Part 2

Third Accumulator Retainer and Ball Replacement




1. Remove the third accumulator retainer and ball assembly, using a 6.3 mm (#4) screw extractor.




2. Scribe a mark at 42 mm (1.653 in) on a 9.5 mm (0.375 in) diameter metal rod. The scribe mark is used to gage the proper depth of the third accumulator retainer and ball assembly.




3. Perform the following functions: line up the oil feed slots in the third accumulator retainer and ball assembly (40) with the servo bore. Using the 9.5 mm (0.375 in) diameter metal rod, install the third accumulator retainer and ball assembly.




4. Ensure that the third accumulator retainer and ball assembly and the scribe mark on the rod are flush with the case surface.




5. Check the third accumulator retainer and ball assembly (40) for alignment. The slot in the retainer must be completely open in the servo bore.

Case Bushing

Removal Procedure

Tools Required
- J 8092 Driver Handle
- J 34196-10 Case Bushing Remover-Installer




1. Remove the case rear oil seal (106) (Y-car Only).
2. Remove the case bushing (7) using J 8092 and J 34196-10.

Installation Procedure

Tools Required
- J 8092 Driver Handle
- J 34196-10 Case Bushing Remover/Installer
- J 42198 Case Rear Oil Seal Installer




1. Install a case bushing (7) using J 8092 and J 34196-10
2. Install a case rear oil seal (106) (Y-car Only) using J 42198.

Manual Shaft Seal Replacement




Install a new manual shaft seal (82).

Low and Reverse Clutch Piston Installation

Tools Required
- J 23327-1 Clutch Spring Compressor
- J 34627 Snap ring Remover and Installer J 42628 Disc




1. Install the transmission (low and reverse clutch outer, center, inner) seals (696) on the low and reverse clutch piston (695).
2. Lubricate the seals with Transjel Reg J 36850 or an equivalent.




3. Install the low and reverse clutch piston (695) into the case. The notch in the piston must be aligned with the parking brake pawl window, in the case.




4. Install the low and reverse clutch spring assembly (694).
1. Using the J 23327-1, compress the low and reverse clutch spring assembly (694).
2. Install the low and reverse clutch retainer ring (693).

Inner Manual Linkage Installation




1. Install the parking lock bracket (86).
2. Install the parking lock bracket bolt (87).
Tighten
Tighten the bolt to 31 N.m (23 lb ft).
3. Inspect the following items:
- The parking brake paw (81) for damage or cracks The parking pawl return spring (80) for being broken or missing.




4. Inspect the following items:
- The manual shaft retainer (83) for damage or cracks
- The manual shaft (84) for damage or burrs
- The parking lock actuator assembly (85) for damage
- The inside detent lever (88) for damage or cracks
- The manual valve link (89) for damage
- The hex head nut (90) for damage or stripped threads
5. Install the following items:
- The inside detent lever (88)
- The parking lock actuator assembly (85)
- The manual shaft (84) (model dependent)
- The manual shaft retainer (83)
- The hex head nut (90)
- The manual valve link (89)
Tighten
Tighten the nut to 31 Newton Meters (23 lb ft).

Reaction Gear and Carrier Inspection




1. Inspect the reaction carrier/support thrust bearing assembly (683) for damage.
2. Inspect the reaction gear support to case bearing (692) for damage.




3. Inspect the internal reaction gear (684) and the internal reaction gear support (685) for proper assembly, stripped splines, cracks, teeth, and lug damage.




4. Check the reaction carrier pinion end play. The end play must not exceed 0.61 mm (0.024 in).
Inspect the reaction carrier for the following conditions:
- Pinion gear damage
- Proper pinion staking
- Excessive pinion washer wear
- Keystoned pinion gears
5. Ensure that the pinions turn freely.




6. Inspect the reaction carrier captive thrust bearing for wear or damage.
1. Without touching the pinion gears, place a bushing or an Output Shaft sleeve (690) onto the bearing race, and turn it with the palm of your hand.
2. Any imperfections will be felt through the bushing.

Reaction Gear and Carrier Installation

Tools Required
J 36850 Assembly Lubricant




1. Install the reaction carrier/support thrust bearing assembly (683) into the internal reaction gear support (685).
2. Install the reaction gear support to case bearing (692) onto the internal reaction gear support (685). Retain the bearing using J 36850 or equivalent.
3. Install the internal reaction gear (684) and the internal reaction gear support (685) into the case.




4. Install the reaction carrier assembly (681) into the internal reaction gear.

Low and Reverse Clutch Spacer Plate Selection

Tools Required
- J 8001 Dial Indicator Set
- J 26900-13 Magnetic Indicator Base




1. Inspect the low and reverse clutch plates for the following conditions:
- Composition material wear
- Composition material heat damage
- Composition material delamination
- Steel plates heat damage Steel plates surface finish damage




2. Stack the low and reverse clutch plate assembly on a flat surface in the following order:
1. One waved plate (682A)
2. Five fiber plate assemblies (682C) and four steel plates (682D), starting with one fiber plate assembly and alternating with steel
3. Low and reverse clutch support (679)




3. Using the J 8001 and the J 26900-13, measure the height of the clutch pack from the work surface to the top of the low and reverse clutch support.
4. Refer to Low and Reverse Clutch Spacer Plate Selection in order to select the proper thickness of the low and reverse clutch selective spacer plate (682 B).




5. Install the proper selective spacer plate (682B) between the wave plate (682A) and the first fiber plate assembly (682C), with the identification side up.
6. The overall height for the clutch pack including the selective spacer plate should be 29.22-29.90 mm (1.15-1.18 in).

Low and Reverse Clutch Plates Installation




1. Install the waved plate.
2. Install the correct selective spacer plate (from the selection procedure).
3. Install the five fiber plate assemblies and four steel plates starting with one fiber plate assembly and alternating with steel.
4. Index the steel plate splines in the case as shown.

Low and Reverse Clutch Support Disassemble

Removal Procedure





1. Remove the low and reverse roller clutch race (675) from the low and reverse clutch support (679) Inspect the race for damage and surface finish.
2. Remove the low and reverse roller retainer ring (677) and the low and reverse roller clutch assembly (678). Inspect the roller clutch assembly for damaged rollers and broken springs.
3. Inspect the low and reverse clutch support (679) for loose cam and cam surface finish. Check the support for cracks and damaged lugs.




4. Clean and install the low and reverse roller clutch assembly (678) into the low and reverse clutch support (679). Install the low and reverse retainer ring (677).

Low and Reverse Clutch Support Installation




1. Install the low and reverse roller clutch race. Simultaneously, turn and insert the race.
2. Rotate the race in order to verify proper operation. The race should only rotate in one direction.




3. Install the low and reverse clutch support retainer spring (680) into the case.




Important: Align the wide low and reverse clutch support notch with the wide case lug.

4. Install the low and reverse clutch support (679), roller clutch and roller clutch race (675) assembly into the case. Position the hub side down during the installation.




Important: Align the opening of the low and reverse clutch support retainer ring (676) with the wide low and reverse clutch support notch and the wide case lug.

5. Install the low and reverse support retainer ring (676) into the case.

Reaction Sun Gear and Shell Installation

Tools Required
- J 34196-1 Reaction Sun Gear Bushing Remover/Installer
- J 8092 Driver Handle

Important: Do not remove the retaining ring (671), except to replace it.




1. Inspect the reaction sun gear (673) for the following defects:
- Nicks
- Scores
- Damaged spline or teeth
- A worn bushing
- A loose or weak retaining ring




2. Use J 34196-1 with J 8092 to remove the reaction sun bushing (672) from the reaction sun gear (673), if a bushing replacement is needed.




3. Using J 34196-1 with J 8092, install a new reaction sun bushing (672) into the reaction sun gear (673).




4. Install the reaction sun gear (673) into the reaction carrier.




5. Install the thrust washer (674) with the tangs pointing down. Index the tangs of the thrust washer with the splines of the low and reverse roller clutch race.




6. Install the reaction sun shell (670) into the reaction sun gear.
7. Install the reaction sun gear shell thrust washer (669) into the reaction sun shell.
8. Index the tangs on the thrust washer (669) into the holes in the reaction sun shell (670).

Reaction Carrier Shaft Replacement

Removal Procedure

Tools Required
- J 23907 Universal Remover with Bearing Adapter
- J 25019-14 Bushing Remover
- J 29369-2 Bushing and Universal Remover
- J 34196-3 Reaction Carrier Shaft and Rear Reverse Input Clutch Housing Bushing Installer
- J 7004-1 Universal Remover
- J 8092 Driver Handle




1. Remove the reaction carrier shaft/internal gear retainer (668) and the reaction carrier shaft (666) from the input internal gear (664).

2. Inspect the reaction carrier shaft (666) and the input internal gear (664) for the following defects:
- Scoring
- Cracking
- Damaged or worn bushings
- A cracked shaft
- A damaged spline Damaged gear teeth




3. Using J 29369-2 with J 23907, remove the reaction carrier shaft front bushing (665).




4. Using J 25019-14 with J 7004-1, remove the reaction carrier shaft rear bushing (667).




5. Using J 34196-3 with J 8092, install a new reaction carrier shaft front bushing (665).




6. Using J 34196-3 with J 8092, install a reaction carrier shaft rear bushing (667).
Input Internal Gear, Reaction Shaft Installation




1. Install the input internal gear (664) and reaction carrier shaft (666) assembly into the sun gear shell. Index the reaction carrier shaft spline into the reaction carrier.
2. Install the input carrier to reaction shaft thrust bearing assembly (663).

Internal Transmission Speed Sensor Rotor Replace

Removal Procedure

Tools Required
- J 8433 Speedometer Gear Puller
- J 21427-01 Speedometer Gear Puller (Adapter) J 36352 Speed Sensor Rotor Installer




1. Inspect the internal transmission speed sensor rotor (699) for cracks or damaged teeth.
2. Inspect all splines on the output shaft (687) for cracks or damaged splines.
3. Remove the output shaft seal (691) and the output shaft sleeve (690) (model dependent).




4. If the internal speed sensor rotor (699) is damaged, replace it.
5. Using J 8433 with J 21427-01, remove the internal speed sensor rotor (699) from the output shaft (687).

Installation Procedure

Important: Do not re-use an internal speed sensor rotor that has been removed.




1. Slip a new internal speed sensor rotor (699) over the output shaft splines.
2. Install the J 36352-4 in the groove on the output shaft (687).
3. Place the J 36352-6 on the output shaft (687). Press on the J 36352-6 until it contacts the J 363524 in the window (the J 36352-4 will be a positive stop for the J 36352-6).

Output Shaft Installation

Tools Required
J 29537-A Output Shaft Support Fixture




1. Install the output shaft(687).




2. Install the J 29837-A.

Input Carrier Inspection




1. Check the input carrier pinion end play. The end play must not exceed 0.61 mm (0.024 in).
2. Inspect the input carrier for pinion gear damage, proper pin stake and key stoned pinion gears. Pinions must rotate freely.

Input Sun Gear Bushings Replacement

Tools Required
- J 5092 Driver Handle
- J 34196B Bushing Set




1. Using J 34196-5 with J 8092, remove the input sun gear front bushing (657) and rear bushing(659).




2. Using J 34196-4 with J 8092, install the input sun gear front bushing (657).
3. Using J 34196-6 with J 8092, install the input sun gear rear bushing (659).

Carrier Inspection and Installation




1. Inspect the input carrier captive thrust bearing assembly. To check the captive thrust bearing in the input carrier (662) for wear, place a bushing or an output shaft sleeve (690) onto the bearing race and turn it with the palm of your hand. Do not touch the pinion gears. Any imperfections will be felt through the bushing.




2. Install the input carrier assembly (662) onto the output shaft.




Important:
- Do not reuse the old output shaft to input carder retainer (661).
- Do not over expand the new output shaft to input carrier retainer during installation.

3. Install a new output shaft to input carrier retainer (661).




4. Remove the J 29837-A.

Input Clutch Assembly Disassemble

Removal Procedure

Tools Required
- J 23327-1 Clutch Spring Compressor
- J 23456 Clutch Spring Compressor Press J 25018-A Clutch Spring Compressor Adapter




1. Remove the reverse input clutch housing and drum assembly (605) from the input clutch assembly (621).
2. Remove the stator shaft/selective washer bearing assembly (615).
3. Remove the selective thrust washer (616).




4. Remove the 3rd and 4th clutch backing plate retainer ring (656).

Notice: The 3rd and 4th clutch plate stack is different for 2.2L models.

5. Remove all 3rd and 4th clutch plates (653-655).
6. Remove the 3-4 clutch boost spring assemblies (600).




7. Remove the forward clutch backing plate retainer ring (651).
8. Remove the forward clutch selective backing plate (650).
9. Remove the forward clutch sprag assembly.




10. Remove all forward clutch plates (646, 648, 649A, 649B).
11. Remove the input sun gear bearing assembly (637).
12. Remove the input housing to output shaft seal (636).
13. Remove all over run clutch plates (645A, 645B).




14. Install the J 23327-1 and the J 25018-A.
15. Compress the overrun clutch spring, using the J 23456.
16. Remove the overrun clutch spring retainer snap ring (635).
17. Remove the J 23327-1 and the J 25018-A.




18. Remove the overrun clutch spring assembly (634).
19. Remove the overrun clutch piston (632)
20. Remove the forward clutch piston (630).
21. Remove the forward clutch housing (628).
22. Remove the 3rd and 4th clutch spring assembly (626).
23. Remove the 3rd and 4th clutch apply ring (625).
24. Remove the 3rd and 4th clutch piston (623).

Input Housing and Shaft Assembly Inspection




1. Inspect the input housing and shaft assembly for the following items:
- Porosity
- Spline wear
- Three turbine shaft checkballs
- Retainer and checkball assembly (620)
- Orificed cup plug (698)
- Lube hole cracks
2. Inspect the turbine shaft oil seal ring grooves for damage or burrs. The oil seal rings (619) must fit loose into the ring grooves.




3. Inspect the oil feed passages for obstructions.
4. Blow air through the passages.

Input Housing and Shaft Assembly Assemble

Installation Procedure

Tools Required
- J 23327-1 Clutch Spring Compressor
- J 23456 Clutch Spring Compressor Press
- J 25015-A Clutch Spring Compressor Adapter
- J 26744-A Universal Seal Installer
- J 29882 Overrun Clutch Inner Seal Protector
- J 29883 Forward Clutch Inner Seal Protector




1. Install a new input to forward clutch housing O-ring seal (622).





2. Inspect the 3rd and 4th clutch piston (623) for the following conditions:
- Porosity or damage
- Seal damage
3. Install the 3rd and 4th clutch piston (623) into the input housing.




4. Inspect the forward clutch housing (628) for the following conditions:
- Proper checkball operation
- Damage or distortion
- Burrs in the seal areas
- Cracks




5. Inspect the forward clutch piston for the following conditions:
- Porosity or damage
- Seal damage Apply leg damage




6. Install the forward clutch piston (630) into the forward clutch housing (628).