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Assembly, UNDERDRIVE Compounder: Assembly

GC0122717Courtesy of CHRYSLER GROUP, LLC
CAUTION:

Lube seal lips with ATF during installation, Use a twisting motion during installation to prevent seal lips from rolling over.

CAUTION:

Do not over stretch. Can cause breakage.

  1. Install NEW  seal rings (1) on the low clutch retainer (2).
    GC0122716Courtesy of CHRYSLER GROUP, LLC
  2. Install the low clutch piston (1) in the low clutch retainer (2).
    GC0122715Courtesy of CHRYSLER GROUP, LLC
  3. Install the low clutch return spring (1) over the low clutch retainer (2).
    GC0122714Courtesy of CHRYSLER GROUP, LLC
  4. Install compressor (special tool #9725, Compressor, Spring) (1) on return spring (3) and slightly compress.
  5. Install the snap ring (4) on the low clutch retainer (2).
  6. Release pressure on press and then remove spring compressor (special tool #9725, Compressor, Spring).
    GC0122713Courtesy of CHRYSLER GROUP, LLC
    1 - SNAP RING (SELECTABLE)
    6 - RETURN SPRING
    2 - CLUTCH HUB
    7 - RETAINER
    3 - REACTION PLATE
    8 - SEALS
    4 - FRICTION DISC
    9 - PISTON
    5 - SEPARATOR PLATE
    10 - SNAP RING
  7. Install the friction discs (4) and the separator plates (5).
  8. Install the reaction plate (3).
  9. Install the snap ring (10).
    GC0122718Courtesy of CHRYSLER GROUP, LLC
  10. Using a Dial Indicator (special tool #C-3339A, Set, Dial Indicator) (1) and air pressure (3), measure the low clutch (2) clearance. The clearance should be 0.48 - 0.76 mm (.019 -.030 in.). Install desired selectable snap ring to achieve correct clearance.
    GC0122719Courtesy of CHRYSLER GROUP, LLC
  11. Using Installer (special tool #6756, Receiver, Ball Joint) (2) and a press (1), install the underdrive compounder bearing (3) to transfer shaft.
  12. Install NEW  seal rings on the transfer shaft.
    GC0183981Courtesy of CHRYSLER GROUP, LLC
  13. Install NEW  bearing races into the transfer shaft bearing retainer (2) using bearing cup installer (special tool #9952, Installer, Bearing Cup) and handle (special tool #C-4171, Driver Handle, Universal).
  14. Lube the transfer shaft and transfer gear bearings with clean ATF+4 transmission fluid.
    GC0122711Courtesy of CHRYSLER GROUP, LLC
  15. Install the transfer shaft (1) on the low clutch (2).
  16. Install the bearing retainer screws and tighten to. Refer to TECHNICAL SPECIFICATIONS .
    GC0122720Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The selectable shim will determine turning torque.

  17. Install the selectable shim (3), transfer gear (2) and the transfer gear nut.
    GC0122721Courtesy of CHRYSLER GROUP, LLC
  18. Using Holder (special tool #9739, Holder, Gear) (1), tighten transfer gear nut to

    Refer to TECHNICAL SPECIFICATIONS .

    GC0122722Courtesy of CHRYSLER GROUP, LLC
  19. Check turning torque using an inch pound torque wrench. Turning torque should be between 8.0 to 18.0 in-lbs (drag), If more than 18.0 in-lbs (drag) choose a larger shim and recheck turning torque. If less than 8.0 in-lbs (drag) choose a smaller shim and recheck turning torque.
  20. Remove transfer gear nut and gear (1).
    GC0122710Courtesy of CHRYSLER GROUP, LLC
  21. Install the Bearing Retainer Assembly Remover (special tool #9908, Adapter, Puller) (1) on the low clutch (2).
    GC0122709Courtesy of CHRYSLER GROUP, LLC
  22. Install the overrunning clutch in the low clutch (2).
    GC0122708Courtesy of CHRYSLER GROUP, LLC
  23. Install the needle bearing (1) on the transfer shaft.
    GC0122706Courtesy of CHRYSLER GROUP, LLC
    1 - INTERNAL SNAP RING
    5 - RETURN COIL SPRING
    9 - # 2 THRUST BEARING
    2 - FRICTION (INNER SPLINE)
    6 - RETAINER
    10 - HUB
    3 - FRICTION (OUTER SPLINE)
    7 - PISTON
    11 - # 1 THRUST BEARING
    4 - RETAINER SNAP RING
    8 - BALANCE PISTON
    12 - REACTION PLATE (SELECTABLE)
  24. Install the direct clutch retainer (7) on the retainer (6).
  25. Install the return coil spring (5) on the balance piston (8).
  26. Install the direct clutch piston (7) in the balance piston (8) using the Direct Clutch Piston Guide (special tool #9727, Installer, Piston).
    GC0122707Courtesy of CHRYSLER GROUP, LLC
  27. Install compressor (special tool #8250, Compressor, Spring) (2) over the direct clutch balance piston (3) and place on a press (1).
  28. Compress spring to install the snap ring (4) at the direct clutch balance piston.
    GC0122706Courtesy of CHRYSLER GROUP, LLC
    1 - INTERNAL SNAP RING
    5 - RETURN COIL SPRING
    9 - # 2 THRUST BEARING
    2 - FRICTION (INNER SPLINE)
    6 - RETAINER
    10 - HUB
    3 - FRICTION (OUTER SPLINE)
    7 - PISTON
    11 - # 1 THRUST BEARING
    4 - RETAINER SNAP RING
    8 - BALANCE PISTON
    12 - REACTION PLATE (SELECTABLE)
  29. Install the inner and outer spline frictions (2, 3).
  30. Install the number two thrust bearing (9).
  31. Install the hub (10).
  32. Install the number one thrust bearing (11).
  33. Install the selectable reaction plate (12).
  34. Install the internal snap ring (1).
    GC0122705Courtesy of CHRYSLER GROUP, LLC
  35. Install the direct clutch (1) on the low clutch (2).
    GC0122704Courtesy of CHRYSLER GROUP, LLC
  36. Install the split bearing (1) using a small pick (2).
    GC0122723Courtesy of CHRYSLER GROUP, LLC
  37. Using a Dial Indicator (special tool #C-3339A, Set, Dial Indicator) (1) and air pressure (4) measure the direct clutch clearance, the clearance should be 0.95 - 1.41 (0.037- 0.056 in). Install desired selectable reaction plate to achieve correct clearance.
    GC0122703Courtesy of CHRYSLER GROUP, LLC
  38. Install the sun gear (2) on the shaft.
  39. Install the NEW  retaining clip on the transfer/underdrive shaft.
    GC0122701Courtesy of CHRYSLER GROUP, LLC
    1 - NEEDLE BEARING
    5 - PLANETARY CARRIER
    9 - #2 NEEDLE BEARING
    2 - SUN GEAR
    6 - #2 SNAP RING
    10 - NEEDLE BEARING
    3 - HELICAL SHIM (SELECT)
    7 - #1 NEEDLE BEARING
    11 - OUTPUT HUB
    4 - #1 SNAP RING
    8 - ANNULUS GEAR
     
  40. Inspect the needle bearing in the output hub for any damage.
  41. Install the thrust washer (9) between the back side of the annulus gear (8) and the front side of the output hub (11).
  42. Install the annulus gear (8).
  43. Install the thrust washer (7) on the front side of the annulus gear.
  44. Install the snap ring (6) that holds the annulus gear.
  45. Install the planetary carrier (5).
  46. With bevel outward, install the snap ring (4) holding the planetary carrier.
    GC0122700Courtesy of CHRYSLER GROUP, LLC
  47. Install the helical shim (1).
    GC0122699Courtesy of CHRYSLER GROUP, LLC
  48. Install the planetary gear set/output hub (1) on the direct clutch (2).
  49. Install the underdrive compounder in the transaxle and measure the helical spacer through the window plug in the bellhousing. Refer to ASSEMBLY .
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