Dodge Durango (DN). Manual — part 129
(15) Using Spring Compressor 8251, compress the
UD/OD balance piston and remove the snap-ring
from the input clutch hub (Fig. 99).
(16) Remove the UD/OD balance piston and piston
return spring from the input clutch retainer (Fig.
100).
(17) Remove the underdrive piston from the input
clutch retainer (Fig. 100).
NOTE: Both the UD/OD balance piston and the
underdrive piston have seals molded onto them. If
the seal is damaged, do not attempt to install a new
seal onto the piston. The piston/seal must be
replaced as an assembly.
(18) Remove the input clutch retainer tapered
snap-ring.
(19) Separate input clutch retainer from input
clutch hub.
(20) Separate OD/reverse piston from input clutch
hub retainer (Fig. 100).
(21) Remove all seals and o-rings from the input
shaft and input hub. The o-rings on the input hub
are color coded. Be sure to make note of which o-ring
belongs in which location.
ASSEMBLY
(1) Install all new seals and o-rings onto the input
shaft and input hub. The o-rings on the input hub
are color coded. Be sure to install the correct o-ring
in the correct location.
(2) Lubricate all seals with Mopar
t ATF+3, type
7176 prior to installation.
(3) Assemble the OD/reverse piston onto the input
clutch hub (Fig. 100).
Fig. 98 Input Clutch Assembly—Part I
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DISASSEMBLY AND ASSEMBLY (Continued)
(4) Assemble the input clutch retainer onto the
input clutch hub.
(5) Install the input clutch retainer tapered snap-
ring with tapered side up onto the input clutch hub.
(6) Install Piston Guides 8504 into the input clutch
retainer (Fig. 101) and onto the input clutch hub to
guide the inner and outer underdrive piston seals
into position.
(7) Install the underdrive piston into the input
clutch retainer and over the input clutch hub (Fig.
100).
(8) Install the UD/OD balance piston return spring
pack into the input clutch retainer.
(9) Install Piston Guide 8252 into the input clutch
retainer (Fig. 102) to guide the UD/OD balance pis-
ton seal into position inside the underdrive piston.
(10) Install the UD/OD balance piston into the
input clutch retainer and the underdrive piston.
(11) Using Spring Compressor 8251, compress the
UD/OD return spring pack and secure the piston in
place with the snap-ring (Fig. 103).
(12) Install the underdrive clutch pack into the
input clutch retainer (Fig. 100).
(13) Install the UD/OD reaction plate lower flat
snap-ring (Fig. 98). The correct snap-ring can be
identified by the two tabbed ears.
Fig. 100 Input Clutch Assembly—Part II
Fig. 99 Compressing UD/OD Balance Piston Using
Tool 8251
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DISASSEMBLY AND ASSEMBLY (Continued)
(14) Install the UD/OD reaction plate into the
input clutch retainer. The reaction plate is to be
installed with the big step down. The reaction plate
is also selectable and should be changed to achieve
the correct clutch clearances.
(15) Install
the
UD/OD
reaction
plate
upper
tapered snap-ring with tapered side up.
(16) Install the input clutch assembly into Input
Clutch Pressure Fixture 8260 (Fig. 104). Mount a
dial indicator to the assembly, push down on the
clutch discs and zero the indicator against the under-
drive clutch discs (Fig. 105). Apply 20 psi of air pres-
sure to the underdrive clutch and record the dial
indicator reading. Measure and record UD clutch
pack measurement in four (4) places, 90° apart. Take
average of four measurements and compare with UD
clutch pack clearance specification. The correct clutch
clearance is 0.76–1.16 mm (0.030–0.063 in.). Adjust
as necessary. Install the chosen reaction plate and re-
measure to verify selection.
(17) Install the overdrive clutch pack into the
input clutch retainer (Fig. 98). The overdrive steel
separator plates can be identified by the lack of the
half-moon cuts in the locating tabs.
Fig. 101 Install Underdrive Piston Using Tool 8504
Fig. 102 Install Balance Piston Using Tool 8252
Fig. 103 Compressing UD/OD Balance Piston Using
Tool 8251
Fig. 104 Input Clutch Assembly Mounted on Tool
8260
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DISASSEMBLY AND ASSEMBLY (Continued)
(18) Install the overdrive clutch wavy snap-ring
with the two tabbed ears into the input clutch
retainer.
(19) Install the OD/reverse reaction plate into the
input clutch retainer. The reaction plate is non-direc-
tional (Fig. 98).
(20) Install the OD/reverse reaction plate flat
snap-ring into the input clutch retainer.
(21) Mount a dial indicator to the assembly and
zero the indicator against the OD/reverse reaction
plate (Fig. 106). Apply 20 psi of air pressure to the
overdrive clutch and record the dial indicator read-
ing. Measure and record OD clutch pack measure-
ment in four (4) places, 90° apart. Take average of
four measurements and compare with OD clutch
pack clearance specification.Verify that the clutch
clearance is 1.016–1.65 mm (0.040–0.065 in.).
(22) Install the reverse clutch pack into the input
clutch retainer (Fig. 98).
(23) Install the reverse reaction plate into the
input clutch retainer.
(24) Install the reverse reaction plate selective
snap-ring into the input clutch retainer. Pull up on
the reaction plate to ensure the plate is properly
seated.
(25) Mount a dial indicator to the assembly, push
down on the clutch discs and zero the indicator
against the reverse clutch discs (Fig. 107). Apply 20
psi of air pressure to the reverse clutch and record
the dial indicator reading. Measure and record
Reverse clutch pack measurement in four (4) places,
90° apart. Take average of four measurements and
compare with Reverse clutch pack clearance specifi-
cation. The correct clutch clearance is 0.81–1.24 mm
(0.032–0.049 in.). Adjust as necessary. Install the cho-
sen snap-ring and re-measure to verify selection.
(26) Remove the reverse clutch pack from the
input clutch retainer.
(27) Install the number 2 bearing onto the under-
drive hub with flat side up/forward with petroleum
jelly.
(28) Install the underdrive hub into the input
clutch retainer.
(29) Install the number 3 bearing into the over-
drive hub with the flat side up/forward with petro-
leum jelly.
(30) Install the overdrive hub into the input clutch
retainer.
(31) Install the number 4 bearing into the reverse
hub with flat side up/forward with petroleum jelly.
(32) Install the reverse hub into the input clutch
retainer.
Fig. 105 Measuring UD Clutch Clearance
Fig. 106 Measuring OD Clutch Clearance
Fig. 107 Measuring Reverse Clutch Clearance
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DISASSEMBLY AND ASSEMBLY (Continued)
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