17. Remove the number one thrust bearing from the input clutch assembly Fig. 9.

Fig. 9
68RFE Cross Sectional
1 - Thrust Bearing No. 1

8 - Thrust Bearing No. 8

2 - Thrust Bearing No. 2

9 - Thrust Bearing No. 9

3 - Thrust Bearing No. 3

10 - Thrust Bearing No. 10

4 - Thrust Bearing No. 4

11 - Thrust Bearing No. 11

5 - Thrust Bearing No. 5

12 - Thrust Bearing No. 12

6 - Thrust Bearing No. 6

13 - Output Shaft Bearing

18. Remove the input clutch assembly from the transmission case Fig. 10.

Fig. 10
Input Clutch Assembly
1 - Thrust Bearing Number 5
2 - Rear Selected Thrust Plate/Shim
3 - Input Clutch Assembly
4 - Thrust Bearing Number 1

19. Remove the number 5 thrust bearing and rear selected thrust plate/shim from the input clutch assembly, or
the 4C clutch retainer/bulkhead Fig. 10.

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J21 FSAR-RSU-4774

20. Remove the 2C/4C clutch retainer/bulkhead tapered snap-ring from the transmission case Fig. 11.

Fig. 11
2C/4C Clutch Retainer/Bulkhead
1 - Snap-Ring
2 - 2C/4C Clutch Retainer/Bulkhead

21. Remove the 2C/4C clutch retainer/bulkhead from the transmission case Fig. 11.
22. Remove the front 2C clutch pack snap-ring from the transmission case Fig. 12.

Fig. 12
2C Clutch Pack
1 - Snap-Ring

3 - Disc

2 - Plate

4 - Reaction Plate

J21 FSAR-RSU-4774

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23. Remove the 2C clutch pack from the transmission case Fig. 12.
24. Remove and DISCARD the rear selective thrust plate/shim from the 4C clutch hub/reaction sun gear
assembly Fig. 13.

Fig. 13
Reaction Annulus And Carrier
1 - Thrust Bearing Number 6
2 - Output End Play Rear Selected Thrust Plate/Shim
3 - 4c Clutch Hub / Reaction Sun Gear Assembly
4 - Thrust Bearing Number 8
5 - Reaction Planetary Carrier
6 - Thrust Bearing Number 9

25. Remove and DISCARD the 4C clutch hub reaction sun gear assembly Fig. 13.
26. Install the 2C reaction plate Fig. 14.

Fig. 14
2C Clutch Pack
1 - Snap-Ring
2 - Plate
3 - Disc
4 - Reaction Plate

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J21 FSAR-RSU-4774

27. Install the 2C clutch pack into the transmission case Fig. 14.
28. Install the flat 2C/4C clutch snap-ring into the transmission case Fig. 14.
29. Install the reaction planetary gear set.
30. Install the number 8 thrust bearing into the 4C clutch hub reaction sun gear assembly with the blue ink
stripe against the sun gear with the inner race facing up Fig. 15.

Fig. 15
Reaction Annulus And Carrier
1 - Thrust Bearing Number 6
2 - Output End Play Rear Selected Thrust Plate/Shim
3 - 4C Clutch Hub / Reaction Sun Gear Assembly
4 - Thrust Bearing Number 8
5 - Reaction Planetary Carrier
6 - Thrust Bearing Number 9

31. Install NEW output shaft rear selected thrust plate/shim onto the NEW 4C clutch hub/reaction sun gear
assembly with the oil grooves facing the hub and the lugs and notches aligned as shown Fig. 16.

Fig. 16
Thrust Plate Alignment
1 - Locating Lugs
2 - Rear Selected Thrust Plate/Shim

NOTE: The angular spacing between the lugs/notches is not uniform.

J21 FSAR-RSU-4774

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32. Install the number 6 thrust bearing against the NEW output shaft rear selected thrust plate/shim with
the flat side against the thrust plate/shim and the raised tabs on the inner race facing the front of the
transmission Fig. 17.
NOTE: Use the thinnest rear selected thrust plate/shim initially to avoid part damage. The correct
and final sized end-play shim is determined in Step 37.

Fig. 17
Reaction Annulus And Carrier
1 - Thrust Bearing Number 6
2 - Output End Play Rear Selected Thrust Plate/Shim
3 - 4C Clutch Hub / Reaction Sun Gear Assembly
4 - Thrust Bearing Number 8
5 - Reaction Planetary Carrier
6 - Thrust Bearing Number 9

NOTE: The rear transmission end-play must be set as the 4C clutch hub/reaction sun gear
assembly is being replaced in addition to the rear selected thrust plate/shim.
33. Install the NEW 4C clutch hub/reaction sun gear assembly into the reaction planetary gear set Fig. 17.
34. Install the 2C/4C retainer/bulkhead into the transmission case Fig. 18. Make sure that the oil feed holes
are pointing toward the valve body area. Rotate the 4C clutch hub/reaction sun gear assembly during the
installation of the 4C retainer/bulkhead to ease installation.

Fig. 18
4C Clutch Retainer/Bulkhead
1 - Snap-Ring
2 - 2C/4C Clutch Retainer/Bulkhead

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J21 FSAR-RSU-4774

35. Install the 2C/4C retainer/bulkhead tapered snap-ring into the transmission case with the taper toward the
front of the case. Make sure that the open ends of the snap-ring are located in the case opening toward the
valve body area Fig. 19.

Fig. 19
Case Opening Snap Ring Location
1 - Snap-Ring
2 - Case Opening

36. Air check the 2C and 4C clutch operation. Refer to the detailed service procedures available in
DealerCONNECT/Service Library under: Service Info> 21 - Transmission and Transfer Case/Automatic
- 68RFE - Diagnosis and Testing.
37. Using Alignment Plate 10065, Output Shaft End-Play Socket 8266-20, handle from End-Play Tool Set
8266B and Dial Indicator C-3339A, measure and record the output shaft end-play. The correct output shaft
end-play is 0.25-0.52 mm (0.010-0.020 in.). Adjust as necessary by installing the chosen output shaft
selective rear selected thrust plate/shim and re-measure the end-play to verify selection Fig. 20.
Output Shaft End Play Rear Selected Thrust Plate/Shim Thickness:
●
●
●
●
●
●
●
●
●
●
●

09 = 2.18 mm (0.086 in.)
10 = 2.33 mm (0.092 in.)
11 = 2.48 mm (0.098 in.)
12 = 2.63 mm (0.103 in.)
13 = 2.78 mm (0.109 in.)
14 = 2.69 mm (0.115 in.)
43 = 3.08 mm (0.121 in.)
16 = 3.23 mm (0.127 in.)
17 = 3.38 mm (0.133 in.)
18 = 3.53 mm (0.139 in.)
19 = 3.68 mm (0.145 in.)

NOTE: The output shaft end play is adjusted by means of a selectable rear selected thrust plate/
shim in front of the 4C clutch hub/reaction sun gear assembly. The selectable rear selected
thrust plate/shim thickness is identified by a numeric numeral molded or stamped into the
spacer.

J21 FSAR-RSU-4774

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Fig. 20
Measure Output Shaft End Play
1 - Tool 10065
2 - Tool 8266-20
3 - Tool C-3339A

38. Install a NEW transmission pan gasket and install the extension/adapter housing onto the transmission
case.
39. Install and torque the bolts to 54 N·m (40 ft. lbs.) in order to hold the extension/adapter housing onto the
transmission case.

Fig. 21
Input Clutch Assembly
1 - Thrust Bearing Number 5
2 - Rear Selected Thrust Plate/Shim
3 - Input Clutch Assembly
4 - Thrust Bearing Number 1

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J21 FSAR-RSU-4774

40. Install the number 5 thrust bearing and the rear selected thrust plate/shim onto the input clutch assembly.
Be sure that the outer race of the bearing is against the thrust plate/shim Fig. 21.
41. Install the input clutch assembly into the transmission case. Make sure that the input clutch assembly is
fully installed by performing a visual inspection through the input speed sensor hole. If the tone wheel teeth
on the input clutch assembly are centered in the hole, the assembly is fully installed Fig. 21.
42. Install the number 1 thrust bearing with the outer race up in the pocket of the input clutch assembly Fig. 21.
43. Install the oil pump into the transmission case making certain the oil pump is flush with the transmission
case Fig. 22.

Fig. 22
Remove Oil Pump
1 - Oil Pump To Case Bolt
2 - Oil Pump

44. Install the bolts to hold the oil pump into the transmission case. Tighten the oil pump bolts to 28 N·m (250
in. lbs.) Fig. 22.
45. Using Adapter 8266-17 from End-play Tool set 8266B and Dial Indicator C-339A, measure and record the
input shaft end-play. The correct end-play is 0.52-0.74 mm (0.020-0.029 in.). Adjust as necessary. Install
the chosen selectable rear selected thrust plate/shim on the number 5 thrust bearing and re-measure the
end-play to verify selection Fig. 23.

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Fig. 23
Measure Input Shaft End Play
1 - Tool 8266-17
2 - Tool C-3339A

Input Shaft End Play Selectable Thrust Plate/Shim Thicknesses:
●
●
●
●
●
●
●
●

30 = 1.99 mm (0.078 in.)
31 = 2.13 mm (0.084 in.)
32 = 2.27 mm (0.089 in.)
33 = 2.41 mm (0.095 in.)
34 = 2.55 mm (0.100 in.)
35 = 2.69 mm (0.106 in.)
36 = 2.83 mm (0.111 in.)
37 = 2.97 mm (0.117 in.)

NOTE: Adapter 8266-17 will fit loosely onto the input shaft, this should not effect the performance
of the adapter.
NOTE: If no input shaft end play is noted, disassemble the input clutch assembly and check for
the #2, #3, or #4 thrust bearing fallen out of position or cracked. Replace any cracked thrust
bearing and reassemble using trans jell or petroleum jelly to retain the thrust bearings.
The selectable thrust plate/shim thickness is identified by a numeric numeral molded or
stamped into the spacer.
NOTE: When measuring the input shaft end-play, two "stops" will be felt. When the input shaft
is pushed inward and the dial indicator zeroed, the first "stop" felt when the input shaft
is pulled outward is the movement of the input shaft in the input clutch housing hub.
This value should not be included in the end-play measured value and therefore must be
recorded and subtracted from the dial indicator reading.

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J21 FSAR-RSU-4774

46. Position the NEW front cover onto transmission case Fig. 24.
NOTE: To avoid contamination and garter spring dislodgement, do not handle the front cover seal
when installing the front cover into the transmission case.

Fig. 24
Front Cover
1 - Front Cover
2 - O-Ring
3 - Snap Ring
4 - Front Cover Seal

47. Using a dead-blow mallet and the front cover installation Tool 9555, install the front cover into the
transmission case Fig. 24.
48. Install the snap ring into the transmission case Fig. 24.
49. Install the valve body. Refer to the detailed service procedures available in DealerCONNECT/Service
Library under: Service Info> 21 - Transmission and Transfer Case/Automatic/Valve Body/ Installation.

J21 FSAR-RSU-4774

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50. Install the primary oil filter and the oil cooler return filter Fig. 25. Tighten the screw to hold the primary oil
filter to the valve body to 4.5 N·m (40 in. lbs.). Using Filter Wrench 8321, tighten the cooler return oil filter
to the transmission case to 9.5 N·m (84 in. lbs.).
CAUTION!
The NEW primary oil filter seal MUST be fully installed flush against the oil pump body. DO NOT
install the seal onto the filter neck and attempt to install the filter and seal as an assembly. Damage
to the transmission will result.

Fig. 25
Remove Primary Oil And Cooler Filters
1 - Primary Oil Filter
2 - Cooler Return Filter
3 - Cooler Return Filter Bypass Valve
4 - Valve Body

51. Install a NEW rubber gasket on the transmission pan and install the transmission oil pan. Tighten the bolts
to 12 N·m (105 in. lbs.).

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J21 FSAR-RSU-4774

52. Install the input speed sensor to the transmission case Fig. 26. Refer to the detailed service procedures
available in DealerCONNECT/Service Library under: Service Info> 21 - Transmission and Transfer Case /
Automatic - 68RFE / Sensor, Speed, Input / Installation.

Fig. 26
Installation - Input Speed Sensor
1 - Output Speed Sensor (Not Removed)
2 - Line Pressure Sensor
3 - Input Speed Sensor

53. Install the manual shift lever to the transmission using a NEW manual shift lever bolt Fig. 27. Tighten the
bolt to 12 N∙m (9 lbs. ft. lbs.).

Fig. 27
Manual Shift Lever
1 - Manual Shift Lever

54. Install the torque converter to the transmission. Refer to the detailed service procedures available in
DealerCONNECT/Service Library under: Service Info> 21 - Transmission and Transfer Case / Automatic 68RFE / Torque Converter / Installation.
55. Using wiTECH, perform a Quick Learn Procedure.
56. Clear DTCs.

POLICY:
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