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HOMESERVICE MANUALSDODGE AND RAM2000INTREPID R/TREPAIR AND DIAGNOSISTRANSMISSIONAUTOMATIC TRANSOVERHAUL - 42LE AUTOMATIC TRANSMISSIONTRANSAXLE REASSEMBLYVALVE BODY & INTERNAL COMPONENTS
2000 Dodge and Ram Intrepid R/T

Valve Body & Internal Components

2000 Dodge and Ram Intrepid R/TSECTION Valve Body & Internal Components
  1. Using NEW gasket, install low-reverse clutch piston retainer in transaxle case. See Figure . Ensure 3 holes on gasket are aligned with 3 holes in transaxle case.
  2. Install and tighten low-reverse clutch piston retainer Torx screws to specification. See TORQUE SPECIFICATIONS  . Install low-reverse clutch piston inside transaxle case.
  3. Ensure components and spring on parking sprag assembly are properly installed. Perform STEP 4. See Figure . Install parking sprag assembly in transaxle case. Ensure guide bracket and sleeve on parking sprag assembly contacts rear of transaxle case.
  4. Install pivot pin and anchor shaft. Install and tighten parking sprag bolt to specification.
  5. Install clutch piston return spring for low-reverse clutch in transaxle case. Using spring compressor, compress clutch piston return spring for low-reverse clutch. See Figure . Install snap ring so ends of snap ring are properly positioned.
    CAUTION: Output shaft bearing preload must be checked and/or adjusted if any of the following components are replaced: rear planetary carrier and output shaft, output shaft bearings or transaxle case. See OUTPUT SHAFT BEARING PRELOAD  under COMPONENT DISASSEMBLY & REASSEMBLY.
  6. Install rear bearing for output shaft and Plate (6618-A) on rear of transaxle case. See Figure . Slightly tighten retaining bolts on plate until bolt heads are below surface of plate. DO NOT fully tighten bolts.
  7. Place transaxle case in press so plate is supported. Ensure clearance is present so output shaft can extend through plate when installed.
  8. Apply small amount of petroleum jelly to output shaft shim. Install output shaft shim on output shaft, just above bearing. Install output shaft in transaxle case. Press output shaft into rear bearing and transaxle case.
  9. Install NEW output shaft nut on output shaft. DO NOT reuse old output shaft nut. Install Holder (6497) on output shaft nut. Using torque wrench and Adapter (6498), tighten output shaft nut by turning counterclockwise. See Figure . Tighten output shaft nut to specification. See TORQUE SPECIFICATIONS  .
  10. Ensure no end play is present on output shaft. Use press and Staking Adapter (6589) to stake output shaft nut against output shaft. Ensure staked area on output shaft nut is fully bottomed in groove area on output shaft. Remove transaxle case from press. Remove plate from rear of transaxle case.
  11. Install transfer drive chain and sprockets. See TRANSFER DRIVE CHAIN & SPROCKETS  . Install 5 low-reverse clutch plates and 5 clutch discs, starting with a clutch plate and alternating with a clutch disc. See Figure . Ensure components are in correct sequence.
  12. Install flat snap ring and one low-reverse clutch plate. Ensure ends of snap ring are positioned between 2 and 3 o'clock position. See Fig 1 .
    Fig 1: Installing Snap Rings
    G94I36697Courtesy of CHRYSLER CORP.
  13. Install low-reverse clutch reaction plate. See Figure . Ensure flat side of low-reverse clutch reaction plate is facing upward, toward oil pump opening. Install tapered snap ring above low-reverse clutch reaction plate. Ensure ends of tapered snap ring are positioned between 9 and 10 o'clock position. See Fig 1 .
    14. CAUTION: Low-reverse clutch clearance must be checked after installing clutch assembly.
  14. To check low-reverse clutch clearance, assemble dial indicator and Dial Indicator Tip (6268) on transaxle case. See Fig 2 . Press low-reverse clutch pack downward and zero dial indicator. Using hook, pull one low-reverse clutch disc upward and note low-reverse clutch clearance on dial indicator. Remove dial indicator.
  15. Low-reverse clutch clearance should be .035-.060" (.89-1.52 mm). If clearance is not within specification, different thickness low-reverse clutch reaction plate can be installed. Low-reverse clutch reaction plates are available in the following thicknesses: .232" (5.89 mm), .242" (6.15 mm), .252" (6.40 mm), .262" (6.65 mm) and .273" (6.93 mm).
    Fig 2: Checking Low-Reverse Clutch Clearance
    G94J36698Courtesy of CHRYSLER CORP.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.