Replacing Intermediate Plate

REPLACING INTERMEDIATE PLATE
1. Remove the transmission/transfer case assembly.





2. Place the transmission on the bench, and remove the torque converter using torque converter handles 18G1501, taking care not to damage the torque converter/oil pump housing oil seal.





3. Remove the twelve hexagonal bolts (inner ring pattern).





4. Remove bellhousing and pump assembly from transmission case and discard the gasket.
5. Remove the eight hexagonal bolts on the rear of the pump.





6. Screw in two of the bolts diagonally opposite each other, tap lightly using a soft headed mallet. This will free the pump assembly from the intermediate plate.
7. Remove the O-ring from the pump housing and discard.
8. Place the bellhousing and intermediate plate assembly on the bench, front side up.
9. Remove the six remaining hexagon bolts and remove the bellhousing from the intermediate plate assembly.
10. Remove the four screw plugs and seal rings from the intermediate plate, discard the seal rings.
11. Remove the oil cooler pipe adaptors and fit them into the new intermediate plate.
12. Fit plugs and new seal rings into the new intermediate plate.
13. Fit intermediate plate assembly onto the bellhousing.
14. Secure with six hexagonal bolts (outer ring pattern) and tighten to 46 Nm (34 ft lb).
15. Place intermediate plate and bellhousing assembly on bench, front face up.
16. Fit the O-ring onto the circumference of the pump housing.
17. Align the dowel with its hole in the intermediate plate and press the pump housing home.
18. Secure the pump housing to the intermediate plate using the eight hexagonal bolts and tighten to 46 Nm (34 ft lb).
19. Place the bellhousing and intermediate plate assembly on the bench, front face up. Using the oil pump rotation sleeve LST111, check that the pump gears rotate freely.
20. Before replacing the intermediate plate and bellhousing assembly check that the thrust washer and axle cage are seated on the A clutch housing.
21. Place the gasket and disc washer onto the bellhousing and intermediate plate assembly using a light grease or Petroleum jelly.
22. Fit bellhousing and intermediate plate assembly onto gearcase and secure with the twelve hexagonal bolts tightened to 10 Nm (7 ft lb).
23. Place the end-float gauge LST111 onto the pump housing and check that the axial play is between 0.2-0.4 mm (0.008-0.016 in). If end-float is incorrect, replace existing washer, situated at the rear of the intermediate plate, with suitable washer to give required end-float stated above.
24. Refit the torque converter into the housing using torque converter handles 18G1501, checking that the dimension from the converter fixing bolt boss to the converter housing face is 50 mm (1.96 in). If this dimension is achieved the converter is properly seated in the housing.
25. Refit the transmission/transfer case assembly.