Steps 41-71

Transmission















Disassembled Views

Transmission Disassembled View (Part 1):

Transmission Disassembled View (Part 2):

Transmission Disassembled View (Part 3):

NOTE: Clutch plate quantity is model dependant based on engine displacement. Refer to Clutch Plate Quantity chart in the Specifications.

NOTE: For vehicles equipped with a 4.6L or 5.4L engine, the Transmission Control Module (TCM) is part of the molded leadframe.

NOTE: For vehicles equipped with a 6.2L engine, the PCM replaces the TCM.


41. NOTE: The flange nut must be loosely installed or an inaccurate reading may be recorded.

Using the Dial Indicator Gauge with Holding Fixture 100-002, lift up on the output shaft flange and record the reading. The reading should be within 0.15-0.35 mm (0.005-0.013 in).

- If the reading is not within the specification, install a different (either thinner or thicker) select fit thrust gear shim.





42. Tighten the output shaft flange nut.
- Tighten to 80 Nm (59 lb-ft).

- After installing the new output shaft flange nut, stake the slots to prevent it from coming loose.





4WD vehicles

43. Install the Dial Indicator Gauge with Holding Fixture 100-002 on the transmission case and position the plunger on the output shaft.





44. Using the Dial Indicator Gauge with Holding Fixture 100-002, lift up on the output shaft and record the reading. The reading should be within 0.15-0.35 mm (0.005-0.013 in).
- If the reading is not within the specification, install a different (either thinner or thicker) select fit thrust gear shim.





All vehicles

45. Install the T6 thrust bearing.





46. Install the direct clutch drum.





47. Install the T5 bearing on the direct clutch assembly.





48. Install the forward and overdrive clutch assembly.





49. Install the selective pump washer.





50. If the front pump assembly was not disassembled and assembled, install a new front pump outer diameter O-ring seal and lubricate it with petroleum jelly.





51. Install a new front pump seal on the Fluid Pump Seal Installer 307-556.





52. Using the Fluid Pump Seal Installer 307-556, install the front pump seal.





53. Install the Transmission Fluid Pump Remover 307-553 on the front pump.





54. Lubricate the transmission case pump bore with petroleum jelly. Using the Transmission Fluid Pump Remover 307-553, position the pump assembly in the case and rotate the pump to insert the pump splines into the front planetary sun gear. Rotate the pump to align the pump-to-case bolts and push the pump into the case.





55. Remove the Transmission Fluid Pump Remover 307-553.





56. Install new front pump bolts with new washers. Tighten the bolts in a crisscross pattern.
- Tighten to 10 Nm (89 lb-in).





57. Install the Transmission End Play Gauge 307-534 on the input shaft to measure the end play.
- Tighten the wing nut.





58. Install the Dial Indicator Gauge with Holding Fixture 100-002 on the Transmission End Play Gauge 307-534.
- Push down on the Transmission End Play Gauge 307-534 and zero out the Dial Indicator Gauge.

- Lift up on the Transmission End Play Gauge 307-534 and record the measurement on the Dial Indicator Gauge. The measurement should be between 0.2-0.4 mm (0.008-0.015 in). If the measurement is not within specification, install a new selective front pump washer.

- Measure the original washer, install a thinner or a thicker washer to achieve the correct measurement.





59. Remove the Dial Indicator Gauge with Holding Fixture 100-002 and the Transmission End Play Gauge 307-534.





60. Install the 4 rubber feed tubes for the center support.

1. Black feed tubes

2. Green feed tube

3. Blue feed tube





61. NOTE: Make sure that the fluid filter seal has been removed. If it has not, use a suitable pick and remove the seal.

NOTE: Add 0.118L (4 oz) of clean transmission fluid to prime the pump.

Install the rubber adapter and prime the fluid pump.





62. Install the thermal bypass valve into the case.





63. NOTE: Transmission Control Module (TCM) molded leadframe shown, PCM molded leadframe similar.

Align the mechatronic assembly guide pins in the alignment holes in the transmission case and position the mechatronic assembly in place.

1. Alignment holes

2. Guide pins





64. NOTE: The mechatronic assembly will not lay flush on the case, this is a normal condition with the rubber feed tubes, the bolts will pull the mechatronic assembly down.

Slightly lift the mechatronic assembly and align the manual valve in the manual valve linkage and position the mechatronic assembly in place.





65. NOTICE: For vehicles equipped with a 4.6L or 5.4L engine, do not touch the electrical connector terminals or the exposed solenoid tabs on the Transmission Control Module (TCM). Electrostatic discharge may occur and may cause damage to the TCM.

Install the mechatronic assembly bolts and tighten the bolts in the sequence shown.
- Tighten to 8 Nm (71 lb-in).





66. NOTICE: For vehicles equipped with a 4.6L or 5.4L engine, do not touch the electrical connector terminals or the exposed solenoid tabs on the Transmission Control Module (TCM). Electrostatic discharge may occur and may cause damage to the TCM.

With the release tab up and unlocked, push the outer shell of the bulkhead electrical connector into the transmission. Make sure that the bulkhead connector is fully seated into the molded leadframe.





67. Press down on the tab and lock the outer shell of the bulkhead electrical connector in place. Make sure that the locking tab is securely locked.





68. Install a new transmission fluid filter.





69. NOTE: The fluid pan gasket can be reused if not damaged.

Install a new transmission fluid pan gasket if required.





70. Install the fluid pan and tighten the bolts in a crisscross pattern.
- Tighten to 12 Nm (106 lb-in).





71. Using the Torque Converter Handle 307-091, install the torque converter. Remove the Torque Converter Handle 307-091.