Dodge Durango (DN). Manual — part 108

WARNING: THE

NEXT

STEP

IN

GEARTRAIN

ASSEMBLY INVOLVES COMPRESSING THE DIRECT
CLUTCH HUB AND SPRING. IT IS EXTREMELY
IMPORTANT THAT PROPER EQUIPMENT BE USED
TO COMPRESS THE SPRING AS SPRING FORCE IS
APPROXIMATELY 830 POUNDS. USE COMPRES-
SOR TOOL C-6227-1 AND A HYDRAULIC-TYPE
SHOP PRESS WITH A MINIMUM RAM TRAVEL OF 6
INCHES. THE PRESS MUST ALSO HAVE A BED
THAT CAN BE ADJUSTED UP OR DOWN AS
REQUIRED. RELEASE CLUTCH SPRING TENSION
SLOWLY AND COMPLETELY TO AVOID PERSONAL
INJURY.

(20) Position Compressor Tool 6227-1 on clutch

hub.

(21) Compress clutch hub and spring just enough

to place tension on hub and hold it in place.

(22) Slowly compress clutch hub and spring. Com-

press spring and hub only enough to expose ring
grooves for clutch pack snap ring and clutch hub
retaining ring.

(23) Realign clutch pack on hub and seat clutch

discs and plates in clutch drum.

(24) Install direct clutch pack snap ring (Fig. 291).

Be very sure snap ring is fully seated in clutch
drum ring groove.

(25) Install clutch hub retaining ring (Fig. 292).

Be very sure retaining ring is fully seated in
sun gear ring groove.

(26) Slowly release press ram, remove compressor

tools and remove geartrain assembly.

GEAR CASE

(1) Position park pawl and spring in case and

install park pawl shaft. Verify that end of spring
with 90° bend is hooked to pawl and straight end of
spring is seated against case.

(2) Install pawl shaft retaining bolt. Tighten bolt

to 27 N·m (20 ft. lbs.) torque.

Fig. 290 Direct Clutch Pack And Clutch Hub

Installation

1 – CLUTCH HUB
2 – DIRECT CLUTCH PACK
3 – CLUTCH DRUM

Fig. 291 Direct Clutch Pack Snap Ring Installation

1 – SPECIAL TOOL 6227–1
2 – DIRECT CLUTCH PACK SNAP RING

Fig. 292 Clutch Hub Retaining Ring Installation

1 – SPECIAL TOOL 6227–1
2 – CLUTCH HUB RETAINING RING

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DISASSEMBLY AND ASSEMBLY (Continued)

(3) Install park lock reaction plug. Note that plug

has locating pin at rear (Fig. 293). Be sure pin
is seated in hole in case before installing snap
ring.

(4) Install reaction plug snap-ring (Fig. 294). Com-

press snap ring only enough for installation; do
not distort it.

(5) Install new seal in gear case. Use Handle

C-4171 and Installer C-3995-A to seat seal in case.

(6) Verify that tab ends of rear bearing locating

ring extend into access hole in gear case (Fig. 295).

(7) Support geartrain on Tool 6227-1 (Fig. 296). Be

sure tool is securely seated in clutch hub.

(8) Install overdrive gear case on geartrain (Fig.

296).

(9) Expand front bearing locating ring with snap

ring pliers (Fig. 297). Then slide case downward until
locating ring locks in bearing groove and release
snap ring.

(10) Install locating ring access cover and gasket

in overdrive unit case (Fig. 298).

OVERDRIVE CLUTCH

(1) Install overdrive clutch reaction ring first.

Reaction ring is flat with notched ends (Fig. 299).

(2) Install wave spring on top of reaction ring (Fig.

300). Reaction ring and wave ring both fit in
same ring groove. Use screwdriver to seat each
ring securely in groove. Also ensure that the ends of
the two rings are offset from each other.

(3) Assemble overdrive clutch pack (Fig. 301).
(4) Install overdrive clutch reaction plate first.

Fig. 293 Reaction Plug Locating Pin And Snap-Ring

1 – REACTION PLUG SNAP RING (DO NOT OVERCOMPRESS

TO INSTALL)

2 – LOCATING PIN
3 – PARK LOCK REACTION PLUG

Fig. 294 Reaction Plug And Snap-Ring Installation

1 – REACTION PLUG SNAP RING
2 – SNAP RING PLIERS

Fig. 295 Correct Rear Bearing Locating Ring

Position

1 – CASE ACCESS HOLE
2 – TAB ENDS OF LOCATING RING

Fig. 296 Overdrive Gear Case Installation

1 – GEARTRAIN ASSEMBLY
2 – GEAR CASE

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DISASSEMBLY AND ASSEMBLY (Continued)

(5) Install first clutch disc followed by first clutch

plate. Then install remaining clutch discs and plates
in same order.

(6) Install clutch pack pressure plate.
(7) Install clutch pack wire-type retaining ring

(Fig. 302).

INTERMEDIATE SHAFT SPACER SELECTION

(1) Place overdrive unit in vertical position. Mount

it on blocks, or in workbench with appropriate size
mounting hole cut into it. Be sure unit is facing
upward for access to direct clutch hub. Also be sure
output shaft is not loaded and internal components
are moved rearward for accurate measurement.

(2) Determine correct thickness intermediate shaft

spacer as follows:

(a) Insert Special Tool 6312 through sun gear,

planetary gear and into pilot bushing in output
shaft. Be sure tool bottoms against planetary
shoulder.

(b) Position Gauge Tool 6311 across face of over-

drive case (Fig. 303). Then position Dial Caliper
C-4962 over gauge tool.

(c) Extend sliding scale of dial caliper downward

through gauge tool slot until scale contacts end of
Gauge Alignment Tool 6312. Lock scale in place.
Remove dial caliper tool and note distance mea-
sured (Fig. 303).

(d) Select proper thickness end play spacer from

spacer chart based on distance measured (Fig.
304).

(e) Remove Gauge Alignment Tool 6312.

OD THRUST PLATE SELECTION

(1) Place overdrive unit in vertical position. Mount

it on blocks, or in workbench with appropriate size
mounting hole cut into it. Be sure unit is facing
upward for access to direct clutch hub. Also be sure
output shaft is not loaded and internal components
are moved rearward for accurate measurement.

(2) Determine correct thickness overdrive piston

thrust plate as follows:

(a) Position Gauge Tool 6311 across face of over-

drive case. Then position Dial Caliper C-4962 over
gauge tool (Fig. 305).

Fig. 297 Seating Locating Ring In Rear Bearing

1 – EXPAND BEARING LOCATING RING WITH SNAP RING

PLIERS

2 – ACCESS HOLE

Fig. 298 Locating Ring Access Cover And Gasket

Installation

1 – TORX SCREWDRIVER (T25)
2 – ACCESS COVER SCREWS

Fig. 299 Overdrive Clutch Reaction Ring Installation

1 – REACTION RING
2 – CLUTCH HUB

Fig. 300 Overdrive Clutch Wave Spring Installation

1 – WAVE SPRING

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DISASSEMBLY AND ASSEMBLY (Continued)

(b) Measure distance to clutch hub thrust bear-

ing seat at four points 90° apart. Then average
measurements by adding them and dividing by 4.

(c) Select and install required thrust plate from

information in thrust plate chart (Fig. 306).
(3) Leave Alignment Tool 6227-2 in place. Tool will

keep planetary and clutch hub splines in alignment

until overdrive unit is ready for installation on trans-
mission.

(4) Transmission speed sensor can be installed at

this time if desired. However, it is recommended that
sensor not be installed until after overdrive unit is
secured to transmission.

OVERDRIVE PISTON

(1) Install new seals on overdrive piston.
(2) Stand transmission case upright on bellhous-

ing.

Fig. 301 46RE Overdrive Clutch Components

1 – REACTION PLATE
2 – CLUTCH PLATES (3)
3 – PRESSURE PLATE
4 – CLUTCH DISCS (4)

Fig. 302 Overdrive Clutch Pack Retaining Ring

Installation

1 – OVERDRIVE CLUTCH PACK RETAINING RING

Fig. 303 Shaft End Play Measurement

1 – SPECIAL TOOL 6312
2 – SPECIAL TOOL 6311
3 – SPECIAL TOOL C-4962

Fig. 304 Intermediate Shaft End Play Spacer

Selection

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DISASSEMBLY AND ASSEMBLY (Continued)