Assembly
TOOLS REQUIRED^ J-38554 Clutch Piston Fitter
^ J-23327 Spring Compressor
^ J-38588 Guide Pin
^ J-36797 Oil Seal Installer
^ J-23075 Spring Compressor
^ J-38428 Piston Fitter
^ J-25025-B Guide Pin
^ Or Equivalent
1. Parking lock and selector lever assembly:
a. Inspect selector shaft seal, replace if necessary.
NOTE: Use a seal installer when replacing the seal.
b. Install selector shaft.
NOTE: Spring pin groove must be positioned inside the case.
c. Install spring pin. Be sure the selector shaft can move freely. Do not push the pin flush with the case surface. Leave enough height for removal.
d. Install actuator assembly.
e. Install parking lock and range selector lever and new 17 mm nut.
^ Torque 22 Nm (16 ft. lbs.).
2. Brake band:
a. Rotate main case to vertical position, extension end facing down.
b. Install brake band assembly.
NOTE: Be sure to align servo pin area with the servo hole.
c. Install thrust bearing.
NOTE: The case bushing acts as a guide for the thrust bearing.
3. Brake drum. Install brake drum.
4. Reaction sun gear:
a. Install reaction sun gear.
b. Install needle bearing.
5. Planetary carrier assembly:
a. Inspect planetary carrier assembly for wear and damage, if necessary renew.
b. Measure pinion end play clearance (A) with a feeler gage. If clearance is outside specified value, replace planetary carrier assembly.
^ Clearance (A) 0.13-0.89 mm (0.005-0.035 inch).
c. Install the thrust bearing on the output shaft.
NOTE: Use petroleum jelly to hold the thrust bearing in place.
d. Align planetary pinions. Each planetary pinion is marked with double points to indicate the master tooth space and exactly opposite with a single point to indicate the master tooth. The markings on the planetary carrier consist of double lines which are to be lined-up with the double points on two opposite pinions; the single lines are to be lined-up with the single points on the other two pinions.
e. After all four pinions are lined-up, slide on third clutch assembly. Rotate third clutch and check mark alignment. Considering that the ring gear tooth between the double points of one planetary pinion is tooth number 1, count the teeth to check that the single points on the two adjacent pinions are between teeth 23 and 24 of the ring gear, and that the ring gear tooth between the double points of the opposite pinion is tooth number 46. If it is not so, remove, realign and try again.
f. Install planetary carrier with third clutch.
NOTE: Do not force. When properly aligned, the parts will fit together easily.
g. Remove the third clutch. Install bearing and washer.
NOTE: Use petroleum jelly to hold the washer and bearing in place.
6. Second and third clutch assemblies:
a. Carefully align second clutch plates inner
b. Install thrust washer, tangs pointing downward, locating tang positioned in slot on second clutch hub.
NOTE: Use petroleum jelly to hold thrust washer in place.
c. Install third clutch and intermediate shaft assembly into the second clutch drum.
d. Install second and third clutch assemblies into the main case. Twist output shaft and clutch assemblies to insure proper fit.
e. Install pressure plate with lip side up, tang facing valve body face.
f. Install reverse clutch plates. Start with a steel plate and alternate with lined plates.
g. Install waved clutch plate, center tang facing valve body side.
SECOND CLUTCH END PLAY MEASUREMENT
a. Install the gauging tool on the case flange and against the intermediate shaft.
b. Position the inner shaft of the gauging tool against the thrust surface of the second clutch hub.
c. Tighten thumb screw. Remove the tool.
c. Fit the spacer ring on the inner shaft of the tool.
d. Measure gap ("G"). Select appropriate size washer as the chart specified.
- Selective washer gauging tool: J-23085-A.
7. Fourth clutch piston:
a. Inspect piston seals and replace if necessary.
b. Lubricate fitter and install on fourth clutch piston.
c. Install fourth clutch piston in adapter case.
d. Remove fitter.
- Fourth clutch piston fitter: J-38554.
8. Fourth clutch spring retainer:
a. Install retainer and spring assembly.
b. Install snap ring in adapter case.
c. Install compressor.
d. Compress retainer and spring assembly. Seat snap ring in groove. Remove compressor.
- Fourth clutch spring compressor: J-23327 and J-23327-90.
9. Adapter case and center support assembly:
a. Install selective washer using petroleum jelly.
b. Install two O-ring seals in main case and adapter case/main case seal ring.
c. Install guide pins.
d. Install adapter case complete to main case.
- Guide pin: J-38588.
10. Thrust washer. Install thrust washer into adapter case, with tangs pointing downwards.
11. Overdrive internal gear.
12. Thrust bearing assembly.
13. Turbine shaft and fourth clutch plates:
a. Preassemble overdrive internal gear and thrust bearing assembly onto the overrun clutch assembly complete.
NOTE: Install bearing assembly, black side up. Use petroleum jelly to keep assembly in place.
b. Complete overdrive carrier and internal gear assembly into adapter case.
c. Install fourth clutch plates in the following order. Steel, Lined, Steel, Steel, Lined, Steel. Steel plates go in with short tang facing towards valve body surface.
14. Fourth clutch retainer:
a. Install fourth clutch retainer.
b. Notch facing up and positioned towards valve body surface.
OVERDRIVE CLUTCH END PLAY MEASUREMENT:
Install the tool on the adapter case flange and against the input shaft. Position the inner shaft of the tool against the thrust surface of the overrun clutch housing. Tighten thumb screw. Remove the tool. Measure gap "G". Select appropriate size washer as the chart specifies. Set selective thrust washer aside.
- Selective washer gauging tool: J-23085-A.
15. Converter housing and oil pump assembly:
a. Install outer seal ring and gasket.
b. Install selective washer.
NOTE: Use petroleum jelly to hold selective washer in place.
c. Install complete converter housing and oil pump assembly to adapter case.
d. Fit and tighten seven outer 13 mm screws.
^ Torque 39 Nm (29 ft. lbs.).
e. Ensure free rotation of pump using rotation tool.
- Pump rotation tool: J-23082-01
OVERDRIVE END PLAY MEASUREMENT:
a. Fit puller on turbine shaft.
b. Position axial play checking tool on converter housing mating face.
c. Pull turbine shaft upwards with puller until first resistance is met. (Due to weight of overdrive complete assembly) Maintain shaft in this position and set indicator to zero. Pull turbine shaft further upwards with puller. Read end play shown on indicator.
^ End play 0.1-0.8 mm (0.004-0.030 inch).
d. Remove axial play checking tool and puller.
- Turbine shaft puller: J-25022 and J-24773-1
NOTE: If end play is not correct, repeat selective washer selection.
16. Speed sensor:
a. Inspect speed sensor O-ring. Replace if necessary.
b. Install speed sensor assembly and 10 mm screw.
^ Torque 9 Nm (78 inch).
MAIN CASE END PLAY MEASUREMENT:
a. Attach axial play checking tool on the extension housing and set indicator to zero on output shaft.
b. Manually push output shaft upwards.
^ End play 0.36 - 0.80 mm (0.014 - 0.03 inch).
c. Remove axial play checking tool.
d. If end play is not correct, repeat selective washer selection.
17. Servo piston:
a. Inspect piston seal ring. Replace if necessary. Ensure brake band is correctly positioned. Rotate output shaft if necessary.
b. Install servo piston fitter in servo bore.
c. Install apply rod, round end toward band, return spring and piston assembly.
d. Install the tool with offset to rear of case.
e. Compress servo piston with seal ring, using fitter while tightening the tool screw.
f. Install servo piston retaining ring.
g. Remove tool.
h. Adjust the brake band by tightening the servo adjusting screw to 4.5 Nm torque. Be certain the lock nut is loose, then back-off the screw five turns exactly. Hold piston sleeve with wrench and tighten lock nut to 18.5 Nm torque. Be certain the adjusting screw does not turn.
- Servo spring compressor: J-23075
- Servo piston fitter: J-38428.
18. Main case valve body and earth harness (12):
a. Install two check balls.
b. Inspect electrical connector and seal, replace if necessary.
c. Install electrical 4 pin connector/main case and wiring harness.
d. Install two guide pins into main case.
- Guide pin: J-25025-B.
e. Install valve body complete assembly and manual valve link.
NOTE: Valve must be extended as the short end of manual valve link is connected to the range selector lever. Long end of link goes into valve.
f. Install seven 13 mm screws.
g. Assemble 8.5mm connector of earth harness under the head of this valve body bolt and reinstall it.
h. Pass earth harness through the hole joining adapter fluid area and main case fluid area.
^ Torque 20 Nm (15 ft. lbs.).
i. Remove two guide pins.
19. Servo cover (11). Install servo cover gasket, cover and four 13 mm screws.
^ Torque 25 Nm (18 ft. lbs.).
20. Wiring harness (10). Connect harness to band control and shift solenoids.
21. Manual detent (9):
a. Install roller and spring assembly with clip.
b. Install two 13 mm screws.
^ Torque 20 Nm (15 ft. lbs.).
22. Oil filter (8). Install oil filter, three 13 mm screws.
^ Torque 20 Nm (15 ft. lbs.).
23. Main case oil pan (7). Install oil pan gasket, magnet, oil pan, sixteen 10 mm screws.
^ Torque 11 Nm (96 inch lbs.).
24. Adapter case valve body (6). Inspect electrical connector and seal. Replace if necessary. Install electrical five pin connector and harness assembly in bottom of adapter case. Install gasket, transfer plate, gasket. Install adapter case valve body complete and seven 13 mm screws.
^ Torque 20 Nm (15 ft. lbs.).
25. Wiring harness (5). Connect harness assembly to converter clutch solenoid, and force motor. Install 6.5 mm connector of earth harness under the head of the converter clutch solenoid bolt. Tighten the converter clutch solenoid bolt.
^ Torque 10 Nm (87 inch lbs.).
26. Adapter case oil pan (4). Install oil pan gasket, oil pan, twelve 10 mm screws. Rotate transmission, with bottom pan facing down.
^ Torque 11 Nm (96 inch lbs.).
27. Mode switch and transmission harness (3):
a. Install transmission harness.
b. Install mode switch, shield and two 10 mm screws.
c. Adjust using setting tool:
^ Selector shaft nut 23 Nm (17 ft. lbs.).
^ 10 mm screw 13 Nm (113 inch lbs).
28. O-ring (2). Install O-ring on turbine shaft.
29. Torque converter (1):
NOTE: The converter assembly must be replaced under any of the following conditions:
- Evidence of damage to the pump assembly
- Metal particles are found after flushing the cooler lines
- External leaks in hub weld area
- Converter Pilot broken, damaged or poor fit into crankshaft
- Converter hub scored or damaged
- Internal failure in stator
- Contamination from engine coolant
- Excess end play.
a. Install converter assembly. Rotate transmission, bell housing up. Spin converter to insure proper fit.
b. Fill transmission through the overfill screw hole of oil pan, using DEXRON-III Automatic transmission fluid.