Chrysler Sebring, Stratus sedan, Sebring Convertible. Manual — part 581
NOTE: The 2/4 Clutch Piston has bonded seals
which are not individually serviceable. Seal replace-
ment requires replacement of the piston assembly.
(45) Orient 2/4 clutch return spring to retainer as
shown in (Fig. 125), and install to transaxle (Fig.
126).
(46) Using tool 5058, compress 2/4 clutch return
spring just enough to install snap ring (Fig. 127).
(47) Install snap ring.
(48) Set up dial indicator as shown in (Fig. 128)
and measure 2/4 clutch clearance. Press down on
clutch pack with finger and zero dial indicator. 2/4
clutch
pack
clearance
is
0.76-2.64
mm
(0.030-0.104 in.). Set up indicator and record mea-
surement in four (4) places. Take average of read-
ings. If clearance is outside this range, the clutch is
assembled improperly. There is no adjustment for
2/4 clutch clearance.
Fig. 125 Proper Orientation of 2/4 Clutch Retainer
and Spring
1 - NOTE POSITION
2 - RETURN SPRING
3 - 2/4 CLUTCH RETAINER
Fig. 126 2/4 Clutch Retainer
1 - 2/4 CLUTCH RETAINER
2 - 2/4 CLUTCH RETURN SPRING
Fig. 127 Install 2/4 Clutch Retainer Snap Ring
1 - TOOL 5058
2 - SCREWDRIVER
3 - SNAP RING
4 - 2/4 CLUTCH RETAINER
Fig. 128 Check 2/4 Clutch Clearance
1 - DIAL INDICATOR
2 - HOOK TOOL
3 - DIAL INDICATOR TIP TOOL 6268
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40TE AUTOMATIC TRANSAXLE
21 - 85
40TE AUTOMATIC TRANSAXLE (Continued)
(49) Install rear sun gear and #7 needle bearing
(Fig. 130).
NOTE: The number seven needle bearing 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 (Fig. 129). A small amount of petrola-
tum can be used to hold the bearing to the rear sun
gear.
(50) Install front carrier/rear annulus assembly
and #6 needle bearing (Fig. 131).
(51) Install front sun gear assembly and #4 thrust
washer (Fig. 132).
Fig. 129 Number 7 Bearing
1 - #7 NEEDLE BEARING
2 - REAR SUN GEAR
Fig. 130 Install Rear Sun Gear and #7 Needle
Bearing
1 - #7 NEEDLE BEARING
2 - REAR SUN GEAR
Fig. 131 Install 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).
Fig. 132 Install Front Sun Gear Assembly
1 - FRONT SUN GEAR ASSEMBLY
2 - #4 THRUST WASHER (FOUR TABS)
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40TE AUTOMATIC TRANSAXLE (Continued)
(52) DETERMINING
#4
THRUST
PLATE
THICKNESS / INPUT SHAFT END PLAY:
(a) Select the thinnest #4 thrust plate thickness
and install to input clutch assembly (Fig. 133). Use
petrolatum to retain.
(b) Install input clutch assembly into position
and verify that it is completely seated by viewing
through input speed sensor hole. If view through
input speed sensor hole is not as shown in (Fig.
134), the input clutch assembly is not seated prop-
erly.
(c) Remove oil pump o-ring (Fig. 135). Be sure
to reinstall oil pump o-ring after selecting the
proper #4 thrust plate.
(d) Install pump and gasket to transmission.
Install and torque bolts.
(e) Set up input shaft for measurement with
Indicator Set C3339 and End Play Set 8266 as
shown in (Fig. 136).
(f) Measure the input shaft end play with the
transaxle in the vertical position. Input shaft end
play must be within 0.005 to 0.025 inch. For
example, if end play reading is 0.055 inch, select
No. 4 Thrust Plate which is 0.071 to 0.074 thick.
This should provide an input shaft end play read-
ing of 0.020 inch which is within specifications.
(g) Refer to the No. 4 thrust plate chart to select
the proper No. 4 thrust plate:
Fig. 133 Select Thinnest No. 4 Thrust Plate
1 - OVERDRIVE SHAFT ASSEMBLY
2 - #4 THRUST PLATE (SELECT)
3 - 3 DABS OF PETROLATUM FOR RETENTION
Fig. 134 View Through Input Speed Sensor Hole
1 - INPUT CLUTCH RETAINER
2 - INPUT SPEED SENSOR HOLE
3 - OIL COOLER FITTINGS
Fig. 135 Remove Oil Pump O-Ring
1 - OIL PUMP ASSEMBLY
2 - O-RING
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40TE AUTOMATIC TRANSAXLE
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40TE AUTOMATIC TRANSAXLE (Continued)
NO. 4 THRUST PLATE CHART
PART NUMBER
THICKNESS
4431665AB
1.60mm (0.063 in.)
3836237AB
1.73mm (0.068 in.)
4431666AB
1.80mm (0.071 in.)
3836238AB
1.96mm (0.077 in.)
4431667AB
2.03mm (0.080 in.)
3836239AB
2.16mm (0.085 in.)
4431668AB
2.24mm (0.088 in.)
3836240AB
2.39mm (0.094 in.)
4431669AB
2.46mm (0.097 in.)
3836241AB
2.62mm (0.103 in.)
4446670AB
2.67mm (0.105 in.)
4446671AB
2.90mm (0.114 in.)
(53) Install input clutch assembly (Fig. 137).
(54) Install #1 caged needle bearing (Fig. 138).
CAUTION:
The
cooler
bypass
valve
must
be
replaced if transaxle failure has occurred. Do not
attempt to reuse or clean old valve.
Fig. 136 Measure Input Shaft End Play Using Tool
8266—Typical
1 - TOOL 8266–8
2 - TOOL 8266–2
3 - TOOL C-3339
Fig. 137 Install Input Clutch Assembly
1 - INPUT CLUTCH ASSEMBLY
2 - #4 THRUST WASHER
Fig. 138 Install No. 1 Caged Needle Bearing
1 - #1 CAGED NEEDLE BEARING
2 - NOTE: TANGED SIDE OUT
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40TE AUTOMATIC TRANSAXLE
JR
40TE AUTOMATIC TRANSAXLE (Continued)
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