Disassembly And Assembly

DISASSEMBLY 

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Courtesy of CHRYSLER GROUP, LLC

1. Remove the reverse reaction plate selective snap-ring (10) from the input clutch retainer.
2. Remove the reverse reaction plate (9) from the input clutch retainer.
3. Remove the reverse hub (7) and reverse clutch pack (8) from the input clutch retainer.
4. Remove the number 4 thrust bearing (5) from the overdrive hub (2).
5. Remove the overdrive hub (2) from the input clutch retainer.
6. Remove the number 3 thrust bearing (1) from the underdrive hub (17).
7. Remove the OD/reverse pressure plate snap-ring (6) from the from the OD/reverse piston.
8. Remove the OD/reverse pressure plate (4), overdrive clutch (13), and UD hub (17) from the input clutch retainer.
9. Remove the number 2 thrust bearing (18) from the input clutch hub.
10. Remove the overdrive clutch wave snap-ring (3) from the from the OD/reverse piston.
11. Remove the UD/OD reaction plate tapered snap-ring (14) from the input clutch retainer.
12. Remove the UD/OD reaction plate (15) from the input clutch retainer.
13. Remove the UD/OD reaction plate flat snap-ring (16) from the input clutch retainer.

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    1 - INPUT CLUTCH HUB

    11 - UD CLUTCH

    2 - O-RING SEALS

    12 - UD OUTER DISC

    3 - SEAL

    13 - INPUT CLUTCH RETAINER

    4 - SNAP-RING

    14 - SEAL

    5 - SNAP-RING

    15 - OD/REV PISTON

    6 - UD BALANCE PISTON

    16 - BELLEVILLE SPRING

    7 - SNAP-RING

    17 - SNAP-RING

    8 - UD PISTON

    18 - SEAL RINGS

    9 - UD SPRING PACK

    19 - INPUT SHAFT

    10 - UD INNER DISC

    20 - LUBRICATION CHECK VALVE AND SNAP-RING

14. Remove the underdrive clutch pack (11) from the input clutch retainer (13).

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    1 - PRESS

    2 - TOOL 8251

    3 - BALANCE PISTON

15. Using Spring Compressor (Special Tool No. 8251, Compressor, Spring) (2) and an arbor press (1), compress the UD balance piston (3) and remove the snap-ring from the input clutch hub.

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    1 - INPUT CLUTCH HUB

    11 - UD CLUTCH

    2 - O-RING SEALS

    12 - UD OUTER DISC

    3 - SEAL

    13 - INPUT CLUTCH RETAINER

    4 - SNAP-RING

    14 - SEAL

    5 - SNAP-RING

    15 - OD/REV PISTON

    6 - UD BALANCE PISTON

    16 - BELLEVILLE SPRING

    7 - SNAP-RING

    17 - SNAP-RING

    8 - UD PISTON

    18 - SEAL RINGS

    9 - UD SPRING PACK

    19 - INPUT SHAFT

    10 - UD INNER DISC

    20 - LUBRICATION CHECK VALVE AND SNAP-RING

16. Remove the UD balance piston (6) and piston return spring (9) from the input clutch retainer (13).
17. Remove the underdrive piston (8) from the input clutch retainer (13).
    NOTE:

    Both the UD 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 (5).
19. Separate input clutch retainer (13) from input clutch hub (1).
20. Separate OD/reverse piston (15) from input clutch hub retainer (13).

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    1 - ARBOR PRESS

    2 - TOOL 8349-1

    3 - OD / REVERSE PISTON

21. Using Arbor Press (1) and tool (Special Tool No. 8349-1, Installer Crank Seal) (2) compress the OD / Reverse belleville spring just enough to remove the snap ring.
22. Remove the belleville spring and snap ring from the OD / Reverse piston (3).
23. 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 

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Courtesy of CHRYSLER GROUP, LLC

Courtesy of CHRYSLER GROUP, LLC

1. Install the belleville spring and snap ring loosely onto the OD / Reverse piston (3).
2. Using an Arbor Press (1) and tool (Special Tool No. 8349-1, Installer Crank Seal) (2) compress the belleville spring just enough to install the snap ring.

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   1 - INPUT CLUTCH HUB

   11 - UD CLUTCH

   2 - O-RING SEALS

   12 - UD OUTER DISC

   3 - SEAL

   13 - INPUT CLUTCH RETAINER

   4 - SNAP-RING

   14 - SEAL

   5 - SNAP-RING

   15 - OD/REV PISTON

   6 - UD BALANCE PISTON

   16 - BELLEVILLE SPRING

   7 - SNAP-RING

   17 - SNAP-RING

   8 - UD PISTON

   18 - SEAL RINGS

   9 - UD SPRING PACK

   19 - INPUT SHAFT

   10 - UD INNER DISC

   20 - LUBRICATION CHECK VALVE AND SNAP-RING

   NOTE:

   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.

3. Check the transmission lubrication check valve (20) located in the input shaft using shop air. The valve should only allow air flow in one direction. If the valve allows no air flow, or air flow in both directions, the valve will need to be replaced.
4. Lubricate all seals with Mopar® ATF +4, Automatic Transmission Fluid, prior to installation.
5. Assemble the OD/reverse piston (15) onto the input clutch retainer (13).
6. Assemble the input clutch retainer (13) onto the input clutch hub (1).
7. Install the input clutch retainer tapered snap-ring (5) with tapered side up onto the input clutch hub (1).

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   1 - PISTON GUIDES 8504

8. Install Piston Installer (Special Tool No. 8504-1, Piston Installer (Outer)) (1) into the input clutch retainer and onto the input clutch hub to guide the inner and outer underdrive piston seals into position.
9. Install the underdrive piston into the input clutch retainer and over the input clutch hub.

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   1 - TOOL 8252

10. Install the UD balance piston return spring pack into the input clutch retainer.
11. Install Piston Installer (Special Tool No. 8252, Installer) (1) into the input clutch retainer to guide the UD balance piston seal into position inside the underdrive piston.

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    1 - PRESS

    2 - TOOL 8251

    3 - BALANCE PISTON

12. Install the UD balance piston (3) into the input clutch retainer and the underdrive piston.
13. Using Spring Compressor (Special Tool No. 8251, Compressor, Spring) (2), compress the UD return spring pack and secure the piston in place with the snap-ring.
    NOTE:

    The 68RFE UD clutch discs (both the internal-and external-toothed discs) can now be identified by the numbers "605/604" which are laser-burned into the friction material facing. Install an outer-toothed disc first then alternate inner and outer discs, ending with an inner-toothed disc on top, install all discs with the friction material facing up.

14. Install the underdrive clutch pack into the input clutch retainer.

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    1 - THRUST BEARING NUMBER 3

    10 - SNAP-RING (SELECT)

    2 - OD HUB/SHAFT

    11 - OD OUTER DISC

    3 - SNAP-RING (WAVE)

    12 - OD INNER DISC

    4 - REV/OD PRESSURE PLATE

    13 - OD CLUTCH

    5 - THRUST BEARING NUMBER 4

    14 - SNAP-RING (TAPERED)

    6 - SNAP-RING (FLAT)

    15 - UD/OD REACTION PLATE

    7 - REVERSE HUB/SHAFT

    16 - SNAP-RING (FLAT)

    8 - REVERSE CLUTCH

    17 - UD HUB/SHAFT

    9 - REVERSE REACTION PLATE

    18 - THRUST BEARING NUMBER 2

15. Install the UD / OD reaction plate lower flat snap-ring (16). The correct snap-ring can be identified by the two tabbed ears.
16. Install the UD / OD reaction plate (15) into the input clutch retainer. The reaction plate is to be installed with the wide face down, and the narrow face up.
17. Install the UD reaction plate upper tapered snap-ring (14) with tapered side up, and with both tips underneath the retainer lugs.

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    1 - INPUT CLUTCH ASSEMBLY

    2 - TOOL 8260

18. Install the input clutch assembly (1) into Input Clutch Pressure Fixture (Special Tool No. 8260A, Fixture, Input Clutch) (2).

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    1 - TOOL C-3339

    2 - UNDERDRIVE CLUTCH PACK

19. Mount a dial indicator (Special Tool No. C-3339A, Set, Dial Indicator) (1) on the input clutch hub. Push down on the UD clutch discs (2) and zero the indicator against the UD clutch discs. Apply 20 psi of air pressure to the UD 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 1.02-1.72 mm (0.040-0.068 in.). The reaction plate is not selective. If the clutch clearance is not within specification, replace the reaction plate along with all the friction and steel discs.

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    1 - THRUST BEARING NUMBER 3

    10 - SNAP-RING (SELECT)

    2 - OD HUB/SHAFT

    11 - OD OUTER DISC

    3 - SNAP-RING (WAVE)

    12 - OD INNER DISC

    4 - REV/OD PRESSURE PLATE

    13 - OD CLUTCH

    5 - THRUST BEARING NUMBER 4

    14 - SNAP-RING (TAPERED)

    6 - SNAP-RING (FLAT)

    15 - UD/OD REACTION PLATE

    7 - REVERSE HUB/SHAFT

    16 - SNAP-RING (FLAT)

    8 - REVERSE CLUTCH

    17 - UD HUB/SHAFT

    9 - REVERSE REACTION PLATE

    18 - THRUST BEARING NUMBER 2

20. Install the overdrive clutch pack (13) into the input clutch retainer. Install an outer toothed disc (11) first and then alternate inner disc (12) and outer discs, ending with a inner toothed disc (12) on top. Install all discs with the friction material facing up.
21. Install the overdrive clutch wavy snap-ring (3) with the two tabbed ears into the OD/reverse piston.
22. Install the OD/reverse pressure plate (4) into the input clutch retainer, with the stepped face down toward the OD clutch.
23. Install the OD/reverse pressure plate flat snap-ring (6) into the OD/reverse piston.

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    1 - TOOL C-3339

    2 - OD/REV REACTION PLATE

24. Mount a dial indicator (Special Tool No. C-3339A, Set, Dial Indicator) (1) on the input clutch hub and zero the indicator against the OD/reverse pressure plate (2). Apply 20 psi of air pressure to the overdrive clutch and record the dial indicator reading. Measure and record OD clutch pack measurement 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 0.75-1.61 mm (0.030-0.063 in.). The OD / Reverse pressure plate is selective. If the clutch clearance is not within specification, select and install the proper pressure plate.
    NOTE:

    The 68RFE uses three (3) selective OD/Rev pressure plates. Two of the three plates have a numeric identification number and a stepped face.

    SELECTABLE END PLAY PRESSURE PLATES

    • One stepped face, identification number 1 = 8.90 mm (0.350 in.)
    • One stepped face, identification number 2 = 9.34 mm (0.367 in.)
    • Both faces flat, no identification number = 9.74 mm (0.383 in.)

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    1 - TOOL C-3339

    2 - REVERSE CLUTCH PACK

25. Install the reverse clutch pack into the input clutch retainer.
26. Install the reverse reaction plate into the input clutch retainer.
27. Install the reverse reaction plate selective snap-ring into the input clutch retainer.
28. Mount a dial indicator to the assembly, push down on the clutch discs, pull up on the reaction plate to ensure the plate is properly seated and zero the indicator against the reverse clutch discs (2). 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 places, 90° apart. Take average of four measurements and compare with Reverse clutch pack clearance specification. The correct clutch clearance is 0.58-1.47 mm (0.023-0.058 in.). Adjust as necessary. Install the chosen snap-ring and re-measure to verify selection.
    NOTE:

    The 68RFE uses one of three (3) different selective snap rings. They are identified by the end cuts (either straight [square] cut or "butterfly" [S-curved] cut):

    SELECTABLE END PLAY SNAP RINGS

    • One Square End, One Buttery Fly End = 1.55 mm (0.061 in.)
    • Both Ends Square Cut = 1.85 mm (0.073 in)
    • Both Ends Buttery Fly Cut = 2.2 mm (0.087 in.)

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    1 - THRUST BEARING NUMBER 3

    10 - SNAP-RING (SELECT)

    2 - OD HUB/SHAFT

    11 - OD OUTER DISC

    3 - SNAP-RING (WAVE)

    12 - OD INNER DISC

    4 - REV/OD PRESSURE PLATE

    13 - OD CLUTCH

    5 - THRUST BEARING NUMBER 4

    14 - SNAP-RING (TAPERED)

    6 - SNAP-RING (FLAT)

    15 - UD/OD REACTION PLATE

    7 - REVERSE HUB/SHAFT

    16 - SNAP-RING (FLAT)

    8 - REVERSE CLUTCH

    17 - UD HUB/SHAFT

    9 - REVERSE REACTION PLATE

    18 - THRUST BEARING NUMBER 2

29. Remove the reverse clutch pack (8) from the input clutch retainer.
30. Install the number 2 thrust bearing (18) onto the underdrive hub (17) with outer race against the hub with petroleum jelly.
31. Install the underdrive hub (17) into the input clutch retainer.
32. Install the number 3 thrust bearing (1) into the overdrive hub (2) with the outer race against the hub with petroleum jelly.
33. Install the overdrive hub (2) into the input clutch retainer.
34. Install the number 4 thrust bearing (5) into the reverse hub with outer race against the hub with petroleum jelly.
35. Install the reverse hub (7) into the input clutch retainer.
36. Install the complete reverse clutch pack (8).
37. Install the reverse reaction plate (9) and snap-ring (10).
38. Push up on reaction plate to allow reverse clutch to move freely.