Steps 51-89

51. CAUTION: Remove the input shaft prior to rotating the transmission.

Remove the input shaft.





52. Using the special tool, install the manual control lever seal.





53. Install the manual control lever shaft assembly.
1. Install the manual control lever shaft assembly.
2. Install and seat the manual lever shaft retaining pin below the case surface.

3. NOTE: Use a crescent wrench on the manual control lever or outer flats of the manual control lever shaft assembly when installing the inner manual valve detent lever nut.

Install the parking pawl actuating rod, the inner manual valve detent lever and the nut onto the manual control lever shaft assembly.

4. NOTE: The manual control valve detent lever spring must be on the inner manual valve detent lever and the detent lever pin must align with the manual shift valve.

Install the manual control valve detent lever spring and the bolt.





54. Install the park pawl.
1. Install the parking pawl shaft.
2. Install the parking pawl.
3. Install the pawl return spring.





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

If removed, install the parking pawl abutment with a new Torx(R)-head screw.





56. NOTE: Make sure the dimple on the parking guide support plate is facing inward and the parking pawl actuating rod is in the parking rod support plate slot.

Install the parking rod guide plate.
1. Install the parking rod guide plate.
2. Install the bolts.





57. Install a new orifice lube plug in the rear of the case. Using a 12 mm (0.48 inch) socket, tap the orifice lube plug into the back of the transmission.





58. Check to make sure that the orifice lube plug is fully seated into the back of the transmission.





59. CAUTION: The extension must have a shoulder or a boss cast in it to hold the orifice lube plug in the back of the case. If the wrong extension housing is used the plug will fall out and cause transmission failure.

Inspect the extension housing for the correct application.





60. CAUTION: The extension must have a shoulder or a boss cast in it to hold the orifice lube plug in the back of the case. If the wrong extension housing is used the plug may become loose and or fall out and cause transmission damage.

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

Install the new extension housing gasket.
1. Verify that the extension has a shoulder cast in it.
2. Install the new extension housing gasket.





61. Install the extension housing, the eight bolts, and the stud.





62. Using the special tool, install the extension housing bushing.





63. NOTE: The extension seal is vehicle-dependent.

Using the special tool, install a new extension housing seal.





64. Tighten the center support assembly, and the intermediate/overdrive cylinder assembly feedbolts.





65. NOTE: The steel EPC check ball has a 6.35 mm (0.25 inch) diameter and is smaller than the other check balls.

Install the spring and the steel EPC check ball.





66. CAUTION: Use care not to damage the rubber check balls.

Install the rubber check balls.





67. CAUTION: Using the incorrect gasket will cause damage to transmission.

Install a new separating plate-to-case gasket on the separating plate.





68. NOTE: Check the placement of the steel EPC check ball under separator plate.

Install the valve body separator plate.





69. Install the separating plate reinforcing plate, with the stamped word UP visible, and install the bolts.





70. CAUTION: Using the incorrect gasket will cause damage to the transmission.

Install a new main control-to-separating plate gasket.





71. Install the solenoid screen assembly by pushing it in and rotating it to lock.





72. NOTE: Prior to installing the solenoid body assembly, coat the case connector bore with petroleum jelly or equivalent.

Install the solenoid body assembly with the nut and the Torch bolts finger-tight.





73. Install the main control valve body, aligning the manual shift valve with the inner manual valve detent lever. Install the nuts and the bolts finger-tight.





74. Install the accumulator body with the nuts and the bolts finger-tight.





75. Tighten all accumulator body, upper and lower control body and solenoid body nuts and bolts.





76. CAUTION: Do not reuse the old filter and seal assembly.

CAUTION: Make sure that the pump bore is clean and the old filter seal has been removed.

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

Install a new filter and seal assembly by pressing it into place.





77. NOTE: Do not discard the gasket unless damaged. This is a reusable gasket.

NOTE: Apply a light coat of petroleum jelly to hold the gasket to the fluid pan.

Position the gasket onto the clean fluid pan. Make sure the magnet is positioned over the dimple in the fluid pan.





78. CAUTION: Mixing the 4x2-style and 4x4-style transmission fluid filters and transmission pan assembly components can cause transmission damage.

Install the correct pan with gasket for this application. Alternately tighten the bolts.





79. With the transmission in NEUTRAL, install and adjust the digital transmission range (TR) sensor.
1. Install the digital TR sensor.
2. Loosely install the bolts.





80. Install the special tool.





81. Tighten the bolts and remove the special tool.
82. Make sure the cooler bypass valve (CBV) has been cleaned and flushed.





83. CAUTION: Failure to correctly install the new rubber-coated sealing washers will result in transmission fluid leaks.

Assemble the CBV as illustrated.
1. Install new sealing washers onto the new CBV case fittings.
2. Install the new CBV case fittings with the new sealing washers onto the CBV assembly.
3. Install new sealing washers.





84. CAUTION: Do not over-tighten.

Install the CBV with the front (inlet) and the rear (outlet) cooler line case fitting.





85. CAUTION: If equipped, use care when installing the sensor, damage to the O-ring could result in a leak. After installing the sensor do not roll the transmission on the bench or damage to the sensor connector or body could result.

Lubricate and install the turbine shaft speed (TSS) sensor.
1. Lubricate and install the TSS sensor.
2. Install the bolt.





86. NOTE: The input shaft is model-dependent.

With the fluid pan facing down, install the input shaft with the long splined end first.





87. CAUTION: Do not damage the fluid pump gear O-ring when installing torque converter.

CAUTION: Make sure the converter hub is fully engaged in the front pump support and gear and rotates freely. Do not damage the hub seal.

CAUTION: If the torque converter slides out, the hub seal may be damaged.

Lubricate the converter hub with clean automatic transmission fluid.





88. CAUTION: Use care when installing the torque converter to avoid damage to the front pump stator support seal.

NOTE: Check the converter crankshaft pilot for nicks or damaged surfaces that can cause interference when installing the transmission to the engine. Check the converter impeller hub for nicks or sharp edges that can damage the pump seal.

NOTE: Carry the torque converter with the handles held in the 6 o'clock and 12 o'clock positions.

Using the special tool, install the torque converter. Push and rotate the converter onto the front pump assembly until it bottoms out.





89. Check the seating of the torque converter.
1. Place the straightedge across the converter housing.
2. Make sure there is a gap between the converter pilot face and the straightedge.
3. Remove the special tools.