Dodge Ram Truck 1500-2500-3500. Manual — part 1662

25. Install the number 8 thrust bearing (1) inside the reaction carrier with the outer race against the reaction plan-

etary carrier (3).

26. Install the reaction planetary gear set and the number 9 thrust bearing (2), with the inner race against the reac-

tion planetary carrier (3), into the transmission case.

27. Install the flat 2C clutch snap-ring into the transmission case.

28. Install the reaction sun gear (4) into the reaction planetary gear set. Make sure the small shoulder is facing the

front of the transmission.

29. Install the number 7 thrust bearing (5) onto the reaction sun gear (4) with the inner race against the sun gear.

30. Install the output shaft selective thrust plate (2)

onto the reaction annulus with the oil grooves fac-
ing the annulus gear and the lugs (1) and notches
aligned as shown.

31. Install the number 6 thrust bearing (7) against the

output shaft selective thrust plate (6) with the flat
side against the thrust plate and the raised tabs
on the inner race facing the front of the transmis-
sion.

32. Install the reaction annulus (8) into the reaction

planetary gear set.

33. Install the 4C retainer/bulkhead (2) into the trans-

mission case. Make sure that the oil feed holes
are pointing toward the valve body area. Rotate
the reaction annulus during the installation of the
4C retainer/bulkhead to ease installation.

34. Install the 4C retainer/bulkhead tapered snap-ring

(1) into the transmission case with the taper
toward the front of the case. Make sure that the
open ends of the snap-ring are located in the
case opening toward the valve body area.

35. Air check the 2C and 4C clutch operation.

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36. Using Alignment Plate 8261 (1), Adapter 8266-17

from End-Play Tool Set 8266 (2) and Dial Indica-
tor C-3339 (3), measure and record the output
shaft end-play. The correct output shaft end-play
is 0.22-0.55 mm (0.009-0.021 in.). Adjust as nec-
essary. Install the chosen output shaft selective
thrust plate and re-measure end-play to verify
selection.

37. Apply a bead of RTV silicone and install the

extension/adapter housing onto the transmission
case.

38. Install and torque the bolts to hold the extension/

adapter housing onto the transmission case. The
correct torque is 54 N·m (40 ft.lbs.).

39. Install the number 5 thrust bearing (1) and selec-

tive thrust plate (2) onto the 4C retainer/bulkhead.
Be sure that the outer race of the bearing is
against the thrust plate.

40. Install the input clutch assembly (3) into the trans-

mission case. Make sure that the input clutch
assembly is fully installed by performing a visual
inspection through the input speed sensor hole. If
the tone wheel teeth on the input clutch assembly
are centered in the hole, the assembly is fully
installed.

41. Install the number 1 thrust bearing (4) with the

outer race up in the pocket of the input clutch
assembly.

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42. Install the oil pump (2) into the transmission case.

43. Install the bolts (1) to hold the oil pump into the

transmission case. Tighten the oil pump bolts to
28 N·m (250 in.lbs.).

44. Using Adapter 8266-1 from End-Play Tool Set

8266 (1) and Dial Indicator C-3339 (2), measure
and record the input shaft end-play. The correct
end-play is 0.46-0.89 mm (0.018-0.035 in.). Adjust
as necessary. Install the chosen thrust plate on
the number 5 thrust bearing and re-measure end-
play to verify selection.

NOTE: When measuring the input shaft end-play,
two

(

stops

(

will be felt. When the input shaft is

pushed inward and the dial indicator zeroed, the
first

(

stop

(

felt when the input shaft is pulled out-

ward is the movement of the input shaft in the
input clutch housing hub. This value should not
be included in the end-play measured value and
therefore must be recorded and subtracted from
the dial indicator reading.

45. Install the transmission front cover (2) into the

transmission case.

46. Install the outer snap-ring (3) to hold the transmis-

sion front cover (2) into the transmission case.

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47. Partially install the inner transmission front cover snap-ring (1) onto the oil pump.

48. Using Installer 8255 (1), install the inner transmis-

sion front cover snap-ring (2) the remainder of the
way onto the oil pump.

49. Install the valve body. Verify that the pin on the

manual lever has properly engaged the TRS
selector plate. Tighten the valve body to transmis-
sion case bolts (1) to 12 N·m (105 in.lbs.).

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