Part 1 of 2

Assembly







1. Inspect the case for cracks and stripped threads. Inspect the gasket surfaces and mating surfaces for burrs. Check the vent for obstructions and check all fluid passages for obstructions and leakage.

2. Inspect the case bushing for scores. Check all parking linkage for wear or damage.






3. Inspect all case threads for damage.











4. Inspect the extension housing for cracks. Inspect the gasket surfaces for burrs or warpage.

5. Inspect the bushing for scores or wear. Replace if required.

6. Inspect the rear seal for hardness, cracks or wear. If the seal shows wear or deterioration, replace the seal.

7. Inspect the seal counterbore and remove all burrs and scores with a crocus cloth.

8. NOTE: Bench-Mounted Holding Fixture T57L-500-B should still be attached to the adapter plate. If it is not, reattach the fixture arm at this time.

Reattach the adapter plate to the extension housing face using four M10 x 30mm screws.






9. WARNING: MAKE SURE THE LOCK PIN ON BENCH-MOUNTED HOLDING FIXTURE T57L-500-B IS SECURE.

Install the transmission case in the Bench-Mounted Holding Fixture T57L-500-B and rotate so the transmission fluid pan rail is facing up.






10. Lubricate and install the main control lever seal using Shift Lever Seal Replacer T74P-77498-A.






11. Assemble the manual valve inner lever and parking pawl actuating rod as shown.






12. Install the manual control lever shaft into the case.






13. CAUTION: Use care not to damage the fluid pan rail surface when installing the retaining pin.

Align the manual control lever shaft with the manual control lever shaft retaining pin. Install the retaining pin.

14. Install the manual valve inner lever and parking pawl actuating rod into the case. Align the flats of the manual valve inner lever with the flats on the manual control lever shaft.






15. CAUTION: To avoid damage, do not allow wrench to strike the manual valve inner lever pin.

Install manual valve inner lever nut and tighten to 41-54 Nm (30-40 lb-ft).






16. CAUTION: The tabs on the No. 11 output shaft thrust washer point into the case.

NOTE: The inside diameter of the No. 11 output shaft thrust washer is smaller than the inside diameter of the No. 10 (2.3L, 3.0L) output shaft thrust hub washer.

Apply petroleum jelly to the No. 11 output shaft thrust washer and install into the rear of the case bore.






17. Install the park gear into the rear case bore.

Reverse Brake Drum Assembly Installation - 2.3L, 3.0L:

Reverse Brake Drum Assembly Installation - 4.0L:

18. Rotate the reverse brake drum assembly clockwise to install. If used, remove the Overrunning Clutch Replacing Guide T74P-77193-A.

No. 10 Output Shaft Hub Thrust Washer Installation - 2.3L, 3.0L:

No. 10 Output Shaft Hub Thrust Washer Installation - 4.0L:

19. CAUTION: The tabs on the No. 10 output shaft hub thrust washer point into the one-way clutch.

NOTE: The size of the No. 10 output shaft hub thrust washer is model dependent.

NOTE: Petroleum jelly can be used to hold the No. 10 output shaft hub thrust washer in place.

Install the No. 10 output shaft hub thrust washer against the one-way clutch.






20. CAUTION: The output shaft is model dependent. The 4.0L output shaft does not have lube holes.

Install the output shaft through the output shaft park gear.

Output Shaft Ring Gear and Hub Assembly Installation - 2.3L, 3.0L:

Output Shaft Ring Gear and Hub Assembly Installation - 4.0L:

21. Install the output shaft ring gear and output shaft hub assembly.

Output Shaft Retaining Ring Installation - 2.3L, 3.0L:

Output Shaft Retaining Ring Installation - 4.0L:

22. CAUTION: Always use a new retaining ring.

Install a new output shaft retaining ring in the output shaft retaining ring groove.






23. NOTE: The output shaft sleeve is only used in 4.0L applications. Use petroleum jelly to hold the sleeve in place.

Install the output shaft sleeve with cone facing up.

No. 8 and 9 Reverse Planetary Carrier Thrust Washer Position - 4.0L:

No. 8 and 9 Rev. Planetary Carrier Thrust Washer Position - 2.3L, 3.0L:

24. CAUTION: The tabs on the thrust washers point into the reverse planetary.

NOTE: Use petroleum jelly to hold the thrust washers in place.

NOTE: The No. 8 and No. 9 reverse planetary carrier thrust washers are model dependent.

Position the No. 8 reverse planetary carrier thrust washer on the front face of the reverse planetary. Position the No. 9 reverse planetary carrier thrust washer on the rear face of the reverse planetary.

Reverse Planetary Assembly Installation - 2.3L, 3.0L:

Reverse Planetary Assembly Installation - 4.0L:

25. CAUTION: Make sure the thrust washers stay in place.

Install the reverse planetary assembly, with No. 8 and No. 9 reverse planetary carrier thrust washers, into the output shaft ring gear.






26. CAUTION: The retaining ring is not used in 4.0L applications.

Pull the reverse brake drum forward and install the retaining ring into reverse brake drum groove. This will hold the reverse planetary assembly in place.






27. CAUTION: Make sure band is resting on the two anchor pins in the case.

Install the reverse band over the reverse brake drum.






28. Install the reverse band servo piston and rod temporarily to hold the reverse clutch band in position.






29. Install the previously assembled forward geartrain assembly.


30. WARNING: MAKE SURE THE LOCK PIN ON BENCH-MOUNTED HOLDING FIXTURE T57L-500-B IS SECURE.

Rotate the transmission assembly so that the converter housing gasket surface is facing up.






31. Place Gage Bar T93T-77003-AH on the case shoulder of the No. 4 intermediate brake drum thrust surface. Set the micrometer on top of the gauge bar as shown.






32. Extend the micrometer probe until it contacts the intermediate brake drum thrust bearing surface. Record the reading as dimension "A."






33. Place the micrometer on the opposite side and extend the micrometer probe until it contacts the intermediate brake drum thrust surface. Record the reading as dimension "B".

34. Add the dimensions "A" and "B", divide the total of "A" and "B" by two. Subtract the gage bar thickness (17.18mm [0.700 inch]). This is dimension "C."






35. Place Gage Bar T93T-77003-AH across the center support. Place micrometer on top of the gage bar as shown. Extend the micrometer probe until it contacts the center support thrust bearing surface. Record the reading as dimension "D".

36. Place the micrometer on the opposite side of Gage Bar T93T-77003-AH and extend the micrometer probe until it contacts the intermediate brake drum thrust surface. Record the dimension as "F".

37. Add dimensions "D" and "F" and divide the total of "D" and "F" by two, then subtract the Gage bar thickness (17.18mm [0.700 inch]). This resulting dimension is "G".






38. Add dimensions "G" and "C". This total is dimension "J". Use the chart below and dimension "J" to choose the proper no. 4 thrust bearing. Reference end play is 0.21-0.51 mm (0.008-0.020 in).






39. Install the intermediate servo actuating lever as shown.






40. NOTE: The intermediate band actuating lever shaft is shorter than the overdrive shaft.

Install the intermediate band actuating lever shaft through the intermediate servo lever.






41. Install the intermediate band apply strut on the intermediate servo lever.






42. NOTE: Make sure the apply strut is aligned with the band notch.

Install the intermediate band.






43. NOTE: Use the intermediate band adjusting screw as a temporary alignment guide.

NOTE: The overdrive and intermediate band anchor struts are the same.

Install the intermediate band anchor strut and intermediate band adjusting screw.






44. NOTE: Use petroleum jelly to hold the No. 4 intermediate brake drum thrust bearing in place.

Install the correctly selected No. 4 intermediate brake drum thrust bearing over the center support as shown.






45. CAUTION: Do not apply pressure to the rear planetary support while installing. Damage to the sealing rings may result. Make sure the rear planetary support is seated.

Position the center support into the reverse clutch drum. Use the input shaft as an aid to seat the center support. Gently wiggle the input shaft from side to side until the center support is seated against the case shoulder. Remove the input shaft.











46. CAUTION: Install the retaining ring in the transmission case groove with the tapered side facing up.

CAUTION: The retaining ring must be installed so the notch opening is not obstructed by the center support retaining ring. This will prevent damage to the turbine shaft speed (TSS) sensor wires.

Install the center support retaining ring in the transmission case groove.






47. Ensure that the nut and cage assembly is in place.






48. Use a 5mm Allen wrench to install the M6 x 20mm center support-to-case capscrew into the nut and cage assembly as shown. Tighten the center support-to-case capscrew to 9-13 Nm (80-115 lb-in).






49. CAUTION: Carefully route the turbine shaft speed (TSS) sensor connector and wiring harness through the opening in the case. Do not damage the wiring.

Route the TSS sensor connector and wiring harness through the opening in the case.






50. Install the turbine shaft speed (TSS) sensor on the center support. Install the TSS screw. Tighten the TSS sensor-to-center support screw to 8-11 Nm (71-97 lb-in).






51. CAUTION: Use only the No. 3 center shaft thrust bearing assembly.

NOTE: No. 3 center shaft thrust bearing assembly has no notches on the outer race.

Install the No. 3 center shaft thrust bearing assembly.






52. CAUTION: Do not bend the exciter wheel.

Install the planetary gear overdrive carrier, overdrive ring gear, overdrive one-way clutch and overdrive center shaft assembly.






53. NOTE: Perform TSS air gap clearance check. This step and the next two steps describe the procedures for checking the turbine shaft speed (TSS) sensor air gap clearance.

Place the thin blade of Turbine Shaft Speed Sensor Gauge T95L-70010-F over the turbine shaft speed (TSS) sensor as shown. Rotate the exciter wheel. The exciter wheel triggering window should pass over the thin blade of the TSS gauge. If it doesn't, the planetary gear overdrive carrier and exciter wheel must be replaced.

54. Place the thick blade of Turbine Shaft Speed Sensor Gauge over the turbine shaft speed (TSS) sensor as shown. Rotate the exciter wheel. The exciter wheel triggering window should not pass over the thick blade of the TSS gauge. If it does, the planetary gear overdrive carrier and exciter wheel must be replaced.

55. Repeat the previous two steps for the remaining exciter wheel triggering windows.






56. Align the clutch plates and overdrive adapter gear and install the overdrive brake and coast clutch drum assembly.






57. Install the overdrive band lever-to-case bracket and overdrive band servo lever as shown.






58. NOTE: The overdrive band actuating lever shaft is longer than the intermediate band actuating lever shaft.

Install the overdrive band actuating lever shaft through the overdrive band lever to case bracket and overdrive band servo actuating lever.






59. Install the overdrive band apply strut.






60. NOTE: If the overdrive band is reused, it must be installed in the same position as when removed.

Install the overdrive band assembly over the overdrive brake and coast clutch drum.






61. NOTE: Use the band adjusting screw as a temporary alignment guide.

Install the overdrive band anchor strut.






62. Install the overdrive band adjusting screw.


63. Perform the front end play check procedure as follows:






a. CAUTION: Be sure the pump body is seated against the washer and overdrive brake and coast clutch drum. The pump body must be below the level of the case gasket surface.

Use petroleum jelly to hold any No. 1 front pump thrust washer on the rear of the pump. The washer tabs go into the pump face. Place the pump into position in the case.






b. CAUTION: The gauge bar must rest on the gasket surface.

Place Gauge Bar T93T-77003-AH across the case as shown.

c. Place a micrometer on the gauge bar and extend the probe until it contacts the pump surface.
d. Read the micrometer and subtract the thickness of the gauge bar (17.78mm [ 0.700 inch]). Record this as dimension "A."
e. Move the gauge bar to the opposite side of the case.
f. Repeat Steps c and d and record this measurement as dimension "B."
g. Add dimensions "A" and "B" together and divide by 2. This is the front end clearance, dimension "C."






h. CAUTION: If the average is below the specification, choose a thinner washer. If the average is above the specification, choose a thicker washer.

NOTE: The front end play specification is 0.018-0.64mm (0.007-0.025 inch).

NOTE: The tabs on the washer go into the pump face.

Remove the pump and install the correct No. 1 thrust washer. Use petroleum jelly to hold the washer in place.






64. Install a new drive gear O-ring.

65. Lubricate Fluid Pump Seal Sizing Tool T95L-70010-G to seat drive gear O-ring.






66. Install Fluid Pump Seal Sizing Tool into pump drive gear to seat drive gear O-ring into groove.


67. Remove Fluid Pump Seal Sizing Tool.






68. CAUTION: The chamber on the inside edge of the small gear must be up when in the pump housing gear pocket. The dimple on the larger gear must be down when in the pump housing gear pocket.

Position the two pump gears into the pump housing. Apply a lubricant to the pump gears to prevent scoring at initial start-up.







69. CAUTION: Make sure the holes in the plate line up with the holes in the pump.

Install the fluid pump adapter plate.






70. CAUTION: Do not allow the pump gears to come out of the pump housing pocket.

NOTE: The notch on the outside of the fluid pump adapter plate will be at the nine o'clock position, relative to the converter housing.

Turn the converter housing face down on the bench. Hold the fluid pump adapter plate against the front pump support and gear to keep the pump gears in place. Turn the pump and adapter plate over and place on the converter housing.






71. Install the six M8 x 35mm Torx� head front pump support and gear screws fingertight only.