Part 1
AUTOMATIC TRANSMISSION ASSEMBLY1. Thoroughly clean the transmission case and extension housing in solvent and blow dry with compressed air.
2. Inspect the transmission case for the following:
1) Stripped bolt hole threads.
2) Gasket and mating surfaces for burrs or nicks.
3) Obstructions to vent and fluid passages.
4) Cracks or warpage.
3. Inspect the extension housing for cracks, burrs or warpage.
4. Inspect the rear case inner race for burrs, nicks, and scoring. If any damage has been found the case will need to be replaced.
5. Inspect case bearing for damage. Replace as needed. Follow Steps 6 through 8 if replacing the case bearing. If not replacing the case bearing, proceed, to Step 8.
6. Remove the case bearing.
1) Install the Bearing Cup Puller SST 308-047 (T77F1102-A) or equivalent with Slide Hammer into case bearing.
2) Remove the case bearing.
^ Use an oil stone to remove any nicks or burrs in the bearing case bore.
Caution: Make sure bearing seal ring is facing drive handle.
7. Install a new case bearing.
1) Assemble and install Driver Handle SST 49 F027 003 and Bearing Installer SST 307-348 (T97T-77110A) or equivalent.
2) Position new case bearing onto bearing installer tool.
8. Tap case bearing into case bearing bore.
Note: If the following tools are unavailable, use Carrier Hanger SST 49 M005 561.
9. Install the Holding Fixture Adapter SST 307-262 (T93T77002-AH) or equivalent.
1) Position the Holding Fixture Adapter SST 307-262 (T93T-77002-AH) or equivalent on the rear of the transmission case.
2) Install the bolts.
10. Attach the fixture arm of the Bench Mounted Holding Fixture SST 307-003 (T57L-500B) or equivalent to the Holding Fixture Adapter.
Warning: Make sure the lock pin on bench-mounted holding fixture is secure.
11. Install transmission into Bench Mounted Holding Fixture SST 307-003 (T57L-500-B).
1) Rotate the transmission so that the oil pan rail is facing up.
12. Using Oil Seal Replacer SST 307-050 (T74P-77498-A) or equivalent, install the manual control lever shaft seal.
1) Lubricate the manual control lever shaft seal with petroleum jelly.
13. Assemble the manual valve inner lever and parking lever actuating rod as shown.
14. Install the manual control lever shaft.
Caution: Use care not to damage the oil 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.
15. Install the manual control lever shaft spring pin.
1) Tap the manual control lever shaft spring pin into the transmission case.
Caution: Align the flats on the manual valve inner lever with the flats on the manual control lever shaft.
16. Install the manual valve inner lever and parking lever actuating rod on to the manual control lever shaft.
Caution: To avoid damage, do not allow the wrench to strike the manual valve inner lever pin.
17. Install the manual valve inner lever nut on the manual control lever shaft and tighten.
Caution: The tabs on the output shaft thrust washer (No. 11) point into the case. Make sure the thrust washer is properly seated.
18. Install the output shaft thrust washer (No. 11).
1) Coat the output shaft thrust washer with petroleum jelly.
19. Install the park gear.
20. Install the reverse brake drum.
1) Rotate the reverse brake drum clockwise to install.
21. If not already installed during subassembly, install the No. 10B needle bearing onto the output shaft ring gear and front/overdrive band servo piston and pin assembly.
1) Coat the needle bearing with petroleum jelly.
22. Install the output shaft through the output shaft park gear.
23. Install the output shaft ring gear and output shaft hub.
Caution: Always install a new output shaft retaining ring.
24. Install a new output shaft retaining ring.
25. Install the output shaft sleeve.
Note: Install the output shaft sleeve with the cone facing up.
26. Install low/reverse planetary carrier needle bearings.
1) Install low/reverse planetary carrier needle bearing (No. 8) on the front face of the low/reverse planetary.
2) Install low/reverse planetary carrier needle bearing (No. 9) on the rear face of the low/reverse planetary.
^ Coat the low/reverse planet carrier needle bearing (No. 8) and low/reverse planetary carrier needle bearing (No. 9) with petroleum jelly.
Caution: Make sure needle bearings stay in place.
27. Install the low/reverse planetary assembly with No. 8 and No. 9 low/reverse planetary carrier needle bearings into the output shaft ring gear.
Caution: The low/reverse brake drum must be pulled forward to install the low/reverse planet snap ring.
28. Install the low/reverse snap ring into the low/reverse brake drum groove.
Caution: Make sure band is resting on the two anchor pins in the case.
29. Install the low/reverse band over the low/reverse brake drum.
30. Temporarily install the low/reverse band servo piston and rod to hold the low/low/reverse band in position.
31. Install the previously assembled forward geartrain assembly.
Warning: Make sure the lock pin on bench-mounted holding fixture is secure.
32. Rotate transmission assembly so that the converter housing surface is facing up.
33. Select the intermediate brake drum thrust bearing (No. 4) as follows:
1) Install a Gauge Bar SST 307-263 (T93T-77003-AH) or equivalent on case assembly shoulder.
2) Set depth micrometer on top of gauge bar.
34. Calculate intermediate brake drum thrust bearing thickness:
1) Extend the micrometer probe until it contacts the intermediate brake drum thrust bearing surface. Record the reading, this is dimension A.
35. Place the micrometer on the opposite side of Gauge Bar and repeat measurement. This is dimension B.
36. Add dimensions A and B, divide the total of A and B by 2. Then subtract the gauge bar thickness 17.78 mm (0.700 in). This is dimension C.
37. Place the Gauge Bar across the center support. Place the micrometer on the top of the Gauge Bar.
1) Extend the micrometer probe until it makes contact with the center support thrust bearing surface. Record this reading as dimension D.
38. Place the micrometer on the opposite side of the center support.
1) Extend the micrometer probe until it makes contact with the center support thrust bearing surface. Record this reading as dimension F.
39. Add dimensions D and F; divide the total of D and F by two. Subtract the Gauge Bar thickness 17.78 mm (0.700 in) dimension E. The result is dimension GR.
40. Add dimensions C and GR. This total is dimension H. Use the following chart to select the proper No. 4 thrust bearing. Reference end play is 0.21-0.51 mm (0.008-0.020 in).
41. Install the intermediate servo actuating lever.
42. Install the intermediate band actuating lever shaft through the intermediate servo actuating lever.
Note: The intermediate band lever shaft is shorter than the front band lever shaft.
43. Install the intermediate band apply strut on the intermediate servo actuating lever.
44. Install the intermediate band.
Note: Make sure that the intermediate apply strut is aligned with the band notch.
45. Install the intermediate band anchor strut and the intermediate band adjustment screw.
Note:
^ Use the intermediate band adjusting screw as a temporary alignment guide.
^ The intermediate and front band anchor struts and band adjustment screws are the same.
46. Install the selected intermediate brake drum thrust washer (No. 4) on the center support.
1) Coat the intermediate brake drum thrust washer with petroleum jelly.
Caution: Do not apply pressure to the center support while installing. Damage to sealing rings could result. Make sure the rear planetary support is seated.
47. Install the center support.
1) Position the center support into the intermediate brake and direct clutch drum.
2) Temporarily insert input shaft and gently wiggle it until the center support is seated against the case shoulder, then remove the input shaft.
Note: Align the center support screw hole with correct case hole.
Caution:
^ Install the center support snap ring with the tapered side facing up.
^ Make sure the notch opening is not obstructed by the center support snap ring.
48. Install the center support snap ring.
1) Position center support snap ring with the tapered side facing up.
2) Install the center support snap ring so that the notch opening is not obstructed.
49. Install the center support locknut and cage.
