Part 2
TransmissionAssembly (Steps 25-71)
Slip yoke transmissions
25. Install a new extension housing seal using the special tool.
All transmissions
26. Install the No. 16 bearing and race.
Early build vehicles
27. Install the output hub and ring gear assembly 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.
30. Install the pressure plate (low/reverse one-way clutch [OWC]) on the last friction plate, with THIS SIDE UP facing upward and with the partial tooth located between 10 and 2 o'clock.
1) For gasoline engine vehicles, install the 12 strut OWC.
2) For diesel engine vehicles, install the 6 strut OWC.
Late build vehicles
31. Assemble the rocker clutch and ring gear assembly.
1) Install the No. 15 hub bearing onto the ring gear hub.
2) Install the rocker clutch, low/reverse clutch pack and carrier and hub assembly into the output hub and ring gear assembly.
32. NOTE: Place the transmission in the horizontal position.
Install the rocker clutch and ring gear assembly into the transmission case.
All vehicles
33. 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 flat snap ring and make sure that the snap ring is fully seated in the case snap ring groove.
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.
34. Install the anti-clunk spring.
35. Verify the anti-clunk spring is correctly seated.
1) Place a straight edge across the machined surface of the transmission case.
2) An air gap should be between the anti-clunk spring and the straight edge.
36. Using the special tools, install the forward geartrain as an assembly.
37. Install the intermediate clutch pressure plate.
^ Position the intermediate clutch pressure plate in the case with the 3 tabs facing downward.
38. Install the intermediate clutch plates, starting with a friction plate.
39. Install the center support with the transmission in a vertical position to avoid damage to the center support Teflon(R) seals.
40. Loosely install the feed bolts.
1) Loosely install the Torx(R) head forward clutch feed bolt into the case toward the rear of the case.
2) Loosely install the hex head intermediate clutch feed bolt into the case toward the front of the case.
41. Using the special tool, install the center support snap ring.
^ The snap ring should be installed with the flat edge facing downward. The gap in the snap ring should be facing in the 6 o'clock position. Tap the snap ring securely into the case.
42. Tighten the feed bolts.
^ Tighten to 33 Nm (24 lb-ft).
43. Install the No. 5 thrust bearing onto the center support.
44. Install the center shaft and ring gear.
45. Install the No. 4 thrust bearing onto the center shaft.
46. Using the special tool, install the coast clutch assembly and overdrive carrier.
47. Install the overdrive clutch assembly snap ring with the gap in the 6 o'clock position.
48. Install the overdrive pressure plate with the notches facing up.
49. Install the overdrive clutch.
^ Start with a friction plate, alternating with a steel plate.
50. Install a new pump gasket.
51. Install the No. 2 thrust bearing.
52. Install the input shaft into the case.
53. NOTE: Alignment pins are used in case holes located at the 5 o'clock and 11 o'clock positions.
Install the special tools into the case in order to install the pump.
54. Check to make sure that the No. 1 thrust washer is installed on the pump stator, and make sure that the No. 2A bearing is installed onto the pump support.
55. NOTE: Pump-to-case alignment pins are used in case holes located at the 11 o'clock and 5 o'clock positions.
Using the special tools, install the pump assembly with the transmission in a vertical position to avoid damage to the pump stator support Teflon(R) seals.
56. Install new pump body-to-case retaining bolts.
^ Tighten to 27 Nm (20 lb-ft).
57. Install a new main control body gasket.
58. Using the special tools, check the function of each clutch. Apply 20 psi (137.9 kPa) of air to each port.
59. Using the special tools, install the solenoid body and loosely install the bolts.
^ While installing the solenoid body, align the manual valve.
60. Tighten all the bolts in the sequence shown.
^ Tighten to 13 Nm (10 lb-ft).
61. Connect the TR sensor connector.
62. NOTE: Prior to installing the transmission fluid filter, make sure that the old seal is not stuck in the case.
Install a new transmission fluid filter.
63. NOTE: Reuse the transmission fluid pan gasket unless it is damaged.
Install the transmission fluid pan gasket to the transmission fluid pan. Make sure the magnet is positioned over the dimple in the transmission fluid pan.
64. Install the transmission fluid pan.
^ Tighten to 20 Nm (15 lb-ft).
65. Install the intermediate shaft and turbine shaft speed (TSS) combination sensor.
1) Install the speed sensor.
2) Install the speed sensor bolt.
^ Tighten to 9 Nm (80 lb-inch).
66. Install the output shaft speed (OSS) sensor.
1) Install the OSS sensor.
2) Install the OSS sensor bolt.
^ Tighten to 9 Nm (80 lb-inch).
67. If a new case was installed, wipe cooler tube case fittings dry. Install new O-rings onto the cooler tube case fittings, apply Threadlock(R) and sealer onto the threads and install into the new case.
^ Tighten to 52 Nm (38 lb-ft).
68. CAUTION: Do not damage the fluid pump gear stator support seal when installing the torque converter.
CAUTION: Make sure the converter hub is fully engaged in the front pump support and gear and rotates freely. Do not damage the hub seal.
CAUTION: If the torque converter slides out, the hub seal may be damaged.
Lubricate the converter hub with clean automatic transmission fluid.
69. CAUTION: Use care when installing the torque converter to avoid damage to the front pump stator support seal.
NOTE: Check the converter crankshaft pilot for nicks or damaged surfaces that can cause interference when installing the transmission to the engine. Check the converter impeller hub for nicks or sharp edges that can damage the pump seal.
Using the special tools, install the torque converter. Push and rotate the converter onto the front pump assembly until it bottoms out.
70. Check the seating of the torque converter.
1) Place the straightedge across the converter housing.
2) Make sure there is a gap between the converter pilot face and the straightedge.
3) Remove the special tools.
71. Use the special tool to hold the torque converter in place when installing the transmission.
