Part 2
TransmissionAssembly (Steps 31-61)
31. NOTE: Make sure that when installing the center support the feed holes on the center support are lined up with the feed holes in the case.
Install the center support into the case.
32. NOTE: Rotate case 180 degrees.
Using the special tool, install the center support snap ring. Tap the snap ring into the case to make sure that it is seated into the case.
33. Using the special tool, lift up on the output shaft and record the reading. The reading should be within 0.15 - 0.35 mm (0.006 - 0.013 inch).
^ If the reading is not within the specification, install a different (either thinner or thicker) select fit thrust gear shim.
34. Install the roller bearing if not previously installed on the direct clutch drum.
35. Install the direct clutch drum.
36. Install the bearing on the direct clutch assembly.
37. Install the forward and overdrive clutch assembly.
38. Install the pump washer.
39. Install the special tool into the case.
40. Using the special tools, install the front pump.
41. NOTE: Make sure that the fluid filter seal has been removed. If it has not, use a suitable pick and remove the seal.
NOTE: Add 0.118 L (4 oz) of clean transmission fluid to prime the pump.
Make sure that the pump is correctly aligned with the case.
42. Loosely install the new front pump bolts with the new washers.
43. Install the remaining front pump bolt. Tighten the bolts in a crisscross pattern.
^ Tighten to 10 Nm (89 inch lbs.)
44. Install the special tool onto the input shaft to measure end play.
^ Tighten the wing nut.
45. Install the remaining special tool.
^ Push down on the special tool and zero out the dial indicator.
^ Lift up on the special tool and record the measurement 0.2 - 0.4 mm (0.008 - 0.015 inch). If the measurement is not within specification install a new pump washer.
^ Measure the original washer, install a thinner or a thicker washer to achieve the correct measurement.
46. Install the park rod actuating plate.
^ Tighten to 10 Nm (89 inch lbs.)
47. Position a new manual control lever seal in place.
48. Using the special tool, install a new manual control lever shaft seal.
49. Position the manual lever and park rod in place.
^ Push down on the park pawl and slide the park rod in place.
50. Install the manual lever in the case.
1 Slide the manual lever in the case.
2 Position the spacer in place while sliding the manual lever into the spacer.
3 Position the manual valve inner lever while sliding the manual lever and lining up the roll pin hole.
4 Install the roll pin.
51. Install the 4 rubber feed tubes for the center support.
1 Black feed tube.
2 Green feed tube.
3 Blue feed tube.
52. Install the thermal bypass valve into the case.
53. Install the rubber adapter.
54. NOTE: The Mechatronic assembly will not lay flush on the case, this is normal, the bolts will pull the Mechatronic assembly down.
Loosely install the 11 Mechatronic bolts.
1 Align the manual valve and control lever linkage.
55. CAUTION: Do not touch the electrical connector pins or the exposed solenoid tabs on the TCM. Electrostatic discharge may occur and may cause damage to the Mechatronic unit.
Tighten the bolts in the sequence shown.
^ Tighten to 6 Nm (53 inch lbs.)
56. CAUTION: Do not touch the electrical connector pins or the exposed solenoid tabs on the TCM. Electrostatic discharge may occur and may cause damage to the Mechatronic unit.
With the release tab up and unlocked, push the outer shell of the bulkhead electrical connector into the transmission. Make sure that the bulkhead connector is fully seated into the TCM.
57. Press down on the tab and lock the outer shell of the bulkhead electrical connector in place. Make sure that the locking tab is securely locked.
58. Install a new transmission fluid filter.
59. NOTE: The fluid pan gasket can be reused if not damaged.
Install a new transmission fluid pan gasket if required.
60. Install the fluid pan and tighten the bolts in a crisscross pattern.
^ Tighten to 14 Nm (10 ft. lbs.)
61. Install the torque converter.
