RAM 1500 Truck 4WD V8-5.9L VIN Z (2002)
a. Position Gauge Tool 6311 across face of overdrive case. Then position Dial Caliper C-4962 over gauge tool (Fig. 198).
b. Measure distance to clutch hub thrust bearing seat at four points 90° apart. Then average measurements by adding them and dividing by 4.
c. Select and install required thrust plate from information in thrust plate chart (Fig. 199).
3. Leave Alignment Tool 6227-2 in place. Tool will keep planetary and clutch hub splines in alignment until overdrive unit is ready for installation
on transmission.
4. Transmission speed sensor can be installed at this time if desired. However, it is recommended that sensor not be installed until after overdrive unit
is secured to transmission.
OVERDRIVE PISTON
1. Install new seals on overdrive piston.
2. Stand transmission case upright on bellhousing.
3. Position Guide Ring 8114-1 on outer edge of overdrive piston retainer.
4. Position Seal Guide 8114-3 on inner edge of overdrive piston retainer.
5. Install overdrive piston in overdrive piston retainer by:
a. Aligning locating lugs on overdrive piston to the two mating holes in retainer.
b. Lubricate overdrive piston seals with Mopar Door Ease, or equivalent.
c. Install piston over Seal Guide 8114-3 and inside Guide Ring 8114-1.
d. Push overdrive piston into position in retainer.
e. Verify that the locating lugs entered the lug bores in the retainer.
6. Install intermediate shaft spacer on intermediate shaft.
7. Install overdrive piston thrust plate on overdrive piston.
8. Install overdrive piston thrust bearing on overdrive piston.
9. Install transmission speed sensor and O-ring seal in overdrive case.
