Transmission Assembly

1. Be sure the No.15 hub bearing is installed. See Figure 48.





2. Install the reverse planet assembly and hub assembly. See Figure 49.





3. Install the reverse clutch plates. See Figure 50.

^ Install the separator plate, alternating between the steel and friction plates. Install a steel plate then a friction plate, then install the one-way clutch (OWC).

^ If the OWC is installed correctly, it should hold when trying to turn it counterclockwise and turn freely when turned clockwise.

4. NOTE: While installing the new snap ring, note the location of the snap ring ends. The ends of the snap ring should be between two (2) teeth on the case.





Install the new snap ring as shown in Figure 51. See Figure 51.





[NEW] ^ Some low/reverse clutch-to-case snap rings have two (2) tangs and are installed with the antirotation tangs at the 12 o'clock and 1 o'clock positions. Snap ring anti-rotation tang ends should be located on either side of the case spline as shown in Figure 52.

5. Install the forward geartrain.





6. Remove the special tools from the forward geartrain. See Figure 53.





7. Install the intermediate clutch pressure plate. See Figure 54.

Position the intermediate clutch pressure

plate in the case with the stepped edge facing downward.





8. Install the intermediate clutch plates, starting with a friction plate. See Figure 55.





9. Install the input shaft to help align the forward/direct clutch assemblies. Install No.6 tabbed thrust washer onto the center support and then install the center support with the transmission in a vertical position to avoid damage to the Teflon seals. Remove the input shaft when the center support is fully installed downward. See Figure 56. [NEW]

10. NOTE: Make sure the center support threads and feed bolts are free of any loose foreign material and are as clean as possible before reinstallation of the feed bolts.





Lightly lubricate the retained feed bolts with clean transmission fluid. Loosely install the bolts. Do not tighten to specification at this time. See Figure 57.





11. Using Special Tool Retaining Ring Pliers 307-343, install the center support snap ring. See Figure 58.

The snap ring should be installed with the flat edge facing downward. The gap in the snap ring should be facing the 6 o'clock position. Tap the snap ring securely into the case.





12. Tighten the feed bolts. See Figure 59.





13. Install the No.5 bearing onto the center shaft assembly using petroleum jelly. See Figure 60. [NEW]





14. Install the center shaft and ring gear. See Figure 61.





15. Install the No. 4 bearing onto the OD planet with petroleum jelly. See Figure 62. [NEW]





16. Using Special Tool Clutch Loading Fixture 307-S383 install the coast clutch assembly and overdrive carrier. See Figure 63.





17. Install the overdrive clutch assembly snap ring with the gap in the 6 o'clock position. See Figure 64.





18. For non-PTO applications, install the overdrive pressure plate with the notches facing up. See Figure 65.





19. For vehicles equipped with a PTO, install the overdrive pressure plate. See Figure 66.

1) Install the larger tab positioned at the top of the case.

2) Install the square end of the plate in the bottom of the case.

^ The P10 pressure plate anti-rotation tab is installed into the 6 o'clock position of the snap ring.





20. Install the overdrive clutch. See Figure 67.

^ Start with a friction plate, alternating with a steel plate.





21. Install a new pump gasket. See Figure 68.





22. Lightly lubricate the No. 2 bearing with petroleum jelly to hold it in place on the pump stator support during the installation of the pump. See Figure 69. [NEW]





23. Install the input shaft into the case. See Figure 70.





24. Install Special Tools Transmission Fluid Pump Aligner 307-222, into the case to assist in pump installation. See Figure 71.

25. Check to make sure the No.1 thrust washer is installed on the pump stator and install the new pump O.D. seal on the pump body.





26. NOTE: Install the pump with the transmission in a vertical position to avoid damage to the Teflon seals.
Install the front pump using the aligner tools to help guide the pump correctly into place, then remove the aligner tools.
See Figure 72. [NEW]





27. Install the forward clutch orifice. See Figure 73. [NEW]





28. Install the new front pump retaining bolts. Tighten the bolts in a star pattern to 27 Nm (20 lb-ft). See Figure 74.





29. Install a new solenoid body gasket. See Figure 75.





30. Using Special Tools Valve Body Aligner 307-456, install the solenoid valve body and loosely install the bolts. See Figure 76.

While installing the solenoid body, align the manual valve.





31. Tighten all the bolts to 10 Nm (89 lb-in) in the sequence shown. See Figure 77.





32. Connect the transmission range sensor connector. See Figure 78.

33. NOTE: Prior to installing the fluid filter, make sure the old seal is not stuck in the case.





Install a new transmission fluid filter. See Figure 79.





34. Unless it is found to be damaged, install the original transmission fluid pan gasket to the fluid pan. If it is found to be damaged, install a new gasket. Make sure the magnet is positioned over the dimple in the fluid pan. See Figure 80.





35. Install the transmission fluid pan and bolts. Tighten the bolts in a criss-cross pattern to 15 Nm (11 lb-ft). See Figure 81.





36. Install the intermediate shaft and turbine shaft speed (TSS) sensor. Tighten the bolt to 9 Nm (80 lb-in). See Figure 82.

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

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

[NEW] NOTE:
A new or remanufactured torque converter must be installed if one or more of the following statements are true:

^ A torque converter malfunction has been determined based on the complete diagnostic procedures.

^ Converter stud(s), impeller hub or bushing is damaged.

^ Discoloration of the torque converter (due to overheating).

^ Evidence of transmission assembly or fluid contamination due to the following transmission or converter failure modes:

^ Major metallic failure.

^ Multiple clutch or clutch plate failures.

^ Sufficient component wear which results in metallic contamination.





Lubricate the converter hub with clean automatic transmission fluid. See Figure 83.

38. 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. To avoid seal damage, install the torque converter with the transmission oriented in the vertical position.





Using Special Tools Torque Converter Handles 307-091,install the torque converter. Push and rotate the converter onto the front pump assembly until it bottoms out. See Figure 84.





39. Check the seating of the torque converter. See Figure 85.

1) Place a straightedge across the converter housing.

2) Make sure there is a gap between the converter pilot face and straightedge.

3) Remove the special tools.





40. Install Special Tool Torque Converter Retainer 307-346. See Figure 86.

41. Reinstall the transmission into the vehicle.

Refer to Section 307-01C of the appropriate 2004 Workshop Repair Manual for instructions. Fill the transmission to specification using MERCON SP(R) Automatic Transmission Fluid (XT-6-QSP).





Notes