Part 2

Transmission















Automatic Transmission - Disassembled View

































NOTICE: Before beginning assembly, carry out and inspect the following:

When building up subassemblies and assembling the transmission, ALWAYS use new gaskets and seals.

All fasteners must be tightened to the torque specification indicated. In addition to appearing in the system, the necessary torques can be found in the General Specifications Chart.

When building up subassemblies, each component part should be lubricated with transmission fluid. It is also good practice to lubricate the subassemblies as they are installed in the case.

Needle bearings, thrust washers and seals should be lightly coated with petroleum jelly during subassembly buildup or transmission assembly.

Many components and surfaces in the transmission are precision machined. Careful handling during disassembly, cleaning, inspection and assembly can prevent unnecessary damage to machined surfaces.


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 Transmission Extension Housing Oil Seal Installer, install a new extension housing seal.





37. Install the OSS sensor and the TSS sensor.

1. Install the TSS sensor.

2. Install the TSS sensor bolt.
- Tighten to 11 Nm (97 lb-in).

3. Install the OSS sensor.

4. Install the OSS sensor bolt.
- Tighten to 12 Nm (106 lb-in).





38. Using the Shift Shaft Fluid Seal Installer, install the manual control lever seal.





39. NOTE: Lubricate the EPC solenoid O-rings with transmission fluid.

Lubricate the EPC solenoid and install it into the case.





40. Install the manual control valve detent lever and park lever actuating rod.





41. Install the manual control lever shaft.

1. Slide the manual control lever 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 with transmission fluid 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 Servo Piston Installer.
- Tighten the bolt to 5.6 Nm (50 lb-in).





46. Install the Dial Indicator Gauge with Holding Fixture.
- Position the Dial Indicator Gauge stem on the flat portion of the reverse servo piston and zero the Dial Indicator Gauge.





47. Loosen the bolt until the piston stops against the Dial Indicator Gauge stem.





48. Verify that the amount of piston travel on the Dial Indicator Gauge 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 Dial Indicator Gauge with Holding Fixture.





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 Servo Piston Remover/Installer, 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 Transmission Air Test Plate, Transmission Test Plate Screw Set and Rubber Tip Air Nozzle, 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.

Inspect the transmission internal harness connector O-ring for damage. If damaged, install a new O-ring. 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: The main control valve body bolts will be tightened in later steps.

Loosely install the 12 short main control valve body bolts.





59. NOTE: Lubricate the EPC solenoid O-rings with transmission fluid.

Position the EPC solenoid bracket and loosely install the bolt.





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-in).





62. Connect the transmission internal harness to the solenoids.

1. Connect the transmission internal harness connector by pressing it in place by hand and fully seating the connector in place.

2. Connect the EPC solenoid by pressing it in place by hand and fully seating the connector in place.

3. Connect the TCC by pressing it in place by hand and fully seating the connector in place.

4. Connect the shift solenoid SSA and SSB by pressing it in place by hand and fully seating the connector in place.

5. Connect the TFT solenoid by pressing it in place by hand and fully seating the connector in place.





63. Install the transmission fluid filter and seal assembly.





64. NOTICE: The transmission internal wire harness needs to be properly routed to avoid the potential of damage to the harness. Pinched or trapped wires may result in a transmission failure.

Make sure the transmission internal wire harness is properly routed.





65. Position the 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 (124 lb-in).





67. Loosely install the TR sensor bolts and sensor.





68. NOTE: The TR Sensor Alignment Gauge is designed to fit snugly.

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

Using the TR Sensor Alignment Gauge, align the TR sensor slots.





69. NOTICE: Tightening one screw before tightening the other may cause the Transmission Range (TR) sensor to bind or become damaged.

Tighten the screws in an alternating sequence.

- Tighten to 9 Nm (80 lb-in).





70. Lightly lubricate the converter hub with transmission fluid.





71. NOTICE: Make sure the converter hub is fully engaged in the front pump support and gear and rotates freely. Do not damage the hub seal.

NOTICE: If the torque converter slides out, the hub seal may be damaged.

Using the Torque Converter Handles, install the torque converter.





72. Install the Torque Converter Retainer.





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