Removal and Replacement

A4LD

REMOVAL
1. Disconnect battery ground cable, then raise and support vehicle.
2. Loosen oil pan attaching bolts and allow fluid to drain. After all the fluid has drained, install two bolts on the rear side of the pan to temporarily hold it in place.
3. Remove converter access cover and adapter plate attaching bolts from lower end of converter housing. Remove converter access cover from the bottom of the engine oil pan on 4 cylinder applications (2.3L) only. Remove one bolt on the access cover of 6 cylinder applications (2.9L), pivot/swing cover open.
4. Remove four flywheel to converter attaching nuts.

CAUTION: On belt driven overhead camshaft engines, never turn crankshaft backward as viewed from the front.

5. Install scribe marks on propeller shaft end yoke and rear axle companion flange, then remove propeller shaft and install extension housing oil seal replacer tool No. T74P-77052-A or equivalent.






6. Disconnect speedometer cable from extension housing.
7. Disconnect shift rod or cable from transmission manual lever.
8. Disconnect kickdown cable at transmission kickdown lever.
9. Remove starter to converter housing attaching bolts and position starter out of way.
10. Disconnect all electrical connectors from transmission.
11. Remove vacuum line from transmission vacuum modulator.
12. Position suitable jack under transmission and raise sightly.






13. Remove engine rear support to crossmember attaching bolts.
14. Remove crossmember to frame side support attaching bolts, then the crossmember insulator and support damper.
15. Lower jack and allow transmission to hang.
16. Position suitable jack under engine assembly and raise engine just enough to gain access to two upper converter housing to engine attaching bolts.






17. Disconnect oil cooler lines from transmission, capping all openings.
18. Remove lower converter housing to engine attaching bolts.
19. Remove transmission filler tube.
20. Secure transmission to jack using suitable safety chain.
21. Remove two upper converter housing to engine attaching bolts.
22. Remove transmission from vehicle.

INSTALLATION






1. Reverse procedure to install. Position the converter to the transmission making sure the converter hub is fully engaged in the pump and rotate the converter until two bumps are felt. Keep pushing and rotating until dimension "A" shown below is reached.

NOTE: Make sure the torque converter rotates freely and is not boundup.

Dimension :A: should be:
Minimum: 10.23mm (7/16")
Minimum: 14.43mm (9/16")
2. With the converter properly installed, place the transmission on the jack and secure with safety chain.
3. Rotate the converter so the drive studs are in alignment with their holes in the flywheel.
4. With the transmission mounted on a transmission jack, move the converter and transmission assembly forward into position being careful not to damage the flywheel and the converter pilot.
During this move, to avoid damage, do not allow the transmission to get into a nose down position as this will cause the converter to move forward and disengage from the pump gear. The converter housing is piloted into position by dowels In the rear of the engine block The converter must rest squarely against the flywheel. This Indicates that the converter pilot is not binding in the engine crankshaft
5. Install two (2) converter housing-to-engine attaching bolts at the engine dowel locations. Tighten to 38-51 N.m (28-38 ft-lb).
6. Install the remaining converter housing-to-engine attaching bolts and tighten to 38-51 N.m (28-38 ft-lb).
7. Remove the safety chain from the transmission.






8. Insert the filler tube in the stub tube and secure it to the cylinder block with the attaching bolt. Tighten the bolt to 38-51 N.m (28-38 ft-lb) If the stub tube is loosened or dislodged, it should be replaced.
9. Install the oil cooler lines in the retaining clip at the cylinder block. Connect the lines to the transmission case.
10. Remove the jack supporting the front of the engine.






11. Raise the transmission. Position the crossmember, insulator and support and damper to the frame side supports and install the attaching bolts.
12. Lower the transmission and install the rear engine support-to-crossmember nut. Tighten the bolt to 80-108 N.m (60-80 ft-lb).
13. Remove the transmission jack.
14. Install the vacuum hose on the transmission vacuum unit. lnstall the vacuum line into the retaining clip.
15. Connect the neutral start switch plug to the switch. Install the converter clutch solenoid connector.
16. Install the starter and tighten the attaching bolts to 20-27 N.m (15-20 ft-lb).
17. Install the four flywheel-to-converter attaching nuts.
When assembling the flywheel to the converter, first install the attaching nuts and tighten to 27-46 N.m (20-34 ft-lb).
18. Install the converter access cover and adapter plate bolts. Tighten the bolts to 16-22 N.m (12-16 ft-lb).
19. Connect the muffler inlet pipe to the exhaust manifold.
20. Connect the transmission shift rod to the manual lever.
21. Connect the downshift cable to the downshift lever.
22. Install the speedometer cable.
23. Install the driveshaft so the marks scribed on the driveshaft and rear axle flange are in alignment. Tighten the companion flange U- bolt attaching nuts to 95-130 N.m (70-95 ft-lb).
24. Adjust the manual and downshift linkage as required.
25. Lower the vehicle. Fill the transmission to the proper level with the specified fluid. Pour in five quarts of fluid; then run the engine and add fluid as required. DEXRON II, SERIES "D".
26. Check the transmission, converter assembly and oil cooler lines for leaks.
27. On vehicles equipped with Electronic Engine Control-IV (EEC-IV), when the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the EEC processor relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy.