Toyota
Dodge Durango
 Service Manual
Transmission and Transfer Case » Disassembly and assembly
Planetary geartrain/output shaft

DISASSEMBLY

(1) Remove planetary snap ring (Fig. 222).

(2) Remove front annulus and planetary assembly from driving shell (Fig. 222).

(3) Remove snap ring that retains front planetary gear in annulus gear (Fig. 223).

(4) Remove tabbed thrust washer and tabbed thrust plate from hub of front annulus (Fig. 224).

(5) Separate front annulus and planetary gears (Fig. 224).

(6) Remove front planetary gear front thrust washer from annulus gear hub.

(7) Separate and remove driving shell, rear planetary and rear annulus from output shaft (Fig. 225).

Fig. 222 Front Annulus And Planetary Assembly Removal Fig. 222 Front Annulus And Planetary Assembly Removal

1 - DRIVING SHELL

2 - FRONT ANNULUS AND PLANETARY ASSEMBLY

3 - PLANETARY SNAP RING

(8) Remove front planetary rear thrust washer from driving shell.

(9) Remove tabbed thrust washers from rear planetary gear.

(10) Remove lock ring that retains sun gear in driving shell. Then remove sun gear, spacer and thrust plates.

Fig. 223 Front Planetary Snap Ring Removal Fig. 223 Front Planetary Snap Ring Removal

1 - FRONT ANNULUS GEAR

2 - PLANETARY SNAP RING

Fig. 224 Front Planetary And Annulus Gear Disassembly Fig. 224 Front Planetary And Annulus Gear Disassembly

1 - FRONT ANNULUS

2 - THRUST WASHER

3 - THRUST PLATE

4 - FRONT THRUST WASHER

5 - FRONT PLANETARY

ASSEMBLY

(1) Lubricate output shaft and planetary components with transmission fluid. Use petroleum jelly to lubricate and hold thrust washers and plates in position.

(2) Assemble rear annulus gear and support if disassembled.

Be sure support snap ring is seated and that shoulder-side of support faces rearward (Fig.

226).

Fig. 225 Removing Driving Shell, Rear Planetary And Rear Annulus Fig. 225 Removing Driving Shell, Rear Planetary And Rear Annulus

1 - REAR ANNULUS

2 - REAR PLANETARY

3 - DRIVING SHELL

4 - OUTPUT SHAFT

(3) Install rear thrust washer on rear planetary gear. Use enough petroleum jelly to hold washer in place. Also be sure all four washer tabs are properly engaged in gear slots.

(4) Install rear annulus over and onto rear planetary gear (Fig. 226).

(5) Install assembled rear planetary and annulus gear on output shaft (Fig. 227). Verify that assembly is fully seated on shaft.

(6) Install front thrust washer on rear planetary gear (Fig. 228). Use enough petroleum jelly to hold washer on gear. Be sure all four washer tabs are seated in slots.

Fig. 226 Assembling Rear Annulus And Planetary Gear Fig. 226 Assembling Rear Annulus And Planetary Gear

1 - REAR ANNULUS GEAR

2 - TABBED THRUST WASHER

3 - REAR PLANETARY

(7) Install spacer on sun gear (Fig. 229).

(8) Install thrust plate on sun gear (Fig. 230). Note that driving shell thrust plates are interchangeable.

Use either plate on sun gear and at front/rear of shell.

Fig. 227 Installing Rear Annulus And Planetary On Output Shaft Fig. 227 Installing Rear Annulus And Planetary On Output Shaft

1 - REAR ANNULUS AND PLANETARY GEAR ASSEMBLY

2 - OUTPUT SHAFT

Fig. 228 Installing Rear Planetary Front Thrust Washer Fig. 228 Installing Rear Planetary Front Thrust Washer

1 - FRONT TABBED THRUST WASHER

2 - REAR PLANETARY GEAR

Fig. 229 Installing Spacer On Sun Gear Fig. 229 Installing Spacer On Sun Gear

1 - SUN GEAR

2 - SUN GEAR SPACER

Fig. 230 Installing Driving Shell Front Thrust Plate On Sun Gear

Fig. 230 Installing Driving Shell Front Thrust Plate On Sun Gear

1 - SPACER

2 - SUN GEAR

3 - THRUST PLATE

(9) Hold sun gear in place and install thrust plate over sun gear at rear of driving shell (Fig. 231).

(10) Position wood block on bench and support sun gear on block (Fig. 232). This makes it easier to align and install sun gear lock ring. Keep wood block handy as it will also be used for geartrain end play check.

Fig. 231 Installing Driving Shell Rear Thrust Plate Fig. 231 Installing Driving Shell Rear Thrust Plate

1 - DRIVING SHELL

2 - SUN GEAR

3 - REAR THRUST PLATE

Fig. 232 Supporting Sun Gear On Wood Block Fig. 232 Supporting Sun Gear On Wood Block

1 - SUN GEAR

2 - DRIVING SHELL

3 - WOOD BLOCK

(11) Align rear thrust plate on driving shell and install sun gear lock ring. Be sure ring is fully seated in sun gear ring groove (Fig. 233).

(12) Install assembled driving shell and sun gear on output shaft (Fig. 234).

(13) Install rear thrust washer on front planetary gear (Fig. 235). Use enough petroleum jelly to hold washer in place and be sure all four washer tabs are seated.

Fig. 233 Installing Sun Gear Lock Ring Fig. 233 Installing Sun Gear Lock Ring

1 - LOCK RING GROOVE

2 - SUN GEAR LOCK RING

3 - DRIVING SHELL

4 - REAR THRUST PLATE

Fig. 234 Installing Assembled Sun Gear And Driving Shell On Output Shaft Fig. 234 Installing Assembled Sun Gear And Driving Shell On Output Shaft

1 - SUN GEAR/DRIVING SHELL ASSEMBLY

2 - OUTPUT SHAFT

Fig. 235 Installing Rear Thrust Washer On Front Planetary Gear Fig. 235 Installing Rear Thrust Washer On Front Planetary Gear

1 - FRONT PLANETARY GEAR

2 - REAR TABBED THRUST WASHER

(14) Install front planetary gear on output shaft and in driving shell (Fig. 236).

(15) Install front thrust washer on front planetary gear. Use enough petroleum jelly to hold washer in place and be sure all four washer tabs are seated.

(16) Assemble front annulus gear and support, if necessary. Be sure support snap ring is seated.

(17) Install front annulus on front planetary (Fig.

236).

Fig. 236 Installing Front Planetary And Annulus Gears Fig. 236 Installing Front Planetary And Annulus Gears

1 - FRONT PLANETARY GEAR

2 - FRONT THRUST WASHER

3 - FRONT ANNULUS GEAR

(18) Position thrust plate on front annulus gear support (Fig. 237). Note that plate has two tabs on it. These tabs fit in notches of annulus hub.

(19) Install thrust washer in front annulus (Fig.

238). Align flat on washer with flat on planetary hub. Also be sure washer tab is facing up.

(20) Install front annulus snap ring (Fig. 239). Use snap ring pliers to avoid distorting ring during installation. Also be sure ring is fully seated.

(21) Install planetary selective snap ring with snap ring pliers (Fig. 240). Be sure ring is fully seated.

(22) Turn planetary geartrain assembly over so driving shell is facing workbench. Then support geartrain on wood block positioned under forward end of output shaft. This allows geartrain components to move forward for accurate end play check.

Fig. 237 Positioning Thrust Plate On Front Annulus Support Fig. 237 Positioning Thrust Plate On Front Annulus Support

1 - FRONT ANNULUS

2 - THRUST PLATE

Fig. 238 Installing Front Annulus Thrust Washer Fig. 238 Installing Front Annulus Thrust Washer

1 - WASHER FLAT ALIGNS WITH FLAT ON PLANETARY HUB

2 - FRONT ANNULUS THRUST WASHER

3 - TAB FACES FRONT

(23) Check planetary geartrain end play with feeler gauge (Fig. 241). Gauge goes between shoulder on output shaft and end of rear annulus support.

(24) Geartrain end play should be 0.12 to 1.22 mm (0.005 to 0.048 in.). If end play is incorrect, snap ring (or thrust washers) may have to be replaced. Snap ring is available in three different thicknesses for adjustment purposes.

Fig. 239 Installing Front Annulus Snap Ring Fig. 239 Installing Front Annulus Snap Ring

1 - SNAP RING PLIERS

2 - FRONT ANNULUS SNAP RING

Fig. 240 Installing Planetary Selective Snap Ring Fig. 240 Installing Planetary Selective Snap Ring

1 - SELECTIVE SNAP RING

2 - SNAP RING PLIERS

Fig. 241 Checking Planetary Geartrain End Play Fig. 241 Checking Planetary Geartrain End Play

1 - OUTPUT SHAFT

2 - REAR ANNULUS GEAR

3 - FEELER GAUGE

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    Dodge Durango Service Manual / Transmission and Transfer Case / Disassembly and assembly / Planetary geartrain/output shaft

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