Part 2

Transmission

Disassembled Views

61. NOTICE: Do not bend the trigger wheel. Make sure that the No. 2 thrust bearing is in this assembly.

Install the planetary gear O/D carrier.

62. Install the O/D brake drum and coast clutch drum assembly.

63. NOTE: Inspect the O/D servo bore for excessive wear. Repair as required.

Install the O/D band servo piston and spring.
- Lubricate the servo bore with transmission fluid.

64. Using the Servo Cover Compressor, install the retaining ring.

65. NOTE: If the O/D band is reused, it must be installed in the same position as when removed.

NOTE: Make sure that the O/D band apply strut is aligned with the band notch.

NOTE: The new O/D 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 O/D band.

66. NOTICE: 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 O/D anchor strut.

1. Band/case side of anchor (small U notch).

2. Main control side of anchor (large U notch).

67. NOTICE: If the strut is installed incorrectly, transmission damage will occur.

Make sure that the O/D band anchor strut is installed in the correct orientation to the case and adjustment screw.

68. Loosely install the adjustment screw.

69. Install the O/D apply strut.

70. NOTICE: If the strut is installed incorrectly, transmission damage will occur.

Make sure that the O/D band apply strut is installed in the correct orientation to the case and piston rod.

71. NOTICE: The torque specifications are critical for this procedure. Failure to use the correct torque specifications may cause transmission damage.

Install the Cushion Spring Compressor.

1. Install the Cushion Spring Compressor and the bolts using the 2 pump screw locations at approximately 6 and 12 o'clock positions.
- Tighten to 15 Nm (133 lb-in).

2. Tighten the center screw.
- Tighten to 1.13 Nm (10 lb-in).

72. NOTE: Align the disc holes on Cushion Spring Compressor with the slot in the Gauge Bar for correct measurement.

Measure the distance with the Depth Micrometer 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 degrees on the opposite side of the Gauge Bar 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 mm (0.70 in) from dimension C and record as dimension D.

75. Select the No. 1 thrust bearing from the following 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 Transmission Fluid Pump Alignment Pins into the transmission case.

78. Install the fluid pump gasket.

79. NOTICE: 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 or damage may occur.

Install the fluid pump.

80. NOTICE: The Transmission Fluid Pump Alignment Pins, Fluid Pump Alignment Set and the Transmission Fluid Pump Alignment Gauge must be used to correctly align the pump with the adapter plate to reduce gear noise, bushing failure and leakage.

Using the Transmission Fluid Pump Alignment Pins, Fluid Pump Alignment Set and the Transmission Fluid Pump Alignment Gauge align the fluid pump to the adapter plate.

81. Install 6 transmission fluid pump housing-to-case screws. Tighten the screws in a star pattern.
- Tighten to 22 Nm (16 lb-ft).

82. Remove Transmission Fluid Pump Alignment Pins and install the 2 remaining screws.
- Tighten to 22 Nm (16 lb-ft).

83. NOTICE: Do not allow the Overdrive (O/D) band adjustment screw to back out. Band strut may fall out of position.

NOTE: 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.

84. NOTICE: The Overdrive (O/D) servo must be installed prior to band adjustment or damage may occur.

Using the Transmission Band Adjustment Set, tighten the O/D band adjustment screw.

- Tighten to 13 Nm (115 lb-in).

- Back the screw off exactly 2 turns and hold that position.

85. Tighten the O/D band locknut.

1. Hold the O/D band adjustment screw stationary.

2. Tighten the O/D band locknut.

- Tighten to 54 Nm (40 lb-ft).

86. NOTICE: Do not allow the intermediate band adjusting screw to back out. The band strut may fall out of position.

NOTE: 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.

87. NOTICE: The intermediate servo must be installed prior to band adjustment or damage may occur.

Using the Transmission Band Adjustment Set, tighten the intermediate band adjustment screw.

- Tighten to 13 Nm (115 lb-in).

- Back the screw off exactly 2 turns and hold that position.

88. Tighten the intermediate band locknut.

1. Hold the intermediate band adjustment screw stationary.

2. Tighten the intermediate band locknut.

- Tighten to 54 Nm (40 lb-ft).

89. Tighten the center support screw.
- Tighten to 11 Nm (97 lb-in).

90. Using the Transmission Air Test Plate and Gaskets, carry out the air pressure test procedure. For additional information, refer to Special Testing Procedures Special Testing Procedures.

91. Install the Valve Body Aligners into the transmission case.

92. Using the Valve Body Aligners, install the main control valve body and loosely install the main control valve body screws.

1. Install the short main control valve body screw.

2. Install the screw with the larger head.

3. Install the remaining main control valve body screws.

93. Remove the Valve Body Aligners and loosely install the main control valve body screw.

94. Tighten the main control valve body screws in the sequence shown.
- Tighten to 10 Nm (89 lb-in).

95. With the manual lever in the NEUTRAL position, install the manual valve detent spring.
- Tighten to 10 Nm (89 lb-in).

96. Install new O-ring seals on the transmission control solenoid body harness connector. Lubricate the O-ring seals with transmission fluid.

97. NOTICE: Inspect the transmission case bore to make sure it is free of foreign material and not damaged. If damaged, transmission leak may occur.

Install the transmission control solenoid body. Tighten the transmission control solenoid body screws in the sequence shown.

- Tighten to 8 Nm (71 lb-in).

98. Install the reverse servo. Tighten the bolts in the sequence shown in 2 stages.
- Stage 1: Tighten bolts to 5 Nm (44 lb-in).

- Stage 2: Tighten bolts to 11 Nm (97 lb-in).

99. NOTICE: Lubricate the transmission fluid filter seals with transmission fluid or they may be damaged.

NOTE: Make sure that the transmission fluid filter seals are correctly seated on the transmission fluid filter.

Lubricate the transmission fluid filter seals and install the transmission fluid filter.

- Tighten to 10 Nm (89 lb-in).

100. NOTE: The transmission fluid pan gasket is reusable. Clean and inspect for damage. If not damaged, the transmission fluid pan gasket should be reused.

Install the transmission fluid pan and transmission fluid gasket and loosely install the transmission fluid pan screws.

101. Tighten the 16 transmission fluid pan screws in a crisscross sequence.
- Tighten to 11 Nm (97 lb-in).

102. Install the park pawl assembly and gasket.

1. Install the park pawl shaft.

2. Install the park pawl return spring.

3. Install the park pawl.

4. Install a new gasket.

RWD vehicles

103. Install the extension housing and the extension housing screws.
- Tighten to 30 Nm (22 lb-ft).

104. Using the Transmission Extension Housing Fluid Seal Installer, install the extension housing seal.

4WD vehicles

105. Install the extension housing and the extension housing screws.
- Tighten to 30 Nm (22 lb-ft).

106. Using the Extension Housing Seal Installer, install the extension housing seal.

107. NOTICE: The Transmission Range (TR) sensor must fit flush against the boss on the case to prevent damage to the sensor.

Install the Transmission Range (TR) sensor and loosely install the screws.

108. NOTICE: 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 TR Sensor Alignment Gauge, align the TR sensor and tighten the screws in an alternating sequence.
- Tighten to 8 Nm (71 lb-in).

109. Install the manual control lever and the manual lever shaft outer nut.
- Tighten to 48 Nm (35 lb-ft).

110. NOTICE: The splines of the input shaft are not the same length on each end. Install the shaft with the shorter splines on the end into the fluid pump or damage may occur.

Install the input shaft.

111. Using the Piston Seal Sizer, make sure that the fluid pump gear seal ring is fully seated.

112. Remove the Piston Seal Sizer.

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

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

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

Lubricate the converter hub with transmission fluid.

114. WARNING: Secure the torque converter in the transmission during removal or installation. The torque converter is heavy and may result in injury if it falls out of the transmission. Failure to follow this instruction may result in serious personal injury.

Using the Torque Converter Handles, install the torque converter by pushing and rotating.

115. Lubricate the torque converter pilot hub with multi-purpose grease.

116. Using one of the speed sensor holes, fill the transmission with 8.5L (9 qt) of transmission fluid.

117. NOTE: Inspect the speed sensor O-ring seals for damage. Install new O-ring seals if damaged. Lubricate the O-ring seals with petroleum jelly to prevent damage to the O-ring seals.

Install the speed sensors.

- Tighten to 14 Nm (124 lb-in).

118. Install the Torque Converter Retainer.