessive hot spots (blue) or other damage. Inspect the fiber discs (3)
for excessive ware or warping. If damage is evident, the clutch assembly will
require replacement.

cardiagn.com
Fig. 706: Overdrive Clutch Retainer & Outer D-Ring Seal
Courtesy of CHRYSLER GROUP, LLC
1. Install the outer D-ring seal (1) into the groove in the overdrive clutch
retainer (2).

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cardiagn.com
Fig. 707: Overdrive Clutch Hub & Inner D-Ring Seal
Courtesy of CHRYSLER GROUP, LLC
2. Install the D-ring seal (1) into the groove in the overdrive clutch hub (2).
3. Apply a light coat of transaxle fluid on the D-ring seals.

Fig. 708: Overdrive Clutch Retainer & Piston

Courtesy of CHRYSLER GROUP, LLC

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4. Install the overdrive clutch piston (1) into the retainer (2).

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Fig. 709: Overdrive Clutch Return Spring & Piston
Courtesy of CHRYSLER GROUP, LLC
5. Install the overdrive clutch return spring (1) into the piston.

Fig. 710: Overdrive Clutch Balance Piston & Piston

Courtesy of CHRYSLER GROUP, LLC

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6. Install the overdrive clutch balance piston (1) into the piston.
7. Place the overdrive clutch, balance piston up, on a suitable arbor press.

cardiagn.com
Fig. 711: Overdrive Clutch, Special Tool #8285 & Balance Piston
Courtesy of CHRYSLER GROUP, LLC
8. Position tool (special tool #8285, Compressor, Spring) (2) on the overdrive
clutch balance piston.
9. Compress the overdrive clutch return spring until the snap-ring groove is
open to receive the snap-ring.

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cardiagn.com
Fig. 712: Balance Piston, Piston & Snap-Ring
Courtesy of CHRYSLER GROUP, LLC
10. Using a suitable snap-ring pliers (1), install the snap-ring (2) to hold the
balance piston into the piston.

Fig. 713: Overdrive Clutch Components

Courtesy of CHRYSLER GROUP, LLC

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11. Starting with a steel plate, stack (in alternating order) four steel plates (4)
and four fiber discs (3). Place the reaction plate on top of the stack, stepped
side up.

cardiagn.com
Fig. 714: Retainer, Overdrive Clutch Reaction Plate, Discs, & Plates
Courtesy of CHRYSLER GROUP, LLC
12. Install the overdrive clutch reaction plate, discs, and plates (1) from the
retainer (2).

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Fig. 715: Overdrive Clutch Retainer & Snap-Ring
Courtesy of CHRYSLER GROUP, LLC
13. Install the snap-ring (1) to hold the reaction plate into overdrive clutch
retainer (2).

NOTE: Verify that end play is within specifications. Refer to

SPECIFICATIONS.

14. Install the overdrive clutch into the transaxle.

NOTE: Before installing the valve body, perform an air test to

determine that the seals were installed properly.
Refer to DIAGNOSIS AND TESTING.

15. Assemble the transaxle.

16. Install the transaxle in the vehicle.
PUMP, FLUID
DISASSEMBLY

DISASSEMBLY

1. Drain the fluid from the transaxle. Refer to FLUID, STANDARD

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PROCEDURES.
2. Remove the transaxle from the vehicle. Refer to REMOVAL.
3. Disassemble the transaxle to gain access to the fluid pump. Refer to
DISASSEMBLY.
4. Remove the 2-6 brake piston from the fluid pump housing. Refer to
BRAKE AND PISTON, 2-6, REMOVAL.

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Fig. 716: Fluid Pump Cover
Courtesy of CHRYSLER GROUP, LLC
5. Remove screws holding fluid pump cover (1) to the fluid pump. It may be
necessary to use an impact driver to loosen the screws to avoid damaging
the Torx® head of the bolts.

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cardiagn.com
Fig. 717: Fluid Pump & Fluid Pump Cover
Courtesy of CHRYSLER GROUP, LLC
6. Separate the fluid pump cover (1) from the fluid pump (2).

Fig. 718: Fluid Pump Housing & Rotor Assembly

Courtesy of CHRYSLER GROUP, LLC
7. Separate the gerotor assembly (2-3) from the fluid pump housing (1).

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ASSEMBLY

ASSEMBLY

NOTE: The fluid pump components must be thoroughly cleaned

before assembly.

NOTE: Inspect fluid pump components for damage or excessive

wear before assembly. If damage is evident, replace the
fluid pump.

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Fig. 719: Fluid Pump Housing & Rotor Assembly
Courtesy of CHRYSLER GROUP, LLC

1. Insert the gerotor assembly (2-3) into the fluid pump housing (1). Center the
rotor to the center of the pump housing bushing.

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Fig. 720: Fluid Pump & Fluid Pump Cover
Courtesy of CHRYSLER GROUP, LLC
2. Place the fluid pump cover (1) over the fluid pump housing (2).

Fig. 721: Fluid Pump Cover

Courtesy of CHRYSLER GROUP, LLC
3. Install screws to hold fluid pump cover (1) to the fluid pump housing. Refer

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to SPECIFICATIONS.
4. Install the 2-6 brake piston from the fluid pump housing. Refer to BRAKE
AND PISTON, 2-6, INSTALLATION.
5. Assemble the transaxle. Refer to DISASSEMBLY.
6. Install the transaxle in the vehicle. Refer to INSTALLATION.
7. Fill the transaxle with specified fluid. Refer to FLUID, STANDARD
PROCEDURES.
BEARINGS, DIFFERENTIAL
REMOVAL

DIFFERENTIAL BEARING

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FWD

1. Remove the transaxle from the vehicle. Refer to REMOVAL.

2. Separate the Bell housing from the transaxle housing. Refer to
DISASSEMBLY.

Fig. 722: Differential & Transaxle Housing

Courtesy of CHRYSLER GROUP, LLC
3. Separate the differential (1) from the transaxle housing (2). Refer to
DISASSEMBLY.

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cardiagn.com
Fig. 723: Differential & Ring Gear
Courtesy of CHRYSLER GROUP, LLC
4. Remove bolts holding the ring gear (3) to the differential (2)

Fig. 724: Differential, Ring Gear & Bearing

Courtesy of CHRYSLER GROUP, LLC
5. Separate the ring gear (1) from the differential (3).

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Fig. 725: Removing Bearing From Differential
Courtesy of CHRYSLER GROUP, LLC
6. Using tools (special tool #C-293-PA, Puller, Press) press (4), (special tool
#C-293-48, Block Set, Puller) collets (5), and (special tool #C-4996,
Adapter, Plug) plug (3), secured in a vise, remove the bearing (2) from the
differential (1) (ring gear side shown in illustration above).
AWD

1. Remove the transaxle from the vehicle. Refer to REMOVAL.

2. Separate the Bell housing from the transaxle housing. Refer to
DISASSEMBLY.

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Fig. 726: Differential & Transaxle Housing
Courtesy of CHRYSLER GROUP, LLC
3. Separate the differential (1) from the transaxle housing (2). Refer to
DISASSEMBLY.

Fig. 727: Differential & Ring Gear

Courtesy of CHRYSLER GROUP, LLC

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4. Remove bolts holding the ring gear (3) to the differential (2)

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Fig. 728: Differential, Ring Gear & Bearing
Courtesy of CHRYSLER GROUP, LLC
5. Separate the ring gear (1) from the differential (3).

Fig. 729: Removing Bearing From Differential

Courtesy of CHRYSLER GROUP, LLC

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6. Using tools press (special tool #C-293-PA, Puller, Press) (4), collets (special
tool #C-293-62, Block Set, Puller) (5), and plug (special tool #9678, Press
Plug) (3), secured in a vise, remove the bearing (2) from the differential (1)
(PTU side shown in illustration above).
DIFFERENTIAL BEARING RACE

The transaxle housing and bell housing must be separated to gain access to the
differential bearings.
1. Remove the transaxle from the vehicle. Refer to REMOVAL.
2. Separate the Bell housing from the transaxle housing. Refer to
DISASSEMBLY.

Fig. 730: Differential & Transaxle Housing

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
3. Separate the differential (1) from the transaxle housing (2). Refer to
DISASSEMBLY.

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Fig. 731: Removing Halfshaft Axle Seal
Courtesy of CHRYSLER GROUP, LLC
4. Using tool (special tool #9664, Remover, Bearing Cup) and slide hammer
(special tool #C-637, Slide Hammer, Universal), remove the halfshaft axle
seal from the bell housing or transaxle housing (bell housing side shown in
illustration above).

Fig. 732: Special Tool #9664

Courtesy of CHRYSLER GROUP, LLC

Fig. 733: Special Tool #C-637

Courtesy of CHRYSLER GROUP, LLC

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cardiagn.com
Fig. 734: Removing Differential Bearing Race
Courtesy of CHRYSLER GROUP, LLC
5. Using special tool (special tool #9664, Remover, Bearing Cup) (inserted into
the relief slots outside the select spacer) and slide hammer (special tool #C-
637, Slide Hammer, Universal) remove the differential bearing race from the
back of the bell housing or transaxle housing (bell housing side shown in
illustration above).

Fig. 735: Special Tool #9664

Courtesy of CHRYSLER GROUP, LLC

Fig. 736: Special Tool #C-637

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Courtesy of CHRYSLER GROUP, LLC

cardiagn.com
Fig. 737: Differential Bearing Race Select Shim
Courtesy of CHRYSLER GROUP, LLC
6. Remove select shim from bottom of differential bearing race bore.
INSTALLATION

DIFFERENTIAL BEARING

WARNING: Use welding gloves or tongs when handling

heated components. Failure to follow these
instructions will result in personal injury.

CAUTION: A bearing heater is used to assembly some

components. Use only a bearing heater/hot plate
and follow manufacture's instructions. Heat
components to 100° - 150° Celsius (212° Min. - 300°
Max Fahrenheit). Never use an open flame to heat
components. Never leave components on heater
for and extended amount of time. If component is
discolored after heating, the component has been
overheated and must not be used. Failure to follow
these instructions will result in component

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damage.

NOTE: If the bearings are being replaced along with the

differential or a transaxle housing component, the select
shim thickness will need to be established. If only the
bearing and race are being replaced, the original shim
can be reused.

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Fig. 738: Hot Plate & Bearing
Courtesy of CHRYSLER GROUP, LLC

1. Using a suitable HOT plate, heat the bearing to near 150° C (300° F). Light
smoke may be produced as the bearing is heated. Do not allow the bearing
to discolor.

NOTE: An infrared thermometer can be used to monitor the

temperature of the bearing as it is heated.

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Fig. 739: Differential, Special Tool #8285 & Bearing
Courtesy of CHRYSLER GROUP, LLC
2. Place the differential (3) on (special tool #8285, Compressor, Spring).

Fig. 740: Special Tool #8285

Courtesy of CHRYSLER GROUP, LLC
While wearing welding gloves, Place heated bearing (2) onto the differential
(3) and allow to cool (ring gear side shown in illustration above).

NOTE: If the bearing does not fall all the way onto the
differential, it was not hot enough. Remove the
bearing and repeat step 1 and 2.
DIFFERENTIAL BEARING RACE

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FWD

NOTE: If the bearings are being replaced along with the

differential or a transaxle housing component, the select
shim thickness will need to be established. If only the
bearing and race are being replaced, the original shim
can be reused.

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Fig. 741: Differential Bearing Race Select Shim
Courtesy of CHRYSLER GROUP, LLC

1. Install the select shim (1) into the bearing race bore in the housing.

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Fig. 742: Special Tool #9668 & Differential Bearing Race
Courtesy of CHRYSLER GROUP, LLC

NOTE: When installing the differential bearing race, do not

allow the race to tip and bind as it is driven into the
bore.

2. Using tools (special tool #9668, Remover/Installer, Bearing Cup) (3) and
(special tool #C-4171, Driver Handle, Universal) (2), carefully drive the
bearing race into the bore in the housing.
3. Prepare to reassemble the transaxle. If necessary, perform the Turning
Torque Measurement procedure.
AWD

NOTE: If the bearings are being replaced along with the

differential or a transaxle housing component, the select
shim thickness will need to be established. If only the
bearing and race are being replaced, the original shim
can be reused.

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Fig. 743: Differential Bearing Race Select Shim
Courtesy of CHRYSLER GROUP, LLC

1. Install the select shim (1) into the bearing race bore in the housing.

Fig. 744: Special Tool #9668 & Differential Bearing Race

Courtesy of CHRYSLER GROUP, LLC

NOTE: When installing the differential bearing race, do not

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allow the race to tip and bind as it is driven into the

bore.

2. Using tools (special tool #C-4310, Installer, Bearing) (3) and (special tool
#C-4171, Driver Handle, Universal) (2), carefully drive the bearing race into
the bore in the housing.
3. Prepare to reassemble the transaxle. If necessary, perform the Turning
Torque Measurement procedure.
DIFFERENTIAL AND RING GEAR
DISASSEMBLY

FWD

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1. Remove the transaxle from the vehicle. Refer to REMOVAL.
2. Disassemble the transaxle to gain access to the differential. Refer to
DISASSEMBLY.
3. Separate the differential from the transaxle housing.

Fig. 745: Differential & Ring Gear

Courtesy of CHRYSLER GROUP, LLC
4. Remove the bolts (2) holding the ring gear (3) to the differential.

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Fig. 746: Differential, Ring Gear & Bearing
Courtesy of CHRYSLER GROUP, LLC
5. Separate the ring gear (1) from the differential (3).

Fig. 747: Differential Case Halves & Screws

Courtesy of CHRYSLER GROUP, LLC
6. Remove the screws (1) holding the differential case halves (2) together.

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Fig. 748: Ring Gear Half & Differential
Courtesy of CHRYSLER GROUP, LLC
7. Separate the ring gear half (1) of the case from the differential (2).

Fig. 749: Side Gear Thrust Washer, Side Gear & Differential
Courtesy of CHRYSLER GROUP, LLC
8. Separate the side gear thrust washer (1) from the side gear (2).

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9. Separate the side gear (2) from the differential (3).

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Fig. 750: Pin, Differential Case & Differential Link Shaft
Courtesy of CHRYSLER GROUP, LLC
10. Remove the pin (1) holding the differential link shaft (3) into the differential
case (2).

Fig. 751: Differential Case & Differential Link Shaft

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Courtesy of CHRYSLER GROUP, LLC

11. Slide the differential link shaft (1) out of the differential case (3).

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Fig. 752: Conical Washers & Pinion Gears
Courtesy of CHRYSLER GROUP, LLC
12. Remove the conical washers (1) and pinion gears (2) from the differential
case.

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Fig. 753: Differential Case & Side Gear
Courtesy of CHRYSLER GROUP, LLC
13. Remove the side gear (1) form the differential case (2).

Fig. 754: Side Gear Thrush Washer & Differential

Courtesy of CHRYSLER GROUP, LLC
14. Remove the side gear thrush washer (1) from the differential (2).

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AWD

1. Remove the transaxle from the vehicle. Refer to REMOVAL.

2. Disassemble the transaxle to gain access to the differential. Refer to
DISASSEMBLY.
3. Separate the differential from the transaxle housing.

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Fig. 755: Differential & Ring Gear
Courtesy of CHRYSLER GROUP, LLC
4. Remove the bolts (2) holding the ring gear (3) to the differential.

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Fig. 756: Differential, Ring Gear & Bearing
Courtesy of CHRYSLER GROUP, LLC
5. Separate the ring gear (1) from the differential (3).

Fig. 757: Differential Case Halves & Screws

Courtesy of CHRYSLER GROUP, LLC
6. Remove the screws (1) holding the differential case halves (2) together.

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Fig. 758: Ring Gear Half & Differential
Courtesy of CHRYSLER GROUP, LLC
7. Separate the ring gear half (1) of the case from the differential (2).

Fig. 759: Side Gear Thrust Washer, Side Gear & Differential
Courtesy of CHRYSLER GROUP, LLC
8. Separate the side gear thrust washer (1) from the side gear (2).

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9. Separate the side gear (2) from the differential (3).

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Fig. 760: Pin, Differential Case & Differential Link Shaft
Courtesy of CHRYSLER GROUP, LLC
10. Remove the pin (1) holding the differential link shaft (3) into the differential
case (2).

Fig. 761: Differential Case & Differential Link Shaft

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Courtesy of CHRYSLER GROUP, LLC

11. Slide the differential link shaft (1) out of the differential case (3).

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Fig. 762: Conical Washers & Pinion Gears
Courtesy of CHRYSLER GROUP, LLC
12. Remove the conical washers (1) and pinion gears (2) from the differential
case.

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Fig. 763: Differential Case & Side Gear
Courtesy of CHRYSLER GROUP, LLC
13. Remove the side gear (1) form the differential case (2).

Fig. 764: Side Gear Thrush Washer & Differential

Courtesy of CHRYSLER GROUP, LLC
14. Remove the side gear thrush washer (1) from the differential (2).

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Fig. 765: Special Tool #L-4454-1 & Differential

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Courtesy of CHRYSLER GROUP, LLC
15. Insert expanding end of collet tool L-4454-1, form tool kit (special tool #L-
4454A, Remover, Bearing Cup) all-the-way into the needle bearing.
16. Tighten the nut until the collet tool is secure in the needle bearing.
17. Place tube receiver tool L-4518-1 from tool kit (special tool #L-4518,
Remover, Bearing Cup) over the collet tool and install the bearing, washer
and nut.

Fig. 766: special tool #L-4518

Courtesy of CHRYSLER GROUP, LLC

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Fig. 767: Differential Housing & Needle Bearing

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
18. Tighten the nut to draw the needle bearing from the differential housing.
19. Using a common flat blade screw and hammer, tap the side gear seal from
the differential housing bore.
ASSEMBLY

FWD

Clean the differential in suitable solvent and inspect components for damage or
debris. Dry the components with regulated 344 kPa (50 psi) shop air. Do not free
spin the bearings with shop air.

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Fig. 768: Side Gear Thrush Washer & Differential
Courtesy of CHRYSLER GROUP, LLC
1. Install the side gear thrush washer (1) into the differential (2).

Fig. 769: Differential Case & Side Gear

Courtesy of CHRYSLER GROUP, LLC
2. Install the side gear (1) into the differential case (2).

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Fig. 770: Conical Washers & Pinion Gears
Courtesy of CHRYSLER GROUP, LLC
3. Install the conical washers (1) and pinion gears (2) into the differential case.

Fig. 771: Differential Case & Differential Link Shaft

Courtesy of CHRYSLER GROUP, LLC
4. Slide the differential link shaft (1) into the differential case (3)

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Fig. 772: Pin, Differential Case & Differential Link Shaft
Courtesy of CHRYSLER GROUP, LLC
5. Install the pin (1) to hold the differential link shaft (3) into the differential
case (2).

Fig. 773: Side Gear Thrust Washer, Side Gear & Differential
Courtesy of CHRYSLER GROUP, LLC

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6. Place the side gear (2) into the differential (3).

7. Place the side gear thrust washer (1) onto the side gear (2).

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Fig. 774: Ring Gear Half & Differential
Courtesy of CHRYSLER GROUP, LLC
8. Place the ring gear half (1) of the case onto the differential (2).

Fig. 775: Differential Case Halves & Screws

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Courtesy of CHRYSLER GROUP, LLC

9. Install the screws (1) to hold the differential case halves (2) together. Refer
to SPECIFICATIONS.

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Fig. 776: Differential, Ring Gear & Bearing
Courtesy of CHRYSLER GROUP, LLC
10. Place the ring gear (1) in position on the differential (3).

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Fig. 777: Differential & Ring Gear
Courtesy of CHRYSLER GROUP, LLC
11. Install the bolts (2) to hold the ring gear (3) to the differential. Refer to
SPECIFICATIONS.
12. Place the differential in position in the transaxle housing.
13. Assemble the transaxle. Refer to ASSEMBLY.
14. Install the transaxle in the vehicle. Refer to INSTALLATION.
AWD

Clean the differential in suitable solvent and inspect components for damage or
debris. Dry the components with regulated 344 kPa (50 psi) shop air. Do not free
spin the bearings with shop air.

1. Apply transmission assembly lube on the lip and tension spring cavity on the
open side of the seal.

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Fig. 778: Seal & Installer

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
2. Insert tool (special tool #C-293-3, Adapter, Bearing/Gear) into open side of
the side gear lip seal.

Fig. 779: Special Tool #C-293-3

Courtesy of CHRYSLER GROUP, LLC

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Fig. 780: Differential Housing, Seal & Tool

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
3. Insert the seal and tool into the bore in the differential housing.

Fig. 781: Tapping Seal Into Housing

Courtesy of CHRYSLER GROUP, LLC
4. Using a suitable hammer, tap the seal into the differential housing bore until
it seats against in inner lip.

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Fig. 782: Side Gear Needle Bearing & Differential Housing

cardiagn.com
Courtesy of CHRYSLER GROUP, LLC
5. Insert the side gear needle bearing into the bore in the differential housing.

Fig. 783: Tapping Seal Into Housing

Courtesy of CHRYSLER GROUP, LLC
6. Using tool (special tool #6342, Installer, Seal) drive the needle bearing into
the differential housing until it seats against the bottom of the bore.

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Fig. 784: Special Tool #6342

Courtesy of CHRYSLER GROUP, LLC

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Fig. 785: Side Gear Thrush Washer & Differential
Courtesy of CHRYSLER GROUP, LLC
7. Install the side gear thrush washer (1) into the differential (2).

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Fig. 786: Differential Case & Side Gear
Courtesy of CHRYSLER GROUP, LLC
8. Install the side gear (1) into the differential case (2).

Fig. 787: Conical Washers & Pinion Gears

Courtesy of CHRYSLER GROUP, LLC
9. Install the conical washers (1) and pinion gears (2) into the differential case.

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Fig. 788: Differential Case & Differential Link Shaft
Courtesy of CHRYSLER GROUP, LLC
10. Slide the differential link shaft (1) into the differential case (3)

Fig. 789: Pin, Differential Case & Differential Link Shaft

Courtesy of CHRYSLER GROUP, LLC
11. Install the pin (1) to hold the differential link shaft (3) into the differential

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case (2).

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Fig. 790: Side Gear Thrust Washer, Side Gear & Differential
Courtesy of CHRYSLER GROUP, LLC
12. Place the side gear (2) into the differential (3).
13. Place the side gear thrust washer (1) onto the side gear (2).

Fig. 791: Ring Gear Half & Differential

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Courtesy of CHRYSLER GROUP, LLC

14. Place the ring gear half (1) of the case onto the differential (2).

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Fig. 792: Differential Case Halves & Screws
Courtesy of CHRYSLER GROUP, LLC
15. Install the screws (1) to hold the differential case halves (2) together. Refer
to SPECIFICATIONS.

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Fig. 793: Differential, Ring Gear & Bearing
Courtesy of CHRYSLER GROUP, LLC
16. Place the ring gear (1) in position on the differential (3).

Fig. 794: Differential & Ring Gear

Courtesy of CHRYSLER GROUP, LLC
17. Install the bolts (2) to hold the ring gear (3) to the differential. Refer to

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SPECIFICATIONS.
18. Place the differential in position in the transaxle housing.
19. Assemble the transaxle. Refer to ASSEMBLY.
20. Install the transaxle in the vehicle. Refer to INSTALLATION.
BEARINGS, TRANSFER GEAR DRIVEN
REMOVAL

TRANSFER GEAR (DRIVEN) BEARING

1. Remove the transaxle from the vehicle. Refer to REMOVAL.

Fig. 795: Transaxle & Transfer Gear

Courtesy of CHRYSLER GROUP, LLC cardiagn.com
2. Disassemble the transaxle to remove the transfer gear. Refer to
DISASSEMBLY.

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Fig. 796: Transfer Gear, Special Tools & Vice
Courtesy of CHRYSLER GROUP, LLC
3. Using tools (special tool #C-293-PA, Puller, Press) press (4), (special tool
#C-293-48, Block Set, Puller) or (special tool #C-293-39, Block Set, Puller)
collets (5), and (special tool #C-4996, Adapter, Plug) plug (3), secured in a
vise, remove the bearing (2) from the transfer gear (1) (pinion side shown in
illustration above).
TRANSFER GEAR (DRIVEN) BEARING RACE

1. Remove the transaxle from the vehicle. Refer to REMOVAL.

2. Disassemble the transaxle. Refer to DISASSEMBLY.

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Fig. 797: Transaxle & Transfer Gear
Courtesy of CHRYSLER GROUP, LLC
3. Remove the transfer gear.

Fig. 798: Transfer Gear Bearing Race, Special Tool #9664 & Special
Tool #C-637
Courtesy of CHRYSLER GROUP, LLC

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4. Using tool (special tool #9664, Remover, Bearing Cup) and slide hammer
(special tool #C-637, Slide Hammer, Universal) (2), remove the transfer
gear bearing race (3) from the bell housing (1) and transaxle housing (bell
housing shown in illustration above).

Fig. 799: Special Tool #9664

Courtesy of CHRYSLER GROUP, LLC

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Fig. 800: Special Tool #C-637
Courtesy of CHRYSLER GROUP, LLC

Fig. 801: Transfer Gear Bearing Select Shim

Courtesy of CHRYSLER GROUP, LLC
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5. Remove select shim (2) from bottom of transfer gear bearing race bore (3).
Mark the shim to aid installation (bell housing shown in illustration above).
INSTALLATION

TRANSFER GEAR (DRIVEN) BEARING

WARNING: Use welding gloves or tongs when handling

heated components. Failure to follow these
instructions will result in personal injury.

CAUTION: A bearing heater is used to assembly some

components. Use only a bearing heater/hot plate
and follow manufacture's instructions. Heat

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components to 100° - 150° Celsius (212° Min. - 300°
Max Fahrenheit). Never use an open flame to heat
components. Never leave components on heater
for and extended amount of time. If component is
discolored after heating, the component has been
overheated and must not be used. Failure to follow
these instructions will result in component
damage.

NOTE: If the bearings are being replaced along with the transfer
gear or a transaxle housing component, the select shim
thickness will need to be established. If only the bearing
and race are being replaced, the original shim can be
reused.

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Fig. 802: Hot Plate & Bearing
Courtesy of CHRYSLER GROUP, LLC

1. Using a suitable HOT plate (1), heat the bearing (2) to near 150° C (300° F).
Light smoke may be produced as the bearing is heated. Do not allow the
bearing to discolor.

NOTE: An infrared thermometer can be used to monitor the

temperature of the bearing as it is heated.

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Fig. 803: Transfer Gear & Heated Bearing
Courtesy of CHRYSLER GROUP, LLC
2. While wearing welding gloves, Place heated bearing (2) onto the transfer
gear (1) and allow to cool (pinion gear side shown in illustration above).

NOTE: If the bearing does not fall all the way onto the
transfer gear, it was not hot enough. Remove the
bearing and repeat step 1 and 2.
TRANSFER GEAR (DRIVEN) BEARING RACE

NOTE: If the bearings are being replaced along with the transfer
gear or transaxle housing component, the select shim
thickness will need to be established. If only the bearing
and race are being replaced, the original shim can be
reused.

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Fig. 804: Transfer Gear Bearing Select Shim
Courtesy of CHRYSLER GROUP, LLC

1. Install the select shim (1) into the bearing race bore in the housing.

Fig. 805: Transfer Gear Bearing Race & Bore

Courtesy of CHRYSLER GROUP, LLC
2. Place the transfer gear bearing race (1) in the bore in the bell housing or

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transaxle housing.

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Fig. 806: Transfer Case Bearing Race, Special Tool #8866 & Special
Tool #C-4171
Courtesy of CHRYSLER GROUP, LLC

NOTE: When installing the transfer case bearing race (4), do

not allow the race to tip and bind as it is driven into
the bore.

3. Using tools (special tool #8866, Installer, Bearing Cup) (3) and (special tool
#C-4171, Driver Handle, Universal) (2), carefully drive the bearing race into
the bore in the housing.
4. Prepare to reassemble the transaxle. If necessary, perform the Turning
Torque Measurement procedure.
BEARINGS, TRANSFER GEAR DRIVE
REMOVAL

REMOVAL

NOTE: The transfer gear (output) support is also the bearing

races for the inner and outer transfer gear bearings. If a
bearing is faulty it is recommended that the entire

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transfer gear assembly (with support) is replaced. The

only reason to disassemble the transfer gear (output) is
to inspect it for damage.

1. Remove the transaxle from the vehicle. Refer to REMOVAL.

2. Disassemble the transaxle. Refer to DISASSEMBLY.

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Fig. 807: Transfer Gear (Output)
Courtesy of CHRYSLER GROUP, LLC
3. Remove the transfer gear (output) from the transaxle case.

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Fig. 808: Transfer Gear Assembly & Holding Fixture
Courtesy of CHRYSLER GROUP, LLC
4. Secure holding fixture (special tool #10423, Fixture, Transfer Gear Holding)
(2) in a suitable vise
5. Place the transfer gear assembly (1) on the holding fixture (2).

Fig. 809: Spanner Groove & Lock Tab

Courtesy of CHRYSLER GROUP, LLC

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6. Using a suitable screw driver pry the lock tab out of the spanner groove.

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Fig. 810: Spanner Wrench & Bearing Support
Courtesy of CHRYSLER GROUP, LLC
7. Using spanner wrench (special tool #10422, Wrench, Spanner) (2), loosen
the spanner nut holding the transfer gear to the bearing support (1).

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Fig. 811: Special Tool #10422

Courtesy of CHRYSLER GROUP, LLC

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Fig. 812: Spanner Nut, Lock & Transfer Gear Assembly
Courtesy of CHRYSLER GROUP, LLC
8. Remove the spanner nut (2) and lock (3) from the transfer gear assembly.

Fig. 813: Transfer Gear Assembly & Special Tool #C-3095-A

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Courtesy of CHRYSLER GROUP, LLC

9. Using a suitable press and tool (special tool #C-3095-A, Installer, Bearing)
or equivalent, press the transfer gear out of the inner bearing.

Fig. 814: Special Tool #C-3095-A

Courtesy of CHRYSLER GROUP, LLC

Fig. 815: Transfer Gear & Outer Bearing

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Courtesy of CHRYSLER GROUP, LLC
10. Place the gear on the spanner wrench on a suitable work surface.
11. Using a suitable punch (2), drive the outer bearing from the transfer gear (1).
INSTALLATION

TRANSFER GEAR (OUTPUT) BEARING INSTALLATION

WARNING: Use welding gloves or tongs when handling

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heated components. Failure to follow these

instructions will result in personal injury.

CAUTION: A bearing heater is used to assembly some

components. Use only a bearing heater/hot plate
and follow manufacture's instructions. Heat
components to 100° - 150° Celsius (212° Min. - 300°
Max Fahrenheit). Never use an open flame to heat
components. Never leave components on heater
for and extended amount of time. If component is
discolored after heating, the component has been
overheated and must not be used. Failure to follow
these instructions will result in component

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damage.

NOTE: If the original bearings or gears are damaged in any way

the entire transfer gear output must be replaced.

Fig. 816: Hot Plate & Bearing

Courtesy of CHRYSLER GROUP, LLC

1. Using a suitable HOT plate (1), heat the bearing (2) to near 150° C (300° F).
Light smoke may be produced as the bearing is heated. Do not allow the

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bearing to discolor.

NOTE: An infrared thermometer can be used to monitor the

temperature of the bearing as it is heated.

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Fig. 817: Transfer Gear & Inner Bearing
Courtesy of CHRYSLER GROUP, LLC
2. While wearing welding gloves, Place heated inner bearing (1) onto the
transfer gear (2) and allow to cool. If the bearing fails to fall all the way onto
the transfer gear, it will need to be removed and reheated.

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Fig. 818: Transfer Gear, Support/Race & Bearing
Courtesy of CHRYSLER GROUP, LLC
3. While heating the outer bearing (1), place the transfer gear support/race (2)
in position on the transfer gear (3).

Fig. 819: Transfer Gear & Outer Bearing

Courtesy of CHRYSLER GROUP, LLC

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4. While wearing welding gloves, Place heated outer bearing (2) onto the
transfer gear and allow to cool. If the bearing fails to fall all the way onto
the transfer gear, it will need to be removed and reheated.

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Fig. 820: Spanner Nut, Lock & Transfer Gear Assembly
Courtesy of CHRYSLER GROUP, LLC
5. Install the lock ring and the spanner nut on the transfer gear (output).
(special tool #10423, Fixture, Transfer Gear Holding) (special tool #10422,
Wrench, Spanner)
6. Tighten the spanner nut to specified torque. Refer to SPECIFICATIONS.

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Fig. 821: Spanner Nut & Lock Tab
Courtesy of CHRYSLER GROUP, LLC
7. Using a suitable pliers (1), bend a lock tab into the spanner nut.
8. Verify that the bearing turning torque is no greater than 1.3 N.m (12 in. lb.)
before installing the transfer gear in the transaxle.
SHIFTER, FLOOR CONSOLE
REMOVAL

REMOVAL

1. Disconnect the battery negative cable.

2. Remove the center floor console. Refer to CONSOLE, FLOOR,
REMOVAL .

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Fig. 822: PRND Wire Connector & Shifter Assembly
Courtesy of CHRYSLER GROUP, LLC
3. Release the wire connector lock and disconnect the PRND wire connector
from the shifter assembly.

Fig. 823: Shifter Assembly & Gear Shift Cable End

Courtesy of CHRYSLER GROUP, LLC

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4. Pry the gear shift cable end (2) from the pin under the shifter assembly (3).
5. Release the shift cable housing retainer and disengage the cable from the
shifter assembly.

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Fig. 824: Gear Shifter
Courtesy of CHRYSLER GROUP, LLC
6. Remove the nuts holding the gear shifter to the floor.
7. Separate the gear shifter from the vehicle.
INSTALLATION

INSTALLATION

1. Place the gear shifter in position on the floor pan.

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Fig. 825: Gear Shifter
Courtesy of CHRYSLER GROUP, LLC
2. Install nuts to hold the gear shifter assembly (1) to the floor pan.
3. Insert the shift cable into the access hole on the front of the shifter and lock
the retainer into the shifter.

Fig. 826: Shifter Assembly & Gear Shift Cable End

Courtesy of CHRYSLER GROUP, LLC

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4. Push the gear shift cable end (2) onto the pin under the shifter assembly (3).

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Fig. 827: PRND Wire Connector & Shifter Assembly
Courtesy of CHRYSLER GROUP, LLC
5. Connect the PRND wire connector into the shifter assembly connector.
6. Install the center floor console. Refer to CONSOLE, FLOOR,
INSTALLATION .
7. Connect the battery negative cable.

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