Part 2
TransmissionAssembly (Steps 17-71)
17. NOTE: Make sure the reverse clutch cylinder lugs are completely seated in the notches of the reverse sun gear.
Install the reverse clutch cylinder assembly.
1. Install the reverse clutch cylinder.
2. Install the No. 2 forward clutch bearing.
18. Install the overdrive band.
^ Position the overdrive band pocket onto the anchor pin.
19. Install the overdrive servo spring.
1. Install the overdrive servo piston return spring.
2. Install the overdrive servo piston.
20. Verify the tip of the piston assembly engages the pocket of the overdrive band.
21. Using the special tool, compress the overdrive servo assembly and install the overdrive servo retaining ring.
22. Install the intermediate clutch pressure plate.
23. NOTE: Before assembly, soak the new clutch discs in clean automatic transmission fluid.
Install the intermediate clutch pack and selective steel plate.
24. Using the special tool, check the intermediate clutch clearance.
1. Position the special tool on the pump case mounting surface.
2. Maintaining downward pressure, use a depth micrometer to measure and verify intermediate clutch clearance is within specification.
If the intermediate clutch is not within specification, install a correct selective plate.
Selective Steel Plates
Selective Steel Plates (Part 1):
Selective Steel Plates (Part 2):
25. Using the special tool, measure end clearance for the No. 1 front pump thrust washer.
1. Position the special tool on the pump case mounting surface.
2. Maintaining downward pressure, use a depth micrometer to measure end play clearance.
Use the No. 1 thrust washer chart to select the correct washer.
No. 1 Thrust Washer Chart
No. 1 Thrust Washer Chart (Part 1):
No. 1 Thrust Washer Chart (Part 2):
26. Install the intermediate anti-rattle clip, if equipped.
27. NOTE: Align the intermediate clutch return spring pack indent with the pump check ball.
Install the intermediate clutch return spring pack.
28. Install the No. 1 front pump support thrust washer.
^ Use petroleum jelly to hold the washer in place.
29. NOTE: The alignment pin is a fabricated M8 x 1.25 mm (0.05 inch) bolt with the head removed.
Install an alignment pin at the top of the case.
30. NOTE: Make sure the gasket is positioned correctly and the case passages are not covered.
Install the pump gasket.
31. NOTE: To aid assembly, shake the input shaft while pushing down on the pump.
Install the pump assembly.
32. Remove the alignment pin and install the front pump bolts.
^ Alternate bolt tightening to set the pump.
^ Tighten to 27 Nm (20 lb-ft).
33. Rotate the transmission to the horizontal position.
34. Install the parking pawl.
1. Position the parking pawl return spring.
2. Position the parking pawl.
3. Install the parking pawl shaft.
35. Install a new extension housing gasket and the extension housing.
1. Position the extension housing.
2. Install the 4 bolts and 2 nuts.
^ Tighten to 28 Nm (21 lb-ft).
36. NOTE: When installing the new seal, make sure that the drain hole in the seal is in the 6 o'clock position.
Using the special tool, install a new extension housing seal.
37. Install the output shaft speed (OSS) sensor and the turbine shaft speed (TSS) sensor.
1. Install the TSS speed sensor and the bolt.
^ Tighten to 11 Nm (8 lb-ft).
2. Install the OSS speed sensor and the bolt.
^ Tighten to 12 Nm (9 lb-ft).
38. Using the special tool, install the manual control lever seal.
39. NOTE: Lubricate the electronic pressure control (EPC) solenoid O-rings with clean automatic transmission fluid.
Lubricate the EPC solenoid and install it into the case.
40. Install the manual valve detent lever and parking lever actuating rod.
41. Install the manual control lever shaft.
1. Slide the manual control shaft into the case.
2. Install the manual lever shaft inner nut.
^ Tighten to 32 Nm (24 lb-ft).
3. Install the manual lever shaft retaining pin.
42. Install the 1-2 accumulator piston assembly.
1. Install the 1-2 accumulator upper spring.
2. Install the 1-2 accumulator.
3. Install the inner and outer 1-2 lower accumulator spring.
4. Install the 1-2 accumulator cover and seal.
43. Install the 1-2 accumulator retaining ring.
44. NOTE: This is not an ordinary installation procedure and does not compensate for band wear. When new piston and rod assembly installation becomes necessary or when a new reverse band has been installed, the reverse piston and rod length must be adjusted.
NOTE: Lubricate the reverse piston seal with clean automatic transmission fluid to facilitate assembly and prevent damage to the seal.
NOTE: Do not install the reverse servo piston cover and seal at this time.
Install the reverse servo piston and rod assembly.
45. Install the special tool.
46. Install the special tool.
^ Position the indicator stem on the flat portion of the reverse servo piston and zero the dial indicator.
47. Loosen the bolt until the piston stops against the tool.
48. Verify that the amount of piston travel on the dial indicator is within specification.
49. If piston travel is not within specification, select and install the correct servo assembly to bring the servo piston travel within specification.
1. One groove
2. Two grooves
3. Three grooves
50. Remove the special tools.
51. Install the reverse servo assembly.
1. Install the rod.
2. Install the piston assembly.
3. Install the reverse servo piston cover and seal.
52. Using the special tool, install the reverse servo retaining ring.
1. Compress the reverse band servo.
2. Install the reverse band servo retaining ring.
53. Install the 2-3 accumulator assembly.
1. Install the accumulator piston.
2. Install the accumulator piston spring.
3. Install the accumulator spring retainer.
54. Using the special tools, apply regulated air pressure to the test ports. Verify that the components are applied and released.
55. NOTE: The tab on the electrical connector is secured by main control valve body.
Install the electrical connector into the case.
56. NOTE: The alignment bolts are valve body assembly bolts and are in the valve body.
Align the main control valve body alignment bolts and position the main control valve body.
57. NOTE: The main control valve body bolts will be tightened in later steps.
Loosely install the 11 long main control valve body bolts.
58. Install the EPC solenoid bracket and loosely install the bolt.
59. NOTE: The main control valve body bolts will be tightened in later steps.
Loosely install the 12 short main control valve body bolts.
60. Install the manual control valve detent lever spring and loosely install the bolt.
61. Tighten the bolts in the sequence shown.
^ Tighten to 10 Nm (89 lb-inch).
62. Inspect the lead frame for damage.
^ Using the special tool, check all the lead frame solenoid connections. The gauge should fit tightly and not fall out after being inserted.
^ If the special tool passes through any lead frame connector pins or does not feel like it makes a good contact, install a new lead frame.
63. Connect the molded lead frame to the solenoids.
^ Connect the bulkhead interconnector by pressing it in place by hand and fully seating the connector in place.
^ Connect the EPC solenoid by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots.
^ Connect the TCC by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots.
^ Connect the shift solenoid SSA and SSB by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots.
64. Install the fluid filter and seal assembly.
65. Position the pan magnet into the transmission fluid pan.
66. NOTE: The pan gasket is reusable. Clean and inspect for damage. If not damaged, the gasket should be reused.
Install the fluid pan.
1. Position the transmission fluid pan and gasket.
2. Install the transmission fluid pan bolts.
^ Tighten to 14 Nm (10 lb-ft).
67. Loosely install the digital transmission range (TR) sensor and bolts.
68. NOTE: The tool is designed to fit snugly.
NOTE: Manual shift lever must be in the NEUTRAL position.
Using the special tool, align the digital TR sensor slots.
69. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged.
Tighten the bolts in an alternating sequence.
^ Tighten to 9 Nm (80 lb-inch).
70. Lightly lubricate the converter hub with clean automatic transmission fluid.
71. 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.
CAUTION: Make sure the converter hub is fully engaged in the front pump support and gear and rotates freely. Do not damage the hub seal.
CAUTION: If the torque converter slides out, the hub seal may be damaged.
Using the special tools, install the torque converter.
72. Lubricate the torque converter pilot hub with multi-purpose grease.
