Part 2

Transmission














































36. Add dimensions C and G. This total is dimension H. Use the following chart to select the correct No. 4 thrust bearing. Reference end play is 0.20-0.54 mm (0.007-0.021 in).







37. Install the intermediate servo actuating lever.





38. NOTE: The intermediate band lever shaft is shorter than the front band lever shaft.

Install the intermediate band actuating lever shaft through the intermediate servo actuating lever.





39. Install the intermediate band apply strut on the intermediate servo actuating lever.





40. NOTE: Make sure that the intermediate apply strut is aligned with the band notch.

Install the intermediate band.





41. NOTE: Use the intermediate band adjusting screw as a temporary alignment guide.

NOTE: The intermediate and front band anchor struts and band adjustment screws are the same.

Install the intermediate band anchor strut and the intermediate band adjustment screw.





42. Install the No. 4 selected intermediate brake drum thrust washer on the center support.
- Coat the intermediate brake drum thrust washer with petroleum jelly.





43. NOTICE: Do not apply pressure to the center support while installing. Damage to sealing rings may result.

NOTE: Align the center support screw hole with correct case hole.


Install the center support.

1. Position the center support into the intermediate brake and direct clutch drum.

2. Temporarily insert the input shaft and gently wiggle it until the center support is seated against the case shoulder, then remove the input shaft.





44. NOTE: Install the center support retaining ring with the tapered side facing up.

NOTE: Make sure the notch opening is not obstructed by the center support retaining ring.

Install the center support retaining ring.

1. Position the center support retaining ring with the tapered side facing up.

2. Install the center support retaining ring so that the notch opening is not obstructed.





45. Install the center support locknut and cage.





46. Loosely install the center support-to-case cap screw.





47. NOTICE: Carefully route the Turbine Shaft Speed (TSS) sensor connector and wiring harness through the opening in the case. Do not damage the wiring.

NOTE: Route Turbine Shaft Speed (TSS) sensor electrical connector and wiring through transmission case opening.

Install the TSS sensor.

1. Install the TSS sensor.

2. Install the TSS sensor screw.
- Tighten to 10 Nm (89 lb-in).





48. NOTE: Use only the No. 3 center shaft thrust bearing.

NOTE: The No. 3 center shaft thrust bearing has no notches on the outer race.

Install the No. 3 center shaft thrust bearing.





49. NOTICE: Do not bend the trigger wheel.

Install the Overdrive (O/D) planetary and One-Way Clutch (OWC) assembly.





50. NOTE: The trigger wheel triggering window should pass over the thin blade of the TSS Gauge. If it does not, a new overdrive planetary carrier and trigger wheel must be installed.

Using the TSS Gauge, check the TSS sensor air gap.

1. Place the thin blade of the TSS Gauge over the TSS sensor.

2. Rotate the trigger wheel and repeat checks for all windows.





51. NOTE: The trigger wheel triggering window should not pass over the thick blade of the TSS Gauge. If it does, a new overdrive planetary carrier and trigger wheel must be installed.

Using the TSS Gauge, check the TSS sensor air gap.

1. Place the thick blade of the TSS Gauge over the TSS sensor.

2. Rotate the trigger wheel and repeat checks for all windows.





52. NOTE: Align the clutch plates and front adapter gear.

Install the front brake drum and coast clutch drum assembly.





53. Install the front servo band lever and front band lever-to-case bracket into the transmission case.





54. NOTE: The front band lever shaft is longer than the intermediate band actuating lever shaft.

Install the front band actuating lever shaft through the front servo band lever.





55. Install the front band apply strut.





56. NOTE: If the front band is reused, it must be installed in its original position.

Install the front band over the front brake and coast clutch drum.





57. NOTE: Use the band adjustment screw as a temporary alignment guide.

Install the front band anchor strut.





58. Install the front band adjusting screw.





59. NOTE: Make sure that the pump body is seated against the thrust washer and the front brake and coast clutch drum. The pump body must be below the level of the case gasket surface.

NOTE: The tabs on the washer go into the pump face.

Carry out the front end play check procedure as follows:

- Coat the No. 1 fluid pump inlet thrust washer with petroleum jelly.

- Install the No. 1 fluid pump inlet thrust washer on the rear of the fluid pump and place the pump into position in the case.





60. NOTE: The Shim Selection Gauge must rest on the gasket surface.

Measure the front end play clearance.

1. Place the Shim Selection Gauge across the case.

2. Insert the Depth Micrometer and extend the Depth Micrometer probe until it contacts the fluid pump face.

- Read the measurement and subtract the Shim Selection Gauge thickness 17.78 mm (0.7 in). This is dimension A.

- Repeat the measurement at the opposite side of the transmission case. This is dimension B.

- Add dimensions A and B together and divide by 2. This is front end clearance, dimension C.





61. NOTE: If the average front end clearance is below the specification, choose a thinner washer. If the average is above the specification, choose a thicker washer.

NOTE: The front end play specification is 0.18-0.70 mm (0.007-0.027 in).

Use dimension C and the chart below to select the correct thickness fluid pump inlet thrust washer (No. 1).

Front End Play Selective Thrust Washer No. 1





62. NOTE: Make sure that the pump body is seated against the thrust washer and the front brake and coast clutch drum. The pump body must be below the level of the case gasket surface.

NOTE: The tabs on the washer go into the pump face.

Remove the pump and install the No. 1 thrust washer onto the pump. After installing selected front pump thrust washer No. 1, repeat the front end play check. Make sure the end play is correct, then remove the pump for assembly.





63. Install a new O-ring seal in the fluid pump drive gear.





64. NOTE: Lubricate the Piston Seal Sizer with multi-purpose grease.

Install the fluid pump drive gear on the Piston Seal Sizer to seat the O-ring seal. Remove the tool.





65. NOTICE: The chamber on the inside edge of the small gear must be up when in the pump housing gear pocket. The dimple on the larger gear must be down when in the pump housing gear pocket. Incorrect installation can result in transmission damage.

Install the pump gears into the fluid pump housing. Apply multi-purpose grease to the pump gear to prevent scoring at start-up.





66. NOTE: Make sure the holes in the plate line up with the holes in the pump.

Install the fluid pump adapter plate.





67. NOTE: Do not allow the pump gears to come out of the pump housing pocket.

NOTE: The notch on the outside of the adapter plate will be at the 9 o'clock position relative to the converter housing.

Install the fluid pump on the converter housing.

- Hold the fluid pump adapter plate against the pump housing. Turn the pump and adapter plate over and place on the converter housing.





68. Loosely install the fluid pump screws.





69. NOTICE: The Transmission Fluid Pump Alignment Gauges and the Fluid Pump Alignment Set must be used to correctly align the transmission fluid pump to the transmission fluid adapter plate. This will prevent seal leakage, gear noise, broken gears and bushing failure.

Align the transmission fluid pump to the transmission fluid pump adapter plate and select the gauge from the Fluid Pump Alignment Set that is the snuggest fit when placed over the fluid pump.