Internal Components
PROCEDURE1. If bushing was removed, position replacement bushing on Case Rear Bushing Replacer T80L-77110-A and install in bushing bore through the front of the case.
2. Thread Impact Slide Hammer T50T-100-A into Bushing Replacer through the back of the case. Install the bushing.
3. With transmission in the vertical position, coat case rear bearing with petroleum jelly and install the No. 9 case rear bearing on the transmission case boss.
4. Install output shaft , ring gear and direct clutch as an assembly.
5. Install retaining ring that supports reverse band.
6. Install the reverse band. Make sure reverse band is seated on anchor pins.
7. Install forward planetary assembly and planetary gear support assembly as a unit.
NOTE: Forward planetary assembly and planetary gear support assembly cannot be installed unless the notch cut in the planetary gear support assembly is aligned with the overdrive band anchor pin. Top of planetary gear support assembly should be below snap ring groove.
Align notch in planetary gear support assembly with overdrive band anchor pin. Rotate the output shaft, if necessary, to align the planet carrier splines with the direct clutch hub splines.
8. Install the case to planet support spring using a screwdriver to position.
NOTE: Forward planetary assembly and planetary gear support assembly cannot be installed unless notch cut in planetary gear support assembly is aligned with overdrive band anchor pin.
9. Install center planet support retaining ring. Reference retainer ring end tab to overdrive band anchor pin.
10. Install forward clutch sun gear, No. 5 thrust bearing, reverse sun gear and shell and No. 4 needle bearing.
11. Install intermediate stub shaft.
12. Install forward clutch hub and No. 3 forward clutch hub front bearing.
13. Install forward clutch assembly.
14. Install reverse clutch cylinder assembly.
NOTE: Wiggle the input shaft while engaging the reverse clutch splines. Make sure the reverse clutch cylinder lugs are completely seated in the notches of the reverse clutch gear and shell.
15. Install overdrive band over reverse clutch assembly and position the pocket of the overdrive band against overdrive band anchor.pin. Install overdrive servo piston return spring and overdrive servo piston assembly. Verify tip of piston assembly engages the pocket of overdrive band. Using Servo Piston Remover/Replacer T92P-70023-A, install piston assembly into the case and compress overdrive servo piston return spring.
16. Make sure band anchor and tip of the piston assembly are properly positioned against band pockets. Tighten tool until piston is below retaining ring groove, install retaining ring, then remove tool.
17. Install intermediate clutch as follows:
a. Clutch pressure plate is the thickest. Install this first with chamfer side down.
b. Clutch plates.
c. Perform Steps 18 and 19 to select the proper intermediate clutch selective steel plate.
18. With proper intermediate plates selected and installed, perform end clearance check for No. 1 thrust washer using the same tools.
19. Measure the intermediate clutch clearance using Depth Micrometer D80P-4201-A or equivalent and Gauge Bar T80L-77003-A.
NOTE: Maintain downward pressure on clutch pack while measuring depth.
a. Set the gauge bar across the pump case mounting surfaces. The depth at the intermediate clutch separator plate is:
42.6-41.7 mm (1.677-1.643 inch)
b. Check the clearance again 180° opposite to ensure the average depth is within tolerance.
c. If the depth is not within tolerance, the following size selective steel plates are available:
1.80-1.70 mm (0.071-0.067 inch)
2.05-1.95 mm (0.081-0.077 inch)
2.31-2.20 mm (0.091-0.087 inch)
2.56-2.46 mm (0.101-0.097 inch)