Part 1
TransmissionPart 1 Of 4:
Part 2 Of 4:
Part 3 Of 4:
Part 4 Of 4:
Special Tool(s)
Material
NOTE: Inspect the transmission case and extension housing for the above:
^ stripped screw hole threads
^ gasket and mating surfaces for burrs or nicks
^ obstructions to vent and fluid passages
^ cracks or warpage
NOTE: Thoroughly clean the transmission case and extension housing in clean automatic transmission fluid and blow dry with compressed air.
NOTE: Lubricate all seals and the servo bores with clean automatic transmission fluid.
Part 1 Of 8:
Part 2 Of 8:
Part 3 Of 8:
Part 4 Of 8:
Part 5 Of 8:
Part 6 Of 8:
Part 7 Of 8:
Part 8 Of 8:
1. Assemble the parts in the order indicated in the above illustrations and tables.
Item 1: Transmission Case Assembly Note
1. WARNING: Make sure the lock pin on the bench-mounted holding fixture is secure. Failure to follow these instructions can result in personal injury.
Using the special tool, install the transmission into the bench with the converter housing facing up.
2. Inspect the case bearing for damage. If damage to the case bearing is indicated, install a new case.
Item 2: Manual Control Lever Seal Assembly Note
1. Using the special tool, install the manual control lever shaft seal and lubricate it with petroleum jelly.
Item 3: Park Pawl Actuating Rod Assembly Note
1. Install the parking lever rod.
Item 4: Manual Control Valve Inner Lever Assembly Note
1. Assemble the manual valve inner lever and parking lever actuating rod as shown.
Item 5: Manual Control Lever Shaft Assembly Note
1. CAUTION: Align the flats on the manual valve inner lever with the flats on the manual control lever shaft.
Install the manual control lever shaft.
Item 6: Manual Control Lever Inner Nut Assembly Note
1. Install the manual valve inner lever onto the manual shaft and loosely install the nut.
Item 7: Manual Control Lever Shaft Retaining Pin Assembly Note
1. CAUTION: Use care not to damage the fluid pan rail surface when installing the spring pin.
NOTE: Align the manual control lever shaft alignment groove with the manual control lever shaft spring pin bore in the transmission case.
Install the manual control lever shaft spring pin.
^ Tap the manual control lever shaft spring pin into the transmission case.
Item 8: Manual Control Lever Inner Nut Assembly Note
1. CAUTION: To avoid damage, do not allow the wrench to strike the manual valve inner lever pin.
Tighten the nut.
Item 9: Output Shaft Thrust Washer No. 11 Assembly Note
1. CAUTION: The tabs on the output shaft thrust washer (No. 11) point into the case. Make sure the thrust washer is correctly seated.
Install the output shaft thrust washer (No. 11).
^ Coat the output shaft thrust washer with petroleum jelly.
Item 12: Reverse Band Assembly Note
1. CAUTION: Make sure the band is resting on the two anchor pins in the case.
Install the low/reverse band over the low/reverse brake drum.
Item 13: Reverse Brake Drum and Clutch Assembly Assembly Note
1. Install the low/reverse brake drum.
^ Rotate the low/reverse brake drum clockwise to install.
Item 14: Reverse Brake Drum Lever Assembly Assembly Note
1. NOTE: The reverse band actuating lever must fit into the notches in the band.
Install the reverse band actuating lever into the reverse band.
Item 17: Output Shaft Ring Gear Assembly Note
1. CAUTION: Do not damage the seal against the case during assembly.
Install the output shaft ring gear, hub and seal.
Item 18: Output Shaft Retaining Ring Assembly Note
1. CAUTION: Always install a new output shaft retaining ring.
Install a new output shaft retaining ring.
Item 19: Output Shaft Sleeve Assembly Note
1. NOTE: Install the output shaft sleeve with the cone facing up. This sleeve will snap into place when correctly installed.
Install the output shaft sleeve.
Item 22: Reverse Brake Drum Retaining Ring Assembly Note
1. CAUTION: The low/reverse brake drum must be pulled forward to install the low/reverse planet retaining ring.
Install the retaining ring.
Item 26: Forward Planet Assembly Assembly Note
1. NOTE: The No. 13 bearing must be correctly seated in the forward planet assembly so the sun gear can be installed correctly.
Install the forward planetary assembly.
Item 35: Intermediate Servo Retaining Ring Assembly Note
1. Using the special tool, install the retaining ring.
Item 37: Intermediate Clutch Drum Bearing No. 4 Assembly Note
1. Using the special tool, measure from the top of the gauge bar to the center support ledge in the case at four places, 90 degrees apart.
^ Add the four measurements, divide by four, and record as dimension A.
2. 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.
3. NOTE: Align the disc holes on the special tool with the slot in the 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 B. Repeat measurement 180 degrees opposite side of the special tool and record as dimension C.
4. Add dimension B to C, divide by two and record as dimension D.
5. Subtract A from D, and record as dimension E.
6. Select the bearing from the above chart, using dimension E.
7. Install the selected No. 4 thrust washer on the direct clutch drum.
^ Coat the thrust washer with petroleum jelly.
Item 38: Intermediate Brake Band Assembly Note
1. NOTE: Make sure that the intermediate band apply strut is aligned with the band notch.
NOTE: If the intermediate band is reused, it must be installed in the same position as when removed.
NOTE: The new intermediate band is 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 intermediate band.
Item 39: Intermediate Brake Band Anchor Strut Assembly Note
1. Install the intermediate band anchor strut.
2. CAUTION: If the strut is installed incorrectly, transmission damage will occur.
Check to make sure that the intermediate band anchor strut is installed in the correct orientation to the case and adjustment screw.
Item 40: Intermediate Brake Band Adjusting Screw Assembly Note
1. Loosely install the screw.
Item 41: Intermediate Brake Band Apply Strut Assembly Note
1. Install the intermediate band apply strut.
2. CAUTION: If the strut is installed incorrectly, transmission damage will occur.
Check to make sure that the intermediate band apply strut is installed in the correct orientation to the case and piston rod.
Item 42: Center Support Assembly Assembly Note
1. NOTE: Align the center support screw hole with correct case hole.
Install the center support.
Item 43: Nut and Cage Assembly Note
1. Install the center support locknut and cage.
Item 44: Center Support Screw Assembly Note
1. Loosely install the screw.
Item 45: Retaining Ring Assembly Note
1. CAUTION: Install the center support retaining ring with the tapered side facing up.
2. 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.
Item 49: Overdrive Servo Retaining Ring Assembly Note
1. Using the special tools, install the retaining ring.
Item 51: Overdrive Planetary Gear Carrier Assembly Assembly Note
1. 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.
Item 53: Overdrive Brake Band Assembly Note
1. 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 new overdrive band is 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.
