Step 1-35
Transmission
Disassembled View
NOTICE: Before beginning assembly, carry out and inspect the following:
- When building up subassemblies and assembling the transmission, ALWAYS use new gaskets and seals.
- All fasteners must be tightened to the torque specification indicated. In addition to appearing, the necessary torques can be found in the Torque Specifications chart.
- When building up subassemblies, each component part should be lubricated with transmission fluid. It is also good practice to lubricate the subassemblies as they are installed in the case.
- Needle bearings, thrust washers and seals should be lightly coated with petroleum jelly during subassembly buildup or transmission assembly.
- Many components and surfaces in the transmission are precision machined. Careful handling during disassembly, cleaning, inspection and assembly can prevent unnecessary damage to machined surfaces.
1. Using the Transmission Extension Housing Remover/Installer and Slide Hammer, install the rear case bushing if removed.
1. Position the rear case bushing and the Transmission Extension Housing Remover/Installer and Slide Hammer inside the case.
2. Assemble the Transmission Extension Housing Remover/Installer and Slide Hammer through the back of the case.
2. Place the transmission in the vertical position.
3. Coat the No. 9 case rear bearing with petroleum jelly and install on the case boss.
4. NOTICE: Make sure the No. 7 and No. 8 needle bearings and direct clutch hub are installed as shown in the Subassembly section. Internal damage and shift problems may occur to the transmission.
Install the output shaft and output shaft ring gear.
5. Coat the No. 8 bearing with transmission fluid and install the No. 8 bearing.
6. Install the direct clutch, No. 7 bearing and support.
7. NOTE: The reverse band support retaining ring is used for assembly purposes during production. The reverse band support retaining ring is not required during assembly and it will not affect the operation of the transmission.
Install the reverse band support retaining ring.
8. NOTE: Make sure the band is seated on the anchor pins.
Install the reverse band.
9. NOTE: The planetary assembly and planetary gear support cannot be installed unless the notch cut in the planetary gear support is aligned with the overdrive band anchor pin.
NOTE: The top of the planetary gear support must be below the snap ring groove.
Install the planetary assembly and planetary gear support as a unit.
- Rotate the output shaft to fully seat the planetary assembly.
10. NOTE: The planet support spring must be compressed and installed below the snap ring groove. When the planet support spring is installed correctly, both ends of the spring will be visible.
Install the case to the planet support spring located at the 1 o'clock position.
11. NOTE: When installing the center support retaining ring the opening of the center support retaining ring should be toward the hole in the case where the Turbine Shaft Speed (TSS) sensor would go.
Install the center support retaining ring.
12. Install the forward clutch sun gear, the No. 5 forward clutch sun gear 2 piece bearing and the reverse sun gear.
13. Install the No. 4 forward clutch hub bearing.
14. Install the intermediate stub shaft.
15. Install the forward clutch hub and the No. 3 forward clutch hub front bearing.
16. Install the forward clutch assembly.
17. NOTE: Make sure the reverse clutch cylinder lugs are completely seated in the notches of the reverse sun gear.
Install the reverse clutch cylinder assembly.
1. Install the No. 2 forward clutch bearing.
2. Install the reverse clutch cylinder.
18. Install the overdrive band.
- Position the overdrive band pocket onto the anchor pin.
19. Install the overdrive servo spring.
1. Install the overdrive servo piston return spring.
2. Install the overdrive servo piston.
20. Verify the tip of the piston assembly engages the pocket of the overdrive band.
21. Using the Servo Piston Remover/Installer, compress the overdrive servo assembly and install the overdrive servo retaining ring.
22. Install the intermediate clutch pressure plate.
23. NOTE: Before assembly, soak the new clutch discs in transmission fluid.
Install the intermediate clutch pack and selective steel plate.
24. Using the Shim Selection Gauge, check the intermediate clutch clearance.
1. Position the Shim Selection Gauge on the pump case mounting surface.
2. Maintaining downward pressure, use a depth micrometer to measure and verify intermediate clutch clearance is within specification.
If the intermediate clutch is not within specification, install a correct selective plate.
Selective Steel Plates
25. Using the Shim Selection Gauge, measure end clearance for the No. 1 front pump thrust washer.
1. Position the Shim Selection Gauge on the pump case mounting surface.
2. Maintaining downward pressure, use a depth micrometer to measure end play clearance.
Use the No. 1 thrust washer chart to select the correct washer.
No. 1 Thrust Washer Chart
26. Install the intermediate clutch anti-rattle clip, if equipped.
27. NOTE: Align the intermediate clutch return spring pack indent with the pump check ball.
Install the intermediate clutch return spring pack.
28. Install the No. 1 front pump support thrust washer.
- Use clean transmission fluid to hold the washer in place.
29. NOTE: The alignment pin is a fabricated M8 x 1.25 mm (0.049 in) bolt with the head removed.
Install an alignment pin at the top of the case.
30. NOTE: Make sure the front pump gasket is positioned correctly and the case passages are not covered.
Install the front pump gasket.
31. NOTE: To aid assembly, shake the input shaft while pushing down on the front pump.
Install the front pump assembly.
32. Remove the alignment pin and install the front pump bolts.
- Alternate bolt tightening to set the pump.
- Tighten to 27 Nm (20 lb-ft).
33. Rotate the transmission to the horizontal position.
34. Install the park pawl.
1. Position the park pawl return spring.
2. Position the park pawl.
3. Install the park pawl shaft.
35. Install a new extension housing gasket and the extension housing.
1. Position the extension housing.
2. Install the 4 bolts and 2 stud bolts.
- Tighten to 55 Nm (41 lb-ft).
