Part 2
AUTOMATIC TRANSMISSION ASSEMBLY Continued50. Install the center support-to-case cap screw.
Caution: Carefully route the turbine shaft speed (TSS) sensor connector and wiring harness through the opening in the case. Do not damage the wiring.
51. Install the turbine shaft speed (TSS) sensor.
1) Install the TSS sensor.
2) Install TSS sensor screw.
Note: Route TSS sensor electrical connector and wiring through transmission case opening.
Caution: Use only the center shaft thrust bearing (No. 3).
52. Install the center shaft thrust bearing (No. 3).
Note: The center shaft thrust bearing (No. 3) has no notches on the outer race.
Caution: Do not bend the trigger wheel.
53. Install the front/overdrive planetary carrier, front/overdrive ring gear, front/overdrive one-way clutch and center shaft assembly.
Caution: The trigger wheel triggering window should pass over the thin blade of the Turbine Shaft Speed Sensor Gauge SST 49 UN01 145. If it does not, the front/overdrive planetary carrier and trigger wheel must be replaced.
54. Using the Turbine Shaft Speed Sensor Gauge SST 49 UN01 145, check TSS sensor air gap.
1) Place the thin blade of the Turbine Shaft Speed Sensor Gauge SST 49 UN01 145 over the TSS. sensor.
2) Rotate the trigger wheel and repeat checks for all windows.
Caution: The trigger wheel triggering window should not pass over the thick blade of the Turbine Shaft Speed Sensor Gauge SST 49 UN01 145. If it does, the front/overdrive planetary carrier and trigger wheel must be replaced.
55. Use the Turbine Shaft Speed Sensor Gauge SST 49 UN01 145 to check TSS sensor air gap.
1) Place the thick blade of the Turbine Shaft Speed Sensor Gauge SST 49 UN01 145 over the TSS sensor.
2) Rotate the trigger wheel and repeat checks for all windows.
56. Install the front/overdrive brake drum and coast clutch drum assembly.
Note: Align the clutch plates and front/overdrive adapter gear.
57. Install the front/overdrive servo band lever and front/overdrive band lever-to-case bracket into the transmission case.
58. Install the front/overdrive band actuating lever shaft through the front servo band lever.
Note: The front/overdrive band lever shaft is longer than the intermediate band actuating lever shaft.
59. Install the front/overdrive band apply strut.
60. Install the front/overdrive band over the front/overdrive brake and coast clutch drum.
Note: If the front/overdrive band is reused, it must be installed in the same position as when removed.
61. Install the front/overdrive band anchor strut.
Note: Use the band adjustment screw as a temporary alignment guide.
62. Install the front/overdrive band adjusting screw.
Caution:
^ Make sure that the pump body is seated against the thrust washer and the front/overdrive brake and coast clutch drum. The pump body must be below the level of the case gasket surface.
^ The tabs on the washer go into the pump face.
63. Perform front end play check procedure as follows:
1) Coat the oil pump inlet thrust washer (No. 1) with petroleum jelly.
2) Install the oil pump inlet thrust washer (No. 1) on the rear of the oil pump and place pump into position in case.
Caution: The Gauge Bar tool must rest on the gasket surface.
64. Measure the front end play clearance.
1) Place Gauge Bar SST 307-263 (T93T-77003-AH) or equivalent across the case.
2) Place depth micrometer on Gauge Bar and extend micrometer probe until it contacts the oil pump face.
3) Read the measurement and subtract Gauge Bar thickness 17.78 mm (0.700 inch). This is dimension A.
4) Repeat the measurement at the opposite side of the transmission case. This is dimension B.
5) Add dimensions A and B together and divide by two. This is front end clearance dimension C.
Caution: If the average front end clearance is below the specification, choose a thinner washer. If the average is above the specification, choose a thicker washer.
65. Use dimension C and the chart below to select the correct thickness oil pump inlet thrust washer (No. 1).
Note: The front end play specification is 0.18-0.70 mm (0.0070.028 in).
Caution:
^ Make sure that the pump body is seated against the thrust washer and the front/overdrive brake and coast clutch drum. The pump body must be below the level of the case gasket surface.
^ The tabs on the washer go into the pump face.
66. Remove pump and install No. 1 thrust washer onto pump. After installing selected front pump thrust washer No. 1, repeat front end play check. Make sure correct end play, then remove pump for assembly.
67. Install a new O-ring in oil pump drive gear.
Caution: Lubricate the Oil Pump Gear O-Ring Installer SST 49 UN01 142 with clean transmission fluid.
68. Install oil pump drive gear on Oil Pump Gear O-Ring Installer SST 49 UN01 142 to seat O-ring. Remove Oil Pump Gear O-Ring Installer SST 49 UN01 142.
Caution: The chamber on the inside edge of the small gear must be up when in the pump housing gear pocket. The dimple on the larger gear must be down when in the pump housing gear pocket.
69. Install the pump gears into the fluid pump housing. Apply grease to pump gear to prevent scoring at start up.
Caution: Make sure the holes in the plate line up with the holes in the pump.
70. Install the fluid pump adapter plate.
Caution: Do not allow the pump gears to come out of the pump housing pocket.
71. Install the oil pump on the converter housing.
1) Hold the oil pump adapter plate against the pump housing. Turn the pump and adapter plate over and place on the converter housing.
Note: The notch on the outside of the adapter plate will be at the 9 o'clock position relative to the converter housing.
72. Loosely install the oil pump bolts.
Caution: Front Pump Aligner Set SST 49 UN01 015 must be used to properly align the oil pump to the oil adapter plate. This will prevent seal leakage, gear noise, broken gears and bushing failure.
73. Align the oil pump to the oil pump adapter plate and select the gauge from Front Pump Aligner Set SST 49 UN01 015 that is the snuggest fit when placed over the oil pump.
74. Thread the gauge into Front Pump Aligner Set SST 49 UN01 015 and slide the tool over the oil pump until it bottoms out in the oil pump gear pocket.
75. Tighten the Allen head screws in a star pattern and remove the pump alignment handle.
76. Install a new oil pump seal ring.
1) Coat the oil pump seal ring with petroleum jelly.
77. Install a new oil pump gasket.
1) Hold the oil pump gasket in place with petroleum jelly.
Note: Make sure the oil pump seal ring is installed on the housing and pump assembly.
Caution: Verify correct seal installation. Make sure seal grooves are clean and free of burrs.
78. Install the front pump support seal.
79. Install the selected No. 1 oil pump thrust washer.
1) Coat the oil pump thrust washer with petroleum jelly.
80. Install Converter Housing/Case Aligner Pins SST 49 UN01 137 into the transmission case.
Caution: The splines on the ends of the input shaft are not the same length. The shorter splines go into the assembly.
81. Install the input shaft.
Caution: Make sure that the oil pump inlet thrust washer (No. 1) selective thrust washer, oil pump gasket, and the oil pump-to-case O-ring remain in the correct position throughout this step.
82. Install the oil pump and converter housing onto the case.
83. Remove Converter Housing/Case Aligner Pins SST 49 UN01 137. Install the new converter housing-to-case bolts. Tighten the bolts in a star pattern.
Note: Lubricate O-rings on converter housing bolts.
84. Remove the input shaft.
Warning: Make sure the lock pin on bench-mounted holding fixture is secure.
85. Rotate transmission assembly so the oil pan rails are facing up.
86. Assemble the front/overdrive servo assembly.
1) Install the front/overdrive servo cover O-ring on front/overdrive servo cover. Coat the front/overdrive servo cover O-ring with petroleum jelly.
2) Install the front/overdrive servo piston into the front/overdrive servo cover.
3) Install the front/overdrive servo piston spring on the front/overdrive servo piston.
Caution:
^ Do not damage the front/overdrive servo to case O-ring during installation.
^ Do not press the front/overdrive servo cover and O-ring past the relief hole in the case or O-ring damage may occur.
87. Using the Servo Cover Compressor SST 49 UN01 144, install the front/overdrive servo assembly into the case.
1) Install Servo Cover Compressor SST 49 UN01 144.
2) Insert the front/overdrive servo assembly into overdrive servo bore in the transmission case.
3) Compress front/overdrive servo cover and install the overdrive servo cover snap ring.
88. Assemble the intermediate servo assembly.
1) Install the intermediate servo cover O-ring on intermediate servo cover. Coat the intermediate servo cover O-ring with petroleum jelly.
2) Install intermediate servo piston into the intermediate servo cover.
3) Install the intermediate servo piston spring on the intermediate servo piston.
Caution:
^ Do not damage servo cover to case O-ring during installation.
^ Do not press the intermediate servo cover and O-ring past the relief hole in the case or O-ring damage may occur.
89. Install the intermediate servo assembly into the case.
1) Install Servo Cover Compressor SST 49 UN01 144.
2) Insert the intermediate servo assembly into intermediate servo bore in the transmission case. Compress servo cover and install the intermediate servo cover snap ring.
Caution:
^ Do not allow front/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.
90. Install new locknut on the band adjustment screw.
Caution: The front/overdrive servo must be installed prior to band adjustment.
91. Tighten front/overdrive band adjustment screw with a "click" type torque wrench and back off front/overdrive band adjustment screw exactly two (2) turns and hold that position.
Note: The wrench will click at the specified torque.
92. While holding the front/overdrive band adjustment screw stationary, tighten the front/overdrive band locknut using a 19 mm wrench.
Caution:
^ Do not allow 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.
93. Install new nut on the band adjustment screw.
Caution: The intermediate servo must be installed prior to band adjustment.
94. Tighten intermediate band adjusting screw and back off intermediate band adjusting screw exactly two (2) turns and hold that position.
Note: The wrench will click at the specified torque.
95. Hold the intermediate band adjustment screw stationary. Tighten the intermediate band locknut.
Caution: Install new O-rings on the 16-pin electrical connector. Coat the O-rings with petroleum jelly.
96. Position the transmission case (16-pin) electrical connector into the case bore.
1) Press the transmission case (16- pin) electrical connector through the case until a click is heard.
Note: Make sure that the tab is in the lock position.
Caution: Do not overstretch the retaining spring.
97. Install the 16-pin electrical connector retaining spring.
Caution: Align the slot on the turbine shaft speed (TSS) sensor electrical connector with the slot in the 16-pin electrical connector.
98. Install the TSS sensor electrical connector into the transmission case (16-pin) electrical connector.
1) Connect the TSS sensor electrical connector.
2) Insert the TSS sensor electrical connector wires into the retaining slot in the 16-pin electrical connector.
99. Install Large Valve Body Guide Pin SST 49 UN01140 and Small Valve Body Guide Pin SST 49 UN01 139 into the transmission case.
1) Install Large Valve Body Guide Pin SST 49 UN01 140 (0.248 DIA).
2) Install Small Valve Body Guide Pin SST 49 UN01 139 (0.235 DIA).
Caution:
^ Make sure main control valve body gasket is aligned.
^ Make sure that the manual valve is correctly aligned with the manual valve inner pin when the main control valve body is installed.
100. Position the main control valve body into the transmission case.