Assembly
ASSEMBLY1. Clean and inspect all components. Replace any components which show evidence of excessive wear or scoring.
2. Install the cooler filter bypass valve.
3. Torque the bypass valve to specification. The valve uses a tapered pipe thread and excessive torque can damage the transmission case. Tighten the cooler filter bypass valve to 4.5 Nm (40 in. lbs.).
4. Install a new selector shaft seal using Seal Installer 8253 (Fig. 28).
5. Install the manual selector shaft and retaining screw. Tighten the manual selector shaft retaining screw to 28 Nm (250 in. lbs.).
6. Install the park pawl, spring, and shaft (Fig. 29).
7. Install the park rod and e-clip (Fig. 29).
8. Install the park rod guide and snap-ring (Fig 29).
9. Install a new dipstick tube seal using Seal Installer 8254 (Fig. 30).
NOTE: Before final assembly of transmission centerline, the 2C/4C clutch components should be installed into position and measured as follows:
10. Install the 2C reaction plate into the transmission case (Fig. 31). The reaction plate is directional. The plate must be installed with the flat side toward the front of the transmission.
11. Install the 2C clutch pack into the transmission case (Fig. 31).
12. Install the flat 2C clutch snap-ring into the transmission case (Fig. 31).
13. Install the 4C retainer/bulkhead into the transmission case. Make sure that the oil feed holes are pointing toward the valve body area.
14. Install the 4C retainer/bulkhead tapered snap-ring into the transmission case. Make sure that the open ends of the snap-ring are located in the case opening toward the valve body area.
15. Using a feeler gauge through the opening in the rear of the transmission case, measure the 2C clutch pack clearance between the 2C reaction plate and the transmission case at four different points. The average of these measurements is the 2C clutch pack clearance. The correct clutch clearance is 0.533 - 1.27 mm (0.021 - 0.050 inch). The reaction plate is not selective. If the clutch pack clearance is not within specification, the reaction plate, all the friction discs, and steels must be replaced.
16. Remove the 4C retainer/bulkhead and all of the 2C clutch components from the transmission case.
17. Install the low/reverse clutch assembly (Fig. 32). Make sure that the oil feed hole points toward the valve body area and that the bleed orifice is aligned with the notch in the rear of the transmission case.
18. Install the snap-ring to hold the low/reverse clutch retainer into the transmission case (Fig. 32). The snap-ring is tapered and must be installed with the tapered side forward. Once installed, verify that the snap-ring is fully seated in the snap-ring groove.
19. Air check the low/reverse clutch and verify correct overrunning clutch operation.
20. Install the number 12 bearing over the output shaft of the rear planetary gear set and onto the low/ reverse clutch assembly. The flat side of the bearing goes toward the clutch assembly.
21. Install the reverse/input planetary assembly through the low/reverse clutch assembly (Fig. 33).
22. Install the park sprag onto the output shaft (Fig. 34).
23. Install the snap-ring to hold the park sprag onto the output shaft (Fig. 35).
24. Install the 2C reaction plate into the transmission case (Fig. 36). The reaction plate is directional. The plate must be installed with the flat side toward the front of the transmission.
25. Install the 2C clutch pack into the transmission case (Fig. 36).
26. Install the number 8 bearing inside the reaction carrier with the round side against the planetary carrier.
27. Install the reaction planetary gear set and the number 9 bearing, with the flat side toward the reaction planetary, into the transmission case (Fig. 37).
28. Install the flat 2C clutch snap-ring into the transmission case (Fig. 36).
29. Install the reaction sun gear into the reaction planetary gear set. Make sure the small shoulder is facing the front of the transmission (Fig. 37).
30. Install the number 7 bearing onto the reaction sun gear with the flat side against the sun gear (Fig. 37).
31. Install the output shaft selective thrust plate onto the reaction annulus with the oil grooves facing the annulus gear and the tabs and notches aligned as shown in (Fig. 38).
32. Install the number 6 bearing against the out-put shaft selective thrust plate with the flat side against the thrust plate (Fig. 37).
33. Install the reaction annulus into the reaction planetary gear set (Fig. 37).
34. Install the 4C retainer/bulkhead into the transmission case. Make sure that the oil feed holes are pointing toward the valve body area. Rotate the reaction annulus during the installation of the 4C retainer/bulkhead to ease installation.
35. Install the 4C retainer/bulkhead tapered snap-ring into the transmission case (Fig. 39). Make sure that the open ends of the snap-ring are located in the case opening toward the valve body area.
36. Air check the 2C and 4C clutch operation.
37. Using Alignment Plate 8261, Adapter 8266-17 from End-Play Tool Set 8266 and Dial Indicator C-3339, measure and record the output shaft end-play (Fig. 40). The correct output shaft end-play is 0.22 - 0.55 mm (0.009 - 0.021 inch). Adjust as necessary. Install the chosen output shaft selective thrust plate and re-measure end-play to verify selection.
38. Apply a bead of RTV silicone and install the extension/adapter housing onto the transmission case.
39. Install and torque the bolts to hold the extension/adapter housing onto the transmission case. The correct torque is 54 Nm (40 ft. lbs.).
40. Install the number 5 bearing and selective thrust plate onto the 4C retainer/bulkhead (Fig. 41).
41. Install the input clutch assembly into the transmission case (Fig. 41). 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 visible, the assembly is fully installed.
42. Install the number 1 bearing with the flat side up in the pocket of the input clutch assembly (Fig. 41).
43. Install the oil pump into the transmission case (Fig. 42).
44. Install the bolts to hold the oil pump into the transmission case. Tighten the oil pump bolts to 28 Nm (250 in. lbs.).
45. Using Adapter 8266-1 from End-Play Tool Set 8266 and Dial Indicator C-3339, measure and record the input shaft end-play (Fig. 43). The correct end-play is 0.46 - 0.89 mm (0.018 - 0.035 inch). Adjust as necessary. Install the chosen thrust plate on the number 5 bearing and re-measure end-play to verify selection.
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 there-fore must be recorded and subtracted from the dial indicator reading.
46. Install the transmission front cover into the transmission case (Fig. 44).
47. Install the outer snap-ring to hold the transmission front cover into the transmission case (Fig. 44).
48. Partially install the inner transmission front cover snap-ring onto the oil pump (Fig. 44).
49. Using Installer 8255, install the inner transmission out cover snap-ring the remainder of the way onto the oil pump (Fig. 45).
50. Install the valve body (Fig. 46). Verify that the pin on the manual lever has properly engaged the TRS selector plate. Tighten the valve body to transmission case bolts to 12 Nm (105 in. lbs.).
51. Verify that the primary oil filter seal is properly installed in the oil pump inlet bore.
52. Install the primary oil filter and the oil cooler return filter (Fig. 47). Tighten the screw to hold the primary oil filter to the valve body to 4.5 Nm (40 in. lbs.). Using Oil Filter Wrench 8321, tighten the cooler return oil filter to the transmission case to 14 Nm (125 in. lbs.).
53. Apply RTV silicone to the oil pan and install the transmission oil pan. Tighten the bolts to 12 Nm (105 in. lbs.).
54. Install the input, output, and line pressure sensors (Fig. 48). Tighten the bolts to 12 Nm (105 in. lbs.).
55. Install the manual shift lever from the transmission. Torque the retaining cross-bolt to 16 Nm (140 in. lbs.).