Steps 1-46

Part 1 Of 2:

Part 2 Of 2:

Special Tool(s)

NOTE: Soak all friction clutch plates in clean automatic transmission fluid.

NOTE: Prior to installation, lightly lubricate all O-ring seals with clean automatic transmission fluid.

NOTE: Lightly lubricate all thrust washers with petroleum jelly to hold them in place during assembly.

1. Mount the transmission case into suitable stand.





2. If removed, use the special tool to install the short fluid inlet tube.





3. CAUTION: If equipped, use care not to misalign the reverse clutch piston in the case bore.

NOTE: Coat the reverse clutch piston seals with petroleum jelly.

Install the reverse clutch piston in the case until it is fully seated in the case.





4. CAUTION: The low/reverse clutch inner race is vehicle-dependent. Refer to the correct parts.

NOTE: Clock position is viewed looking into the converter housing with the top of the transmission in the 12 o'clock position.

Install the reverse clutch return spring assembly.
1 Install the reverse clutch return spring assembly.
2 Install the low/reverse one-way clutch inner race.
3 Make sure that the lubrication hole on the face is in the 5 o'clock position.





5. Install two 5/16-24 x 3 inch bolts with nuts in to the low/reverse one-way clutch inner race.
1 Hold the nut.
2 Turn the bolt to compress the low/reverse piston return spring.





6. Install three of the one-way clutch inner race bolts and remove the two 5/16-24 x 3 bolts.





7. NOTE: Alternate tightening bolts from one side to the other (not in a circle).

Install the remaining bolts retaining the low/reverse one-way clutch inner race to the case.





8. CAUTION: The low/reverse clutch, one-way clutch is vehicle-dependent. Refer to the correct parts.

NOTE: When the reverse clutch and the low one-way clutch are installed, the reverse clutch should rotate clockwise. The one-way clutch will hold and not let the clutch hub rotate counterclockwise.

Install the reverse clutch hub and the low one-way clutch assembly over the low/reverse one-way clutch inner race by pressing the hub inward and rotating it clockwise to seat fully.





9. CAUTION: The number of plates is vehicle-dependent.

NOTE: No stack-up clearance measurement is required.

NOTE: Clock position is viewed looking into the converter housing with the top of the transmission in the 12 o'clock position.

Install the reverse clutch pack assembly.
1 Install the cushion spring.
2 Install the reverse clutch plates starting with an external spline steel plate and alternating with internal splined friction plates.
3 Install the reverse clutch pressure plate.
4 Install the reverse clutch pressure plate retainer snap ring with the ring opening between the 12 o'clock and 3 o'clock positions.





10. NOTE: Apply petroleum jelly to the No. 13 parking gear bearing to hold it in place.

Install the No. 13 parking gear bearing.





11. CAUTION: Use care not to damage the output shaft drive sprocket speed sensor wheel. This will cause an incorrect reading at the output shaft speed (OSS) sensor, which will cause a repeat repair.

Install the output shaft.





12. NOTE: Lubricate the thrust bearing with petroleum jelly to hold it in place during assembly.

Install the No. 12 thrust bearing onto the rear surface of the hub assembly.





13. Install the output shaft ring gear assembly.





14. WARNING: Do not overextend the output shaft retaining ring during installation. Make sure the output shaft retaining ring is securely seated in the groove. Failure to follow these instructions may result in personal injury.

Install the new output shaft retaining ring onto the output shaft.





15. Install the reverse planet assembly.
1 Install the No. 11 thrust washer.
2 Install the reverse planet.
3 Install the No. 10B thrust washer.





16. Install the reverse planet retaining ring into the reverse clutch hub, making sure the retaining ring is fully seated.





17. NOTE: The large outer diameter radius of the needle bearing must be installed facing inward.

NOTE: Lightly lubricate the needle bearing with petroleum jelly to hold it in place during assembly.

Verify the No. 8B forward clutch needle bearing is installed.





18. Install the forward clutch cylinder assembly onto the intermediate brake drum by rotating it until fully seated.





19. NOTE: Lightly lubricate the thrust bearing with petroleum jelly to hold it in place during assembly.

Verify the No. 9A forward clutch thrust bearing is installed (black side facing up).





20. NOTE: Lightly lubricate the thrust washer with petroleum jelly to hold it in place during assembly.

Place the No. 8C forward clutch hub thrust washer onto the forward hub and ring gear assembly.





21. Place the forward hub and ring gear assembly into the intermediate brake drum and forward clutch cylinder assemblies.





22. NOTE: Lightly lubricate the thrust bearing with petroleum jelly to hold it in place during assembly.

Verify the No. 10A forward planet assembly thrust bearing is installed.





23. Place the forward planet assembly into the forward hub and ring gear assembly.





24. NOTE: The thrust bearing notched inner race must face outward and the large outer diameter radius must face inward.

Verify the No. 9B forward clutch thrust bearing is installed.





25. Align the notches with the lugs and position the input shell onto the intermediate brake drum. Rotate the input shell until fully seated.





26. NOTE: When installing the special tool. each leg of the tool must be rotated separately to engage notches on the input shell, prior to tightening the top cross bar.

Using the special tool, lower the direct clutch, forward clutch and input shell as an assembly into the case.





27. Install the intermediate band with the ear resting on the anchor pin.





28. NOTE: Prior to installation, lightly lubricate the piston seal with clean automatic transmission fluid.

Gently press the intermediate band servo assembly piston into the case bore.





29. NOTE: Clock position is viewed looking into the converter housing with the top of the transmission in the 12 o'clock position.

Install the intermediate clutch pack.
1 Install the intermediate clutch pressure plate.
2 Install the intermediate clutch pack starting with an internal spline plate and alternating with external spline plates.
3 Install the intermediate clutch pressure apply plate with blank area (no teeth) in the 6 o'clock and 12 o'clock positions.





30. NOTE: The following stack-up check measurement indicates not only the amount of space existing between the center support assembly and the intermediate brake drum, it also will indicate if the unit has been correctly built to this point.

Measure the stack up.
1 Hold the thrust washer against the center support assembly.
2 Extend the probe of the special tool into the hole until flush with the No. 6 center support thrust washer surface.
3 Record this as reading 1.





31. CAUTION: Do not misalign the center support in the case bore. This can cause case bore damage.

NOTE: Make sure the No. 6 center support thrust washer is on the center support prior to installation.

Install the center support assembly with the feed holes aligned in the case.





32. Make a second measurement after installation of the center support.
1 Extend the probe of the special tool into the hole in the center support assembly until flush with the No. 6 center support thrust washer.
2 Record this as reading 2.





33. Subtract reading 1 from reading 2. Record this as reading 3. If the final dimension is outside specified limits, this indicates that the transmission has been assembled incorrectly.





34. CAUTION: Do not tighten the bolts at this time. This could cause transmission failure.

Loosely install two new feedbolts.





35. NOTE: Clock position is viewed looking into the converter housing with the top of the transmission in the 12 o'clock position.

Install the intermediate clutch return spring with the dished surface inward and one spring leg in the 6 o'clock position.





36. CAUTION: Do not misalign the intermediate/overdrive cylinder assembly. This can damage the case bore.

Install the intermediate/overdrive cylinder assembly with the feed holes aligned with the holes in the case.





37. NOTE: Clock position is viewed looking into the converter housing with the top of the transmission in the 12 o'clock position.

Install the intermediate/overdrive cylinder retaining ring over the intermediate/overdrive cylinder with the ring opening in the 6 o'clock position to allow for the correct fluid drainback.





38. Install the special tool.
1 Rotate the special tool clockwise to lock in place.
2 Tighten the handle.





39. CAUTION: Make sure the snap ring is fully seated into the case. Transmission failure could occur.

NOTE: Clock position is viewed looking into the converter housing with the top of the transmission in the 12 o'clock position.

Seat the intermediate/overdrive cylinder retaining ring into the case ring groove with the ring opening in the 6 o'clock position.





40. CAUTION: Do not tighten the bolts at this time. Transmission failure could occur.

Loosely install a new intermediate/overdrive cylinder feedbolt.





41. Loosen the center bolt and remove the special tool.





42. NOTE: The special tool must be used to install the coast clutch assembly or damage to the overdrive one-way clutch may occur.

NOTE: Use petroleum jelly to hold the No. 5 thrust bearing on the center shaft during assembly.

Using the special tool, install the coast clutch and No. 5 thrust bearing assembly.
1 Install the No. 5 thrust bearing.
2 Install the coast clutch assembly.





43. NOTE: The number of plates in the clutch pack is vehicle-dependent.

NOTE: Clock position is viewed looking into the converter housing with the top of the transmission in the 12 o'clock position.

Install the overdrive clutch pack.
1 Install the overdrive clutch pack starting with a steel plate and alternating with friction plates.
2 Install the overdrive clutch pressure plate with the dot facing outward and in the 12 o'clock position.





44. NOTE: Clock position is viewed looking into the converter housing with the top of the transmission in the 12 o'clock position.

Install the overdrive clutch pressure plate retainer snap ring with the ring opening in the 6 o'clock position.





45. Check the stack-up clearance.
^ Using a feeler gauge, check the stack-up clearance in 3 places, 120 degrees apart.
^ If the clearance is not to specification, install the correct selective overdrive clutch pressure plate retainer snap ring and recheck the clearance.





46. NOTE: Lightly lubricate the gasket with petroleum jelly to hold it in place during assembly.

Install the new pump gasket. Aligning the holes in the gasket with the holes in the case.