Dodge Durango (DN). Manual — part 100

Fig. 185 Assembling Front And Rear Clutches

1 – FRONT CLUTCH ASSEMBLY
2 – REAR CLUTCH ASSEMBLY
3 – REAR CLUTCH SPLINED HUB

Fig. 186 Intermediate Shaft Thrust Washer

1 – BE SURE WASHER GROOVES FACE OUT AS SHOWN
2 – REAR CLUTCH RETAINER HUB
3 – OUTPUT SHAFT THRUST WASHER

Fig. 187 Front/Rear Clutch Assemblies

1 – FRONT AND REAR CLUTCH ASSEMBLIES

Fig. 188 Front Band And Linkage

1 – LEVER
2 – STRUT
3 – ANCHOR
4 – FRONT BAND

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DISASSEMBLY AND ASSEMBLY (Continued)

OIL PUMP

(1) Install oil pump Pilot Studs C-3288-B in case

(Fig. 189).

(2) Install new oil pump gasket on pilot studs and

seat it in case. Be sure gasket is properly aligned
with fluid passages in case (Fig. 189).

(3) Coat front clutch thrust washer with petroleum

jelly to hold it in place. Then install washer over
reaction shaft hub and seat it on pump (Fig. 190).

CAUTION: The thrust washer bore (I.D.), is cham-
fered on one side. Make sure the chamfered side is
installed so it faces the pump.

(4) Check seal rings on reaction shaft support. Be

sure rings are hooked together correctly. Also be sure
fiber thrust washer is in position (Fig. 191). Use
extra petroleum jelly to hold washer in place if nec-
essary.

(5) Lubricate

oil

pump

seals

with

petroleum

Mopar

t ATF Plus 3, type 7176.

(6) Mount oil pump on pilot studs and slide pump

into case opening (Fig. 192). Work pump into case
by hand. Do not use a mallet or similar tools to
seat pump.

(7) Remove pilot studs and install oil pump bolts.

Tighten pump bolts alternately and evenly to fully
seat pump in case. Then final-tighten pump bolts to
20 N·m (15 ft. lbs.) torque.

(8) Verify correct installation. Rotate input and

intermediate shafts and check for bind. If bind exists,
components are either mis-assembled, or not seated.
Disassemble and correct as necessary before proceed-
ing.

Fig. 189 Oil Pump Gasket And Pilot Studs

1 – OIL PUMP GASKET
2 – PILOT STUDS C-3288–B

Fig. 190 Front Clutch Thrust Washer

1 – THRUST WASHER
2 – CHAMFERED SIDE OF WASHER BORE GOES TOWARD

PUMP

Fig. 191 Reaction Shaft Seal Ring And Thrust

Washer

1 – SEAL RINGS
2 – REACTION SHAFT SUPPORT
3 – THRUST WASHER (FIBER)

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DISASSEMBLY AND ASSEMBLY (Continued)

INPUT SHAFT END PLAY CHECK

NOTE: Overdrive unit must be installed in order to
correctly measure the input shaft end-play.

(1) Measure input shaft end play (Fig. 193).

NOTE: If end play is incorrect, transmission is
incorrectly assembled, or reaction shaft thrust
washer is incorrect. The reaction shaft thrust
washer is selective.

(a) Attach Adapter 8266–5 to Handle 8266–8.
(b) Attach

dial

indicator

C-3339

to

Handle

8266–8.

(c) Install the assembled tool onto the input

shaft of the transmission and tighten the retaining
screw on Adapter 8266–5 to secure it to the input
shaft.

(d) Position the dial indicator plunger against a

flat spot on the oil pump and zero the dial indica-
tor.

(e) Move input shaft in and out and record read-

ing. End play should be 0.86 - 2.13 mm (0.034 -
0.084 in.). Adjust as necessary.

ACCUMULATOR, VALVE BODY, OIL PAN, AND TORQUE
CONVERTER

(1) Install accumulator inner spring, piston and

outer spring (Fig. 194).

(2) Verify that park/neutral position switch has

not been installed in case. Valve body can not be
installed if switch is in position.

(3) Install new valve body manual shaft seal in

case (Fig. 195). Lubricate seal lip and manual shaft
with petroleum jelly. Start seal over shaft and into
case. Seat seal with 15/16 inch, deep well socket.

(4) Install valve body as follows:

(a) Start park rod into park pawl. If rod will not

slide past park pawl, pawl is engaged in park gear.
Rotate overdrive output shaft with suitable size 12
point socket; this will free pawl and allow rod to
engage.

(b) Align and seat valve body on case. Be sure

manual lever shaft and overdrive connector are
fully seated in case.

(c) Install and start all valve body attaching

bolts by hand. Then tighten bolts evenly, in a diag-
onal pattern to 12 N·m (105 in. lbs.) torque. Do
not overtighten valve body bolts. This could
result in distortion and cross leakage after
installation.
(5) Install new filter on valve body. Tighten filter

screws to 4 N·m (35 in. lbs.).

(6) Install seal on park/neutral position switch.

Then install and tighten switch to 34 N·m (25 ft.
lbs.).

Fig. 192 Oil Pump

1 – SEAT OIL PUMP IN CASE BY HAND
2 – REMOVE PILOT STUDS WHEN PUMP IS SEATED

Fig. 193 Checking Input Shaft End Play

1 – TOOL 8266-8
2 – TOOL 8266-5
3 – TOOL C-3339

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DISASSEMBLY AND ASSEMBLY (Continued)

CAUTION: If the condition of the transmission
before the overhaul procedure caused excessive
metallic or fiber contamination in the fluid, replace
the torque converter and reverse flush the cooler(s)
and cooler lines. Fluid contamination and transmis-
sion failure can result if not done.

(7) Install torque converter. Use C-clamp or metal

strap to hold converter in place for installation.

BAND ADJUSTMENT AND FINAL

(1) Adjust front and rear bands as follows:

(a) Loosen locknut on each band adjusting screw

4-5 turns.

(b) Tighten both adjusting screws to 8 N·m (72

in. lbs.).

(c) Back off front band adjusting screw 2-7/8

turns.

(d) Back off rear band adjusting screw 2 turns.
(e) Hold each adjusting screw in position and

tighten locknut to 34 N·m (25 ft. lbs.) torque.

(2) Install magnet in oil pan. Magnet seats on

small protrusion at corner of pan.

(3) Position new oil pan gasket on case and install

oil pan. Tighten pan bolts to 17 N·m (13 ft. lbs.).

(4) Install throttle valve and shift selector levers

on valve body manual lever shaft.

(5) Apply small quantity of dielectric grease to ter-

minal pins of solenoid case connector and neutral
switch.

(6) Fill

transmission

with

recommended

fluid.

Refer to Service Procedures section of this group.

OVERRUNNING CLUTCH CAM/OVERDRIVE
PISTON RETAINER

NOTE: TO SERVICE THE OVERRUNNING CLUTCH
CAM AND THE OVERDRIVE PISTON RETAINER,
THE TRANSMISSION GEARTRAIN AND OVERDRIVE
UNIT MUST BE REMOVED FROM THE TRANSMIS-
SION.

DISASSEMBLY

(1) Remove the overdrive piston (Fig. 196).
(2) Remove the overdrive piston retainer bolts.
(3) Remove overdrive piston retainer.
(4) Remove case gasket.
(5) Tap old cam out of case with pin punch. Insert

punch through bolt holes at rear of case (Fig. 197).
Alternate position of punch to avoid cocking cam dur-
ing removal.

(6) Clean clutch cam bore and case. Be sure to

remove all chips/shavings generated during cam
removal.

Fig. 194 Accumulator Piston And Springs

1 – ACCUMULATOR PISTON
2 – OUTER SPRING
3 – INNER SPRING

Fig. 195 Manual Lever Shaft Seal

1 – 15/16

88

SOCKET

2 – SEAL

Fig. 196 Overdrive Piston Removal

1 – OVERDRIVE CLUTCH PISTON
2 – INTERMEDIATE SHAFT
3 – SELECTIVE SPACER
4 – PISTON RETAINER

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DISASSEMBLY AND ASSEMBLY (Continued)