Part 2

Transmission

Assembly (Steps 31-73)

31. NOTE: To aid assembly, shake the input shaft while pushing down on the pump.

Install the pump assembly.





32. Remove the alignment pin and install the front pump bolts.
^ Alternate bolt tightening to set the pump.
^ Tighten to 27 Nm (20 lb-ft).





33. Rotate the transmission to the horizontal position.
34. Install the parking pawl.
1) Position the parking pawl return spring.
2) Position the parking pawl.
3) Install the parking pawl shaft.





35. Install a new extension housing gasket and the extension housing.
1) Position the extension housing.
2) Install the 4 bolts and 2 nuts.
^ Tighten to 27 Nm (20 lb-ft).





36. NOTE: When installing the new seal, make sure that the drain hole in the seal is in the 6 o'clock position.

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





37. Install the output shaft speed (OSS) sensor and the turbine shaft speed (TSS) sensor.
1) Install the TSS speed sensor.
2) Install the TSS speed sensor bolt.
^ Tighten to 11 Nm (8 lb-ft).
3) Install the OSS speed sensor.
4) Install the OSS speed sensor bolt.
^ Tighten to 12 Nm (9 lb-ft).





38. Using the special tool, install the manual control lever seal.





39. NOTE: Lubricate the electronic pressure control (EPC) solenoid O-rings with clean transmission fluid.

Lubricate the EPC solenoid and install it into the case.





40. Install the manual valve detent lever and parking lever actuating rod.





41. Install the manual control lever shaft.
1) Slide the manual control shaft into the case.
2) Install the manual control lever shaft inner nut.
^ Tighten to 31 Nm (23 lb-ft).
3 Install the manual control lever shaft retaining pin.





42. Install the 1-2 accumulator piston assembly.
1) Install the 1-2 accumulator upper spring.
2) Install the 1-2 accumulator.
3) Install the 1-2 accumulator lower spring.
4) Install the 1-2 accumulator cover and seal.





43. Install the 1-2 accumulator retaining ring.





44. NOTE: This is not an ordinary installation procedure and does not compensate for band wear. When new piston and rod assembly installation becomes necessary, or when a new reverse band has been installed, the reverse piston and rod length must be adjusted.

NOTE: Lubricate the reverse piston seal to facilitate assembly and prevent damage to the seal.

NOTE: Do not install the reverse servo piston cover and seal at this time.

Install the reverse servo piston and rod assembly.





45. Install the special tool.
^ Tighten the bolt to 5.6 Nm (50 lb-inch).





46. Install the special tool.
^ Position the indicator stem on the flat portion of the reverse servo piston and zero the dial indicator.





47. Loosen the bolt until the piston stops against the tool.





48. Verify that the amount of piston travel on the dial indicator is within specification.





49. If piston travel is not within specification, select and install the correct servo assembly to bring the servo piston travel within specification.
1) 1 groove
2) 2 grooves
3) 3 grooves





50. Remove the special tools.





51. Install the reverse servo assembly.
1) Install the rod.
2) Install the piston assembly.
3) Install the reverse servo piston cover and seal.





52. Using the special tool, install the reverse servo retaining ring.
1) Compress the reverse band servo.
2) Install the reverse band servo retaining ring.





53. Install the 2-3 accumulator assembly.
1) Install the accumulator piston.
2) Install the accumulator piston spring.
3) Install the accumulator spring retainer.





54. Using the special tools, apply regulated air pressure to the test ports. Verify that the components are applied and released.





55. NOTE: The tab on the electrical connector is secured by the main control valve body.

Install the electrical connector into the case.





56. NOTE: The alignment bolts are valve body assembly bolts and are in the valve body.

Align the main control valve body alignment bolts and position the main control valve body.





57. NOTE: The main control valve body bolts will be tightened in later steps.

Loosely install the 11 long main control valve body bolts.





58. NOTE: Lubricate the EPC solenoid O-rings with clean automatic transmission fluid.

Position the EPC solenoid bracket and loosely install the bolt.





59. NOTE: The main control valve body bolts will be tightened in later steps.

Loosely install the 12 short main control valve body bolts.





60. Install the manual control valve detent lever spring and loosely install the bolt.





61. Tighten the main control valve body and cover plate bolts in the sequence shown.
^ Tighten to 10 Nm (89 lb-inch).





62. Inspect the lead frame for damage.
^ Using the special tool, check all the lead frame solenoid connections. The gauge should fit tightly and not fall out after being inserted.
^ If the special tool passes through any lead frame connector pins or does not feel like it makes a good contact, install a new lead frame.





63. Connect the molded lead frame to the solenoids.
^ Connect the bulkhead interconnector by pressing it in place by hand and fully seating the connector in place.
^ Connect the EPC solenoid by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots.
^ Connect the TCC by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots.
^ Connect the shift solenoid SSA and SSB by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots.





64. Install the transmission fluid filter and seal assembly.





65. Position the transmission fluid pan magnet into the transmission fluid pan.





66. NOTE: The transmission fluid pan gasket is reusable. Clean and inspect for damage. If not damaged, the transmission fluid pan gasket should be reused.

Install the transmission fluid pan.
1) Position the transmission fluid pan and gasket.
2) Install the transmission fluid pan bolts.
^ Tighten to 14 Nm (10 lb-ft).





67. Loosely install the digital transmission range (TR) sensor bolts and sensor.





68. NOTE: The tool is designed to fit snugly.

NOTE: Manual shift lever must be in the NEUTRAL position.

Using the special tool, align the digital TR sensor slots.





69. CAUTION: Tightening one screw before tightening the other may cause the digital TR sensor to bind or become damaged.

Tighten the screws in an alternating sequence.
^ Tighten to 9 Nm (80 lb-inch).





70. Lightly lubricate the converter hub with clean transmission fluid.





71. WARNING: Secure the torque converter in the transmission during removal or installation. The torque converter is heavy and may result in injury if it falls out of the transmission. Failure to follow this instruction may result in serious personal injury.

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.

Using the special tools, install the torque converter.





72. Install the special tool.





73. Lubricate the torque converter pilot hub with multi-purpose grease.