Part 1

Transmission (Part 1)

Special Tool(s):

Material:

Transmission, Disassembled View (Part 1):

Transmission, Disassembled View (Part 2):

Transmission, Disassembled View (Part 3):

Transmission, Disassembled View (Part 4):

Transmission, Disassembled View (Part 5):

Transmission, Disassembled View (Part 6):

Transmission, Disassembled View (Part 7):

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.

All transmissions
1. Mount the transmission case into a suitable stand.

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

3. If removed, use the special tool to install a new Teflon(R) Seal retainer.
^ Install 2 new Teflon(R) seals.

4. 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.

5. Install the reverse clutch return spring assembly.

6. WARNING: Do not over compress the return spring or damage to the spring will occur.

Using the special tools, install the reverse clutch return spring snap ring.

7. NOTE: The use of petroleum Jelly will hold the No. 17 thrust bearing or washer in place during assembly.

For vehicles equipped with a slip yoke, install the No. 17 park, gear thrust bearing. For vehicles equipped with a fixed yoke, install the No. 17 park gear thrust washer.

8. WARNING: Be careful when installing the output shaft not to damage the seals or a transmission leak could occur.

Install the output shaft.

9. CAUTION: The Torx(R) screw has a threadlocking compound. If the screw is removed, it must be discarded and a new screw installed.

If removed, install the parking pawl abutment with a new Torx(R) screw.
^ Tighten to 25 Nm (18 ft. lbs.).

10. Install the parking pawl.
1 Install the parking pawl shaft.
2 Install the parking pawl.
3 Install the parking pawl return spring.

11. NOTE: Make sure the dimple on the parking guide support plate is facing inward.

Install the parking rod guide plate.
1 Install the parking rod guide plate.
2 Install the bolts.
^ Tighten to 25 Nm (18 ft. lbs.).

12. Install a new orifice lube plug in the rear of the case. Using a 12 mm socket, tap the orifice lube plug into the back of the transmission. Check to make sure that the orifice lube plug is fully seated into the back of the transmission.

13. Install a new extension housing gasket.

14. Install the extension housing.
^ Tighten to 48 Nm (35 ft. lbs.).

15. Using the special tool, install a new manual control lever seal.

16. Install the transmission range (TR) sensor, park rod assembly and loosely install the bolts.

17. Install the manual control lever.

18. Install the roll pin into the case.

19. Install a new roll pin. Leave 2 mm (0.08 inch) of the pin exposed.

20. Tighten the TR sensor bolts.
^ Tighten to 10 Nm (89 inch lbs.).

Fixed yoke transmissions
21. Using the special tool, install a new extension housing seal.

22. Inspect the new output shaft nut O-ring for cuts. A new nut must be installed.

23. Using the special tool, install the output shaft nut.
^ Tighten to 200 Nm (148 ft. lbs.).

24. Install the output flange and a new bolt.
^ Tighten to 135 Nm (100 ft. lbs.).

Slip yoke transmissions
25. Install a new extension housing seal using the special tool.

All transmissions
26. Install the No. 16 bearing and race.

27. Install the ring gear, hub and the No. 15 hub bearing.

28. Install the reverse carrier and hub assembly.

29. Install the low/reverse clutch plates.
^ Start with a steel plate on the bottom, followed by a friction plate.
^ Alternately stack the remaining steel and friction plates.
^ Add the pressure plate (low/reverse one-way clutch) on the last friction plate, with THIS SIDE UP facing upward.

Diesel engines

30. CAUTION: Do not apply air pressure to move the low/reverse piston without first installing the friction plates and the snap ring, or damage to the snap ring will occur.

Install a new snap ring and make sure that the snap ring is fully seated in the case snap ring groove.

Diesel applications: Install a new flat snap ring so the tang ends are in the gaps to the right and to the left of the case spline as shown.
^ Check the function of the reverse clutch by applying air to the correct passage (through the case valve body worm trail) for the reverse clutch.