Steps 61-123

61. NOTE: Align the center support screw hole with correct case hole.

Install the center support.





62. Install the center support locknut and cage.





63. Loosely install the screw.





64. 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.





65. Install the center shaft thrust bearing (No. 3).





66. Install the overdrive ring gear, overdrive one-way clutch and center shaft assembly.





67. 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.





68. Install the overdrive brake drum and coast clutch drum assembly.





69. 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.





70. Install the overdrive anchor strut.





71. CAUTION: If the strut is installed incorrectly, transmission damage will occur.

Check to make sure that the overdrive band anchor strut is installed in the correct orientation to the case and adjustment screw.





72. Loosely install the screw.





73. Install the overdrive apply strut.





74. CAUTION: If the strut is installed incorrectly, transmission damage will occur.

Check to make sure that the overdrive band apply strut is installed in the correct orientation to the case and piston rod.





75. 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 bolts using the two pump screw locations at approximately 6 and 12 o'clock positions.
2 Tighten the center screw.





76. 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.
77. Add dimension A to B, divide by two and record as dimension C.
78. Subtract the thickness of the gauge bar 17.78 mm (0.71 inch) from dimension C, and record as dimension D.





79. Select the No.1 thrust bearing from the following chart using dimension D.





80. Install the selected No. 1 fluid pump input thrust washer.
Coat the fluid pump input thrust washer with petroleum jelly.





81. Install the special tools into the transmission case.





82. Install the pump gasket.





83. 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.





84. 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.





85. Install screws. Tighten the screws in a star pattern.





86. Remove the special tools and install the two remaining screws.





87. CAUTION: Do not allow overdrive band adjustment screw to back out. Band strut could fall out of position.

CAUTION: 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.





88. 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 (2) turns and hold that position.





89. Tighten the overdrive band locknut.
1 Hold the overdrive band adjustment screw stationary.
2 Tighten the overdrive band locknut.





90. CAUTION: Do not allow the intermediate band adjusting screw to back out. Band strut could fall out of position.

CAUTION: 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.





91. CAUTION: The intermediate servo must be installed prior to band adjustment.

Tighten the intermediate band adjustment screw. Then back off the screw exactly (2) turns and hold that position.





92. Tighten the intermediate band locknut.
1 Hold the intermediate band adjustment screw stationary.
2 Tighten the intermediate band locknut.





93. Tighten the center support screw.





94. Install the special tools into the transmission case.





95. Install the main control valve body and loosely install the screws.





96. Remove the special tools, and loosely install the screw.





97. Tighten the screws in the sequence shown.





98. With the manual lever in the NEUTRAL position, install the manual valve detent spring.





99. Install new O-ring seals on the solenoid body connector. Lubricate the O-ring seals with clean automatic transmission fluid.





100. CAUTION: Inspect the transmission case bore to make sure it is free of debris and not damaged. If damaged, transmission leak may occur.

Install the solenoid body. Tighten bolts in sequence shown.





101. Install the reverse servo. Tighten the bolts in the sequence shown in two stages.
^ Stage 1: Tighten bolts to 5 Nm (44 inch lbs.).
^ Stage 1: Tighten bolts to 11 Nm (8 ft. lbs.).





102. 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.





103. 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 and loosely install the screws.





104. Tighten the 16 screws in a crisscross sequence.





105. NOTE: The 4x2 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.





4x2 vehicles
106. Install the extension housing.





107. Using the special tool, install the extension housing seal.





4x4 vehicles
108. Install the extension housing.





109. Using the special tool, install the extension housing seal.





All vehicles

110. CAUTION: The [1][2]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.





111. 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.





112. Install the outer manual lever.





113. 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.





114. Using the special tool, make sure that the fluid pump gear seal ring is fully seated.





115. Remove the special tool.





116. CAUTION: Do not damage the fluid pump gear O-ring seal when installing torque converter.

CAUTION: Make sure the converter hub is fully engaged in the pump support and gear and rotates freely. Do not damage the hub seal.

CAUTION: If the torque converter slides out, the hub seal may be damaged.

Lubricate the converter hub with clean automatic transmission fluid.





117. 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.





118. Lubricate the torque converter pilot hub with multipurpose grease.





119. 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 flex plate adapter assembly and eight nuts.





120. Install two torque converter flex plate adapter nuts.





121. Using one of the speed sensor holes, fill the transmission with 8.5 ltr (9 quarts) of automatic transmission fluid.





122. NOTE: Inspect O-ring seal for damage. Install new if damaged.

Lubricate the O-ring seals with petroleum jelly to prevent damage to the O-ring seals.
Install the sensors.
123. 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.