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Special Tool(s)
NOTE: Inspect the transmission case and extension housing for the following:
^ stripped screw hole threads
^ gasket and mating surfaces for burrs or nicks
^ Obstructions to vent and fluid passages
^ cracks or warpage
NOTE: Thoroughly clean the transmission case and extension housing in solvent and blow dry with compressed air,
NOTE: Lubricate all seals and the servo bores with clean automatic transmission fluid.
1. If installing a new transmission case bearing, only carry out the listed steps.
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2. Illustration 1 of 2. Assemble the components in the order indicated in the following illustration and table.
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3. Illustration 2 of 2. Assemble the components in the order indicated in the following illustration and table.
Item 1: Transmission Case Assembly Note
1. WARNING: Make sure the lock pin on the bench-mounted holding fixture is secure. Failure to follow these instructions can result in personal injury.
Using the special tool, install the transmission into the bench with the converter housing facing up.
Item 2: Case Bearing Disassembly Note
1. Inspect case bearing for damage. Install a new component as necessary.
2. Using the special tool, remove the damaged case bearing.
^ Use an oil stone to remove any nicks or buffs in the bearing case bore.
Item 2: Case Bearing Assembly Note
1. Assemble the special tools.
2. CAUTION: Make sure the bearing seal ring is facing the drive handle.
Install the bearing on the special tools.
3. Using the special tool, tap the case bearing into the case bearing bore.
Item 3: Manual Control Lever Seal Assembly Note
1. Using the special tool, install the manual control lever shaft seal and lubricate it with petroleum jelly.
Item 4: Park Pawl Actuating Rod Assembly Note
1. Install the parking lever rod.
Item 5: Manual Control Valve Inner Lever Assembly Note
1. Assemble the manual valve inner lever and parking lever actuating rod as shown.
Item 6: Manual Control Lever Shaft Assembly Note
1. CAUTION: Align the flats on the manual valve inner lever with the flats on the manual control lever shaft.
Install the manual control lever shaft.
Item 7: Manual Control Lever Inner Nut Assembly Note
1. Install the manual valve inner lever onto the manual shaft and loosely install the nut.
Item 8: Manual Control Lever Shaft Retaining Pin Assembly Note
1. CAUTION: Use care not to damage the fluid pan rail surface when installing the retaining pin.
NOTE: Align the manual control lever shaft alignment groove with the manual control lever shaft spring pin bore in the transmission case.
Install the manual control lever shaft spring pin.
^ Tap the manual control lever shaft spring pin into the transmission case.
Item 9: Manual Control Lever Inner Nut Assembly Note
1. CAUTION: To avoid damage, do not allow the wrench to strike the manual valve inner lever pin.
Tighten the nut.
Item 10: Output Shaft Thrust Washer No. 11 Assembly Note
1. CAUTION: The tabs on the output shaft thrust washer (No. 11) point into the case. Make sure the thrust washer is correctly seated.
Install the output shaft thrust washer (No. 11).
^ Coat the output shaft thrust washer with petroleum jelly.
Item 13: Reverse Band Assembly Note
1. CAUTION: Make sure the band is resting on the two anchor pins in the case.
Install the low/reverse band over the low/reverse brake drum.
Item 14: Reverse Brake Drum and Clutch Assembly Assembly Note
1. Install the low/reverse brake drum.
^ Rotate the low/reverse brake drum clockwise to install.
Item 15: Reverse Brake Drum Lever Assembly Assembly Note
1. NOTE: The reverse band actuating lever must fit into the notches in the band.
Install the reverse hand actuating lever into the reverse band.
Item 18: Output Shaft Ring Gear Assembly Note
1. CAUTION: Do not damage the seal against the case during assembly.
Install the output shaft ring bear hub and seal.
Item 19: Output Shaft Retaining Ring Assembly Note
1. CAUTION: Always install a new output shaft retaining ring.
Install a new output shaft retaining ring.
Item 20: Output Shaft Sleeve Assembly Note
1. NOTE: Install the output shaft sleeve with the cone facing up. This sleeve will snap into place when correctly installed.
Install the output shaft sleeve.
Item 23: Reverse Brake Drum Retaining Ring Assembly Note
1. CAUTION: The low/reverse brake drum must be pulled forward to install the low/reverse planet retaining ring.
Install the retaining ring.
Item 27: Forward Planet Assembly Assembly Note
1. NOTE: The No. 13 bearing must be correctly seated in the forward planet assembly so the sun gear can be installed correctly.
Install the forward planetary assembly.
Item 35: Intermediate Servo Retaining Ring Assembly Note
1. Using the special tool, install the retaining ring.
Item 37: Intermediate Clutch Drum Bearing No. 4 Assembly Note
1. Using the special tool, measure from the top of the gauge bar to the center support ledge in the case at four places, 90° apart.
^ Add the four measurements, divide by four, and record as dimension A.
2. CAUTION: The torque specifications are critical for this procedure. Failure to use the correct torque specifications may cause transmission damage.
Install the special tool.
1 Install the special tool and the screws using the two pump screw locations at approximately 6 and 12 o'clock positions.
2 Tighten the center screw.
3. NOTE: Align the disc holes on the special tool with the slot in the gauge bar for correct measurement.
Measure the distance from the top of the gauge bar to the drum bearing surface through the hole in the disc and record as dimension B. Repeat measurement 180 degrees opposite side of the special tool and record as dimension C.
4. Add dimension B to C, divide by two and record as dimension D.
5. Subtract A from D, and record as dimension E.
6. Select the bearing from the following chart, using dimension E.
7. Install the selected No. 4 thrust washer on the direct clutch drum.
^ Coat the thrust washer with petroleum jelly.
Item 38: Intermediate Brake Band Assembly Note
1. NOTE: Make sure that the intermediate band apply strut is aligned with the band notch.
NOTE: If the intermediate band is reused, it must be installed in the same position as when removed.
NOTE: The intermediate band is new, and dark in color. This is a normal condition of the band. Hairline cracks in the band are also considered normal. Do not install a new band based solely on the color.
Install the intermediate band.
Item 39: Intermediate Brake Band Anchor Strut Assembly Note
1. Install the intermediate band anchor strut.
2. CAUTION: If the strut is installed incorrectly, transmission damage will occur.
Check to make sure that the intermediate band anchor strut is installed in the correct orientation to the case and adjustment screw.
Item 40: Intermediate Brake Band Adjusting Screw Assembly Note
1. Loosely install the screw.
Item 41: Intermediate Brake Band Apply Strut Assembly Note
1. Install the intermediate band apply strut.
2. CAUTION: If the strut is installed incorrectly, transmission damage will occur.
Check to make sure that the intermediate band apply strut is installed in the correct orientation to the case and piston rod.
Item 42: Center Support Assembly Assembly Note
1. NOTE: Align the center support screw hole with correct case hole.
Install the center support.
Item 43: Nut and Cage Assembly Note
1. Install the center support locknut and cage.
Item 44: Center Support Screw Assembly Note
1. Loosely install the screw.
Item 45: Retaining Ring Assembly Note
1. CAUTION: Install the center support retaining ring with the tapered side facing up.
CAUTION: Make sure the notch opening is not obstructed by the center support retaining ring.
Install the center support retaining ring.
1 Make sure the center support retaining ring is installed with the tapered side facing up.
2 Make sure the opening of the center support retaining ring is positioned correctly.
Item 48: Overdrive Servo Retaining Ring Assembly Note
1. Using the special tools, install the retaining ring.
Item 50: Overdrive Planetary Gear Carrier Assembly Assembly Note
1. CAUTION: Do not bend the trigger wheel. Make sure that the No. 2 thrust bearing is in this assembly.
Install the planetary gear overdrive carrier.
Item 52: Overdrive Brake Band Assembly Note
1. NOTE: If the overdrive band is reused, it must be installed in the same position as when removed.
NOTE: Make sure that the overdrive band apply strut is aligned with the band notch.
NOTE: The overdrive band is new, and dark in color. This is a normal condition of the band. Hairline cracks in the band are also considered normal. Do not install a new band based solely on the color.
Install the overdrive band.