Part 3

Transmission














































70. Thread the Fluid Pump Alignment Set over Transmission Fluid Pump Alignment Gauges and then over the fluid pump until it bottoms out in the fluid pump gear pocket.






71. Tighten the fluid pump screws in a star pattern and remove the pump alignment handle.
- Tighten to 26 Nm (19 lb-ft).





72. Install a new fluid pump seal ring.
- Coat the fluid pump seal ring with petroleum jelly.





73. NOTE: Make sure the fluid pump seal ring is installed on the housing and pump assembly.

Install a new fluid pump gasket.

- Hold the fluid pump gasket in place with petroleum jelly.





74. NOTICE: Be careful not to overstretch the seal ring past the seal ring groove or damage to the seal will occur.

Using the Transmission Fluid Pump Seal Installer and the Transmission Fluid Pump Seal Aligner, install the fluid pump seal ring.





75. NOTE: Verify correct seal installation. Make sure seal grooves are clean and free of burrs.

Verify that the seal is installed correctly.





76. NOTICE: Failure to correctly size the seal will damage the seal when the torque converter is installed.

Using the Transmission Fluid Pump Seal Sizer, size the seal to the correct size. Leave the Transmission Fluid Pump Seal Sizer on the seal for 2 minutes to obtain the correct seal size.





77. Install the selected No. 1 fluid pump thrust washer.
- Coat the fluid pump thrust washer with petroleum jelly.





78. Install the Torque Converter Aligners into the transmission case.





79. NOTE: The splines on the ends of the input shaft are not the same length. The shorter splines go into the assembly.

Install the input shaft.





80. NOTE: Make sure that the No. 1 fluid pump inlet thrust washer selective thrust washer, fluid pump gasket and the fluid pump-to-case O-ring seal remain in the correct position throughout this step.

Install the fluid pump and converter housing onto the case.





81. NOTE: Lubricate the O-ring seals on the converter housing screws.

Remove the Torque Converter Aligners. Install the new converter housing-to-case screws. Tighten the screws in a star pattern.

- Tighten to 47 Nm (35 lb-ft).





82. Remove the input shaft.





83. WARNING: Always verify that the lockpin on the bench-mounted holding fixture is correctly secured to help prevent unexpected component rotation. Failure to follow this instruction may result in serious personal injury.

Rotate the transmission assembly so the fluid pan rails are facing up.

84. Assemble the front servo assembly.

1. Install the front servo cover O-ring seal on the front servo cover. Coat the front servo cover O-ring seal with petroleum jelly.

2. Install the front servo piston into the front servo cover.

3. Install the front servo piston spring on the front servo piston.





85. NOTICE: Do not damage the front servo-to-case O-ring seal during installation.

NOTICE: Do not press the front servo cover and O-ring seal past the relief hole in the case or O-ring seal damage can occur.

Using the Servo Cover Compressor, install the front servo assembly into the case and install the front servo cover retaining ring.





86. Assemble the intermediate servo assembly.

1. Install the intermediate servo cover O-ring seal on the intermediate servo cover. Coat the intermediate servo cover O-ring seal with petroleum jelly.

2. Install the intermediate servo piston into the intermediate servo cover.

3. Install the intermediate servo piston spring on the intermediate servo piston.





87. NOTICE: Do not damage servo cover-to-case O-ring seal during installation or O-ring seal damage can occur.

NOTICE: Do not press the intermediate servo cover and O-ring seal past the relief hole in the case or O-ring seal damage can occur.

Using the Servo Cover Compressor, install the intermediate servo assembly into the case and install the intermediate servo cover retaining ring.





88. NOTE: Do not allow front band adjustment screw to back out. The band strut may fall out of position.

NOTE: Install, but do not tighten, a new locknut on the band adjustment screw. Apply petroleum jelly to the locknut seal.

Install a new locknut on the band adjustment screw.





89. NOTE: The front servo must be installed prior to band adjustment.

NOTE: The wrench will click at the specified torque.

Using the Transmission Band Adjustment Set, tighten the front band adjustment screw.

- Tighten to 14 Nm (124 lb-in).

- Back off the front band adjustment screw exactly 2 turns and hold that position.





90. Tighten the front band locknut.

1. Hold the front band adjustment screw stationary.

2. Tighten the front band locknut.
- Tighten to 54 Nm (40 lb-ft).





91. NOTE: Do not allow the intermediate band adjusting screw to back out. The band strut could fall out of position.

NOTE: Install, but do not tighten, a new locknut on the band adjustment screw. Apply petroleum jelly to the locknut seal.

Install a new nut on the band adjustment screw.





92. NOTE: The intermediate servo must be installed prior to band adjustment.

NOTE: The wrench will click at the specified torque.

Using the Transmission Band Adjustment Set, tighten the intermediate band adjustment screw.

- Tighten to 14 Nm (124 lb-in).

- Back off the intermediate band adjustment screw exactly 2 turns and hold that position.





93. Tighten the intermediate band locknut.

1. Hold the intermediate band adjustment screw stationary.

2. Tighten the intermediate band locknut.
- Tighten to 54 Nm (40 lb-ft).





94. NOTE: Install new O-ring seals on the 16-pin electrical connector. Coat the O-ring seals with petroleum jelly.

NOTE: Make sure that the tab is in the lock position.

Position the transmission case 16-pin electrical connector into the case bore.

- Press the transmission case 16-pin electrical connector through the case until a click is heard.





95. NOTICE: Do not overstretch the retaining spring. Overstretching may damage the spring.

Install the 16-pin electrical connector retaining spring.





96. NOTE: Align the slot on the TSS sensor electrical connector with the slot in the 16-pin electrical connector.

Install the TSS sensor electrical connector into the transmission case 16-pin electrical connector.

1. Connect the TSS sensor electrical connector.

2. Insert the TSS sensor electrical connector wires into the retaining slot in the 16-pin electrical connector.





97. Tighten the center support screw.
- Tighten to 11 Nm (97 lb-in).





98. Install the Valve Body Aligners into the transmission case.





99. NOTE: Make sure main control valve body gasket is aligned.

NOTE: Make sure that the manual valve is correctly aligned with the manual valve inner pin when the main control valve body is installed.

Position the main control valve body into the transmission case.





100. NOTE: The screws will be tightened in later steps.

Loosely install the 4 M6 x 45 mm (1.771 in) screws.





101. NOTE: The main control valve body screws will be tightened in later steps.

Loosely install the 2 M6 x 35 mm (1.377 in) screws.





102. NOTE: The main control valve body screw will be tightened in later steps.

Loosely install the M6 x 30 mm (1.181 in) screw.





103. Remove the Valve Body Aligners.





104. NOTE: The main control valve body screws will be tightened in later steps.

Loosely install the 16 M6 x 40 mm (1.574 in) screws.





105. Tighten the screws in the sequence shown.
- Tighten to 10 Nm (89 lb-in).