Dodge Durango (DN). Manual — part 103

Fig. 216 Front Clutch Retainer Bushing

Replacement Tools

1 – SPECIAL TOOL C-4171
2 – SPECIAL TOOL SP-3629
3 – SPECIAL TOOL SP-5511
4 – SPECIAL TOOL C-4171
5 – FRONT CLUTCH RETAINER

Fig. 217 Front Clutch Spring Position

1 – 9 SPRING CLUTCH

Fig. 218 Typical Method Of Measuring Front Clutch

Pack Clearance

1 – FEELER GAUGE
2 – WAVED SNAP RING
3 – FEELER GAUGE

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DISASSEMBLY AND ASSEMBLY (Continued)

REAR CLUTCH

DISASSEMBLY

(1) Remove fiber thrust washer from forward side

of clutch retainer.

(2) Remove input shaft front/rear seal rings.
(3) Remove selective clutch pack snap ring (Fig. 219).
(4) Remove top pressure plate, clutch discs, steel

plates, bottom pressure plate and wave snap ring
and wave spring (Fig. 219).

(5) Remove clutch piston with rotating motion.
(6) Remove and discard piston seals.
(7) Remove input shaft snap-ring (Fig. 220). It

may be necessary to press the input shaft in slightly
to relieve tension on the snap-ring

(8) Press input shaft out of retainer with shop

press and suitable size press tool. Use a suitably
sized press tool to support the retainer as close to the
input shaft as possible.

Fig. 219 Rear Clutch Components

1 – PISTON SPRING
2 – REAR CLUTCH PISTON
3 – CLUTCH PISTON SEALS
4 – OUTPUT SHAFT THRUST WASHER (METAL)
5 – INPUT SHAFT SNAP RING
6 – REAR CLUTCH RETAINER
7 – INPUT SHAFT
8 – REAR CLUTCH THRUST WASHER (FIBER)
9 – CLUTCH PACK SNAP RING (SELECTIVE)

10 – TOP PRESSURE PLATE
11 – CLUTCH DISCS (4)
12 – BOTTOM PRESSURE PLATE
13 – WAVE SPRING
14 – CLUTCH PLATES (3)
15 – RETAINER SEAL RING
16 – SHAFT REAR SEAL RING (PLASTIC)
17 – SHAFT FRONT SEAL RING (TEFLON)

Fig. 220 Removing/Installing Input Shaft Snap-Ring

1 – REAR CLUTCH RETAINER
2 – INPUT SHAFT SNAP RING
3 – SNAP RING PLIERS

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DISASSEMBLY AND ASSEMBLY (Continued)

ASSEMBLY

(1) Soak clutch discs in transmission fluid while

assembling other clutch parts.

(2) Install new seal rings on clutch retainer hub

and input shaft if necessary (Fig. 221).

(a) Be sure clutch hub seal ring is fully seated in

groove and is not twisted.
(3) Lubricate splined end of input shaft and clutch

retainer with transmission fluid. Then press input
shaft into retainer (Fig. 223). Use a suitably sized
press tool to support retainer as close to input shaft
as possible.

(4) Install input shaft snap-ring (Fig. 220).
(5) Invert retainer and press input shaft in oppo-

site direction until snap-ring is seated.

(6) Install new seals on clutch piston. Be sure lip

of each seal faces interior of clutch retainer.

(7) Lubricate lip of piston seals with generous quan-

tity of Mopar

t Door Ease. Then lubricate retainer hub

and bore with light coat of transmission fluid.

(8) Install clutch piston in retainer. Use twisting

motion to seat piston in bottom of retainer. A thin
strip of plastic (about 0.020” thick), can be used to
guide seals into place if necessary.

CAUTION: Never push the clutch piston straight in.
This will fold the seals over causing leakage and
clutch slip. In addition, never use any type of metal
tool to help ease the piston seals into place. Metal
tools will cut, shave, or score the seals.

Fig. 221 Rear Clutch Retainer And Input Shaft Seal

Ring Installation

1 – REAR CLUTCH RETAINER HUB SEAL RING
2 – INPUT SHAFT SEAL RINGS

Fig. 222 Input Shaft Seal Ring Identification

1 – PLASTIC REAR SEAL RING
2 – TEFLON FRONT SEAL RING (SQUEEZE RING TOGETHER

SLIGHTLY BEFORE INSTALLATION FOR BETTER FIT)

Fig. 223 Pressing Input Shaft Into Rear Clutch

Retainer

1 – INPUT SHAFT
2 – REAR CLUTCH RETAINER
3 – PRESS RAM

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DISASSEMBLY AND ASSEMBLY (Continued)

(9) Install piston spring in retainer and on top of

piston (Fig. 224). Concave side of spring faces down-
ward (toward piston).

(10) Install wave spring in retainer (Fig. 224). Be

sure spring is completely seated in retainer groove.

(11) Install

bottom

pressure

plate

(Fig.

219).

Ridged side of plate faces downward (toward piston)
and flat side toward clutch pack.

(12) Install first clutch disc in retainer on top of bot-

tom pressure plate. Then install a clutch plate followed
by a clutch disc until entire clutch pack is installed (4
discs and 3 plates are required) (Fig. 219).

(13) Install top pressure plate.
(14) Install selective snap ring. Be sure snap ring

is fully seated in retainer groove.

(15) Using a suitable gauge bar and dial indicator,

measure clutch pack clearance (Fig. 225).

(a) Position gauge bar across the clutch drum

with the dial indicator pointer on the pressure
plate (Fig. 225).

(b) Using two small screw drivers, lift the pres-

sure plate and release it.

(c) Zero the dial indicator.
(d) Lift the pressure plate until it contacts the

snap-ring and record the dial indicator reading.
Clearance should be 0.635 - 0.914 mm (0.025 -

0.036 in.). If clearance is incorrect, steel plates, discs,
selective snap ring and pressure plates may have to
be changed.

The selective snap ring thicknesses are:
• .107–.109 in.

• .098–.100 in.

• .095–.097 in.

• .083–.085 in.

• .076–.078 in.

• .071–.073 in.

• .060–.062 in.
(16) Coat rear clutch thrust washer with petro-

leum jelly and install washer over input shaft and
into clutch retainer (Fig. 226). Use enough petroleum
jelly to hold washer in place.

(17) Set rear clutch aside for installation during

final assembly.

Fig. 224 Piston Spring/Wave Spring Position

1 – REAR CLUTCH RETAINER
2 – PISTON SPRING
3 – WAVE SPRING
4 – CLUTCH PISTON

Fig. 225 Checking Rear Clutch Pack Clearance

1 – DIAL INDICATOR
2 – PRESSURE PLATE
3 – SNAP RING
4 – STAND
5 – REAR CLUTCH
6 – GAUGE BAR

Fig. 226 Installing Rear Clutch Thrust Washer

1 – REAR CLUTCH RETAINER
2 – REAR CLUTCH THRUST WASHER

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DISASSEMBLY AND ASSEMBLY (Continued)