62TE Automatic Transmission - Service Information: Diagnosis

ROAD TEST

Prior to performing a road test, verify that the fluid level, fluid condition, and linkage adjustment have been approved.

During the road test, the transaxle should be operated in each position to check for slipping and any variation in shifting.

If the vehicle operates properly at highway speeds, but has poor acceleration, the converter stator overrunning clutch may be slipping. If acceleration is normal, but high throttle opening is needed to maintain highway speeds, the converter stator clutch may have seized. Both of these stator defects require replacement of the torque converter and thorough transaxle cleaning.

Slipping clutches can be isolated by comparing the clutch application chart with clutch operation encountered on a road test. This chart identifies which clutches are applied at each position of the selector lever.

A slipping clutch may also set a DTC and can be determined by operating the transaxle in all selector positions.

62TE		ELEMENTS APPLIED
GEAR	RATIO	UD	OD	R	2-4	L-R	LC	DC	ORC
1	4.127	A				A	A ^		H
2	2.842	A				A		A
3 *	2.284	A			A		A ^		H
4	1.573	A			A			A
4	1.452	A	A				A ^		H
5	1.000	A	A					A
6	0.689		A		A			A
R	3.215			A		A	A

CLUTCH APPLICATION

A = Applied

H = Holding

* = Limp-in Mode

^ = Applied in coast only

The process of elimination can be used to detect any unit which slips and to confirm proper operation of good units. Road test analysis can diagnose slipping units, but the cause of the malfunction cannot be determined. Practically any condition can be caused by leaking hydraulic circuits or sticking valves.

Scheme 682

Scheme 682: REMOVAL

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Open hood.
Disconnect negative battery cable.
Unplug the electrical connector (1) to the intake air temperature sensor (2) at the air box.
Remove the hold down bolt (1) and hose clamp (2) at the air box.
Remove the air box.
Disconnect gearshift cable (1) from transaxle manual valve lever (2).
Disconnect gearshift cable from the bracket.
Disconnect the electrical connector (2) at the crankshaft position sensor (3).
Remove hold down bolt (1) at the crankshaft position sensor (3).
Remove the crankshaft position sensor (3).
Disconnect oil cooler lines from transaxle using Disconnect Tool 8875A. Refer to «Cooling - Standard Procedure»(ref-353584-S11330501202010011200000) . NOTE: The transmission harness will be removed with the transaxle.
Unplug the transaxle electrical connector at the powertrain control module.
Remove the transaxle upper bellhousing-to-block bolts (3).
Remove rear transaxle mount bracket bolts (1).
Remove the bolt (2) holding the ground cable (3) to the front mount bracket (1).
Raise the vehicle on the hoist.
Remove both halfshafts. Refer to «Differential and Driveline/Half Shaft - Removal»(ref-353569-S23433654932010011200000) .
Remove the front and both side splash shields. Refer to «Body/Exterior/SHIELD, Splash - Removal»(ref-353577-S07665419552010011200000) .
Remove the PTU, if equipped.
Remove the mount through bolt (1).
Remove the transmission crossmember bolts (2).
Remove the transmission crossmember.
Remove the front mount bracket bolts (1).
Remove the front mount bracket (2).
Disconnect starter motor electrical connectors and remove the retaining bolts (3), starter motor (1) and shim (2).
Remove bolts (3) to exhaust bracket.
Remove cross under pipe. Refer to «Exhaust System/PIPE, Exhaust Crossunder - Removal»(ref-353615-S40083911602010011200000) .
Remove bolts (2) to stand off bracket (4).
Remove bracket (4).
Remove torque converter dust shield bolt (3).
Remove torque converter dust shield (2).
Remove the torque converter-to-driveplate bolts (1). Upon removing bolts, a tight-tolerance (slotted) bolt will be encountered. Mark this location (driveplate and converter) with paint for assembly reference.
Install a transmission jack and support the engine. Secure transaxle to jack. NOTE: The bolts on each side of the inspection opening were removed with the exhaust bracket.
Remove the transaxle-to-engine lower bolts (2).
Remove left side transmission mount bolts (2) and remove the mount (1).
Lower transaxle from engine compartment.
Disconnect solenoid/pressure switch assembly connector (2).
Disconnect both output speed sensor connectors (1, 2).
Disconnect input speed sensor connector.
Remove the harness from transaxle.

Scheme 701

Scheme 701: DISASSEMBLY

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Scheme 775

Remove the speed sensors (1, 2 and 3).
Remove bolts (1) at the oil filter pan (2).
Remove the oil filter pan (2).
Remove the bolts (1) at the oil filter (2).
Remove the oil filter (2).
Remove the oil filter seal (1) at the case. NOTE: Keep the Front Sound Dampener Cover if replacing the unit
If equipped remove the fasteners (1) and the Front Sound Dampener Cover (2). NOTE: Keep the Top Sound Dampener Cover if replacing the unit
If equipped remove the Top Sound Damper Cover (1).
Remove bolts (2) at the valve body oil pan (1).
Remove the pressure tap plug (2) at valve body pan.
Remove the valve body pan.
Remove the electrical connector (1) at the range sensor (4).
Remove the bolt (3) holding the detent spring.
Remove the detent spring (2).
Remove valve body bolts (1).
Remove valve body (1) from oil transfer tubes and manual valve (3) from rooster comb.
Remove oil transfer tubes (2) from the case. 1 - UD ACCUMULATOR 5 - LC ACCUMULATOR 2 - 2/4 ACCUMULATOR 6 - DC ACCUMULATOR 3 - LR ACCUMULATOR 7 - OD ACCUMULATOR 4 - 2/4 CLUTCH OIL SUPPLY SEAL
Remove all six accumulators (1, 2, 3, 5, 6 and 7) from case along with the accumulator return springs.
Remove the 2/4 clutch oil supply seal (4) from the case.
Remove the manual lever, TRS and seal. See «Removal»(ref-353619-S00055126832010011200000) . 1 - END PLAY FIXTURES 8266A 2 - DIAL INDICATOR C-3339A
Measure input shaft end play. Place transaxle so input shaft is vertical. Set up end play fixtures 8266A (1,2) and dial indicator (3). Input shaft end play should be within 0.13-0.64 mm (0.005-0.025 in.) Record indicator reading for reference upon reassembly.
Remove the front pump bolts (1). CAUTION: Be sure input speed sensor is removed before removing oil pump.
Install slide hammers C-3752 (1) on oil pump.
Remove oil pump assembly (1).
Remove oil pump gasket (2). CAUTION: If transaxle failure has occurred, the cooler bypass valve must be replaced. Do not re-use or attempt to clean valve.
Remove cooler bypass valve (2). 1 - #1 CAGED NEEDLE BEARING 2 - NOTE: TANGED SIDE OUT
Remove number one needle bearing (1). 1 - INPUT CLUTCH ASSEMBLY 2 - #4 THRUST WASHER
Remove input clutch assembly (1). 1 - OVERDRIVE SHAFT ASSEMBLY 2 - #4 THRUST PLATE (SELECT) 3 - 3 DABS OF PETROLATUM FOR RETENTION
Remove number four thrust plate (2). 1 - FRONT SUN GEAR ASSEMBLY 2 - #4 THRUST WASHER (FOUR TABS)
Remove front sun gear assembly (1) and number four thrust washer (2). 1 - #6 NEEDLE BEARING 2 - FRONT CARRIER AND REAR ANNULUS ASSEMBLY (TWIST AND PULL OR PUSH TO REMOVE OR INSTALL).
Remove front carrier/rear annulus assembly (2) and number six needle bearing (1). 1 - #7 NEEDLE BEARING 2 - REAR SUN GEAR NOTE: The number seven needle bearing (1) has three anti-reversal tabs and is common with the number five and number two position. The orientation should allow the bearing to seat flat against the rear sun gear (1) when put together.
Remove rear sun gear (2) and number seven needle bearing (1). 1 - SPRING COMPRESSING 5058A 2 - SCREWDRIVER 3 - SNAP RING 4 - 2/4 CLUTCH RETAINER NOTE: Verify that Compressor 5058A is centered properly over the 2/4 clutch retainer before compressing. If necessary, fasten the 5058A bar to the bellhousing flange with any combination of locking pliers and bolts to center the tool properly.
Setup the Spring Compressor 5058A (1), Compress 2/4 clutch return spring (4) (just enough to remove snap ring) and remove snap ring (3). 1 - 2/4 CLUTCH RETAINER 2 - 2/4 CLUTCH RETURN SPRING NOTE: The 2/4 Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.
Remove 2/4 clutch retainer (1). 1 - 2/4 CLUTCH RETURN SPRING
Remove 2/4 clutch return spring (1). 1 - CLUTCH PLATE (4) 2 - CLUTCH DISC (4)
Remove 2/4 clutch pack (1,2). Tag 2/4 clutch pack for reassembly identification. 1 - LOW/REVERSE CLUTCH REACTION PLATE 2 - SCREWDRIVER 3 - LOW/REVERSE TAPERED SNAP RING (TAPERED SIDE UP) 4 - OIL PAN FACE 5 - LONG TAB
Remove tapered snap ring (3). 1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP)
Remove low/reverse reaction plate (1). 1 - ONE DISC FROM LOW/REVERSE CLUTCH
Remove one low/reverse clutch disc (1). 1 - SCREWDRIVER 2 - LOW/REVERSE REACTION PLATE FLAT SNAP RING 3 - DO NOT SCRATCH CLUTCH PLATE
Remove low/reverse reaction plate snap ring (2). 1 - CLUTCH PLATES (5) 2 - CLUTCH DISCS (5)
Remove low/reverse clutch pack (1,2).
Remove transfer gear cover-to-case bolts (2).
Remove transfer gear cover (1).
Remove the oil scavenger (2).
Bend back the locking tabs (2) at the output transfer gear retaining strap (3).
Remove the bolts (1) at the output transfer gear retaining strap (3).
Remove the output transfer gear retaining strap (3).
Install the Gear Holder 9739 (2) onto the output transfer gear (3).
Remove the output transfer gear bolt (1).
Grind the staked tabs (1) from the transfer gear (underdrive compounder side).
Install the Gear Holder 9739 (1) onto the transfer gear (underdrive compounder side) and remove the nut.
Lift the transfer gear from the underdrive compounder shaft.
Using Gear Puller L-4407A (1) and Thrust Button 6055 (3) remove output shaft transfer gear (2) and select shim. 1 - BEARING PULLER 5048 WITH JAWS 5048-5 AND THRUST PAD L-4539-2 2 - WRENCHES 3 - OUTPUT GEAR
Using Bearing Puller 5048 with Jaws 5048-5 and Thrust Pad L-4539-2 (1) remove output gear bearing cone.
Using Press Puller C-293-PA (1), Adaptors 9738 (3) and Press Plug 9678 remove compounder transfer gear bearing cone.
Remove rear carrier assembly (1) from transaxle (2). 1 - BEARING PULLER 5048 WITH JAWS 5048-3 AND THRUST BUTTON 6055 2 - WRENCHES 3 - REAR CARRIER ASSEMBLY
Remove rear carrier assembly (3) bearing cone using bearing puller 5048 with Jaws 5048-3 and thrust utton 6055. 1 - SPRING COMPRESSOR DISC 6057 2 - SPRING COMPRESSOR 5059-A 3 - FORCING SCREW 5058A-3
Install spring compressor disk 6057 (1), spring compressor 5059-A (2) and forcing screw 5058A-3 (3). 1 - LOW/REVERSE CLUTCH RETURN SPRING 2 - SNAP RING (INSTALL AS SHOWN IN ILLUSTRATION) 3 - SPRING COMPRESSOR DISC 6057 4 - SPRING COMPRESSOR 5059-A 5 - FORCING SCREW 5058A-3
Compress low/reverse spring using spring compressor 5059-A (4). 1 - SNAP RING OPENING MUST BE BETWEEN SPRING LEVERS (AS SHOWN IN ILLUSTRATION) 2 - SNAP RING PLIERS 3 - SPRING COMPRESSOR DISC 6057
Remove snap ring (1) at low/reverse piston return spring. 1 - LOW/REVERSE PISTON RETURN SPRING 2 - PISTON
Remove low/reverse spring compressor tool and low reverse piston return spring (1). 1 - LOW/REVERSE CLUTCH PISTON 2 - BONDED SEAL 3 - BONDED SEAL NOTE: The Low/Reverse Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.
Remove low/reverse clutch piston (1). 1 - LOW/REVERSE CLUTCH PISTON RETAINER 2 - SCREWDRIVER 3 - TORX-LOC SCREWS
Remove low/reverse piston retainer-to-case screws (3). 1 - LOW/REVERSE CLUTCH PISTON RETAINER 2 - GASKET
Remove low/reverse piston retainer (1). 1 - GASKET HOLES MUST LINE UP 2 - LOW/REVERSE CLUTCH PISTON RETAINER GASKET
Remove low/reverse piston retainer-to-case gasket (2), gasket holes must line up (1).
Using a hammer and suitable drift (2), drive out inner output bearing cup (1).
Using bearing cup puller 6062A (1), remove outer output bearing cup (2).
Remove the snap ring (1) at the underdrive compounder assembly (2).
Remove four bolts (1) at the compounder bearing retainer.
Install puller adapter 9908 (2) to the compounder bearing retainer.
Install Slide Hammer C-3752 (1) to puller adapter 9908 (2) and pull the underdrive compounder assembly from the case. NOTE: Insure that the planetary gear set / output hub is removed as part of the underdrive compounder assembly.
Remove the underdrive compounder assembly (2).
Remove the bolts (1) at the remote pinion cover (2).
Remove the remote pinion (1) and the remote pinion cover (2) from the case.
Remove the remote pinion cover (1) from the remote pinion (2).
Using Remover 8913 (2) and Brace 8915 (1) remove the remote pinion cover bearing cup (3) and selective shim.
Using Remover 8912 and Brace 8915 (1, 2) pull remote pinion small bearing cup (3) from the case.
Remove the differential output bearing cover bolts (1).
Remove differential output bearing cover (2).
Remove the differential cover bolts (1).
Remove the differential cover (1).
Remove the out seal (2), oil singer (3) and the small bearing cup (4).
Remove the large bearing cup.
Remove the differential.
Remove the manual lever and TRS. See «Removal»(ref-353619-S00055126832010011200000) .
Remove the set screw (1) for the park pawl shaft.
Remove the snap ring (1) for the park guide assembly (2).
Remove the park guide assembly (1).
Remove the plug (1) to allow the park pawl shaft to be removed.
Slide the shaft (1) out of the park pawl (3).
Remove the park pawl shaft (1).
Remove the park pawl (1) and the park pawl spring (2).

Scheme 776

Scheme 776: ASSEMBLY

CAUTION

The cooler bypass valve must be replaced if transaxle failure has occurred. Do not attempt to reuse or clean old valve.

Note. If transaxle is being overhauled (clutch and/or seal replacement), the TCM/PCM Quick Learn procedure must be performed. Refer to Electrical/Electronic Control Modules/MODULE, Powertrain Control - Standard Procedure .

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Scheme 800

Install both output bearing cups (2) using Installer 5050A (1). 1 - GASKET HOLES MUST LINE UP 2 - LOW/REVERSE CLUTCH PISTON RETAINER GASKET
Install low/reverse piston retainer gasket (2) Make sure gasket holes line up with case (1). 1 - LOW/REVERSE CLUTCH PISTON RETAINER 2 - GASKET
Install low/reverse piston retainer (1). 1 - LOW/REVERSE CLUTCH PISTON RETAINER 2 - SCREWDRIVER 3 - TORX-LOC SCREWS
Install low/reverse piston retainer-to-case screws (3) and tighten to 5 N.m (45 in. lbs.). 1 - LOW/REVERSE CLUTCH PISTON 2 - BONDED SEAL 3 - BONDED SEAL NOTE: The Low/Reverse Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.
Install low/reverse clutch piston (1). 1 - LOW/REVERSE PISTON RETURN SPRING 2 - PISTON
Install low/reverse piston return spring (1). 1 - DISC 6057 2 - COMPRESSOR 5059-A 3 - COMPRESSOR BAR 5058A-3
Install Disk 6057 (1) , Compressor 5059-A (2) and Compressor Bar 5058A-3 (3). 1 - LOW/REVERSE CLUTCH RETURN SPRING 2 - SNAP RING (INSTALL AS SHOWN IN ILLUSTRATION) 3 - DISC 6057 4 - COMPRESSOR 5059 5 - COMPRESSOR BAR 5058-3
Install low/reverse spring compressor into position. 1 - SNAP RING OPENING MUST BE BETWEEN SPRING LEVERS (AS SHOWN IN ILLUSTRATION) 2 - SNAP RING PLIERS 3 - DISC 6057
Compress low/reverse piston and install snap ring (1). 1 - ARBOR PRESS RAM 2 - INSTALLER 6053 3 - NEW BEARING CONE 4 - REAR CARRIER ASSEMBLY
Install rear carrier bearing cone (3) using Installer 6053 (1).
Install rear carrier assembly (1) to transaxle case. 1 - ARBOR PRESS RAM 2 - HANDLE C-4171 3 - INSTALLER 5052 4 - OUTPUT GEAR
Install output gear bearing cone using Installer 6758 (3). 1 - GEAR CHECKING PLATE L-4432 2 - DIAL INDICATOR 3 - SPECIAL SCREWS 6260 4 - OUTPUT GEAR
OUTPUT GEAR BEARING ADJUSTMENT: With output gear removed, install a 4.50 mm (0.177 in.) gauging shim on the rear carrier assembly hub, using grease to hold the shim in place. Using Holder 6259, install output gear, bearing assembly and bolt. Tighten to 271 N.m (200 ft. lbs.). Measure bearing end play. Attach Gear Checking Plate L-4432 (1) to the gear. Push and pull the gear while rotating back and forth to ensure seating of bearing rollers. Using a dial indicator mounted to the transaxle case, measure output gear end play. Refer to the «OUTPUT GEAR BEARING SHIM CHART»(ref-353619-S30969340212010011200000) for the required shim to obtain proper bearing setting. Use Holder 6259 to remove the output gear retaining bolt and washer. To remove the output gear, use Gear Puller L-4407A. Remove the gauging shim and install the proper shim determined by the chart. Use grease to hold the shim in place. OUTPUT GEAR BEARING SHIM CHART End Play Shim Needed Part Number 0.05mm (0.002 in.) 4.42mm (0.174 in.) 4412830AB 0.08mm (0.003 in.) 4.38mm (0.172 in.) 4412829AB 0.10mm (0.004 in.) 4.38mm (0.172 in.) 4412829AB 0.13mm (0.005 in.) 4.34mm (0.171 in.) 4412828AB 0.15mm (0.006 in.) 4.30mm (0.169 in.) 4412827AB 0.18mm (0.007 in.) 4.30mm (0.169 in.) 4412827AB 0.20mm (0.008 in.) 4.26mm (0.168 in.) 4412826AB 0.23mm (0.009 in.) 4.22mm (0.166 in.) 4412825AB 0.25mm (0.010 in.) 4.22mm (0.166 in.) 4412825AB 0.28mm (0.011 in.) 4.18mm (0.165 in.) 4412824AB 0.30mm (0.012 in.) 4.14mm (0.163 in.) 4412823AB 0.33mm (0.013 in.) 4.14mm (0.163 in.) 4412823AB 0.36mm (0.014 in.) 4.10mm (0.161 in.) 4412822AB 0.38mm (0.015 in.) 4.10mm (0.161 in.) 4412822AB 0.41mm (0.016 in.) 4.06mm (0.160 in.) 4412821AB 0.43mm (0.017 in.) 4.02mm (0.158 in.) 4412820AB 0.46mm (0.018 in.) 4.02mm (0.158 in.) 4412820AB 0.48mm (0.019 in.) 3.98mm (0.157 in.) 4412819AB 0.51mm (0.020 in.) 3.94mm (0.155 in.) 4412818AB 0.53mm (0.021 in.) 3.94mm (0.155 in.) 4412818AB 0.56mm (0.022 in.) 3.90mm (0.154 in.) 4412817AB 0.58mm (0.023 in.) 3.90mm (0.154 in.) 4412817AB 0.61mm (0.024 in.) 3.86mm (0.152 in.) 4412816AB 0.64mm (0.025 in.) 3.82mm (0.150 in.) 4412815AB 0.66mm (0.026 in.) 3.82mm (0.150 in.) 4412815AB 0.69mm (0.027 in.) 3.78mm (0.149 in.) 4412814AB 0.71mm (0.028 in.) 3.74mm (0.147 in.) 4412813AB 0.74mm (0.029 in.) 3.74mm (0.147 in.) 4412813AB 0.76mm (0.030 in.) 3.70mm (0.146 in.) 4412812AB 0.79mm (0.031 in.) 3.66mm (0.144 in.) 4412811AB 0.81mm (0.032 in.) 3.66mm (0.144 in.) 4412811AB 0.84mm (0.033 in.) 3.62mm (0.143 in.) 4412810AB 0.86mm (0.034 in.) 3.62mm (0.143 in.) 4412810AB 0.89mm (0.035 in.) 3.58mm (0.141) 4412809AB 0.91mm (0.036in.) 3.54mm (0.139 in.) 4412808AB 0.94mm (0.037 in.) 3.54mm (0.139 in.) 4412808AB 0.97mm (0.038 in.) 3.50mm (0.138 in.) 4412807AB
Install the output transfer gear (3) and bearing assembly using Installer 6261 (2).
Install NEW output transfer gear retaining bolt and washer.
Install Holder 9739 (1) onto the output transfer gear (2).
Tighten output transfer gear retaining bolt to 271 N.m (200 ft. lbs.).
Using an inch pound torque wrench, check output shaft turning torque. Output shaft turning torque should be within 3-8 in. lbs. If the turning torque is too high, install a 0.04 mm (0.0016 in.) thicker shim. If the turning torque is too low, install a 0.04 mm (0.0016 in.) thinner shim. Repeat until the proper turning torque of 3-8 in. lbs. is obtained. 1 - CLUTCH PLATES (5) 2 - CLUTCH DISCS (5)
Install low/reverse clutch pack (1,2). Leave uppermost disc out until snap ring is installed. 1 - SCREWDRIVER 2 - LOW/REVERSE REACTION PLATE FLAT SNAP RING 3 - DO NOT SCRATCH CLUTCH PLATE
Install low/reverse reaction plate flat snap ring (2), insure you do not scratch clutch plate (3). 1 - ONE DISC FROM LOW/REVERSE CLUTCH
Install remaining low/reverse clutch disc (1). 1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP)
Install low/reverse reaction plate with flat side up (1).
Use as a reference while installing tapered snap ring. 1 - SCREWDRIVER 2 - TAPERED SNAP RING (INSTALL AS SHOWN IN ILLUSTRATION)
Install tapered snap ring (with tapered side up) (2). 1 - DIAL INDICATOR 2 - DIAL INDICATOR TIP TOOL 6268 3 - HOOK TOOL
Set up dial indicator (1) to measure low/reverse clutch clearance. Press down on clutch pack with finger and zero dial indicator. Low/Reverse clutch pack clearance is 0.89-1.47 mm (0.035-0.058 in.) . Set up indicator and record measurement in four places. Take average of readings and select the proper low/reverse reaction plate to achieve specifications. LOW/REVERSE REACTION PLATE CHART PART NUMBER THICKNESS 4799846AA 5.88 mm (0.232 in.) 4799847AA 6.14 mm (0.242 in.) 4799848AA 6.40 mm (0.252 in.) 4799849AA 6.66 mm (0.262 in.) 4799855AA 6.92 mm (0.273 in.)
Install 2/4 clutch pack (1, 2). 1 - NOTE POSITION 2 - RETURN SPRING 3 - 2/4 CLUTCH RETAINER NOTE: The 2/4 Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.
Orient 2/4 clutch return spring to retainer (3). 1 - 2/4 CLUTCH RETAINER 2 - 2/4 CLUTCH RETURN SPRING
Install 2/4 clutch retainer to transaxle (1, 2). 1 - COMPRESSING TOOL 5058A 2 - SCREWDRIVER 3 - SNAP RING 4 - 2/4 CLUTCH RETAINER
Using Compressing Tool 5058A (1), compress 2/4 clutch return spring just enough to install snap ring (3).
Install snap ring. 1 - DIAL INDICATOR 2 - HOOK TOOL 3 - DIAL INDICATOR TIP 6268
Set up dial indicator (1) and measure 2/4 clutch clearance. Press down on clutch pack with finger and zero dial indicator. 2/4 clutch pack clearance is 0.76-2.64 mm (0.030-0.104 in.). Set up indicator and record measurement in four places. Take average of readings. If clearance is outside this range, the clutch is assembled improperly. There is no adjustment for 2/4 clutch clearance. 1 - #7 NEEDLE BEARING 2 - REAR SUN GEAR NOTE: The number seven needle (1) bearing has three anti-reversal tabs and is common with the number five position. The orientation should allow the bearing to seat flat against the rear sun gear. A small amount of petrolatum can be used to hold the bearing to the rear sun gear (2). 1 - #7 NEEDLE BEARING 2 - REAR SUN GEAR
Install rear sun gear (2) and number seven needle bearing (1). 1 - #6 NEEDLE BEARING 2 - FRONT CARRIER AND REAR ANNULUS ASSEMBLY (TWIST AND PULL OR PUSH TO REMOVE OR INSTALL).
Install front carrier/rear annulus assembly (2) and number six needle bearing (1). 1 - FRONT SUN GEAR ASSEMBLY 2 - #4 THRUST WASHER (FOUR TABS)
Install front sun gear assembly (1) and number four thrust washer (2). 1 - OVERDRIVE SHAFT ASSEMBLY 2 - #4 THRUST PLATE (SELECT) 3 - 3 DABS OF PETROLATUM FOR RETENTION
Select the thinnest number four thrust plate thickness (2) and install to input clutch assembly. Use petrolatum to retain (3).
Install input clutch assembly into position and verify that it is completely seated by viewing through input speed sensor hole (3). If view through input speed sensor hole is not as shown in illustration, the input clutch assembly (2) is not seated properly. 1 - OIL PUMP ASSEMBLY 2 - O-RING
Remove oil pump O-ring (2). Be sure to reinstall oil pump O-ring after selecting the proper number four thrust plate.
Install pump and gasket to transmission. Install and torque bolts. 1 - END PLAY SOCKET SET 8266A 2 - DIAL INDICATOR C-3339A
Set up input shaft for measurement with Indicator Set C-3339A (3) and End Play Set 8266A (1,2).
Measure the input shaft end play with the transaxle in the vertical position. Input shaft end play must be within 0.13-0.64 mm (0.005 to 0.025 in.) For example, if end play reading is 0.055 in. select number four Thrust Plate which is 0.071-0.074 in. thick. This should provide an input shaft end play reading of 0.020 in. which is within specifications.
Refer to the number four thrust plate chart «NO. 4 THRUST PLATE CHART»(ref-353619-S38719857702010011200000) to select the proper number four thrust plate. NO. 4 THRUST PLATE CHART PART NUMBER THICKNESS 4431665AB 1.60mm (0.063 in.) 3836237AB 1.73mm (0.068 in.) 4431666AB 1.80mm (0.071 in.) 3836238AB 1.96mm (0.077 in.) 4431667AB 2.03mm (0.080 in.) 3836239AB 2.16mm (0.085 in.) 4431668AB 2.24mm (0.088 in.) 3836240AB 2.39mm (0.094 in.) 4431669AB 2.46mm (0.097 in.) 3836241AB 2.62mm (0.103 in.) 4446670AB 2.67mm (0.105 in.) 4446671AB 2.90mm (0.114 in.)
Install input clutch assembly (1). 1 - #1 CAGED NEEDLE BEARING 2 - NOTE: TANGED SIDE OUT
Install number one caged needle bearing (1) note: tanged side out (2). CAUTION: The cooler bypass valve must be replaced if transaxle failure has occurred. Do not attempt to reuse or clean old valve.
Install cooler bypass valve (1) with O-ring end towards rear of case.
Install oil pump gasket (1).
Install oil pump (2).
Install oil pump-to-case bolts (1) and tighten 30 N.m (265 in. lbs.). 1 - STIRRUP 2 - OUTPUT GEAR RETAINING BOLT
Install output gear stirrup (1) with serrated side out. 1 - RETAINING STRAP 2 - STIRRUP 3 - RETAINING STRAP BOLTS
Install retaining strap (1).
Install strap bolts (3) but do not tighten at this time. 1 - RETAINING STRAP 2 - STIRRUP
Rotate stirrup (2) clockwise against flats of retaining bolt. 1 - RETAINING STRAP 2 - STIRRUP
Tighten stirrup strap bolts to 23 N.m (200 in. lbs.). 1 - RETAINING STRAP TABS 2 - RETAINING STRAP 3 - STIRRUP
Bend tabs (1) on strap up against flats of bolts.
Install the differential, bearing cups, shim, seals and oil slinger into case.
Install the differential cover.
Install the differential cover bolts (1) and tighten to 61 N.m (45 ft. lbs.).
Install the differential output bearing cover (2).
Install the differential output bearing cover bolts (1) and tighten to 12 N.m (105 in. lbs.). NOTE: Remote pinion gear must NOT be installed while checking turning torque.
Using the Turning Torque Tool 9735 (1) and an inch pound torque wrench (2) check the differential turning torque, it should be 10 to 22 in-lbs (drag). If turning torque is more than 22 in-lbs (drag) decrease shim size behind the end cover and recheck. If turning torque is less than 10 in-lbs (drag) increase shim size.
After proper turning torque is achieved for the differential remove the differential from the case and set aside keeping the correct shim with the differential.
Install the remote pinion bearing cup in the case (small cup) using Installer 9730 and Handle C-4171.
Install the remote pinion bearing cup in the cover using Installer 9729 and Handle C-4171.
Install the remote pinion (2) into the transaxle case.
Install the remote pinion cover (2) into transaxle case.
Install the bolts (1) at the remote pinion cover (2) and tighten to 12 N.m (105 in. lbs.). NOTE: Differential assembly must not be installed when checking for pinion drag torque.
Check turning torque using Differential Bearing Torque Tool C-4995A (2) and an inch pound torque wrench (1). Turning torque for the remote pinion gear should be 2 to 8 in-lbs (drag). If more than 8 in-lbs (drag) decrease shim size under the remote pinion bearing cover cup. If turning torque is less than 2 in-lbs (drag) increase the shim size under the remote pinion bearing cover cup.
Install Holder 9908 (2) onto the compounder bearing retainer to help in installation.
Install the compounder bearing retainer into the transaxle case.
Remove Holder 9908 from the compounder bearing retainer.
Install all the bolts at the compounder bearing retainer and tighten to 12 N.m (105 in. lbs.).
Install snap ring (1) at top of the compounder bearing retainer. NOTE: Insure End Play Tool 9951 is not binding in support plate that is bolted to the case. NOTE: Always use original shim to determine end play.
Remove plug at case (3).
Install compounder End Play Tool 9951 (2) through the hole in the front case.
Install Dial Indicator C-3339A (1) onto End Play Tool 9951.
Use moderate downward pressure on End Play Tool 9951 and zero Dial Indicator C-3339A.
Use moderate upward pressure on End Play Tool 9951 and take reading from Dial Indicator C-3339A.
Remove End Play Tool 9951 and zero Dial Indicator C-3339A.
Adjust shim thickness in the underdrive unit to 0.010 to 0.020".
Install the correct (select) helical shim and assemble the underdrive compounder. See «Assembly»(ref-353619-S06695244912010011200000) and retest.
Using Mopar lock AND seal adhesive install plug back into case and tighten to 24 N.m (18 ft. lbs.). 1 - ARBOR PRESS RAM 2 - HANDLE C-4171 3 - INSTALLER 5052 4 - OUTPUT GEAR
Install the transfer gear (underdrive compounder side) cone using Installer 6756 (3).
Install Holder 9739 (1) onto the transfer gear (underdrive compounder side) (2).
Install a new transfer gear (underdrive compounder side) nut and tighten to 271 N.m (200 ft. lbs.).
Use Staking Tool 9721 and stake the new nut.
Install the differential, bearing cups, shim and oil slinger into case.
Use a bead of MOPAR® ATF RTV (MS-GF41).
Install the differential cover.
Install the differential cover bolts (1) and tighten to 61 N.m (45 ft. lbs.).
Use a bead of MOPAR® ATF RTV (MS-GF41).
Install the differential output bearing cover (2) and tighten bolts to 12 N.m (105 in. lbs.).
Install differential oil seals into the case using installer MD998334-01.
Install the oil scavenger (2).
Install the transfer gear cover (1), use a bead of MOPAR® ATF RTV (MS-GF41).
Install transfer gear cover-to-case bolts (2) and tighten to 12 N.m (105 in. lbs.).
Install the park pawl tube (1) into case (2) making sure guide pin aligns with hole in case.
Install the snap ring (1) for the park pawl tube.
Install the park pawl (1) and the park pawl spring (2).
Install the park pawl shaft (1).
Install the park pawl shaft and park pawl pipe plug tighten to 27 N.m (20 ft. lbs.).
Install the set screw (1) for the park pawl shaft and tighten to 1 N.m (10 in. lbs.).
Install the manual lever, TRS and seal. See «Installation»(ref-353619-S34647029422010011200000) . 1 - UD ACCUMULATOR 5 - LC ACCUMULATOR 2 - 2/4 ACCUMULATOR 6 - DC ACCUMULATOR 3 - LR ACCUMULATOR 7 - OD ACCUMULATOR 4 - 2/4 CLUTCH OIL SUPPLY SEAL
Install all six accumulators (1, 2, 3, 5, 6 and 7) into case along with the accumulator return springs.
Install a new 2/4 clutch oil supply seal (4) into the case. NOTE: Install transmission oil on the oil transfer tubes O-rings.
Install the oil transfer tubes (2) into the case/compounder.
Install valve body (1) onto the oil transfer tubes and manual valve (3) at the rooster comb.
Install the valve body bolts (1) and tighten to 7 N.m (50 in. lbs.).
Install the detent spring (2).
Install the bolt (3) holding the detent spring and tighten to 7 N.m (50 in. lbs.).
Install the electrical connector (1) at the range sensor (4).
Install the valve body oil pan, use a bead of MOPAR® ATF RTV (MS-GF41).
Install the valve body oil pan bolts and tighten to 6 N.m (53in. lbs.).
Install the pressure tap plug (2) at valve body pan and tighten to 9 N.m (45 in. lbs.).
Install the fluid filter seal (1) at the case.
Install the fluid filter (2).
Install the fluid filter mounting nuts and tighten to 5 N.m (40 in. lbs.).
Install the fluid filter oil pan, use a bead of MOPAR® ATF RTV (MS-GF41).
Install the fluid filter oil pan bolts and tighten to 6 N.m (53 in. lbs.).
If equipped install the Front Sound Dampener Cover (2) and the fasteners (1).
Install the speed sensors (1, 2 and 3) and tighten bolts to 12 N.m (105 in. lbs.).
If equipped install the Top Sound Dampener Cover (1).

Scheme 801

Install the wiring harness onto the transaxle.
Connect input speed sensor connector.
Connect both output speed sensor connectors (1, 2).
Connect solenoid/pressure switch assembly connector (2). NOTE: The two transaxle-to-engine bolts next to the inspection cover will have a exhaust bracket under them.
Install transaxle into position. Install the transaxle-to-engine two outer lower bolts and torque to 70 N.m 52 ft. lbs.).
Install torque converter-to-driveplate bolts (1) and tighten to 88 N.m (65 ft. lbs.).
Install torque converter dust shield and bolt tighten to 6 N.m (53 in. lbs.).
Install bolts (2) to stand off bracket (4) and tighten to 95 N.m (70 ft. lbs.).
Install bolts (3) to exhaust bracket.
Install the cross under pipe. Refer to «Exhaust System/PIPE, Exhaust Crossunder - Installation»(ref-353615-S30669991642010011200000) . 1 - STARTER MOTOR 2 - SHIM 3 - BOLTS
Install the starter motor. Refer to «Electrical - Engine Systems/Starting/STARTER - Installation»(ref-353594-S03536378442010011200000) .
Install the PTU if equipped.
Install the front mount bracket (2).
Install the front mount bracket bolts (1) and tighten to 100 N.m (74 ft. lbs.).
Install the transmission crossmember and tighten to 50 N.m (37 ft. lbs.).
Install front mount through bolt and tighten to 50 N.m (37 ft. lbs.)
The front and both side splash shields. Refer to «Body/Exterior/SHIELD, Splash - Installation»(ref-353577-S13753255322010011200000)
Lower the vehicle.
Install the left side mount bolts and tighten to 100 N.m (74 ft. lbs.)
Install the rear mount and bolts, tighten to 100 N.m (74 ft. lbs.).
Install the bolt (2) holding the ground cable (3) to the front mount bracket (1) and tighten to 50 N.m (37 ft. lbs.).
Install the transaxle-to-engine upper bolts and tighten to 70 N.m (52 ft. lbs.).
Install halfshaft assemblies. Refer to «Differential and Driveline/Half Shaft - Installation»(ref-353569-S33188263152010011200000) .
Install and connect crankshaft position sensor (1) and tighten to 12 N.m (105 in. lbs.).
Connect oil cooler lines to transaxle. An audible 'click' should be heard. Verify connection by pulling outward. Refer to «STANDARD PROCEDURE»(ref-353584-S11016185952010011200000) .
Connect gearshift cable to the bracket
Connect gearshift cable to transaxle manual valve lever. Verify adjustment.
Connect the powertrain control module electrical connector.
Install the air box (3) and the engine cover.
Connect the intake air tempter sensor electrical connector (1).
Connect negative battery cable.

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Scheme 802: SCHEMATICS AND DIAGRAMS

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62TE Automatic Transmission - Service Information: Diagnosis Dodge Journey I