E4OD
ASSEMBLENOTE: Soak all friction clutch plates in clean transmission fluid for fifteen minutes. Lightly lubricate all 0-ring seals with ATF before installing. Lightly grease all thrust washers to hold them in place during assembly.
1. Mount transmission in suitable stand.
2. Rotate transmission so bellhousing is facing up.
3. Install inner and outer seals on reverse clutch piston.
4. Using clutch spring compressor tool No. T65L-77515-A or equivalent, install reverse clutch piston. Remove tool after installing piston.
Installing Reverse Clutch Inner Race Attaching Bolts:
5. Install reverse piston return spring assembly and one-way clutch inner race. Attach to case as shown in the Installing Reverse Clutch Inner Race Attaching Bolts image, and torque bolts.
6. With bellhousing facing up, install reverse clutch pack. Starting with an external spline plate, alternate external spline plates and internal spline plates.
7. Install snap ring.
8. Rotate transmission to horizontal position.
Installing Thrust Washer No. 7B368:
9. Grease steel side of thrust washer No. 7B368 and place on rear of case. Ensure bronze side of thrust washer is facing outward.
10. Install snap ring and park gear onto output shaft, then the output shaft into rear of transmission.
11. Install reverse hub and low-reverse one-way clutch.
Removing Ring Gear And Hub Assembly:
12. Install output shaft hub and reverse ring gear, placing needle bearing assembly on rear surface of hub.
13. Install new snap ring on output shaft.
14. Install reverse plate carrier assembly into hub with thrust washers No. 7D423 on each side of carrier.
15. Install snap ring.
16. Rotate transmission so bellhousing is facing up.
17. Lower entire subassembly into case. If necessary, rotate output shaft to seat reverse sun gear.
18. Remove tool holding subassembly together.
19. Install intermediate band. Ensure one ear is resting on reaction pin.
20. Install servo snap ring, retaining plate, piston, rod assembly, and servo spring.
21. Install intermediate pressure plate, clutch pack starting with internal spline plate and apply plate.
22. Determine endplay as follows:
a. Use depth micrometer D80P-4201-A or equivalent to access area between thrust surfaces of center support and intermediate brake drum.
b. Remove case iron seals from center support to allow easy insertion into intermediate brake drum.
Center Support Drilled Hole Location:
c. Place micrometer over drilled hole in center support fixture.
Endplay Measurements, Reading A:
d. Extend micrometer probe until it is flush with thrust washer surface. Record micrometer reading. This is reading A.
e. Install center support into intermediate brake drum. Ensure center support is fully seated in transmission case.
f. Place depth micrometer over drilled hole in center support.
Endplay Measurements, Reading B:
g. Extend micrometer probe until it contacts thrust washer surface of intermediate brake drum, as shown in the Endplay Measurement Reading B image. This is reading B.
h. Subtract reading A from reading B. The difference between these readings is Dimension A, shown in the Endplay Measurement, Reading B image. This is the space between thrust surfaces.
i. Subtract thrust washer thickness from dimension A to determine final endplay. Endplay must be within 0.081-0.032 inch.
j. If final dimension is not within specifications, possible causes include improper assembly, missing parts, or parts out of specification. These require unit overhaul.
k. Remove center support from intermediate brake drum. Position washer No. 7L326 on rear of center support.
l. If removed, install cast iron seals on center support.
23. Install center support and align with holes in feed port. Install but do not tighten two feed bolts.
24. Install intermediate clutch return spring, noting the following:
a. Dished surface must face inward.
Intermediate Clutch Return Spring, Leg Location:
b. Locate one spring leg pointing to top of transmission.
c. Intermediate clutch return spring locator legs must be properly located inside of center support circular cast rib.
25. Install intermediate/overdrive cylinder assembly into case, noting the following:
a. Align cylinder assembly locator tab with center support.
b. Align feed hole with hole in case.
c. Install but do not tighten one feed bolt.
Installing Clutch Spring Compressor:
26. Place tools shown, in the Installing Clutch Spring Compressor image, onto intermediate clutch cylinder assembly. Torque tool center bolt to 65 in lbs.
27. Seat selective snap ring into case groove. Ensure ring opening is at bottom of case for proper oil drainback.
28. Attach dial indicator with magnetic base No. D78P-4201-B or equivalent to compressor bar. Place stylus onto compressor plate and zero dial.
29. Release torque on tool center bolt and note reading on indicator. Reading must be within 0.054-0.026 inch. If reading is not within specifications, repeat procedure using correct selective snap ring.
30. Selective snap rings are available in following sizes:
a. 0.061-0.057 inch.
b. 0.080-0.076 inch.
c. 0.100-0.098 inch.
Torquing Feed Bolts:
31. Remove clutch spring tool assembly, then torque three feed bolts.
Installing Thrust Washer No. 7DO14 And Needle Bearing Assembly No. 7E486:
32. Using grease, place needle bearing assembly on rear face of center shaft. Install center shaft, overdrive ring gear, overdrive planetary gear set, and coast clutch cylinder as an assembly.
33. Install overdrive clutch pack starting with steel plate, then pressure plate with dot facing outward and toward top of transmission.
34. Install trial selective snap ring. Using feeler gauge check stack-up. Clearance should not exceed 0.047-0.022 inch.
35. If clearance is not within specifications, install correct selective snap ring and recheck. Selective snap rings are available in following sizes:
a. 0.061-0.057 inch.
b. 0.080-0.076 inch.
c. 0.100-0.098 inch.
d. 0.120-0.118 inch.
e. 0.140-0.137 inch.
36. Install pump gasket into case.
37. Install tools shown in the Installing Thrust Washer No. 7DO14 And Needle Bearing Assembly No. 7E486 image, into pump threaded holes, then thrust washer No. 7D014 and needle bearing assembly No. 7E486 onto pump.
Alignment Pin Location:
38. Install input shaft (long splined end first) and alignment pin No. T89T-70010 or equivalent into case.
39. Install pump into case. Ensure filter inlet tube bore is towards valve body mounting surfaces.
40. Remove old rubber coated washer from pump to case bolts. Install new pump bolt washers.
41. Remove aligning pin, then install pump attaching bolts and torque. Draw pump into case evenly.
42. Remove input shaft.
43. Install manual lever seal, then manual lever detent spring bolt and torque bolt.
44. Install manual lever, inner lever, park actuating rod assembly, and nut. Torque manual lever nut.
45. Install manual lever roll pin. Ensure pin is just below case surface.
46. Install parking pawl, pin, and parking pawl return spring on rear of transmission. Ensure return spring end rests on inside surface of case.
47. Install parking pawl abutment with Torx head bolt and torque bolt.
48. Attach parking rod guide plate ensuring plate dimple is facing inward. Torque bolts.
49. Install manual lever position sensor. Using gear position sensor adjuster No. T89T-70010-J or equivalent align sensor for neutral gear position. Torque bolts.
50. Place gasket on extension housing, then install extension housing and wiring bracket to case. Torque bolts. On 4WD models, two bottom bolts are longer.
51. Rotate transmission so pan surface is facing up.
52. Install same number of check balls noted during disassembly in to transmission case pockets. Due to design changes, the transmission may be equipped with one of the following:
Check Ball Locations, Units With 9 Rubber Check Balls:
a. 9 rubber check balls.
Check Ball Locations, Units With 10 Rubber Check Balls And 1 Steel Check Ball:
b. 10 rubber check balls and 1 steel check ball.
EPC Blow-Off Ball And Spring Location:
53. After installing check balls, install Electronic Pressure Control (EPC) blow-off spring and blow-off spring and ball.
54. Install case-to-separator plate gasket, then separator plate.
55. Attach reinforcing plate with stamped UP facing up. Torque bolts. Check placement of EPC blow-off ball.
56. Install new separator-to-control gasket.
57. Install solenoid screen into separator plate. Turn and lock solenoid screen.
58. Install accumulator body over studs. Torque nut and bolts.
59. Lower main control body over studs aligning manual valve with manual lever. Torque nut and bolts.
60. Coat solenoid body assembly with M1C172-A grease or equivalent, then install solenoid body over stud. Torque bolts and one nut.
61. Install new filter and seal assembly.
62. Place pan magnet on dimple in bottom of pan, then install new pan gasket.
63. Install pan to transmission. Torque bolts.
64. If removed, install stub tube. Alignment stripe should be farthest outboard when installed.
65. Install input shaft, long splined end first.