Part 2 of 2
Transmission ContinuedItem 56: Fluid Pump Support Thrust Washer No. 1 Assembly Note
1. 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.
2. NOTE: Align the disc holes on special tool with the slot in 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 A. Repeat measurement 180 degrees opposite side of the special tool and record as dimension B.
3. Add dimension A to B, divide by two and record as dimension C.
4. Subtract the thickness of the gauge bar 17.78 mm (0.71 inch) from dimension C, and record as dimension D.
5. Select the No. 1 thrust bearing from the chart shown using dimension D.
6. Install the selected No. 1 fluid pump input thrust washer.
^ Coat the fluid pump input thrust washer with petroleum jelly.
Item 57: Fluid Pump Gasket Assembly Note
1. Install the special tools into the transmission case.
2. Install the pump gasket.
Items 58 and 59: Fluid Pump Assembly Assembly Note
1. CAUTION: Make sure that the fluid pump inlet thrust washer (No. 1), selective thrust washer, fluid pump gasket, and the fluid pump-to-case O-ring seal remain in the correct position throughout this step.
Install the fluid pump.
2. CAUTION: The special tools must be used to correctly align the pump with the adapter plate to reduce gear noise, bushing failure, and leakage.
Using the special tool, align the fluid pump to the adapter plate
3. Install screws. Tighten the screws in a star pattern
4. Remove the special tools and install the two remaining screws.
Item 60: Band Adjusting Locknut Assembly Note
1. CAUTION: Do not allow overdrive band adjustment screw to back out. Band strut could fall out of position. Install, but do not tighten, a new locknut on the band adjustment screw. Apply petroleum jelly to the locknut seal.
Install a new locknut on the band adjustment screw
2. CAUTION: The overdrive servo must be installed prior to band adjustment.
Using the special tool, tighten the overdrive band adjustment screw. Then back off the screw exactly (1.5) turns and hold that position
3. Tighten the overdrive band locknut.
1 Hold the overdrive band adjustment screw stationary.
2 Tighten the overdrive band locknut.
Item 61: Band Adjusting Locknut Assembly Note
1. CAUTION: Do not allow the intermediate band adjusting screw to back out. Band strut could fall out of position. Install, but do not tighten, a new locknut on the band adjustment screw. Apply petroleum jelly to the locknut seal.
Install new nut on the band adjustment screw.
2. CAUTION: The intermediate servo must be installed prior to band adjustment.
Tighten the intermediate band adjustment screw. Then back off the screw exactly (1.5) turns and hold that position.
3. Tighten the intermediate band locknut.
1 Hold the intermediate band adjustment screw stationary.
2 Tighten the intermediate band locknut.
Item 62: Bolt Assembly Note
1. Tighten the center support bolt.
Items 63, 64, 65 and 66: Main Control and Screws Assembly Note
1. Install the special tools into the transmission case.
2. Using the special tools. install the main control valve body and loosely install the screws.
1 Install the short screw.
2 Install the screw with the larger head.
3 Install the remaining screws.
3. Remove the special tools, and loosely install the screw.
4. Tighten the screws in the sequence shown.
Items 67 and 68: Manual Valve Detent Spring and Screw Assembly Note
1. With the manual lever in the NEUTRAL position, install the manual valve detent spring.
Items 70, 71 and 72: Solenoid Body Screws Assembly Note
1. CAUTION: Inspect the transmission case bore to make sure it is free of debris and not damaged. If damaged, a transmission leak may occur.
Install the solenoid body. Tighten screws in sequence shown.
Item 74: Reverse Servo Screws Assembly Note
1. Install the reverse servo. Tighten the screws in the sequence shown in two stages.
^ Stage 1: Tighten screws to 5 Nm (44 inch lbs.).
^ Stage 2: Tighten screws to 11 Nm (8 ft. lbs.).
Items 75 and 76: Transmission Fluid Filter and Screws Assembly Note
1. CAUTION: Lubricate the fluid filter seals with clean automatic transmission fluid or they may be damaged.
NOTE: Make sure that the fluid filter seals are correctly seated on the filter.
Lubricate the seals and install the transmission fluid filter.
Item 77: Transmission Fluid Pan Gasket Assembly Note
1. NOTE: The transmission fluid pan gasket is reusable. Clean and inspect for damage. If not damaged, the gasket should be reused.
Install the transmission fluid pan and gasket.
Item 78: Transmission Fluid Pan Assembly Note
1. Install the transmission fluid pan and loosely install the screws.
Item 79: Transmission Fluid Pan Screws Assembly Note
1. Tighten the 16 screws in a crisscross sequence.
Items 80, 81, 82 and 83: Park Pawl Assembly Note
1. NOTE: The 4x2 vehicle is shown, the 4x4 is similar.
Install the parking pawl assembly and gasket.
1 Install the parking pawl shaft.
2 Install the parking pawl return spring.
3 Install the parking pawl.
4 Install a new gasket.
Item 86: Extension Housing Seal Assembly Note
1. Using the special tool, install the extension housing seal.
Item 87: Output Shaft Flange Assembly Note
1. Using the special tools, install the outpost shaft flange.
Items 89 and 90: Transmission Range (TR) Sensor Screws Assembly Note
1. CAUTION: The digital transmission range sensor must fit flush against the boss on the case to prevent damage to the sensor.
Install the digital Transmission Range (TR) sensor and loosely install the screws.
2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged.
NOTE: The manual lever must be in the NEUTRAL position.
Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence.
Item 91: Input Shaft Assembly Note
1. CAUTION: The splines of the input shaft are not the same length on both ends. The shaft end with the shorter splines goes into the fluid pump.
Install the input shaft.
Item 92: Front Fluid Pump Seal Assembly Note
1. NOTE: Check and make sure that the garter spring in the seal has not popped off of the converter hub seal.
Install a new seal onto the special tool.
2. Using the special tool, install a new converter hub seal
Item 93: Fluid Pump Assembly Assembly Note
1. Using the special tool, make sure that the fluid pump gear seal ring is fully seated
2. Remove the special tool
Item 94: Torque Converter Assembly Note
1. CAUTION: Do not damage the fluid pump gear O-ring seal when installing the torque converter. Make sure the converter hub is fully engaged in the pump support and gear and rotates freely. Do not damage the hub seal. If the torque converter slides out, the hub seal may become damaged.
Lubricate the converter hub with clean automatic transmission fluid
2. WARNING: The torque converter can fall out if the transmission is tipped. Failure to follow these instructions may cause personal injury.
Using the special tools, install the torque converter by pushing and rotating.
3. Lubricate the torque converter pilot hub with multipurpose grease.
Items 95 and 96: Flexplate Adapter Plate and Nuts Assembly Note
1. CAUTION: The special tool must be used to correctly align the adapter plate to the converter or transmission damage could occur. In order to correctly install the special service tool, it must be installed using one round and one oblong hole. Using two oblong holes will cause damage to the transmission.
NOTE: Align the identifying mark made on the nut, stud, and adapter plate during disassembly for correct installation.
If the vehicle is equipped, use the special tool to install the torque converter flexplate adapter assembly and eight nuts.
2. Install two torque converter flexplate adapter nuts.
Item 97: Speed Sensor Assembly Note
1. Using one of the speed sensor holes, fill the transmission with 8.5L (9 quarts) of automatic transmission fluid.
2. NOTE: Inspect the speed sensor O-ring seals for damage. If damage to the seal is found, install a new seal. Lubricate the O-ring seals with petroleum jelly to prevent damage to the O-ring seals.
Install the speed sensors.
3. Before installing transmission, make sure that the transmission cooling system (tube and cooler) have been thoroughly flushed. If contamination cannot be removed or correct flow cannot be obtained, install a new cooler and/or tubes.