Part 7
2-4 Servo Assembly InstallationTools Required
- J 22269-01 Piston Remover
- J 29714-A Servo Cover Compressor
1. Inspect the 4th apply piston (25), the 2-4 servo cover (28), the 2nd apply piston (17), and the servo piston inner housing (20) for the following conditions:
- Cracks
- Scoring
- Burrs and nicks
2. Install the following seals:
- The 4th apply piston outer oil seal ring (26) on the 4th apply piston (25).
- The 2-4 servo cover O-ring seal (27) on the 2-4 servo cover (28).
- The 2nd apply piston outer (18) and inner (19) oil seal rings on the 2nd apply piston (17).
- The O-ring seal (21) on the servo piston inner housing (20).
3. Install the servo cushion outer spring (16), the servo cushion inner spring (105) (model dependent) and the cushion spring retainer (15) in the 2nd apply piston (17).
4. Use the J 22269-01 and compress the second apply piston assembly (17).
5. Install the second apply piston retaining ring (14).
6. Assemble the 2-4 servo components in the order shown: (12-15, 17, 20, 22-25, 28, 29).
7. Install the 2-4 servo assembly into the 2-4 servo bore.
8. Install the J 29714-A.
9. Tighten the bolt on the J 29714-A in order to compress the servo cover.
10. Install the servo cover retaining ring.
Case Extension Bushing Replacement (2WD Applications Only)
Tools Required
- J 8092 Driver Handle
- J 23062-14 Bushing Remover
- J 34196B Bushing Service Set
1. Inspect the case extension for the following conditions:
- Porosity
- Cracks
- Nicks
- Burrs
- Worn bushings
2. Remove the case extension oil seal assembly (34) (model dependent).
3. Using the J 23062-14 and the J 8092 remove the case extension bushing (33).
4. Using the J 34196-4 and the J 8092, install a case extension bushing (33).
Speed Sensor and Case Extension Installation (2WD Applications Only)
Tools Required
J 21426 Rear Seal Installer
1. Using the J 21426 install an output shaft sleeve (690) and an output shaft seal (691). Do not push the sleeve past the machined surface on the output shaft.
2. Install the case extension to case seal (30) and the case extension (31).
3. Install the case extension to case bolts (32).
Tighten
Tighten the bolts to 45 N.m (33 lb ft).
4. Inspect the internal transmission speed sensor for the following conditions:
- Cracks
- Nicks
- Damage
5. Install a new O-ring seal (37) on the internal transmission speed sensor (36).
6. Install the internal transmission speed sensor (36).
7. Install the Speed Sensor retaining bolt (35).
Tighten
Tighten the bolt to 12 N.m (9 lb ft).
8. Using the J 21426, install the case extension oil seal assembly (34) (model dependent).
Torque Converter End Play Check
Tools Required
- J 8001 Dial Indicator
- J 26900-13 Dial Indicator Post
- J 35138 End Play Checking Tool
1. Inspect the torque converter and replace if any of the following conditions exist:
- Evidence of damage to the pump assembly.
- Metal particles are found after flushing the cooler and cooler lines.
- External leaks in the hub area.
- Converter pilot is broken, damaged or poor fit into the crankshaft.
- Converter hub is scored or damaged.
- Internal damage to the stator.
- Contamination from engine coolant.
- Excessive end play.
Important: The torque converter should not be replaced if the fluid has an odor, discoloration or no evidence of metal or clutch plate material.
Flushing the torque converter is not recommended.
2. Install the J 35138, the J 26900-13 and the J 8001.
The end play for a 245 mm torque converter should be 0-0.5 mm (0-0.020 in).
3. The end play for a 298 mm torque converter should be 0-0.6 mm (0-0.024 in)
4. Remove the tools.
Torque Converter Installation
Tools Required
J 21366 Converter Holding Strap
1. Install the torque converter.
2. Install the J 21366.
Holding Fixture Removal
Tools Required
J 8763-02 Holding Fixture and Base
Remove the transmission from the J 8763-02.
AT Oil Cooler Flushing
Preparation
1. After the repaired or replacement transmission is installed in the vehicles, do not reconnect the oiler cooler pipes.
2. Remove the fill cap on the J 35944 and fill the can with 0.6 L (20-21 oz.) of flushing solution. Do not overfill.
3. Install the fill cap on the J 35944 and pressurize the flusher can, using a shop air supply regulated at 550-700 kPa (80-100 psi).
4. Connect the J 35944 discharge hose to the oil cooler return pipe.
5. Clip the discharge hose onto the oil drain container.
6. Attach the J 35944 to the under carriage of the vehicle with the hook provided and connect the hose from the J 35944 to the other (feed) oil cooler pipe.
7. With the water valve on the J 35944 in the OFF position, connect the water hose from the water supply to the J 35944.
8. Turn ON the water supply at the faucet.
Initial Flush
1. Turn the water valve on the J 35944 to the ON position and allow the water to flow through the oil cooler pipes for 10 seconds to remove any remaining transmission fluid. If the water does not flow through the cooler and pipes, the cause of the blockage must be diagnosed and the plugged component must be repaired or replaced. Continue with the cooler flushing and flow check procedure once the blockage is corrected.
2. Turn the water supply on the J 35944 to the OFF position and clip the discharge hose onto the five gallon pail with a lid.
3. Turn the water valve on the J 35944 to the ON position and depress the trigger to mix cooler flushing solution into the water flow. Use the clip provided on the handle to hold the trigger down. The discharge will foam vigorously when the solution is introduced into the water stream.
4. Flush the oil cooler and pipes with water and solution for two minutes. During this flush, attach the air supply to the air valve located on the J 35944 for 3 to 5 seconds at the end of even 15 to 20 second interval to create a surge action
5. Release the trigger and turn the water valve on the J to the OFF position.
Back Flush
1. Disconnect both hoses from the oil cooler pipes and then connect them to the opposite oil cooler pipe. This will allow the oil cooler and pipes to be back flushed.
2. Repeat steps 3 and 4 on the Initial Flush Procedure.
3. Release the trigger on the J 35944 and allow water only to rinse the oil cooler and pipes for one minute.
4. Turn OFF the water supply at the faucet.
5. Attach the air supply to the valve on the J 35944 and blow out the water from the oil cooler and pipes. Continue until no water comes out of the discharge hose.
Flow Check
1. Disconnect both hoses from the oil cooler pipes. Connect the oil cooler feed pipe to the transmission and the return pipe to the discharge hose. Refer to Transmission Specifications. Clip the discharge hose onto the empty oil drain container.
2. Confirm the transmission is filled with automatic transmission fluid.
3. Start the engine with the transmission in PARK range and run for 30 seconds. A minimum of 1.9 L (2 quarts) must be discharged during this 30 second of time.
- If fluid flow is greater than 1.9 L (2 quarts) in 30 seconds, go to step 7.
- If fluid flow is less than 1.9 L (2 quarts) in 30 seconds, perform the following diagnosis:
4. Disconnect the oil cooler feed line at the radiator.
5. Connect the discharge hose to the cooler feed line. Clip the discharge hose onto the empty oil drain container.
6. Start the engine with the transmission in PARK and fun for 30 seconds. A minimum of 1.9 L (2 quarts) must discharge during the 30 second run time. Do the following according to flow rate:
- Insufficient feed flow: Inspect the transmission.
- Sufficient feed flow: Inspect the cooler return pipe and the cooler.
7. Remove the discharge hose, reconnect the cooler feed and return pipes to the transmission and refill the unit to the proper fluid level.
Refer to specifications for the correct automatic transmission capacity.