Dodge Durango (DN). Manual — part 102

Fig. 209 Oil Pump And Reaction Shaft Components

1 – OIL SEAL
2 – VENT BAFFLE
3 – OIL PUMP BODY
4 – GASKET
5 – REACTION SHAFT SUPPORT
6 – SEAL RINGS

7 – BOLTS (6)
8 – #1 THRUST WASHER (SELECTIVE)
9 – INNER GEAR
10 – OUTER GEAR
11 – “O” RING

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DISASSEMBLY AND ASSEMBLY (Continued)

OIL PUMP BUSHING REMOVAL

(1) Position pump housing on clean, smooth sur-

face with gear cavity facing down.

(2) Remove bushing with Tool Handle C-4171 and

Bushing Remover SP-3550 (Fig. 210).

REACTION SHAFT SUPPORT BUSHING REMOVAL

(1) Assemble Cup Tool SP-3633, Nut SP-1191 and

Bushing Remover SP-5301 (Fig. 212).

(2) Hold cup tool firmly against reaction shaft.

Thread remover tool into bushing as far as possible
by hand.

(3) Using wrench, thread remover tool an addi-

tional 3-4 turns into bushing to firmly engage tool.

(4) Tighten tool hex nut against cup tool to pull

bushing from shaft. Clean all chips from shaft and
support after bushing removal.

ASSEMBLY

OIL PUMP BUSHING INSTALLATION

(1) Assemble Tool Handle C-4171 and Bushing

Installer SP-5118.

(2) Place bushing on installer tool and start bush-

ing into shaft.

(3) Tap bushing into place until Installer Tool

SP-5118 bottoms in pump cavity. Keep tool and bush-

ing square with bore. Do not allow bushing to become
cocked during installation.

(4) Stake pump bushing in two places with blunt

punch. Remove burrs from stake points with knife
blade (Fig. 211).

REACTION SHAFT SUPPORT BUSHING INSTALLATION

(1) Place reaction shaft support upright on a clean,

smooth surface.

(2) Assemble Bushing Installer Tools C-4171 and

SP-5302. Then slide new bushing onto installer tool
(Fig. 212).

(3) Start bushing in shaft. Tap bushing into shaft

until installer tool bottoms against support flange.

(4) Clean reaction shaft support thoroughly after

bushing replacement (to remove any chips).

(1) Lubricate pump gears with transmission fluid

and install them in pump body.

(2) Install thrust washer on reaction shaft support

hub. Lubricate washer with petroleum jelly or trans-
mission fluid before installation.

(3) If reaction shaft seal rings are being replaced,

install new seal rings on support hub. Lubricate seal
rings with transmission fluid or petroleum jelly after
installation. Squeeze each ring until ring ends are
securely hooked together.

CAUTION: The reaction shaft support seal rings
will break if overspread, or twisted. If new rings are
being installed, spread them only enough for instal-
lation. Also be very sure the ring ends are securely
hooked together after installation. Otherwise, the
rings will either prevent pump installation, or break
during installation.

Fig. 210 Oil Pump Bushing

1 – SPECIAL TOOL C-4171
2 – SPECIAL TOOL SP-3550
3 – BUSHING
4 – SPECIAL TOOL SP-5118
5 – SPECIAL TOOL C-4171
6 – PUMP HOUSING

Fig. 211 Staking-Deburring Oil Pump Bushing

1 – TWO STAKES
2 – NARROW BLADE
3 – BLUNT PUNCH

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DISASSEMBLY AND ASSEMBLY (Continued)

(4) Align and install reaction shaft support on

pump body.

(5) Install bolts attaching reaction shaft support to

pump. Tighten bolts to 20 N·m (175 in. lbs.) torque.

(6) Install new pump seal with Installer Tool

C-3860-A (Fig. 213). Use hammer or mallet to tap
seal into place.

(7) Install new O-ring on pump body. Lubricate oil

seal and O-ring with petroleum jelly.

(8) Cover pump assembly to prevent dust entry

and set aside for assembly installation.

FRONT CLUTCH

DISASSEMBLY

(1) Remove waved snap ring and remove reaction

plate, clutch plates and clutch discs.

(2) Compress clutch piston retainer and piston

springs with Compressor Tool C-3863-A (Fig. 214).

(3) Remove retainer snap ring and remove com-

pressor tool.

(4) Remove clutch piston springs (Fig. 215). Note

position of piston springs for assembly refer-
ence.

(5) Remove clutch piston from retainer with a

twisting motion.

(6) Remove and discard clutch piston inner and

outer seals.

(7) Assemble Tool Handle C-4171 and Bushing

Remover SP-3629 (Fig. 216).

(8) Insert remover tool in bushing and drive bush-

ing straight out of clutch retainer.

Fig. 212 Reaction Shaft Bushing

1 – SPECIAL TOOL SP-1191
2 – SPECIAL TOOL C-4171
3 – SPECIAL TOOL SP-3633
4 – SPECIAL TOOL SP-5301
5 – SPECIAL TOOL SP-5302
6 – BUSHING
7 – REACTION SHAFT
8 – BUSHING

Fig. 213 Oil Pump Seal

1 – SPECIAL TOOL C-3860–A
2 – PUMP BODY
3 – PUMP SEAL

Fig. 214 Removing Front Clutch Spring Retainer

Snap Ring

1 – SPECIAL TOOL C-3863–A
2 – SNAP RING

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DISASSEMBLY AND ASSEMBLY (Continued)

ASSEMBLY

(1) Mount Bushing Installer SP-5511 on tool han-

dle (Fig. 216).

(2) Slide new bushing onto installer tool and start

bushing into retainer.

(3) Tap new bushing into place until installer tool

bottoms against clutch retainer.

(4) Remove installer tools and clean retainer thor-

oughly.

(5) Soak clutch discs in transmission fluid.
(6) Install new inner and outer seals on clutch pis-

ton. Be sure seal lips face interior of retainer.

(7) Lubricate new inner and outer piston seals

with Ru-Glyde, or Mopar

t Door Ease.

(8) Install clutch piston in retainer. Use twisting

motion to seat piston in bottom of retainer. A thin
strip of plastic (about 0.015 - 0.020 in. 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.

(9) Install and position nine clutch piston springs

(Fig. 217).

(10) Install

spring

retainer

on

top

of

piston

springs.

(11) Compress spring retainer and piston springs

with Tool C-3863-A.

(12) Install spring retainer snap ring and remove

compressor tool.

(13) Install clutch plates and discs (Fig. 215).

Three clutch discs, three steel plates and one reac-
tion plate are required.

(14) Install reaction plate followed by waved snap

ring.

(15) Check clutch pack clearance with feeler gauge

(Fig. 218). Clearance between waved spring and pres-
sure plate should 1.78 - 3.28 mm (0.070 - 0.129 in.).
If clearance is incorrect, clutch plates, clutch discs,
snap ring, or pressure plate may have to be changed.

Fig. 215 Front Clutch Components

1 – INNER PISTON SEAL
2 – CLUTCH PISTON
3 – CLUTCH PISTON SPRING RETAINER
4 – CLUTCH PLATES
5 – CLUTCH PACK SNAP RING (WAVED)
6 – REACTION PLATE

7 – CLUTCH DISCS
8 – RETAINER SNAP RING
9 – CLUTCH PISTON SPRINGS (9)
10 – OUTER PISTON SEAL
11 – FRONT CLUTCH RETAINER

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DISASSEMBLY AND ASSEMBLY (Continued)