Dodge Durango (DN). Manual — part 99

ASSEMBLY

Do not allow dirt, grease, or foreign material to

enter the case or transmission components during
assembly. Keep the transmission case and compo-
nents clean. Also make sure the tools and workbench
area used for reassembly operations are equally
clean.

Shop towels used for wiping off tools and your

hands must be made from lint free materials. Lint
will stick to transmission parts and could interfere
with valve operation or even restrict fluid passages.

Lubricate transmission clutch and gear compo-

nents with Mopar

t ATF Plus 3, type 7176, during

reassembly. Soak clutch discs in transmission fluid
before installation.

Use Mopar

t Door Ease, or Ru-Glyde on piston

seals and O-rings to ease installation. Petroleum jelly
can also be used to lubricate and hold thrust washers
and plates in position during assembly.

Do not use chassis grease, bearing grease,

white grease, or similar lubricants on any part.
These types of lubricants can eventually block or
restrict fluid passages and valve operation. Use
petroleum jelly only.

Do not force parts into place. The transmission

components and sub-assemblies are easily installed
by hand when properly aligned. If a part seems dif-
ficult to install, it is either misaligned or incorrectly
assembled. Verify that thrust washers, thrust plates
and seal rings are correctly positioned.

The planetary geartrain, front/rear clutch assem-

blies and oil pump are all much easier to install
when the transmission case is upright. Either tilt the
case upward with wood blocks, or cut a hole in the
bench large enough for the intermediate shaft and
rear support. Then lower the shaft and support into
the hole and support the rear of the case directly on
the bench.

FRONT/REAR SERVO

(1) Lubricate rear servo piston seal with Mopar

t

Door Ease or ATF Plus 3. Lubricate servo bore in
case with ATF Plus 3.

(2) Install rear servo piston in case. Position piston

at slight angle to bore and insert piston with twisting
motion (Fig. 172).

(3) Install rear servo spring and retainer in case

bore (Fig. 173). Be sure spring is seated on piston.

(4) Compress rear servo piston with C-clamp or

Valve Spring Compressor C-3422-B and install servo
piston snap ring (Fig. 174).

(5) Lubricate front servo piston components and

servo bore in case with transmission fluid.

(6) Install front servo piston in bore. Carefully

“run” small, suitable tool around piston ring to press
it back into groove and ease installation (Fig. 175).

Rotate piston into bore at same time. Rock piston
slightly to ease piston ring past snap ring groove and
into bore.

(7) Bottom front servo piston in bore and install

servo spring.

(8) Install front servo piston rod guide as follows:

(a) Place Tool SP-5560 (or similar size tool) on

guide and position C-clamp on tool and case (Fig.
176).

(b) Slowly compress rod guide while simulta-

neously easing seal ring into bore with suitable
tool.
(9) Install rod guide snap ring (Fig. 176).

Fig. 172 Rear Servo Piston

1 – REAR SERVO PISTON

Fig. 173 Rear Servo Piston Spring And Retainer

1 – PISTON SPRING
2 – REAR SERVO PISTON
3 – SPRING RETAINER

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DISASSEMBLY AND ASSEMBLY (Continued)

OVERRUNNING CLUTCH, REAR BAND, AND LOW-REVERSE
DRUM

(1) Install overrunning clutch components if not

yet installed.

(2) Position rear band and link in case (Fig. 177).
(3) Install low-reverse drum (Fig. 178). Slide drum

through rear band, onto piston retainer hub and into
engagement with overrunning clutch and race.

(4) Install thrust washer in low-reverse drum spot-

face (Fig. 179). Use petroleum jelly to hold washer in
place.

(5) Install snap ring that secures low-reverse drum

to piston retainer hub (Fig. 179).

(6) Insert band reaction pin part way into case and

band link (Fig. 180).

Fig. 174 Rear Servo Snap Ring

1 – TOOL C-4470
2 – C-CLAMP
3 – REAR SERVO SPRING RETAINER
4 – RETAINER SNAP RING

Fig. 175 Front Servo Piston

1 – USE SUITABLE TOOL TO HELP SEAT PISTON RING
2 – FRONT SERVO PISTON

Fig. 176 Front Servo Rod Guide And Snap Ring

1 – C-CLAMP
2 – ROD GUIDE
3 – SMALL SCREWDRIVER
4 – ROD GUIDE SNAP RING
5 – TOOL SP-5560

Fig. 177 Rear Band And Link

1 – REAR BAND
2 – BAND LINK

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DISASSEMBLY AND ASSEMBLY (Continued)

(7) Install rear band adjusting lever, reaction lever,

and strut (Fig. 181). Be sure levers and strut are
aligned and engaged before seating band reaction pin
in case.

PLANETARY GEARTRAIN, FRONT/REAR CLUTCH, AND
FRONT BAND

(1) Remove Alignment Shaft 6227-2, if installed

previously.

(2) Install assembled intermediate shaft and plan-

etary geartrain (Fig. 182). Support shaft carefully
during installation. Do not allow shaft bearing/
bushing

surfaces

to

become

nicked

or

scratched.

Fig. 178 Low-Reverse Drum

1 – LOW-REVERSE DRUM
2 – REAR BAND LINK
3 – HUB OF OVERDRIVE PISTON RETAINER

Fig. 179 Low-Reverse Drum Snap Ring

1 – LOW-REVERSE DRUM
2 – TABBED WASHER
3 – SNAP RING

Fig. 180 Rear Band Reaction Pin

1 – REACTION PIN
2 – BAND LINK
3 – REAR BAND
4 – O-RINGS

Fig. 181 Rear Band Levers And Strut

1 – ADJUSTING SCREW AND NUT
2 – ADJUSTING LEVER
3 – REACTION LEVER
4 – STRUT

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DISASSEMBLY AND ASSEMBLY (Continued)

(3) Lubricate intermediate shaft thrust plate with

petroleum jelly and install plate on shaft pilot hub
(Fig. 183).

(4) Check input shaft front seal rings, fiber thrust

washer and rear seal ring (Fig. 184). Be ends of rear
seal ring are hooked together and diagonal cut ends
of front seal rings are firmly seated against each
other as shown. Lubricate seal rings with petroleum
jelly after checking them.

(5) Assemble front and rear clutches (Fig. 185).

Align lugs on front clutch discs. Mount front clutch
on rear clutch. Turn front clutch retainer back and

forth until front clutch discs are fully seated on rear
clutch splined hub.

(6) Install intermediate shaft thrust washer in hub

of rear clutch retainer (Fig. 186). Use petroleum jelly
to hold washer in place. Position washer so grooves
are facing outward. Washer only fits one way in
clutch retainer hub.

(7) Place transmission case in upright position, or

place blocks under front end of transmission repair
stand to tilt case rearward. This makes it easier to
install front/rear clutch assembly.

(8) Align discs in rear clutch. Then install and

engage assembly in front planetary and driving shell
(Fig. 187). Turn clutch retainers back and forth until
both clutches are seated.

(9) Position front band lever in case and over servo

rod guide. Then install front band lever pin in case
and slide it through lever.

(10) Coat threads of front band pin access plug

with sealer and install it in case. Tighten plug to 17
N·m (13 ft. lbs.) torque.

(11) Slide front band over front clutch retainer and

install front band strut and anchor (Fig. 188).

(12) Tighten front band adjusting screw until band

is tight on clutch retainer. This will hold clutches in
place while oil pump is being installed. Verify that
front/rear clutch assembly is still properly
seated before tightening band.

Fig. 182 Intermediate Shaft And Planetary Geartrain

1 – INTERMEDIATE SHAFT AND PLANETARY GEAR TRAIN

ASSEMBLY

Fig. 183 Intermediate Shaft Thrust Plate

1 – SHAFT THRUST PLATE
2 – INTERMEDIATE SHAFT PILOT HUB

Fig. 184 Input Shaft Seal Ring And Thrust Washer

1 – FRONT SEAL RINGS
2 – INPUT SHAFT
3 – REAR SEAL RING
4 – THRUST WASHER

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DISASSEMBLY AND ASSEMBLY (Continued)