Selective Thrust Washer & External Components

1. Position the Depth Micrometer D80P-4201-A or equivalent on Gauge Bar T80L-77003-A so that the depth is measured at the reverse clutch drum thrust face. Check the end play 180° opposite to determine the average depth. Refer to the Selective Thrust Washers chart for specifications.





2. install No. 1 thrust washer on pump body using petroleum jelly to hold in place.
3. Install pump gasket. Make sure pump gasket is positioned and case passages are covered.





4. To maintain pump-to-case alignment, use a fabricated M8-1.25 mm bolt (head removed) as a guide. Install in the 12 o'clock position using petroleum jelly on pump-to-case seal surfaces to aid pump installation.





5. To aid assembly, grasp input shaft and wiggle shaft while pressing down on pump.





6. Remove alignment bolt and install pump-to-case bolts. Alternate bolt tightening to draw the pump fully into the case. Tighten to 20-26 Nm (15-19 ft. lbs.).





7. Place transmission in the horizontal position. Install parking pawl and parking pawl return spring. Slide parking pawl shaft into case through parking pawl.





8. Install output shaft speed sensor (OSS). Tighten bolt to 7-10 Nm (62-88 inch lbs.).





9. Install manual control lever seal using Shift Lever Seal Replacer T74P-77498-A.





10. Install EPC solenoid.





11. If removed, install new extension housing bushing using Extension Housing Bushing Replacer T80L-77034-A.





12. Install new extension housing gasket and extension housing. Tighten bolts to 25-30 Nm (19-22 ft. lbs.).





13. Install extension housing seal using Extension Housing Seal Replacer T61 L-7657-B.





14. Position manual valve detent lever and parking lever actuating rod into case. Parking lever actuating rod must be positioned over parking pawl.
15. Slide manual control lever into case and position through detent. Install nut and tighten to 26-37 Nm (20-27 ft. lbs.).
16. Install manual lever shaft retaining pin.





17. Install fluid screen into case (head first).
18. Install reverse band servo spring, reverse band servo piston and rod. When band and/or piston and rod assembly replacement becomes necessary, determine the correct length of the reverse servo piston, proceed as follows:
a. Lubricate the reverse piston seal to facilitate assembly and to prevent damage to the seal.
b. Install the reverse servo piston and return spring. Do not install the piston cover or retaining ring.





c. Install Servo Piston Selection Tool T80L-77030-A. Tighten the band apply bolt on Servo Piston Selection Tool T80L-77030-A to 5.6 Nm (50 inch lbs.).





d. Attach Dial Indicator with Bracketry TOOL-4201-C or equivalent and position the indicator stem on the flat portion of the piston. Zero the dial indicator.
e. Thread the bolt out of the selector tool until the piston stops against the bottom of the tool.
f. Read the amount of piston travel on the dial indicator.
^ If the travel is 2.845-6.020 mm (0.112-0.237 inch), the piston length is within specification.
^ If the travel is not within specification, selective pistons are available in the following lengths:
74.56 mm (2.936 inch) 1 groove
75.92 mm (2.989 inch) 2 grooves
77.29 mm (3.043 inch) 3 grooves
Length of rod measured from piston surface to end of rod. Select the proper rod to bring the servo piston travel within specification.
g. Remove the servo selection tool and dial indicator.
h. Lubricate the cover seal to facilitate assembly and to prevent damage to the seal. Place servo cover and retaining ring in servo bore.





19. Tighten screw on Servo Piston Remover/Replacer T92P-70023-A to allow enough clearance to install retaining ring.





20. Install the components for 2-3 accumulator in the following order:
^ upper accumulator seal
^ accumulator piston
^ lower accumulator seal
^ accumulator piston spring
^ accumulator spring retainer

NOTE: Retainer is secured by main control.








21. Install the components for 1-2 accumulator in the following order:
^ 1-2 accumulator spring
^ accumulator piston seal
^ accumulator piston
^ lower accumulator seal
^ 1-2 accumulator spring
^ cover and seal assembly
^ accumulator piston retaining ring





22. Align and install wiring connector into case. Inspect O-ring and replace if required.

NOTE: Tab on connector is secured by main control.

23. Position main control valve body using the two alignment bolts as a guide.





24. Install the EPC solenoid bracket. Loosely install one long 6 mm bolt.
25. Loosely install 11 long and 12 short bolts.





26. Install manual control valve detent lever spring and one bolt.





27. Tighten the 25 main control valve body-to-case bolts to 9-11 Nm (80-97 inch lbs.).





28. Connect wiring connectors to transmission fluid temperature sensor (TFT), shift solenoids, TCC solenoid and EPC solenoid.





29. Install new filter and grommet.





30. Install transmission range (TR) sensor on manual control lever and loosely install bolts.





31. Position manual control lever in NEUTRAL. Insert Transmission Range (TR) Sensor (Manual Lever Position Sensor Alignment Tool) T93P-70010-A into slots. Align all three slots on TR sensor with three tabs on tool.

NOTE: PARK is the last detent when the manual control lever is full forward. Return two detents toward output shaft for NEUTRAL.

32. Tighten TR sensor bolts to 7-10 Nm (62-88 inch lbs.).





33. Clean, inspect and install pan-to-case gasket and transmission pan. Tighten all bolts to 12-15 Nm (106-132 inch lbs.).

NOTE: Transmission pan-to-case gasket is reuseable if not damaged.