i have a 04 neon plain jane with a sohc 2.0 auto trans went bad so i removed it and dropped it off at my tranny guy. i forgot to write down the type of transmission it was and the numbers off of it. so is this the A604 (41TE)?

he wants to charge me $800 to put new clutches in it and a used torque converter.

i can get one used that works for $475 from a local junk yard

i can buy a complete rebuild kit for $162 and then get a torque converter for under $150 and rebuild it myself.

i built Chrysler transmissions in high school so im sure if i had a book and the tools i could do this one too.

where is a good place to buy a rebuild kit and where is a good place to buy torque converters?

also is there any rebuild books available for these and where can i buy some tools to rebuild this?

if anyone who has been doing this or does do this any helpful info is greatly appreciated. if i can do this one i might start rebuilding these things on the side like i used to in high school.

thanks again in advance.

 

nobody on this site really helps anybody do they?

 

try this site for your parts: www.rockauto.com

as for instructions try this site: www.alldatadiy.com
this site requires a paid membership

DISASSEMBLY

NOTE: If transaxle is being overhauled (clutch and/or seal replacement) or replaced, it is necessary to perform the PCM/TCM Quick Learn Procedure.

NOTE: This procedure does not include final drive (differential) disassembly.

1. Remove input and output speed sensors.
2. Remove three (3) solenoid/pressure switch assembly-to-case bolts.

1. Remove solenoid/pressure switch assembly and gasket (Fig. 9).

1. Remove oil pan-to-case bolts (Fig. 10).

1. Remove oil pan (Fig. 11).

1. Remove oil filter (Fig. 12).
2. Turn manual valve fully clock-wise to get park rod into position for removal.

1. Remove valve body-to-case bolts (Fig. 13).

CAUTION: Do not handle the valve body assembly from the manual valve. Damage can result.

1. Using a screwdriver, push park rod rollers away from guide bracket (Fig. 14) and remove valve body assembly (Fig. 15).

NOTE: Depending on engine application, some accumulators will have two springs and others will have one spring. The springs are color-coded according to application and year. When disassembling, mark accumulator spring location to ease assembly.

1. Remove underdrive and overdrive accumulators (Fig. 16).

1. Remove low/reverse accumulator snap ring (Fig. 17).

1. Remove low/reverse accumulator plug (Fig. 18).

1. Remove low/reverse accumulator piston using suitable pliers (Fig. 19). Remove piston and springs (Fig. 20).

1. Measure input shaft end play. Place transaxle so input shaft is vertical. Set up end play set and dial indicator as shown in (Fig. 21). Input shaft end play should be within 0.13 - 0.64 mm (0.005 - 0.025 inch) If outside of this range, a #4 thrust plate change is required. Record indicator reading for reference upon reassembly.

1. Remove oil pump-to-case bolts (Fig. 22).

CAUTION: Be sure input speed sensor is removed before removing oil pump.

1. Install pullers Tool C-3752 as shown in (Fig. 23).

1. Remove oil pump assembly (Fig. 24) (Fig. 25).

1. Remove oil pump gasket (Fig. 26).

CAUTION: If transaxle failure has occurred, the cooler bypass valve must be replaced. Do not re-use or attempt to clean valve.

1. Remove cooler bypass valve (Fig. 27).

1. Remove #1 needle bearing (Fig. 28).

1. Remove input clutch assembly (Fig. 29).

1. Remove #4 thrust plate (Fig. 30).

1. Remove front sun gear assembly and #4 thrust washer (Fig. 31).

1. Remove front carrier/rear annulus assembly and #6 needle bearing (Fig. 32).

1. Remove rear sun gear and #7 needle bearing (Fig. 33).

NOTE: The number 7 needle bearing has three antireversal tabs and is common with the number five and number two position. The orientation should allow the bearing to seat flat against the rear sun gear (Fig. 34). A small amount of petrolatum can be used to hold the bearing to the rear sun gear.

1. Setup tool 5058 as shown in (Fig. 35). Compress 2/4 clutch return spring Oust enough to remove snap ring) and remove snap ring.

NOTE: Verify that Tool 5058 is centered properly over the 2/4 clutch retainer before compressing. If necessary, fasten the 5058 bar to the bellhousing flange with any combination of locking pliers and bolts to center the tool properly.

NOTE: The 2/4 Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.

1. Remove 2/4 clutch retainer (Fig. 36).

1. Remove 2/4 clutch return spring (Fig. 37).

1. Remove 2/4 clutch pack (Fig. 38). Tag 2/4 clutch pack for reassembly identification.

1. Remove tapered snap ring (Fig. 39).

1. Remove low/reverse reaction plate (Fig. 40).

1. Remove one low/reverse clutch disc (Fig. 41).

1. Remove low/reverse reaction plate snap ring (Fig. 42).

 

DISASSEMBLY Continued

1. Remove low/reverse clutch pack (Fig. 43).

1. Remove transfer gear cover-to-case bolts (Fig. 44).

1. Remove transfer gear cover (Fig. 45).

1. Using Tool 6259, remove transfer shaft gear-to-shaft nut and coned washer (Fig. 46) (Fig. 47).

1. Using tool L-4407A, remove transfer shaft gear (Fig. 48).

1. Remove transfer gear shim (select) (Fig. 49).

1. Remove bearing cup retainer (Fig. 50).

1. Remove transfer gear bearing cone using setup shown in (Fig. 51).

1. Remove transfer shaft bearing cup from retainer using Tool 6062 (Fig. 52).

1. Using Tool 6051, remove transfer shaft bearing snap ring (Fig. 53).

1. Using tool 5049A, remove transfer shaft from transaxle (Fig. 54).

1. Slip bearing cup retainer and oil baffle off of shaft (Fig. 55).

1. Using tool P-334, press transfer shaft bearing cone off of shaft (Fig. 56).
2. Bend output gear retaining strap ears flat to allow bolt removal.

1. Remove output shaft stirrup strap bolts (Fig. 57).

1. Remove stirrup and strap (Fig. 58).

1. Using Tool 6259 (Fig. 59), remove output shaft gear-to-shaft bolt and washer (Fig. 60).

1. Using Tool 1-4407A, and button 6055, remove output gear from shaft (Fig. 61).

1. Remove output gear bearing shim (select) (Fig. 62).

1. Using setup as shown in (Fig. 63), remove output gear bearing cone.

1. Remove rear carrier assembly from transaxle (Fig. 64).

1. Remove rear carrier assembly bearing cone using setup shown in (Fig. 65).

1. Install low/reverse spring compressor tool as shown in (Fig. 66) (Fig. 67).

1. Compress low/reverse piston return spring and remove snap ring (Fig. 68).

1. Remove low/reverse spring compressor tool and low reverse piston return spring (Fig. 69).

1. Using a suitable punch , drive out park guide bracket pivot shaft plug (Fig. 70).

1. Using ordinary pliers, remove pivot shaft and guide bracket assembly (Fig. 71).

1. Inspect guide bracket components for excessive wear and replace if necessary (Fig. 72).

NOTE: The Low/Reverse Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.

1. Remove low/reverse clutch piston (Fig. 73).

1. Remove low/reverse piston retainer-to-case screws (Fig. 74).

1. Remove low/reverse piston retainer (Fig. 75).

1. Remove low/reverse piston retainer-to-case gasket (Fig. 76).

1. Using a hammer and suitable drift, drive out inner output bearing cup (Fig. 77).

1. Using tool 6062, remove outer output bearing cup (Fig. 78).

 

wow thats what i was looking for thank you! I AM GREATLY APPRECIATIVE FOR THAT INFO. did this come rite out of the rebuild book? looks like a computer version of the book as i remember.

members like you are the reason these forums survive!

 

Those were just the dis-assembly instructions. I'll add the assembly instructions for you as well.

 

ASSEMBLY

CAUTION: The cooler bypass valve must be replaced if transaxle failure has occurred. Do not attempt to reuse or clean old valve.

NOTE: If transaxle is being overhauled (clutch and/or seal replacement), the TCM/PCM Quick Learn procedure must be performed.

1. Install both output bearing cups using Tool 5050 (Fig. 79).

1. Install low/reverse piston retainer gasket (Fig. 80). Make sure gasket holes line up with case.

1. Install low/reverse piston retainer (Fig. 81).

1. Install low/reverse piston retainer-to-case bolts (Fig. 82) and torque to 5 Nm (45 inch lbs.).

NOTE: The Low/Reverse Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.

1. Install low/reverse clutch piston (Fig. 83).

1. Assemble park guide bracket assembly (Fig. 85) (Fig. 84).

1. Install guide bracket into position and insert pivot shaft (Fig. 86).

1. Install anchor shaft and plug (Fig. 87). Make sure guide bracket and split sleeve are in contact with the rear of the transaxle case.

1. Install low/reverse piston return spring (Fig. 88).

1. Install low/reverse spring compressor into position (Fig. 89). Compress low/reverse piston and install snap ring as shown in (Fig. 90).

1. Install rear carrier bearing cone using Tool 6053 (Fig. 91).

1. Install rear carrier assembly to transaxle case (Fig. 92).

1. Install output gear bearing cone using Tool 5052 (Fig. 93).
2. OUTPUT GEAR BEARING ADJUSTMENT:

1. With output gear Installed, install a 4.50 mm (0.177 inch) gauging shim (Fig. 95) on the rear carrier assembly hub, using grease to hold the shim in place.
2. Using Tool 6259, install output gear and bearing assembly. Torque to 271 Nm (200 ft. lbs.).

1. Measure bearing end play. Attach Tool L-4432 to the gear (Fig. 94).
2. Push and pull the gear while rotating back and forth to ensure seating of bearing rollers.
3. Using a dial indicator mounted to the transaxle case, measure output gear end play as shown in (Fig. 94).
4. Refer to the output gear bearing shim chart for the required shim to obtain proper bearing setting.
5. Use Tool 6259 to remove the output gear retaining bolt and washer. To remove the output gear, use Tool L4407A.
6. Remove the gauging shim and install the proper shim determined by the chart. Use grease to hold the shim in place.

OUTPUT GEAR BEARING SHIM CHART

1. Install the output gear and bearing assembly using Tool 6261 (Fig. 96).

1. Install NEW output gear retaining bolt and washer (Fig. 97). Using Tool 6259, torque output gear retaining bolt to 271 Nm (200 ft. lbs.) (Fig. 98).

1. Using an inch pound torque wrench (Fig. 99), check output shaft turning torque. Output shaft turning torque should be within 3 - 8 inch lbs. If the turning torque is too high, install a 0.04 mm (0.0016 inch) thicker shim. If the turning torque is too low, install a 0.04 mm (0.0016 inch) thinner shim. Repeat until the proper turning torque of 3-8 inch lbs. is obtained.

1. Install output gear stirrup with serrated side out (Fig. 100).

1. Install retaining strap (Fig. 101).
2. Install strap bolts but do not tighten at this time (Fig. 101).

1. Rotate stirrup clockwise against flats of retaining bolt (Fig. 102).

1. Torque stirrup strap bolts to 23 Nm (200 inch lbs.) (Fig. 103).

1. Bend tabs on strap up against flats of bolts (Fig. 104).

1. Install transfer shaft bearing cone using Tool 6052 (Fig. 105).

1. Install bearing cup and oil baffle to transfer shaft (Fig. 106).

1. Using Tool 5049A, install transfer shaft (Fig. 107).

1. Using Tool 6051, install transfer shaft bearing snap ring (Fig. 108).

1. Install transfer shaft bearing cup into retainer using Tool 6061 (Fig. 109).

1. Install bearing cup retainer to transaxle (Fig. 110).

1. Install transfer gear bearing cone to transfer gear using Tool 5052 (Fig. 111).
2. TRANSFER GEAR BEARING ADJUSTMENT:

1. Install a 4.66 mm (0.184 inch) gauging shim on the transfer shaft (Fig. 112).
2. Install transfer shaft gear using Tool 6261. Using Tool 6259, install transfer shaft gear retaining nut to 271 Nm (200 ft. lbs.).
3. Measure end play. Attach Tool L4432 to the transfer gear.
4. Mount a steel ball with grease into the end of the transfer shaft.
5. Push and pull the gear while rotating back and forth to ensure seating of the bearing rollers.
6. Using a dial indicator, measure transfer shaft end play.
7. Refer to the transfer shaft bearing shim chart for the required shim combination to obtain the proper bearing setting.
8. Use Tool 6259 to remove the retaining nut and washer. Remove the transfer shaft gear using Tool L4407A.
9. Remove the gauging shim (Fig. 112) and install the proper shim indicated by the chart.

TRANSFER SHAFT BEARING SHIM CHART

1. Install the transfer shaft gear using Tool 6261 (Fig. 113).

CAUTION: Install a NEW retaining nut, as the original nut MUST NOT be reused.

1. Install the new retaining nut and washer.

1. Using Tool 6259, torque transfer gear retaining nut to 271 Nm (200 ft. lbs.) (Fig. 114).
2. Measure transfer shaft end play. Transfer shaft end play should be within 0.05 - 0.10 mm (0.002 - 0.004 inch) . If the end play is too high, install a 0.04 mm (0.0016 inch) thicker shim. If the end play is too low, install a 0.04 mm (0.0016 inch) thinner shim. Repeat until 0.05 - 0.10 mm (0.002 - 0.004 inch) end play is obtained.

1. Install a bead of Mopar ATF RTV (MS-GF41) to transfer gear cover (Fig. 115).

1. Install transfer gear cover-to-case bolts and torque to 20 Nm (175 inch lbs.) torque (Fig. 116).

1. Install low/reverse clutch pack (Fig. 117). Leave uppermost disc out until snap ring is installed.

1. Install low/reverse reaction plate flat snap ring (Fig. 118).

1. Install remaining low/reverse clutch disc (Fig. 119).

 

ASSEMBLY Continued

1. Install low/reverse reaction plate with flat side up (Fig. 120).

1. Install tapered snap ring (with tapered side up) as shown in (Fig. 121) (Fig. 122).

1. Set up dial indicator as shown in (Fig. 123) to measure low/reverse clutch clearance. Press down on clutch pack with finger and zero dial indicator. Low/Reverse clutch pack clearance is 0.89 - 1.47 mm (0.035 - 0.058 inch) . Set up indicator and record measurement in four (4) places. Take average of readings and select the proper low/reverse reaction plate to achieve specifications.

LOW/REVERSE REACTION PLATE CHART

1. Install 2/4 clutch pack (Fig. 124).

NOTE: The 2/4 Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.

1. Orient 2/4 clutch return spring to retainer as shown in (Fig. 125), and install to transaxle (Fig. 126).

1. Using tool 5058, compress 2/4 clutch return spring just enough to install snap ring (Fig. 127).
2. Install snap ring.

1. Set up dial indicator as shown in (Fig. 128) and measure 2/4 clutch clearance. Press down on clutch pack with finger and zero dial indicator. 2/4 clutch pack clearance is 0.76 - 2.64 mm (0.030 - 0.104 inch) . Set up indicator and record measurement in four (4) places. Take average of readings. If clearance is outside this range, the clutch is assembled improperly. There is no adjustment for 2/4 clutch clearance.

1. Install rear sun gear and #7 needle bearing (Fig. 130).

NOTE: The number seven needle bearing has three anti-reversal tabs and is common with the number five and number two position. The orientation should allow the bearing to seat flat against the rear sun gear (Fig. 129). A small amount of petrolatum can be used to hold the bearing to the rear sun gear.

1. Install front carrier/rear annulus assembly and #6 needle bearing (Fig. 131).

1. Install front sun gear assembly and #4 thrust washer (Fig. 132).
2. DETERMINING #4 THRUST PLATE THICKNESS/INPUT SHAFT END PLAY

1. Select the thinnest #4 thrust plate thickness and install to input clutch assembly (Fig. 133). Use petrolatum to retain.

1. Install input clutch assembly into position and verify that it is completely seated by viewing through input speed sensor hole. If view through input speed sensor hole is not as shown in (Fig. 134), the input clutch assembly is not seated properly.

1. Remove oil pump O-ring (Fig. 135). Be sure to reinstall oil pump O-ring after selecting the proper #4 thrust plate.
2. Install pump and gasket to transmission. Install and torque bolts.

1. Set up input shaft for measurement with Indicator Set C3339 and End Play Set 8266 as shown in (Fig. 136).
2. Measure the input shaft end play with the transaxle in the vertical position. Input shaft end play must be within 0.005 to 0.025 inch. For example, if end play reading is 0.055 inch, select No. 4 Thrust Plate which is 0.071 to 0.074 thick. This should provide an input shaft end play reading of 0.020 inch which is within specifications.
3. Refer to the No. 4 thrust plate chart to select the proper No. 4 thrust plate:

NO. 4 THRUST PLATE CHART

1. Install input clutch assembly (Fig. 137).

1. Install #1 caged needle bearing (Fig. 138).

CAUTION: The cooler bypass valve must be replaced if transaxle failure has occurred. Do not attempt to reuse or clean old valve.

1. Install cooler bypass valve with O-ring end towards rear of case (Fig. 139).

1. Install oil pump gasket (Fig. 140).

1. Install oil pump assembly (Fig. 141).

1. Install oil pump-to-case bolts and torque to 27 Nm (20 ft. lbs.) (Fig. 142).

1. Install low/reverse accumulator (Fig. 143).

1. Install low/reverse accumulator plug (Fig. 144).

1. Install low/reverse accumulator snap ring (Fig. 145).

NOTE: Depending on engine application, some accumulators will have two springs, and others will have one spring. The springs are color-coded for application and year.

1. Install underdrive and overdrive accumulators and springs (Fig. 146).

1. Install valve body to transaxle (Fig. 147). Rotate manual valve shaft fully clockwise to ease installation. Make sure park rod rollers are positioned within park guide bracket.

1. Install and torque valve body-to-case bolts to 12 Nm (105 inch lbs.) (Fig. 148).

1. Install oil filter and new O-ring (Fig. 149).

1. Apply an 1/8 inch bead of Mopar ATF RTV (MSGF41) to oil pan and immediately install to case (Fig. 150).
2. Install oil pan-to-case bolts and torque to 19 Nm (165 inch lbs.).

1. Install solenoid/pressure switch assembly and gasket to case (Fig. 151).

1. Install and tighten solenoid/pressure switch assembly-to-transaxle case bolts to 12 Nm (110 inch lbs.) (Fig. 152).
2. Install and torque input and output speed sensors to case to 27 Nm (20 ft. lbs.).

 

i found a rebuild kit on e-bay for $162 shipped to my house. and i can buy a new T.C. for $200 and if i can find some tools id do it myself. im confident in my mechanical skills to do it since i did it 8-9 years ago. just need good instructions and the proper tools and patience.

does the sound on those parts sound rite to you? if you think i can get a beter deal somewhere else let me know.

where can i get these tools or where can i rent them to do this?

 

It depends on what the kit comes with. This is what I found

PARTS AUTHORITY Part # DK9200S Banner Kit: Paper & Rubber Kit, Front & Rear Seal, Ring Kit and Friction Clutches

Total $97.79


PARTS AUTHORITY Part # DK9200 Master Kit: Paper & Rubber Kit, Front & Rear Seal, Ring Kit, Friction Clutches, Steel Plate

Total $113.79


PARTS AUTHORITY Part # MRK9200A Deluxe Kit: Paper & Rubber Kit, Front & Rear Seal, Ring Kit, Friction Clutches, Steel Plate, Filter, Modulator, Band, Popular Bushings, Popular Washers

Total $214.79


As for the tools your going to have to do searching for it. Check your local Autozone but don't get your hopes up. They'll probably have 10% of what you need. Just type the name of the tool in Google and it will come up and just use your best judgement.