Part 1

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 case bearing for damage. If damaged replace bearing. Refer to steps a-d.





a. Install Bearing Cup Puller T77F-1102-A with Impact Slide Hammer TOOL-1OO-A onto case bearing. Remove bearing.





b. Inspect case bore for nicks and burrs. Remove with oil stone prior to installation of new bearing.





c. Install Drive Handle T80T-4000-W into Case Bearing Installation Tool T97T-7711O-A. Install new bearing on Case Bearing Installation Tool T97T-77110-A. Make sure bearing seal ring is facing Drive Handle T80T-4000-W.





d. Using a hammer, tap bearing into place with Case Bearing Installation Tool T97T-77110-A.

3. Check all parking linkage for wear or damage.





4. Inspect all case threads for damage.
5. Inspect the extension housing for cracks. Inspect the gasket surfaces for burrs or warpage.
6. Inspect the bushing for scores or wear. Replace if required.
7. Inspect the rear seal for hardness, cracks or wear. If the seal shows wear or deterioration replace the seal.
8. Inspect the seal counterbore and remove all burrs and scores with a crocus cloth.
9. Reattach the adapter plate to the extension housing face using four M10 x 30mm screws.

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.





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

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





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





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





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





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

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

15. 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.





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

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





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

CAUTION: The tabs on the No. 11 output shaft thrust washer point into the case. Ensure that the thrust washer is properly seated.





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





19. Rotating the reverse brake drum assembly clockwise and install into case.





20. If not already installed, use petroleum jelly to install No. 1 OB thrust bearing onto output shaft hub.





21. Install the output shaft through the output shaft park gear.

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

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

Output Shaft Retaining Ring Installation - 4.0L:

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

CAUTION: Always use a new retaining ring.





24. Install the output shaft sleeve with cone facing up. D15343-A

NOTE: Use petroleum jelly to hold the sleeve in place.





25. Position the No. 8 reverse planetary carrier needle bearing on the front face of the reverse planetary. Position the No. 9 reverse planetary carrier needle bearing on the rear face of the reverse planetary.

NOTE: Use petroleum jelly to hold the needle bearings in place.





26. Install the reverse planetary assembly, with No. 8 and No. 9 reverse planetary carrier needle bearings, into the output shaft ring gear.

CAUTION: Make sure the needle bearings stay in place.





27. 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.





28. Install the reverse band over the reverse brake drum.

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





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





30. Install the previously assembled forward geartrain assembly.
31. Rotate the transmission assembly so that the converter housing gasket surface is facing up.

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

32. Select the No. 4 intermediate brake drum thrust bearing as follows:





a. Place Gauge Bar T93T-77003-AH on the case assembly shoulder. Set the micrometer on top of the gauge bar as shown.
b. Extend the micrometer probe until it contacts the No. 4 thrust bearing surface at the intermediate brake drum. This is dimension "A".
c. Remove the micrometer and record dimension "A."
d. Place the micrometer on the opposite side of gauge bar. Extend the micrometer probe until it contacts the No. 4 thrust bearing surface at the intermediate brake drum. This is dimension "B. "
e. Add dimensions "A" and "B" together divide by 2, then subtract the thickness of Gauge Bar T93T-77003-AH (17.78 mm [0.700 inch]). This is dimension "C."





f. See the chart and use dimension "C" to select the proper thrust bearing.





33. Install the intermediate servo actuating lever as shown.





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

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





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





36. Install the intermediate band.

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





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

NOTE:
^ Use the intermediate band adjusting screw as a temporary alignment guide.
^ The overdrive and intermediate band anchor struts are the same.





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

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





39. 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.

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.








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

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





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





42. Use a 5 mm Allen wrench to install the M6 x 20 mm 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 inch lbs.).





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

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





44. Install the turbine shaft speed (TSS) sensor on the center support. Use a T30 Tort Socket to install the TSS screw. Tighten the TSS sensor-to-center support screw to 8-11 Nm (71-97 inch lbs.).





45. Install the No. 3 center shaft thrust bearing assembly.

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.





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

CAUTION: Do not bend the trigger wheel.





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

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.





48. Place the thick blade of Turbine Shaft Speed Sensor Gauge over the turbine shaft speed (TSS) sensor as shown. Rotate the trigger wheel. The trigger wheel window should not pass over the thick blade of the TSS gauge. If it does, the planetary gear overdrive carrier and trigger wheel must be replaced.
49. Repeat the previous two steps for the remaining trigger wheel windows.





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





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





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

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





53. Install the overdrive band apply strut.





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

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





55. Install the overdrive band anchor strut.

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





56. Install the overdrive band adjusting screw.
57. Perform the front end play check procedure as follows:





a. Use petroleum jelly to hold any No. 1 fluid 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.

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.





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

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

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

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 0.18-0.70mm (0.007-0.023 in).
^ The tabs on the washer go into the pump face.

i. Verify front end clearance is correct; repeat steps a-g.

NOTE: Front end clearance specification is 0.18-0.70 mm (0.007-0.028 in).





58. Install a new drive gear O-ring.
59. Lubricate Fluid Pump Seal Sizing Tool T95L-70010-G to seat drive gear O-ring.





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





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

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.





63. Install the fluid pump adapter plate.

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





64. 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.

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.





65. Install the six M8 x 35mm Torx head front pump support and gear screws finger tight only.





66. Select the gauge that will be the snuggest fit when placed over the fluid pump support and gear.

CAUTION: Fluid Pump Alignment Set T74P-77103-X must be used to properly align the front pump support and gear to the fluid pump adapter plate. This will prevent seal leakage, gear noise, broken gears and bushing failure.





67. Thread the gauge into Pump Alignment Handle T74P-77103-H (Part of T74P-77103-X, Fluid Pump Alignment Set). Slide the tool over the front pump support and gear until it bottoms out in the pump gear pocket. This centers the pump to the converter housing.





68. Use a Torch 40 socket wrench to tighten the six M8 x 35mm fluid pump support and gear-to-converter housing screws. Tighten the fluid pump support and gear-to-converter housing screws in a star pattern to 22-28 Nm (16-21 ft. lbs.). Remove the Pump Alignment Handle.





69. Install a new fluid pump seal ring.