Part 2

Transmission



















Disassembled Views


































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





62. 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 automatic transmission fluid.





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





64. 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.





65. 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/case side and the large U-shaped notch toward the main control side.

Install the O/D band anchor strut.

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

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





66. NOTICE: 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.





67. Loosely install the adjustment screw.





68. Install the O/D apply strut.





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

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





70. 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 o'clock and 12 o'clock positions.
- Tighten to 15 Nm (133 lb-in).

2. Tighten the center screw.
- Tighten to 1 Nm (9 lb-in).





71. NOTE: Align the disc holes on Cushion Spring Compressor 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 degrees on the opposite side of the Gauge Bar and record as dimension B.





72. Add dimension A to B, divide by 2 and record as dimension C.

73. Subtract the thickness of the gauge bar 17.78 mm (0.70 in) from dimension C and record as dimension D.

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







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





76. Install the Transmission Fluid Pump Alignment Pins into the transmission case.





77. Install the pump gasket.





78. 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.





79. NOTICE: The Fluid Pump Alignment Set, Transmission Fluid Pump Alignment Pins 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 Fluid Pump Alignment Set, Transmission Fluid Pump Alignment Pins and the Transmission Fluid Pump Alignment Gauge, align the fluid pump to the adapter plate.





80. Install the fluid pump housing screws. Tighten the screws in a star pattern.
- Tighten to 25 Nm (18 lb-ft).





81. Remove the Fluid Pump Alignment Set, Transmission Fluid Pump Alignment Pins and the Transmission Fluid Pump Alignment Gauge and install the 2 remaining screws.
- Tighten to 25 Nm (18 lb-ft).





82. NOTICE: Do not allow 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.





83. 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 in 2 stages.

- Stage 1: Tighten to 14 Nm (124 lb-in).
- Stage 2: Back off the screw exactly 1.5 turns and hold that position.





84. 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).





85. NOTICE: Do not allow the intermediate band adjusting screw to back out. Band strut could 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 nut on the band adjustment screw.





86. 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 in 2 stages.

- Stage 1: Tighten to 14 Nm (124 lb-in).
- Stage 2: Back off the screw exactly 1.5 turns and hold that position.





87. 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).





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





89. 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.





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





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

1. Install the short screw.

2. Install the screw with the larger head.

3. Install the remaining screws.





92. Remove the Valve Body Aligners and loosely install one screw.





93. Tighten the screws in the sequence shown.
- Tighten to 10 Nm (89 lb-in).





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





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





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

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

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





97. Install the reverse servo. Tighten the bolts in the sequence shown in 2 stages.
- Stage 1: Tighten to 5 Nm (44 lb-in).
- Stage 2: Tighten to 11 Nm (97 lb-in).





98. NOTICE: Lubricate the transmission fluid pan filter seals with automatic transmission fluid or they may be damaged.

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

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

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





99. 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 gasket on the transmission fluid pan.





100. Install the transmission fluid pan and tighten the screws in a crisscross sequence.
- Tighten to 11 Nm (97 lb-in).





101. Install the drain plug.
- Install a new gasket onto the drain plug assembly.

- Tighten to 26 Nm (19 lb-ft).





102. 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.





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





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





105. Using the Drive Pinion Flange Installer and Output Shaft Flange Installer, install the output shaft flange.





106. Install a new output shaft flange nut.
- Tighten to 130 Nm (96 lb-ft).





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

Install the 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 8 Nm (71 lb-in).





109. NOTICE: 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 or damage may occur.

Install the input shaft.





110. Using the Piston Seal Sizer, make sure that the front fluid pump seal assembly is fully seated.





111. Remove the Piston Seal Sizer.





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

NOTICE: Make sure the converter hub is fully engaged in the pump support and gear and 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 automatic transmission fluid.





113. 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.





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





115. NOTICE: The Flex Plate Aligner must be used to correctly align the adapter plate to the converter or transmission damage may occur. In order to correctly install the Flex Plate Aligner, it must be installed using 1 round and 1 oblong hole. Using 2 oblong holes will cause damage to the transmission.

NOTE: Position the adapter plate on the torque converter and identify the position of the orange or green paint daub on the converter face.

If the vehicle is equipped, use the Flex Plate Aligner to install the torque converter flexplate adapter assembly and 8 nuts.

- Tighten to 44 Nm (32 lb-ft).





116. Remove the Flex Plate Aligner and install the remaining torque converter flexplate adapter nuts.
- Tighten to 44 Nm (32 lb-ft).





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





118. NOTE: Inspect 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 sensors.

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