Steps 41-77

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, the necessary torques can be found in the Torque Specifications chart.
- When building up subassemblies, each component part should be lubricated with transmission fluid. It is also recommended 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.


41. NOTE: Lubricate the Electronic Pressure Control (EPC) solenoid O-rings with transmission fluid.

Lubricate the EPC solenoid and install it into the case.





42. Install the manual valve detent lever and the park lever actuating rod.





43. 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 lever shaft retaining pin.





44. Install the 1-2 accumulator piston assembly.

1. Install the 1-2 accumulator spring.

2. Install the 1-2 accumulator.

3. Install the inner and outer 1-2 accumulator springs.

4. Install the 1-2 accumulator cover and seal.





45. Install the 1-2 accumulator springs and install the accumulator piston retaining ring.





46. NOTE: This is not an ordinary installation procedure and does not compensate for band wear. If a new piston and rod assembly or 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.

Install the reverse servo piston and return spring.





47. Install the Servo Piston Installer and tighten the band apply bolt.
- Tighten to 5.6 Nm (50 lb-in).





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





49. Loosen the bolt until the piston stops against the Dial Indicator Gauge.





50. Verify that the amount of piston travel on the Dial Indicator Gauge is within specification.





51. If piston travel is not within specification, select and install the correct servo assembly to bring the servo piston travel within specification.

1. One groove.

2. Two grooves.

3. Three grooves.





52. Remove the Dial Indicator Gauge with Holding Fixture.





53. Install the reverse servo assembly.

1. Install the rod.

2. Install the piston assembly.

3. Install the reverse servo piston cover and seal.





54. 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.





55. Install the 2-3 accumulator assembly.

1. Install the accumulator piston.

2. Install the accumulator piston spring.

3. Install the accumulator spring retainer.





56. Using the Transmission Air Test Plate and Transmission Test Plate Screw Set, use a Rubber Tip Air Nozzle to apply regulated air pressure to the test ports. Verify that the components are applied and released.





57. NOTE: The tab on the transmission internal harness connector is secured by the main control valve body.

Inspect the transmission internal harness connector O-ring for nicks or cuts. If damage is indicated, install a new O-ring. Install the transmission internal harness connector into the case.





58. 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.





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

Loosely install the 11 long main control valve body bolts.





60. Install the Electronic Pressure Control (EPC) solenoid bracket and loosely install the bolt.





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

Loosely install the 12 short main control valve body bolts.





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





63. Tighten the bolts in the sequence shown.
- Tighten to 10 Nm (89 lb-in).





64. Inspect the transmission internal harness for damage.

65. 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 Torque Converter Clutch (TCC) by pressing it in place by hand and fully seating the connector in place.

4. Connect Shift Solenoid A (SSA) and Shift Solenoid B (SSB) by pressing it in place by hand and fully seating the connector in place.

5. Connect the Transmission Fluid Temperature (TFT) sensor.





66. Install the fluid filter and seal assembly.





67. 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 that the internal wire harness is properly routed.





68. Position the pan magnet onto the fluid pan.





69. 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 and gasket.

1. Position the transmission fluid pan and transmission fluid pan gasket in place.

2. Install the transmission fluid pan bolts.
- Tighten to 14 Nm (124 lb-in).





70. Install the Transmission Range (TR) sensor and bolts.

1. Install the TR sensor.

2. Loosely install the bolts.





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

NOTE: The manual control lever must be in the NEUTRAL position.

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





72. NOTICE: Tightening one bolt before tightening the other may cause the sensor to bind or become damaged.

Tighten the bolts in an alternating sequence.

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





73. Install the manual control lever.

1. Position the manual control lever.

2. Install a new manual control lever outer nut.
- Tighten to 33 Nm (24 lb-ft).





74. Install the transmission vent tube.

75. Lightly lubricate the converter hub with automatic transmission fluid.





76. 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.





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