Dodge Durango

 Service Manual

Transmission and Transfer Case » Disassembly and assembly
Oil pump and reaction shaft support

DISASSEMBLY

(1) Remove seal ring from housing and reaction shaft support (Fig. 196).

(2) Mark pump housing and support assembly for alignment reference.

(3) Remove bolts attaching pump body to support (Fig. 197).

< Fig. 196 Removing Pump Seal Ring

1 - PUMP HOUSING SEAL RING

Fig. 197 Pump Support Bolts

1 - REACTION SHAFT SUPPORT

2 - PUMP

(4) Separate support from pump housing (Fig.

198).

(5) Remove inner and outer gears from reaction shaft support (Fig. 199).

(6) If pump seal was not removed during transmission disassembly, remove seal with punch and hammer.

(7) Remove front clutch thrust washer from support hub (Fig. 200).

OIL PUMP BUSHING REPLACEMENT

(1) Remove pump bushing with Tool Handle C-4171 and Bushing Remover SP-3551 from Tool Set C-3887-J (Fig. 201).

(2) Install new pump bushing with Tool Handle C-4171 and Bushing Installer SP-5117 (Fig. 201).

Bushing should be flush with pump housing bore.

Fig. 198 Separating Pump Housing From Reaction Shaft Support

1 - REACTION SHAFT SUPPORT

2 - PUMP HOUSING

Fig. 199 Pump Gear Removal

1 - REACTION SHAFT SUPPORT

2 - INNER GEAR

3 - OUTER GEAR

Fig. 200 Support Hub Thrust Washer

1 - BUSHING

2 - REACTION SHAFT SUPPORT

3 - THRUST WASHER

4 - HUB

(3) Stake new pump bushing in two places with blunt punch (Fig. 202). Remove burrs from stake points with knife blade afterward.

Fig. 201 Removing Oil Pump Bushing

1 - SPECIAL TOOL C-4171

2 - SPECIAL TOOL SP-3551

3 - BUSHING

4 - SPECIAL TOOL SP-5117

5 - BUSHING

6 - SPECIAL TOOL C-4171

7 - PUMP HOUSING

Fig. 202 Staking Oil Pump Bushing

1 - NARROW BLADE

2 - BLUNT PUNCH

3 - TWO STAKES

REACTION SHAFT SUPPORT BUSHING REMOVAL

(1) Assemble Bushing Remover Tools SP-1191, 3633 and 5324 (Fig. 203). Do not clamp any part of reaction shaft or support in vise.

(2) Hold Cup Tool SP-3633 firmly against reaction shaft and thread remover SP-5324 into bushing as far as possible by hand. Then thread remover tool 3-4 additional turns into bushing with a wrench.

(3) Turn remover tool hex nut down against remover cup to pull bushing from shaft. Clean all chips from shaft after bushing removal.

(4) Lightly grip old bushing in vise or with pliers and back remover tool out of bushing.

(5) Assemble Bushing Installer Tools C-4171 and SP-5325 (Fig. 203).

(6) Slide new bushing onto Installer Tool SP-5325.

(7) Position reaction shaft support upright on a clean smooth surface.

(8) Align bushing in bore. Then tap bushing into place until Bushing Installer SP-5325 bottoms.

(9) Clean reaction shaft support thoroughly after installing bushing.

Fig. 203 Replacing Reaction Shaft Support Bushing

1 - SPECIAL TOOL SP-1191

2 - SPECIAL TOOL SP-3633

3 - SPECIAL TOOL C-4171

4 - SPECIAL TOOL SP-5325

5 - REACTION SHAFT

6 - SPECIAL TOOL SP-5324

7 - BUSHING

ASSEMBLY

(1) Lubricate gear bore in pump housing with transmission fluid.

(2) Lubricate pump gears with transmission fluid.

(3) Support pump housing on wood blocks (Fig.

204).

(4) Install outer gear in pump housing (Fig. 204).

Gear can be installed either way (it is not a one-way fit).

(5) Install pump inner gear (Fig. 205).

CAUTION: The pump inner gear is a one way fit.

The bore on one side of the gear inside diameter (I.D.) is chamfered. Be sure the chamfered side faces forward (to front of pump).

Fig. 204 Supporting Pump And Installing Outer Gear

1 - OUTER GEAR

2 - PUMP HOUSING

3 - WOOD BLOCKS

Fig. 205 Pump Inner Gear Installation

1 - OUTER GEAR

2 - INNER GEAR

(6) Install new thrust washer on hub of reaction shaft support. Lubricate washer with transmission fluid or petroleum jelly.

(7) If reaction shaft seal rings are being replaced, install new seal rings on support hub (Fig. 206).

Lubricate seal rings with transmission fluid or petroleum jelly after installation. Squeeze each ring until ring ends are securely hooked together.

CAUTION: The reaction shaft support seal rings will break if overspread, or twisted. If new rings are being installed, spread them only enough for installationinstallation.

Also be very sure the ring ends are securely hooked together after installation. Otherwise, the rings will either prevent pump installation, or break during installation.

Fig. 206 Hub Seal Ring Position

1 - SEAL RINGS

2 - SUPPORT HUB

(8) Install reaction shaft support on pump housing (Fig. 207).

(9) Align reaction support on pump housing. Use alignment marks made at disassembly. Or, rotate support until bolt holes in support and pump housing are all aligned (holes are offset for one-way fit).

Fig. 207 Assembling Reaction Shaft Support And Pump Housing

1 - PUMP HOUSING

2 - REACTION SHAFT SUPPORT

(10) Install all bolts that attach support to pump housing. Then tighten bolts finger tight.

(11) Tighten support-to-pump bolts to required torque as follows: (a) Reverse pump assembly and install it in transmission case. Position pump so bolts are facing out and are accessible.

(b) Secure pump assembly in case with 2 or 3 bolts, or with pilot studs.

(c) Tighten support-to-pump bolts to 20 N*m (15 ft. lbs.).

(d) Remove pump assembly from transmission case.

(12) Install new oil seal in pump with Special Tool C-4193 and Tool Handle C-4171 (Fig. 208). Be sure seal lip faces inward.

(13) Install new seal ring around pump housing.

Be sure seal is properly seated in groove.

(14) Lubricate lip of pump oil seal and O-ring seal with transmission fluid.

Valve body

Transmission

Overrunning clutch cam/overdrive piston retainer

Front servo piston

Rear servo piston

Oil pump and reaction shaft support

Front clutch

Rear clutch

Planetary geartrain/output shaft

Overdrive unit