Steps 1-35

Transmission

Special Tool(s):

Material:

Disassembly

Transmission, Disassembled View (Part 1):

Transmission, Disassembled View (Part 2):

Transmission, Disassembled View (Part 3):

Transmission, Disassembled View (Part 4):

Transmission, Disassembled View (Part 5):

Transmission, Disassembled View (Part 6):

Transmission, Disassembled View (Part 7):

Transmission, Disassembled View (Part 8):

Transmission, Disassembled View (Part 9):

Transmission, Disassembled View (Part 10):

Transmission, Disassembled View (Part 11):

Early Build Vehicles with Externally Mounted Remote Filter

CAUTION: Early build vehicles, those equipped with an externally mounted remote filter, are also equipped with a different design sump filter and bottom pan. Always pair the sump filter with the correct bottom pan design, to avoid cavitation, filter cracking and transmission damage.

Late Build Vehicles Without Remote Filter and With Serviceable High Efficiency Sump Filter (HESF)

CAUTION: Late build vehicles replace the remote filter with a serviceable high efficiency sump filter (HESF), which requires a wider and deeper bottom pan. Always pair the sump filter with the correct bottom pan design, to avoid cavitation, filter cracking and transmission damage.

NOTE: Soak all friction clutch plates in clean automatic transmission fluid.

NOTE: Prior to installation, lightly lubricate all O-ring seals with clean automatic transmission fluid.

NOTE: Lightly lubricate all thrust washers with petroleum jelly to hold them in place during assembly.

All transmissions

1. Mount the transmission case into a suitable stand.

2. If removed, use the special tool to install the short fluid inlet tube.

3. If removed, use the special tool to install a new Teflon(R) seal retainer.
- Install 2 new Teflon� seals.

4. NOTE: Coat the reverse clutch piston seals with petroleum jelly.

Install the reverse clutch piston in the case until it is fully seated in the case.

5. Install the reverse clutch return spring assembly.

6. WARNING: Do not over compress the return spring or damage to the spring will occur.

Using the special tools, install the reverse clutch return spring snap ring.

7. NOTE: The use of petroleum jelly will hold the No. 17 thrust bearing or washer in place during assembly.

For vehicles equipped with a slip yoke, install the No. 17 park gear thrust bearing. For vehicles equipped with a fixed yoke, install the No. 17 park gear thrust washer.

8. WARNING: Be careful when installing the output shaft not to damage the seals or a transmission leak could occur.

Install the output shaft.

9. CAUTION: The Torx� screw has a threadlocking compound. If the screw is removed, it must be discarded and a new screw installed.

If removed, install the parking pawl abutment with a new Torx(R) screw.
- Tighten to 25 Nm (18 lb-ft).

10. Install the parking pawl.
1. Install the parking pawl shaft.
2. Install the parking pawl.
3. Install the parking pawl return spring,

11. NOTE: Make sure the dimple on the parking guide support plate is facing inward.

Install the parking rod guide plate.
1. Install the parking rod guide plate.
2. Install the bolts.
- Tighten to 25 Nm (18 lb-ft).

12. Install a new orifice lube plug in the rear of the case. Using a 12-mm socket, tap the orifice lube plug into the back of the transmission. Check to make sure that the orifice lube plug is fully seated into the back of the transmission.

13. Install a new extension housing gasket.

14. Install the extension housing.
- Tighten to 48 Nm (35 lb-ft).

15. Using the special tool, install a new manual control lever seal.

16. Install the transmission range (TR) position sensor, park rod assembly and loosely install the bolt.

17. Install the manual control lever.

18. Install the roll pin into the case.

19. Install a new roll pin. Leave 2 mm (0.08 in) of the pin exposed.

20. Tighten the TR position sensor bolts.
- Tighten to 10 Nm (89 lb-in).

Fixed yoke transmissions

21. Using the special tool, install a new extension housing seal.

22. Inspect the new output shaft nut O-ring for cuts. A new nut must be installed.

23. Using the special tool, install a new output shaft nut.
- Tighten to 200 Nm (148 lb-ft).

24. Install the output flange and a new bolt.
- Tighten to 130 Nm (96 lb-ft).

Slip yoke transmissions

25. Install a new extension housing seal using the special tool.

All transmissions

26. Install the No. 16 bearing and race.

27. Install the ring gear, hub and the No. 15 hub bearing.

28. Install the reverse carrier and hub assembly.

29. Install the low/reverse clutch plates.
- Start with a steel plate on the bottom, followed by a friction plate.
- Alternately stack the remaining steel and friction plates.
- Add the pressure plate (low/reverse one-way clutch) on the last friction plate, with THIS SIDE UP facing upward.

Diesel engines

30. CAUTION: Do not apply air pressure to move the low/reverse piston without first installing the friction plates and the snap ring, or damage to the snap ring will occur. Install a new snap ring and make sure that the snap ring is fully seated in the case snap ring groove.

Diesel applications: Install a new flat snap ring so the tang ends are in the gaps to the right and to the left of the case spline as shown.

- Check the function of the reverse clutch by applying air to the correct passage (through the case valve body worm trail) for the reverse clutch.

Gasoline engines

31. CAUTION: Do not apply air pressure to move the low/reverse piston without first installing the friction plates and the snap ring, or damage to the snap ring will occur. Install a new snap ring and make sure that the snap ring is fully seated in the case snap ring groove.

Gas applications: Install a new wavy snap ring so the tang ends are in the gaps to the right and to the left of the case spline as shown. The circle ID mark must be installed upwards on the left hand side.
- Check the function of the reverse clutch by applying air to the correct passage (through the case valve body worm trail) for the reverse clutch.

All engines

32. Using the special tools, install the forward geartrain as an assembly.

33. Install the intermediate clutch pressure plate.
- Position the intermediate clutch pressure plate in the case with the 3 tabs facing downward.

34. Install the intermediate clutch plates, starting with a friction plate.

35. Install the center support with the transmission in a vertical position to avoid damage to the center support Teflon(R) seals.