DODGE TOWN AND COUNTRY 2001 Service Manual

ASSEMBLY
(1) Install front clutch piston, return spring, and
retainer (Fig. 119) (Fig. 120).
(2) Compress front clutch return spring using Tool
C3575A and install snap ring (Fig. 121).(3) Install front clutch pack (Fig. 122).
(4) Install reaction plate and waved snap ring (Fig.
123) (Fig. 124).
Fig. 120 Front Clutch Return Spring and Piston
1 - LIP SEALS
2 - PISTON
3 - RETURN SPRING RETAINER
4 - SNAP RING
5 - PISTON RETURN SPRING
6 - FRONT CLUTCH RETAINER
Fig. 121 Front Clutch Return Spring Snap Ring
1 - COMPRESSOR TOOL C-3575-A
2 - FRONT CLUTCH RETAINER
3 - SNAP RING
4 - SNAP RING PLIERS
Fig. 122 Front Clutch (4-Disc Shown)
1 - FRONT CLUTCH RETAINER
2 - CLUTCH PLATES
3 - DRIVING DISCS
Fig. 123 Thick Steel Plate and Waved Snap Ring
1 - WAVED SNAP RING
2 - THICK STEEL PLATE
3 - FRONT CLUTCH RETAINER
21 - 84 AUTOMATIC - 31THRS
CLUTCH - FRONT (Continued)
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(5) Using feeler gauge, measure front clutch clear-
ance (Fig. 125).Front clutch clearance should be
within 1.27-2.79 mm (0.050-0.110 in.) and is not
adjustable.
CLUTCH - REAR
DESCRIPTION
The rear clutch assembly (Fig. 132) is composed of
the input shaft, rear clutch retainer, pressure plate,
clutch plates, driving discs, piston, Belleville spring,
and snap-rings. The Belleville spring acts as a lever
to multiply the force applied on to it by the apply pis-
ton. The increased apply force on the rear clutch
pack, in comparison to the front clutch pack, is
needed to hold against the greater torque load
imposed onto the rear pack. The rear clutch is
directly behind the front clutch and is considered a
driving component.
NOTE: The number of discs and plates may vary
with each engine and vehicle combination.
OPERATION
To apply the clutch, pressure is applied between
the clutch retainer and piston. The fluid pressure is
provided by the oil pump, transferred through the
control valves and passageways, and enters the
clutch through the hub of the reaction shaft support.
With pressure applied between the clutch retainer
and piston, the piston moves away from the clutch
retainer and compresses the clutch pack. This action
applies the clutch pack, allowing torque to flow
through the input shaft into the driving discs, and
into the clutch plates and pressure plate that are
lugged to the clutch retainer. The waved snap-ring is
used to cushion the application of the clutch pack. In
some transmissions, the snap-ring is selective and
used to adjust clutch pack clearance.
When pressure is released from the piston, the
spring returns the piston to its fully released position
and disengages the clutch. The release spring also
helps to cushion the application of the clutch assem-
bly. When the clutch is in the process of being
released by the release spring, fluid flows through a
vent and one-way ball-check-valve located in the
clutch retainer. The check-valve is needed to elimi-
nate the possibility of plate drag caused by centrifu-
gal force acting on the residual fluid trapped in the
clutch piston retainer.
Fig. 124 Front Clutch Waved Snap Ring
1 - WAVED SNAP RING
2 - SCREWDRIVER
3 - FRONT CLUTCH ASSEMBLY
Fig. 125 Measuring Front Clutch Plate Clearance
1 - FEELER GAUGE
2 - FRONT CLUTCH ASSEMBLY
RSAUTOMATIC - 31TH21-85
CLUTCH - FRONT (Continued)
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DISASSEMBLY
(1) Remove rear clutch snap ring (Fig. 126) (Fig.
132).
(2) Remove rear clutch pack (Fig. 127).(3) Remove piston/belleville snap ring (Fig. 128).
(4) Remove rear clutch piston and belleville spring
(Fig. 129).
Fig. 126 Rear Clutch Outer Snap Ring
1 - SCREWDRIVER
2 - SNAP RING
3 - REAR CLUTCH ASSEMBLY
Fig. 127 Rear Clutch (4-Disc Shown)
1 - REAR CLUTCH RETAINER
2 - CLUTCH PLATES
3 - THICK STEEL PLATE
4 - SNAP RING (SELECTIVE)
5 - DRIVING DISCS
6 - PRESSURE PLATE
Fig. 128 Piston Spring Waved Snap Ring
1 - REAR CLUTCH RETAINER
2 - PISTON SPRING
3 - SCREWDRIVER
4 - WAVED SNAP RING
Fig. 129 Rear Clutch Piston and Piston Spring
1 - INPUT SHAFT
2 - REAR CLUTCH RETAINER
3 - PISTON SPRING
4 - WAVED SNAP RING
5 - PISTON
6 - PISTON SEALS
21 - 86 AUTOMATIC - 31THRS
CLUTCH - REAR (Continued)
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Remove input shaft-to-clutch retainer snap ring
(Fig. 130) (Fig. 131). Press input shaft out of retainer
if necessary.
Fig. 130 Input Shaft Snap Ring
1 - INPUT SHAFT
2 - REAR CLUTCH RETAINER
3 - SNAP RING PLIERS
4 - SNAP RING
Fig. 131 Input Shaft Snap
1 - INPUT SHAFT
2 - REAR CLUTCH RETAINER
3 - SNAP RING
RSAUTOMATIC - 31TH21-87
CLUTCH - REAR (Continued)
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Fig. 132 Rear Clutch Assembly
1 - SNAP RING (SELECT)
2 - REACTION PLATE
3 - CLUTCH DISC
4 - CLUTCH PLATE
5 - REACTION PLATE
6 - CLUTCH RETAINER
7 - INPUT SHAFT8 - SNAP RING
9 - PISTON
10 - SPRING
11 - SNAP RING (WAVE)
12 - SEAL
13 - SEAL
21 - 88 AUTOMATIC - 31THRS
CLUTCH - REAR (Continued)
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ASSEMBLY
(1) Install input shaft-to-clutch retainer snap ring
(Fig. 133) (Fig. 134) (Fig. 132).(2) Install rear clutch piston, belleville spring and
waved snap ring (Fig. 135). Install snap ring using a
suitable screwdriver (Fig. 136).
Fig. 133 Install Input Shaft Snap Ring
1 - INPUT SHAFT
2 - REAR CLUTCH RETAINER
3 - SNAP RING PLIERS
4 - SNAP RING
Fig. 134 Input Shaft Snap Ring
1 - INPUT SHAFT
2 - REAR CLUTCH RETAINER
3 - SNAP RING
Fig. 135 Rear Clutch Piston and Piston Spring
1 - INPUT SHAFT
2 - REAR CLUTCH RETAINER
3 - PISTON SPRING
4 - WAVED SNAP RING
5 - PISTON
6 - PISTON SEALS
Fig. 136 Piston Spring Waved Snap Ring
1 - REAR CLUTCH RETAINER
2 - PISTON SPRING
3 - SCREWDRIVER
4 - WAVED SNAP RING
RSAUTOMATIC - 31TH21-89
CLUTCH - REAR (Continued)
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(3) Install rear clutch pack (Fig. 137).
(4) Install snap ring using a suitable screwdriver
(Fig. 138).(5) Using feeler gauges, measure rear clutch clear-
ance (Fig. 139).Rear clutch clearance should be
within 0.71-1.10 mm (0.028-0.043 in.).
FINAL DRIVE
DISASSEMBLY
NOTE: The differential is serviced as an assembly.
Service is limited to bearing cups and cones. Any
other failure must be repaired by differential assem-
bly and transfer shaft replacement.
(1) Remove transfer shaft.
(2) Measure differential bearing turning torque.
(Refer to 21 - TRANSMISSION/TRANSAXLE/AUTO-
MATIC - 31TH/BEARINGS - ADJUSTMENTS)
(3) Remove adapter plate seal.
(4) Remove differential cover-to-transaxle case
bolts (Fig. 140).
(5) Remove differential cover (Fig. 141). Clean sur-
faces of old adhesive prior to reassembly.
(6) Remove bearing retainer axle seal using slide
hammer C-637 and Tool 7794A, or Tool L-4518.
(7) Remove differential bearing retainer-to-trans-
axle case bolts (Fig. 142).
Fig. 137 Rear Clutch (4-Disc Shown)
1 - REAR CLUTCH RETAINER
2 - CLUTCH PLATES
3 - THICK STEEL PLATE
4 - SNAP RING (SELECTIVE)
5 - DRIVING DISCS
6 - PRESSURE PLATE
Fig. 138 Rear Clutch Outer Snap Ring
1 - SCREWDRIVER
2 - SNAP RING
3 - REAR CLUTCH ASSEMBLY
Fig. 139 Measuring Rear Clutch Plate Clearance
1 - REAR CLUTCH ASSEMBLY
2 - FEELER GAUGE
3 - SELECTIVE SNAP RING
21 - 90 AUTOMATIC - 31THRS
CLUTCH - REAR (Continued)
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(8) Remove bearing retainer from transaxle. Use to
L-4435 to aid in removal by rotating retainer out of
assembly (Fig. 143). Clean surfaces of old adhesive
prior to reassembly.
(9) Remove adapter plate-to-transaxle case bolts.WARNING: HOLD ON TO DIFFERENTIAL WHILE
REMOVING EXTENSION HOUSING TO PREVENT IT
FROM ROLLING OUT OF TRANSAXLE.
Fig. 140 Differential Cover Bolts
1 - DIFFERENTIAL COVER
2 - DIFFERENTIAL COVER BOLT
Fig. 141 Remove Differential Cover
1 - GOVERNOR PRESSURE PLUG
2 - DIFFERENTIAL COVER
3 - 1/8 INCH BEAD OF R T V SEALANT
4 - DIFFERENTIAL ASSEMBLY
Fig. 142 Differential Bearing Retainer Bolts
1 - DIFFERENTIAL BEARING RETAINER
2 - DIFFERENTIAL BEARING RETAINER BOLTS (6)
Fig. 143 Remove Bearing Retainer Using Tool
L-4435
1 - GOVERNOR PRESSURE PLUG
2 - DIFFERENTIAL BEARING RETAINER
3 - SPECIAL TOOL L-4435
RSAUTOMATIC - 31TH21-91
FINAL DRIVE (Continued)
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(10) Remove extension housing from transaxle
case. Use Tool L-4435 to aid in removal by rotating
plate out of assembly. Clean surfaces of old adhesive
prior to reassembly.
(11) Measure and record differential side gear end
play using dial indicator C-3339 and Tool C-4995 as
shown in (Fig. 144) and (Fig. 145).Side gear end
play must be within 0.001-0.013 in. Replace dif-
ferential assembly if outside this range.(12) Remove differential bearing cone (from exten-
sion housing side) using Tool C-293, and adapters
C-293-3, and C-293-36 (Fig. 146).
(13) Set up tools as shown in (Fig. 147) and (Fig.
148) to facilitate differential bearing removal from
ring gear side.
Fig. 144 Checking Side Gear End Play
1 - SPECIAL TOOL C-4996 (NOTE POSITION)
2 - DIAL INDICATOR SET
3 - DIFFERENTIAL ASSEMBLY
4 - SIDE GEAR
Fig. 145 Checking Side Gear End Play (Typical)
1 - SPECIAL TOOL C-4996 (NOTE POSITION)
2 - DIAL INDICATOR SET
3 - DIFFERENTIAL ASSEMBLY
Fig. 146 Remove Differential Bearing Cone
(Extension Housing Side)
1 - SPECIAL TOOL C-293
2 - SPECIAL TOOL C-293-36
3 - SPECIAL TOOL C-293-3
Fig. 147 Differential Bearing Removal Set-Up (Ring
Gear Side)
1 - SPECIAL TOOL L-4539-2
2 - SPECIAL TOOL 5048
3 - SPECIAL TOOL 5048-4
21 - 92 AUTOMATIC - 31THRS
FINAL DRIVE (Continued)
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(14) Remove differential bearing cone (Fig. 149).(15) Remove bearing retainer bearing cup using
Tool 6062A (Fig. 150) (Fig. 151). Remove shim and oil
baffle.
Fig. 148 Position Tool 5048 Over Button and Collets
at Differential Bearing
1 - SPECIAL TO0L 5048
2 - DIFFERENTIAL
3 - SPECIAL TOOL 5048-4
Fig. 149 Remove Differential Bearing Cone
1 - SPECIAL TOOL 5048
2 - RING GEAR
Fig. 150 Position Bearing Cup Remover Tool in
Retainer
1 - SPECIAL TOOL 6062A
2 - DIFFERENTIAL BEARING RETAINER
Fig. 151 Remove Bearing Cup using 6062A
1 - SPECIAL TOOL 6062A
2 - DIFFERENTIAL BEARING RETAINER
RSAUTOMATIC - 31TH21-93
FINAL DRIVE (Continued)
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