Assemble

1. Install parking pawl shaft, parking pawl, plug, retainer and pawl return spring, as per figure.

2. Place actuator assembly over parking pawl.

3. Install seal and manual shaft.

4. Install nut on shaft and torque to 18 ft. lbs.

5. Install roll pin, then parking lock bracket with two bolts, torque bolts to 18 ft. lbs.

6. Install selective thrust washer determined by rear endplay measurement in step 25 of disassembly. Washer must be installed smooth side up and retained with Transjel J-36850 or equivalent.

7. Install rear band. Ensure band tab lines up with servo pin hole.

8. Install spacer to bottom of case splines. Leave opening of snap ring at 3 o'clock position.

9. Attach gear unit assembly installer tool No. J-38868 or equivalent to main shaft.




10. With transmission in vertical position, align bolt hole in center support with hole in case and carefully lower gear unit/center support assembly into case, as shown in figure.

11. Install beveled snap ring flat side down with end gap at the 3 o'clock position using snap ring tool No. J-28585 or equivalent.

12. Perform rear endplay measurement as described in step 25 of disassembly.

13. Install center support locating tool No. J-23093 or equivalent into center support direct clutch passage through case. Apply pressure on center support locating tool, seating center support splines counterclockwise against case splines.

14. Install new case to center support bolt. Torque bolt to 32 ft. lbs., then ensure bolt head is seated to bottom of case, being careful to not over torque.

15. Dip all composition intermediate clutch plates in Dexron III transmission fluid, then install steel and composition plates alternately, starting with steel plate.

16. Install intermediate clutch plate with flat side down, then install snap ring.




17. Insert feeler gauge between backing plate and snap ring to check for intermediate clutch piston travel. Clearance should be 0.040-0.107 inch, per the figure.

18. Install front band. Ensure band is in its proper position and has freedom of movement.

19. Align intermediate clutch plates using intermediate clutch pack alignment tool No. J-24396 or equivalent. Leave tool in place.

20. Apply compressed air through center support bolt hole to engage intermediate clutch, then remove alignment tool keeping air applied to hold clutch plates in place.




21. Lower direct clutch assembly into case using direct clutch assembly installer tool No. J-38733 or equivalent, as seen in the figure, then remove air pressure.





22. Install forward clutch assembly using forward clutch assembly installer tool No. J-38358-A or equivalent, as seen in the figure. When forward clutch assembly is installed correctly, the distance between top of speed sensor ring and pump gasket surface is approximately 3.85 - 3.89 inches.

23. Install fourth clutch assembly into case.




24. Install new fourth clutch bolt through case fluid passages into fourth clutch housing, as in the figure. Torque bolt to 11-13 ft. lbs. being very careful to not over torque bolt.

25. Rotate transmission to horizontal position.

26. Install complete turbine shaft and overdrive carrier assembly into case. Ensure assembly is fully engaged and at the level of fourth clutch housing.

27. Install selective thrust washer on top of overrun housing, then place a straightedge across pump and cage assembly surfaces. They should be flush




28. Install fourth clutch plates, starting with steel plate first, into fourth clutch housing around overdrive carrier assembly. Install steel plates with narrow tang (V-notch) at one o'clock position in housing, as seen in the figure.




29. Install backing plate with wide surface against composition plate, then snap ring into fourth clutch housing, as in the figure.




30. Install pump gasket onto transmission case using guide pin tools No. J-25025-1 or equivalent at twelve o'clock and five o'clock positions, as in the figure.




31. Install oil pump assembly in transmission case using pump installing tool No. J-37789 or equivalent, as in the figure. Bolt holes closest together are towards channel face.

32. Install six pump bolts and torque to 18 ft. lbs. If turbine shaft cannot be rotated as pump is pulled into place, the overrun, fourth, and/or roller clutch housings have not been installed properly to index with all clutch plates. This must be corrected before pump is fully installed.

33. Perform front unit endplay check as described in step 24 of disassembly.




34. Install front servo assembly into case, as seen in the figure. Ensure tapered end of piston pin contacts band.

35. Perform band apply pin check as described in step 17 of disassembly.




36. Install rear accumulator spring in case bore, as seen in the figure.

37. Install rear servo assembly into case bore, then new cover gasket, cover and six bolts. Torque bolts to 18 ft. lbs.




38. Install check balls in proper fluid passage locations, then PWM screen, as seen in the figure.

39. Install spacer plate to case gasket.




40. Install complete valve body assembly onto case using guide pin tool No. J-25025-5 or equivalent, as seen in the figure.

41. Attach manual valve to detent lever.

42. Install pressure switch manifold onto valve body assembly, then spring and roller assembly.

43. Install three wiring clips, fluid indicator stop and lube pipe clamp.




44. Install 21 valve body bolts and torque to 97 inch lbs. in sequence shown in the figure.

45. Install six pressure switch manifold bolts and torque to 97 inch lbs. in sequence shown in the figure.

46. Install lube pipe with long end in case and short end into valve body, then lube pipe clip and short bolt.

47. Attach wiring harness to six connectors.




48. Install filter neck seal and filter into case, as seen in the figure.

49. Install pan gasket, pan magnet, pan and 17 bolts. Torque pan bolts to 18 ft. lbs.




50. Install O-ring, orifice assembly, seal and snap ring to rear of case, as shown in the figure.

51. Install extension housing and six bolts. Torque extension housing bolts to 25 ft. lbs.


52. Install new rear seal using seal installer tool No. J-38694 or J-38869 or equivalents.

53. Install both speed sensor and bracket assemblies into transmission case, then bolts. Torque speed sensor bolts to 97 inch lbs.


54. Rotate transmission to vertical position, then install torque converter using converter holding strap tool No. J-21366 or equivalent. Engage turbine shaft, stator shaft, and lugs on pump driven gear until converter is fully engaged.