Part 2
TransmissionAssembly (Steps 41-80)
41. Install the direct clutch drum.
42. Using a depth micrometer with an appropriate length extension, measure from the top of the gauge bar to the center support ledge in the case at 4 places 90 degrees apart.
^ Add the 4 measurements, divide by 4 and record as dimension A.
43. 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 2 pump screw locations at approximately 6 and 12 o'clock positions.
^ Tighten to 15 Nm (11 ft. lbs.)
2 Tighten the center screw.
^ Tighten to 1.13 Nm (10 inch lbs.)
44. 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 B. Repeat the measurement 180 degrees on the opposite side of the special tool and record as dimension C.
45. Add dimension B to C, divide by 2 and record as dimension D.
46. Subtract A from D and record as dimension E.
47. Select the bearing from the chart, using dimension E.
48. 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 it was when removed.
NOTE: The new intermediate 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 intermediate band.
49. CAUTION: To avoid a fall out condition of the strut from the screw during assembly and function, the small U-shaped notch should be toward the band and the large U-shaped notch toward the main control side.
Install the intermediate band anchor strut.
1 Band/case side of anchor (small U notch).
2 Main control side of anchor (large U notch).
50. 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.
51. Loosely install the screw.
52. Install the intermediate band apply strut.
53. 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.
54. Install the selected No. 4 thrust washer on the direct clutch drum.
^ Coat the thrust washer with petroleum jelly.
55. NOTE: Align the center support screw hole with correct case hole.
Install the center support.
56. Install the center support locknut and cage.
57. Loosely install the screw.
58. 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.
59. Install the center shaft thrust bearing (No. 3).
60. Install the overdrive ring gear, overdrive one-way clutch and center shaft assembly.
61. 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.
62. Install the overdrive brake drum and coast clutch drum assembly.
63. Install the overdrive band servo piston and spring.
^ Lubricate the servo bore with clean automatic transmission fluid.
64. Using the special tools, install the retaining ring.
65. 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.
66. CAUTION: To avoid a fall out condition of the strut from the screw during assembly and function, the small U-shaped notch should be toward the band and the large U-shaped notch toward the main control side.
Install the overdrive anchor strut.
1 Band/case side of anchor (small U notch).
2 Main control side of anchor (large U notch).
67. 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.
68. Loosely install the screw.
69. Install the overdrive apply strut.
70. 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.
71. 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 2 pump screw locations at approximately 6 and 12 o'clock positions.
^ Tighten to 15 Nm (11 ft. lbs.)
2 Tighten the center screw.
^ Tighten to 1.13 Nm (10 inch lbs.)
72. 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 the measurement 180° on the opposite side of the special tool and record as dimension B.
73. Add dimension A to B, divide by 2 and record as dimension C.
74. Subtract the thickness of the gauge bar 17.78 following chart using dimension D.
75. Select the No. 1 thrust bearing from the chart using dimension D.
76. Install the selected No. 1 fluid pump input thrust washer.
^ Coat the fluid pump input thrust washer with petroleum jelly.
77. Install the special tools into the transmission case.
78. Install the pump gasket.
79. 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.
80. 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.
