2020-2025 Stellantis 850RE D Clutch Repair TSB 21-009-25

Owners of certain 2020-2025 Stellantis vehicles equipped with the Eight-Speed Auto 850RE Transmission (Sales Code DFT), including the Jeep Wrangler 850RE D Clutch models, may experience issues related to the D clutch. This is addressed by Technical Service Bulletin (TSB) 21-009-25 REV. B, issued on April 5, 2025. This bulletin supersedes TSB 21-009-25 REV. A, dated February 01, 2025, which should be removed from dealer files. All revisions in the current bulletin are highlighted with asterisks and include an updated Customer Symptom statement and Repair Procedure step.

Symptoms

Customers may notice a Malfunction Indicator Lamp (MIL) illumination on their dashboard. This typically occurs when the vehicle has accumulated at least 7,000 miles (11,265 km). In addition to the MIL, owners might experience one or more of the following:

• Transmission slips when shifting
• Vehicle will not move in reverse
• Vehicle will not shift higher than third gear

Fault Codes / DTCs

When these symptoms are present, one or more of the following Diagnostic Trouble Codes (DTCs) may be set:

Code	Description
P0733-00	Gear 3 Shift Incorrect Ratio
P1DA8-00	Incorrect Gear Ratio Clutch A B or D Defective
P1D92-00	Incorrect Gear Ratio - Clutch 4 Defective

Diagnosis / Trigger Conditions

This TSB applies specifically if the customer experiences a Malfunction Indicator Lamp (MIL) illumination, the vehicle has at least 11,265 km (7,000 mi.), and one or more of the listed DTCs (P0733-00, P1DA8-00, P1D92-00) are present. If these conditions are met, the repair procedure outlined in the bulletin should be followed. The underlying cause of these issues is identified as a D clutch repair.

Repair Procedure Summary

The repair outlined in TSB 21-009-25 REV. B involves replacing the D clutch within the 850RE transmission. This is a comprehensive procedure requiring significant disassembly and reassembly of the transmission components. Technicians should refer to the detailed service procedures available in DealerCONNECT/Service Library for complete instructions.

Initial Disassembly

1. Verify Conditions: Confirm the presence of DTCs P0733, P1DA8, or P1D92 and that the vehicle has at least 1,265 km (7,000 mi.). If not, the bulletin does not apply.
2. Remove Torque Converter: The torque converter is removed as shown in Fig. 2.
3. Remove Extension Housing (4WD Only): For vehicles equipped with 4WD, the transmission housing extension bolts and the extension housing are removed (Fig. 3).
4. Remove Output Shaft Seal: The transmission output shaft seal is carefully removed (Fig. 4).
5. Remove Output Shaft Snap Ring (4x4 Only): For 4x4 vehicles, the output shaft snap ring is removed (Fig. 5).
6. Remove Output Shaft Flange Locknut Staking (2WD Only): For 2WD vehicles, the output shaft flange locknut staking is removed (Fig. 6).
7. Remove Output Shaft Flange: Using a flange holder, the output shaft flange nut is removed, followed by the output shaft flange. The flange sealing surface is inspected for damage and replaced if necessary.

Accessing Internal Components

8. Remove Transmission Oil Pan: The 13 transmission oil pan bolts are removed (Fig. 7). The gasket should be inspected for reuse; if cut or torn, it must be replaced. The transmission oil pan and gasket are then carefully removed.
9. Remove Hydraulic Impulse Oil Storage (H.I.S): If equipped, the H.I.S connector is disconnected, and the H.I.S accumulator and its bolts are removed (Fig. 8).
10. Remove Valve Body Assembly: The valve body assembly end retainer bolts are removed (Fig. 9). The electrical connector lock is lifted to release the internal harness end. The Output Speed Sensor (OSS) bolt is removed, and the OSS is gently lifted out (Fig. 10).
11. Remove Electrical Harness Insulator: Using Guide Sleeve 10377, the electrical harness insulator is carefully pulled straight out from the transmission case (Fig. 11).
12. Remove Valve Body: The valve body assembly bolts are removed in the specified order, and the valve body is then removed (Fig. 12).

Transmission Internal Disassembly

13. Remove Fluid Port and Transfer Tube: The fluid port is removed from the transmission or valve body assembly (Fig. 13). The fluid transfer tube and its O-rings are also removed.
14. Remove Input Shaft O-ring: The input shaft O-ring is removed using a small pick or equivalent tool (Fig. 14).
15. Remove Oil Pump Housing: The 14 oil pump housing bolts are removed and DISCARDED (Fig. 15). The input shaft O-ring must be removed before the oil pump. The oil pump housing is then carefully pried away from the case using a flat blade screwdriver (Fig. 16) and removed.
16. Remove B Clutch Spring Damper: The B clutch spring damper is removed (Fig. 17).
17. Remove Park Pawl Lock Rod Guide Plate: The park pawl lock rod guide plate bolts are removed, and the plate is taken off (Fig. 18). NOTE: The transmission must be in a vertical position before the main stack is removed to prevent damage to the drums.
18. Remove P4 Annulus Drum Assembly: The input/output shaft and P4 annulus drum assembly are removed from the case (Fig. 19).
19. Disassemble P4 Annulus Drum: The input/output shaft and P4 annulus drum assembly are positioned on a Press Fixture 8925-3 (Fig. 20). The B clutch pack is then removed.
20. Further Disassembly: The P1 annulus/B clutch hub assembly is removed from the P4 annulus drum (Fig. 21). The thrust bearing and holding plate are removed from the P1 planetary carrier. NOTE: Three pieces are intended to be used in multiple locations around the drum to prevent damage from prying (Fig. 22).
21. Remove Snap Ring and Planetary Carriers: Rings, Support 10378 is positioned on the P4 annulus drum assembly (Fig. 23). The snap ring is pried from the opposite side of the snap ring openings to release it. The P1 planetary carrier is removed, followed by the input shaft with P2 planetary carrier from the drum assembly (Fig. 24), and then the thrust bearing and washer.
22. Remove D Clutch Drum Components: The P2 annulus/P3 sun gear is removed from the drum assembly (Fig. 25), followed by the D clutch drum from the P4 annulus drum. NOTE: Again, three pieces are intended to be used in multiple locations around the drum to prevent damage from prying.
23. Remove P4 Planetary Carrier Lock Ring: The P4 planetary carrier/output shaft lock ring is removed by gently prying the locking tabs open and turning the lock ring to center the locating tabs in the output shaft tab openings. This lock ring must be DISCARDED, and a NEW one installed during assembly (Fig. 26).

Reassembly with New Components

24. Install P4 Planetary Carrier: A NEW P4 planetary carrier/output shaft assembly is installed into the P4 annulus drum. If a park gear was removed from the old assembly, it is installed.
25. Install P4 Planetary Carrier Lock Ring: The NEW P4 planetary carrier/output shaft lock ring is installed by turning it to center the lock ring tabs in the output shaft tab openings and gently staking the locking tabs closed (Fig. 27).
26. Install D Clutch Drum and Gears: The D clutch drum is installed into the P4 annulus drum (Fig. 28). The P2 annulus/P3 sun gear is installed in the drum assembly (Fig. 29), followed by the thrust bearing and washer.
27. Install Input Shaft and Snap Ring: The input shaft with P2 planetary carrier is installed into the drum assembly (Fig. 30). The snap ring is then installed in the correct orientation (Fig. 31).
28. Install P1 Annulus/B Clutch Hub and Plates: The thrust bearing and holding plate are installed onto the P1 planetary carrier, and the selectable shim is installed to the P1 annulus/B clutch hub. The P1 annulus/B clutch hub assembly is installed onto the P4 annulus drum (Fig. 32). The B clutch discs and plates are installed (Fig. 34), noting the composition of friction plates, wave springs, steel plates, cover plate, snap ring, and wave plate (Fig. 33).
29. Install P4 Annulus Drum Assembly: The snap ring is installed. The input/output shaft and P4 annulus drum assembly are installed into the case (Fig. 35). NOTE: The transmission must be in a vertical position when installing the main stack to prevent damage to the drums.
30. Install Park Pawl Lock Rod: The park pawl lock rod is installed onto the fork (Fig. 36). The park pawl lock rod guide plate is positioned, and the three retaining bolts are installed and tightened to 10 N-m (89 In. Lbs.).
31. Install B Clutch Damper Spring: The B clutch damper spring is installed on the assembly (Fig. 37).
32. Install Oil Pump Housing: The oil pump housing assembly is carefully positioned into the case. A NEW input shaft O-ring is installed (Fig. 38). NOTE: The oil pump must be firmly pressed in place before drawing it in with bolts.
33. Install Oil Pump Cover Bolts: The 14 NEW oil pump cover retaining bolts are installed (Fig. 39). Bolts one, seven, and nine are pre-tightened to 6 N-m (53 in. lb.). Working in a clockwise pattern, starting with number one, all bolts are tightened to 10 N-m (89 in. lb.), followed by an additional 90° turn.

Final Assembly and Post-Repair Procedures

34. Install MPR Lever: The MPR lever is temporarily installed to release tension on the shift fork (Fig. 40). The MPR lever is installed 180 degrees offset, the retaining nut is hand-tightened, and the lever is secured with a tie strap to maintain the park release fork's position.
35. Install Fluid Transfer Tube: NEW fluid transfer tube O-rings are installed, and the fluid transfer tube is installed to the transmission case (Fig. 41).
36. Install Valve Body Assembly: Valve body alignment pins are installed as guides. The valve body assembly is positioned, ensuring the shift fork lines up properly. The valve body assembly bolts are installed (Fig. 42) and tightened to 8 N-m (71 In. Lbs.). After several bolts are hand tightened, the guide pins are removed.
37. Install Electrical Harness Guide Sleeve: Using Guide Sleeve 10377, the electrical harness guide sleeve is carefully installed into the transmission case (Fig. 43). The electrical connector lock is latched by pushing it down (Fig. 44).
38. Install OSS and H.I.S: The valve body assembly end bolt and electrical connector lock bolt are installed and tightened to 8 N-m (71 In. Lbs.). When installing the OSS, care must be taken to position the OSS guide pin correctly to avoid sensor damage (Fig. 45, Fig. 46). If equipped, the H.I.S and its bolts are installed (Fig. 47) and tightened to 8 N-m (71 In. Lbs.). The OSS is installed, and its bolt is tightened to 8 N-m (71 In. Lbs.) (Fig. 48). The H.I.S wire harness connector is connected.
39. Final MPR Lever Adjustment: The tie strap is removed, and the MPR lever is returned to its original position (Fig. 49). The MPR lever nut is installed and tightened to 12 N-m (9 Ft. Lbs.).
40. Install Oil Pan and Output Shaft Seal: The transmission oil pan and gasket are positioned (Fig. 50). The 13 transmission oil pan bolts are installed and tightened to 10 N-m (89 In. Lbs.). NOTE: This applies for 4x4 only. A NEW output shaft seal is positioned over the output shaft and against the transmission case (Fig. 51), then installed using Seal Installer 9677 (Fig. 52).
41. Install Extension Housing (4x4 Only): For 4x4 vehicles only, the extension housing is positioned, and its bolts are installed and tightened to 27 N-m (20 Ft. Lbs.) (Fig. 53).
42. Install Output Flange (2WD Only): For 2WD vehicles, the seal is removed and DISCARDED from the output flange and replaced with a NEW seal (Fig. 54). The output shaft flange is installed using a NEW output flange nut and washer. A 34 mm, 12-point socket is used to hold the flange during installation. CAUTION: The nut must be staked to prevent vibration from backing the nut out or loose (Fig. 55).
43. Install Torque Converter: The torque converter is installed (Fig. 56). Refer to DealerCONNECT/Service Library for detailed procedures.
44. Install WL 4x4 Output Shaft O-ring/Seal: For WL 4x4 models only, the O-ring/seal is installed to the output shaft (Fig. 57). NOTE: Seal color can vary for this O-ring/seal.
45. Transmission Pre-fill and Installation: Before installing the transmission in the vehicle, it is pre-filled as outlined in the DealerCONNECT/Service Library. The transmission is then installed into the vehicle.
46. wiTECH Quick Learn Procedure: Use wiTECH to complete the Quick Learn Procedure and clear any Diagnostic Trouble Codes.

Required Tools or Parts

This repair requires specific parts and special tools:

Spare Parts

Qty (AR)	Part No.	Description	Notes
1	68676890AB	Shaft Kit, Output	D Clutch Repair Kit (4x4 JL, JT, WD, WK)
1	68676891AB	Shaft Kit, Output	D Clutch Repair Kit (4x4 WL)
1	68676887AB	Shaft Kit, Output	D Clutch Repair Kit (4x4 DS, DT, DX, WS)
1	68239499AD	Shaft Kit, Output	D Clutch Repair Kit (AWD LA, LD, LX)
1	68676892AB	Shaft Kit, Output	D Clutch Repair Kit (RWD LA, LD, LX)
1	68676894AB	Shaft Kit, Output	D Clutch Repair Kit (RWD WD, WK, WL)
1	68676893AB	Shaft Kit, Output	D Clutch Repair Kit (RWD DS, DT, DX, WS)
10	68218925AB		Automatic Transmission Fluid

Special Tools/Equipment

Description	Ref. No.
Guide Sleeve	10377
Press Fixture	8925-3
Bearing/Gear	1130
Rings, Support	10378
Installer, Seal	9677

Important Warnings

• Electrostatic Discharge (ESD) Caution: The Transmission Control Module (TCM), or Transmission Control Module Assembly (TCMA), is extremely sensitive to Electrostatic Discharge (ESD). Always use a ground strap and follow the ESD guidelines for Electrostatic Discharge Sensitive Devices. Failure to follow these instructions may result in damage to the TCM/TCMA.
• TCM Adaptation Procedure: If the transmission is being reconditioned (clutch/seal replacement) or replaced, it is necessary to perform the TCM Adaptation Procedure. Refer to the detailed service procedures available in DealerCONNECT/Service Library under: Service Info>08 - Electrical/8E - Electronic Control Modules/Module, Transmission Control/Module Programming.
• Fluid Note: It is normal for the transmission to have fine debris present in the oil pan and stuck to the magnets. Burnt oil and debris do not warrant a transmission replacement for D piston seal failure.
• Transmission Fluid Compatibility: A unique transmission fluid has been developed for this transmission. This fluid is NOT compatible with ATF+4 or any other current FCA US LLC transmission fluid. For specifics about this unique fluid, consult FLUIDS, LUBRICANTS AND GENUINE PARTS.
• Output Shaft Seal Installation: The output shaft seal must be installed flush with the case. Driving the seal deeper could damage the seal causing a leak.
• Output Flange Nut Staking: For 2WD vehicles, the output flange nut must be staked to prevent vibration from backing the nut out or loosening.

Owner Action

If your 2020-2025 Stellantis vehicle, including the Jeep Wrangler 850RE D Clutch models, exhibits a Malfunction Indicator Lamp (MIL) illumination, transmission shifting problems, or sets any of the DTCs P0733-00, P1DA8-00, or P1D92-00, it is recommended to visit an authorized Stellantis dealer. The dealer will diagnose the issue and perform the necessary D clutch repair according to TSB 21-009-25 REV. B. This repair is reimbursable within the provisions of the warranty.

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Source: NHTSA ID: 11016879