Fig. 28: Identifying Solenoid/Pressure Switch Assembly & Gasket

1. - SOLENOID/PRESSURE SWITCH ASSEMBLY
2. - GASKET

NOTE: If transaxle is being overhauled (clutch and/or seal replacement) or replaced, it is necessary to perform the PCM/TCM Quick Learn Procedure.

NOTE: This procedure does not include final drive (differential) disassembly.

1. Remove input and output speed sensors.

2. Remove the solenoid/pressure switch assembly-to-case bolts.

3. Remove solenoid/pressure switch assembly and gasket (2).

Fig. 29: Identifying Oil Pan Bolts

1. - OIL PAN BOLTS (USE RTV UNDER BOLT HEADS)

4. Remove oil pan-to-case bolts (1) .

Fig. 30: Removing/Installing Oil Pan

1. - OIL PAN
2. - 1/8 INCH BEAD OF MOPAR ATF RTV (MS-GF41)
3. - OIL FILTER

5. Remove oil pan (1) .

Fig. 31: Removing/Installing Oil Filter

1. - OIL FILTER
2. - O-RING

6. Remove oil filter (1) .

Fig. 32: Removing/Installing Valve Body-To-Case Bolts

1. - VALVE BODY ATTACHING BOLTS (18)
2. - VALVE BODY

7. Turn manual valve fully clockwise to get park rod into position for removal.

8. Remove valve body-to-case bolts (1) .

Fig. 33: Identifying Push Park Rod Rollers & Guide Bracket

1. - PARK SPRAG ROLLERS
2. - SCREWDRIVER
3. - PARK SPRAG GUIDE BRACKET

9. Using a screwdriver (2), push park rod rollers away from guide bracket (3) .

Fig. 34: Removing/Installing Valve Body Assembly

1. - VALVE BODY

CAUTION: Do not handle the valve body assembly from the manual valve.

Damage can result.

10. Remove valve body assembly (1).

Fig. 35: Removing/Installing Underdrive & Overdrive Accumulators

1. - RETURN SPRING
2. - UNDERDRIVE CLUTCH ACCUMULATOR
3. - SEAL RING (2)
4. - OVERDRIVE CLUTCH ACCUMULATOR

NOTE: Depending on engine application, some accumulators will have two springs and others will have one spring. The springs are color-coded according to application and year. When disassembling, mark accumulator spring location to ease assembly.

11. Remove underdrive (2) and overdrive (4) accumulators.

Fig. 36: Removing/Installing Low/Reverse Accumulator Snap Ring

1. - SNAP RING
2. - PLUG

12. Remove low/reverse accumulator snap ring (1) .

Fig. 37: Removing/Installing Low/Reverse Accumulator Plug

1. - ADJUSTABLE PLIERS
2. - PLUG

13. Remove low/reverse accumulator plug (2) .

Fig. 38: Removing/Installing Low/Reverse Accumulator Piston

1. - ACCUMULATOR PISTON

14. Remove low/reverse accumulator piston (1) using suitable pliers.

Fig. 39: Removing/Installing Low/Reverse Accumulator Return Springs

1. - ACCUMULATOR PISTON
2. - SEAL RINGS
3. - RETURN SPRINGS
4. - (NOTE NOTCH)

15. Remove low/reverse accumulator return springs (3) .

Fig. 40: Measuring Input Shaft End Play Using End Play Fixtures 8266 & Dial Indicator C-3339A

1. - END PLAY FIXTURES 8266A
2. - DIAL INDICATOR C-3339A

16. Measure input shaft end play. Place transaxle so input shaft is vertical. Set up End Play fixture and dial indicator (2,3) . Input shaft end play should be within 0.13-0.64 mm (0.005-0.025 in.). If outside of this range, a #4 thrust plate change is required. Record indicator reading for reference upon reassembly.

Fig. 41: Removing/Installing Oil Pump-To-Case Bolts

1. - PUMP ATTACHING BOLTS
2. - PUMP HOUSING

17. Remove oil pump-to-case bolts (1) .

Fig. 42: Identifying Slide Hammers C-3752 & Oil Pump

1. - SLIDE HAMMERS C-3752
2. - PUMP

CAUTION: Be sure input speed sensor is removed before removing oil pump.

18. Install slide hammers C-3752 (1) .

Fig. 43: Removing/Installing Oil Pump Assembly

1. - "PUSH IN" ON INPUT SHAFT WHILE REMOVING PUMP

19. Remove oil pump assembly (1) .

Fig. 44: Removing/Installing Oil Pump Gasket

1. - PUMP GASKET

20. Remove oil pump gasket (1) .

Fig. 45: Removing/Installing Cooler Bypass Valve

1. - COOLER BYPASS VALVE

CAUTION: If transaxle failure has occurred, the cooler bypass valve must be replaced. Do not re-use or attempt to clean valve.

21. Remove cooler bypass valve (1) .

Fig. 46: Removing/Installing #1 Caged Needle Bearing

1. - #1 CAGED NEEDLE BEARING
2. - NOTE: TANGED SIDE OUT

22. Remove #1 needle bearing (1) .

Fig. 47: Removing/Installing Input Clutch Assembly

1. - INPUT CLUTCH ASSEMBLY
2. - #4 THRUST WASHER

23. Remove input clutch assembly (1) .

Fig. 48: Removing/Installing #4 Thrust Plate

1. - OVERDRIVE SHAFT ASSEMBLY
2. - #4 THRUST PLATE (SELECT)
3. - 3 DABS OF PETROLATUM FOR RETENTION

24. Remove #4 thrust plate (2) .

Fig. 49: Removing/Installing Front Sun Gear Assembly

1. - FRONT SUN GEAR ASSEMBLY
2. - #4 THRUST WASHER (FOUR TABS)

25. Remove front sun gear assembly (1) and #4 thrust washer (2).

Fig. 50: Removing/Installing Front Carrier/Rear Annulus Assembly

1. - #6 NEEDLE BEARING
2. - FRONT CARRIER AND REAR ANNULUS ASSEMBLY (TWIST AND PULL OR PUSH TO REMOVE OR INSTALL).

26. Remove front carrier/rear annulus assembly (2) and #6 needle bearing (1).

Fig. 51: Removing/Installing Rear Sun Gear

1. - #7 NEEDLE BEARING
2. - REAR SUN GEAR

27. Remove rear sun gear (2) and #7 needle bearing (1)

Fig. 52: Removing/Installing #7 Needle Bearing

1. - #7 NEEDLE BEARING
2. - REAR SUN GEAR

NOTE: The number 7 needle bearing (1) has three anti-reversal tabs and is common with the number five and number two position. The orientation should allow the bearing to seat flat against the rear sun gear (2). A small amount of petrolatum can be used to hold the bearing to the rear sun gear.

Fig. 53: Removing/Installing Snap Ring

1. - SPRING COMPRESSOR 5058A
2. - SCREWDRIVER
3. - SNAP RING
4. - 2/4 CLUTCH RETAINER

28. Setup spring compressor 5058A (1) , Compress 2/4 clutch return spring (4) (just enough to remove snap ring) and remove snap ring (3).

NOTE: Verify that spring compressor 5058A is centered properly over the 2/4 clutch retainer before compressing. If necessary, fasten the 5058A bar to the bellhousing flange with any combination of locking pliers and bolts to center the tool properly.

Fig. 54: Removing/Installing 2/4 Clutch Retainer

1. - 2/4 CLUTCH RETAINER
2. - 2/4 CLUTCH RETURN SPRING

NOTE: The 2/4 Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.

29. Remove 2/4 clutch retainer (1) .

Fig. 55: Removing/Installing 2/4 Clutch Return Spring

1. - 2/4 CLUTCH RETURN SPRING

30. Remove 2/4 clutch return spring (1) .

Fig. 56: Removing/Installing 2/4 Clutch Pack

1. - CLUTCH PLATE (4)
2. - CLUTCH DISC (4)

31. Remove 2/4 clutch pack (1,2) . Tag 2/4 clutch pack for reassembly identification.

Fig. 57: Removing/Installing Tapered Snap Ring

1. - LOW/REVERSE CLUTCH REACTION PLATE
2. - SCREWDRIVER
3. - LOW/REVERSE TAPERED SNAP RING (TAPERED SIDE UP)
4. - OIL PAN FACE
5. - LONG TAB

32. Remove tapered snap ring (3) .

Fig. 58: Removing/Installing Low/Reverse Reaction Plate

1. - LOW/REVERSE REACTION PLATE (FLAT SIDE UP)

33. Remove low/reverse reaction plate (1) .

Fig. 59: Removing/Installing Low/Reverse Clutch Disc

1. - ONE DISC FROM LOW/REVERSE CLUTCH

34. Remove one low/reverse clutch disc (1) .

Fig. 60: Removing/Installing Low/Reverse Reaction Plate Snap Ring

1. - SCREWDRIVER
2. - LOW/REVERSE REACTION PLATE FLAT SNAP RING
3. - DO NOT SCRATCH CLUTCH PLATE

35. Remove low/reverse reaction plate snap ring (2) .

Fig. 61: Removing/Installing Low/Reverse Clutch Pack

1. - CLUTCH PLATES (5)
2. - CLUTCH DISCS (5)

36. Remove low/reverse clutch pack (1,2) .

Fig. 62: Removing/Installing Transfer Gear Cover-To-Case Bolts

1. - REAR COVER BOLTS
2. - REAR COVER
3. - USE SEALANT ON BOLTS

37. Remove transfer gear cover-to-case bolts (1) .

Fig. 63: Removing/Installing Transfer Gear Cover

1. - REAR COVER
2. - 1/8 INCH BEAD OF MOPAR ATF RTV (MS-GF41)

38. Remove transfer gear cover (1) .

Fig. 64: Identifying Holder 6259

1. - TRANSFER SHAFT GEAR
2. - OUTPUT GEAR
3. - HOLDER 6259

39. Install holder 6259 (3) .

Fig. 65: Removing/Installing Transfer Shaft Gear Nut & Coned Washer

1. - TRANSFER SHAFT
2. - LOCK WASHER
3. - NUT

40. Remove transfer shaft gear-to-shaft nut (3) and coned washer (2).

Fig. 66: Removing/Installing Transfer Shaft Gear

1. - GEAR PULLER L-4407A
2. - TRANSFER SHAFT GEAR

41. Using Gear Puller L-4407A (3) remove transfer shaft gear (2).

Fig. 67: Removing/Installing Transfer Gear Shim (Select)

1. - TRANSFER SHAFT GEAR
2. - BEARING CUP RETAINER
3. - SHIM (SELECT)

42. Remove transfer gear shim (select) (3) .

Fig. 68: Removing/Installing Bearing Cup Retainer

1. - ALIGN INDEXING TAB TO SLOT
2. - BEARING CUP RETAINER

43. Remove bearing cup retainer (2) .

Fig. 69: Removing Transfer Gear Bearing Cone

1. - WRENCHES
2. - BEARING PULLER 5048 WITH JAWS 5048-4 AND THRUST PAD L-4539-2
3. - TRANSFER SHAFT GEAR

44. Remove transfer gear bearing cone using setup using bearing puller 5048 with jaws 5048-4 and thrust pad L-4539-2 (2) .

Fig. 70: Removing Transfer Shaft Bearing Cup

1. - WRENCHES
2. - BEARING CUP PULLER 6062A
3. - TRANSFER SHAFT BEARING CUP RETAINER

45. Remove transfer shaft bearing cup from retainer (3) using bearing cup puller 6062A (2).

Fig. 71: Removing/Installing Transfer Shaft Bearing Snap Ring

1. - SNAP RING PLIERS 6051A
2. - TRANSFER SHAFT BEARING SNAP RING
3. - TRANSFER SHAFT

46. Using Snap Ring Pliers 6051A (1) remove transfer shaft bearing snap ring (2).

Fig. 72: Removing/Installing Transfer Shaft

1. - REMOVER/INSTALLER 5049-A
2. - TRANSFER SHAFT
3. - OUTPUT GEAR

47. Using the Remover/Installer 5049-A (1) remove transfer shaft (2) from transaxle.

Fig. 73: Identifying Bearing Cup Retainer & Oil Baffle

1. - BEARING CUP
2. - BEARING CONE
3. - TRANSFER SHAFT
4. - OIL BAFFLE
5. - O-RING

48. Slip bearing cup retainer (1) and oil baffle (4) off of shaft.

Fig. 74: Identifying Bearing Splitter P-334, Transfer Shaft Bearing Cone, & Transfer Shaft

1. - ARBOR PRESS RAM
2. - TRANSFER SHAFT
3. - BEARING SPLITTER P-334
4. - BEARING CONE

49. Using Bearing Splitter P-334 (3) press transfer shaft bearing cone (4) off of shaft (2).

Fig. 75: Removing/Installing Retaining Strap Bolts

1. - RETAINING STRAP
2. - STIRRUP
3. - RETAINING STRAP BOLTS

50. Bend output gear retaining strap (1) ears flat to allow bolt removal.

51. Remove output shaft stirrup strap bolts (3)

Fig. 76: Removing/Installing Stirrup & Strap

1. - OUTPUT GEAR BOLT
2. - RETAINING STRAP
3. - STIRRUP

52. Remove stirrup (3) and strap (2).

Fig. 77: Identifying Holder 6259

1. - OUTPUT GEAR
2. - HOLDER 6259

53. Install Holder 6259 (2).

Fig. 78: Removing/Installing Output Gear Bolt & Washer

1. - OUTPUT GEAR
2. - BOLT
3. - CONED LOCK WASHER

54. Remove output shaft gear-to-shaft bolt (2) and washer (3)

Fig. 79: Removing Output Gear

1. - OUTPUT GEAR
2. - THRUST BUTTON 6055
3. - WRENCHES
4. - GEAR PULLER L4407A
5. - BOLTS L4407-6

55. Using Gear Puller L4407A (4) and thrust button 6055 (2), remove output gear (1) from shaft.

Fig. 80: Removing Output Gear Bearing Shim (Select)

1. - REAR CARRIER ASSEMBLY
2. - SHIM (SELECT)
3. - OUTPUT GEAR

56. Remove output gear bearing shim (select) (2)

Fig. 81: Removing Output Gear Bearing Cone

1. - BEARING PULLER 5048 WITH JAWS 5048-5 AND THRUST PAD L-4539-2
2. - WRENCHES
3. - OUTPUT GEAR

57. Using bearing puller 5048 with jaws 5048-5 and thrust pad L-4539-2 (1) Remove output gear bearing cone.

Fig. 82: Removing/Installing Rear Carrier Assembly

1. - REAR CARRIER ASSEMBLY

58. Remove rear carrier assembly (1) from transaxle.

Fig. 83: Removing Rear Carrier Assembly Bearing Cone

1. - BEARING PULLER 5048 WITH JAWS 5048-3 AND THRUST BUTTON 6055
2. - WRENCHES
3. - REAR CARRIER ASSEMBLY

59. Remove rear carrier assembly (3) bearing cone using bearing puller 5048 with jaws 5048-3 and thrust button 6055.

Fig. 84: Identifying Spring Compressor 5059-A, Spring Compressor Disc 6057, & Forcing Screw 5058A-3

1. - SPRING COMPRESSOR DISC 6057
2. - SPRING COMPRESSOR 5059-A
3. - FORCING SCREW 5058A-3

60. Install disk 6057 (1) , spring compressor 5059-A (2) and forcing screw 5058A-3 (3).

Fig. 85: Removing/Installing Low/Reverse Spring Compressor

1. - LOW/REVERSE CLUTCH RETURN SPRING
2. - SNAP RING (INSTALL AS SHOWN IN ILLUSTRATION)
3. - SPRING COMPRESSOR DISC 6057
4. - SPRING COMPRESSOR 5059-A
5. - FORCING SCREW 5058A-3

61. Install low/reverse spring compressor .

Fig. 86: Removing/Installing Remove Snap Ring

1. - SNAP RING OPENING MUST BE BETWEEN SPRING LEVERS (AS SHOWN IN ILLUSTRATION)
2. - SNAP RING PLIERS
3. - SPRING COMPRESSOR DISC 6057

62. Compress low/reverse piston return spring and remove snap ring (1) .

Fig. 87: Removing/Installing Low/Reverse Piston Return Spring

1. - LOW/REVERSE PISTON RETURN SPRING
2. - PISTON

63. Remove low/reverse spring compressor tool and low reverse piston return spring (1)

Fig. 88: Driving Out Park Guide Bracket Pivot Shaft Plug

1. - GUIDE BRACKET ANCHOR SHAFT
2. - PIVOT SHAFT
3. - ANCHOR SHAFT PLUG

64. Using a suitable punch , drive out park guide bracket pivot shaft plug (3)

Fig. 89: Removing/Installing Pivot Shaft & Guide Bracket Assembly

1. - ANTIRACHET SPRING
2. - GUIDE BRACKET
3. - PIVOT SHAFT
4. - PAWL

65. Using ordinary pliers, remove pivot shaft (3) and guide bracket assembly (2).

Fig. 90: Identifying Guide Bracket Components

66. Inspect guide bracket components for excessive wear and replace Anti-ratching spring (1), guide bracket (2), Split sleeve (3), spacer (4), pawl (5) and stepped spacer (6) if necessary.

Fig. 91: Identifying Low/Reverse Clutch Piston & Bonded Seals

1. - LOW/REVERSE CLUTCH PISTON
2. - BONDED SEAL
3. - BONDED SEAL

NOTE: The Low/Reverse Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.

67. Remove low/reverse clutch piston (1) .

Fig. 92: Removing/Installing Low/Reverse Piston Retainer-To-Case Screws

1. - LOW/REVERSE CLUTCH PISTON RET
2. - SCREWDRIVER
3. - TORX-LOC SCREWS

68. Remove low/reverse piston retainer-to-case screws (3)

Fig. 93: Removing/Installing Low/Reverse Piston Retainer

1. - LOW/REVERSE CLUTCH PISTON RETAINER
2. - GASKET

69. Remove low/reverse piston retainer (1) .

Fig. 94: Removing/Installing Low/Reverse Piston Retainer-To-Case Gasket

1. - GASKET HOLES MUST LINE UP
2. - LOW/REVERSE CLUTCH PISTON RETAINER GASKET

70. Remove low/reverse piston retainer-to-case gasket (2) , gasket holes must line up (1).

Fig. 95: Removing Inner Output Bearing Cup

1. - OUTPUT BEARING CUPS (REPLACE IN PAIRS)
2. - HAMMER
3. - BRASS DRIFT

71. Using a hammer (2) and suitable drift (3), drive out inner output bearing cup (1).

Fig. 96: Removing Outer Output Bearing Cup

1. - BEARING CUP PULLER 6062A

72. Using bearing cup puller 6062A (1) , remove outer output bearing cup.