Steps 1 - 32

Transmission











Special Tool(s)





Material

NOTE: The pressure switches shown in this procedure will not be applicable to all vehicle applications. Some vehicles will not have the pressure switches or the harness installed in the valve body.

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 seal retainer.
^ Install two new Teflon 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 overcompress the return spring, damage to the spring will occur.

Using the special tool, 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 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 screw.





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.





12. 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. 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.





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





16. Install the transmission range 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 transmission range sensor bolts.

Fixed yoke transmissions





21. Use the special tool and install a new extension housing seal.





22. Inspect the output shaft nut O-ring for cuts. If there is any damage to the nut or seal, a new nut must be installed.





23. Using the special tool, install the output shaft nut.





24. If the vehicle is equipped with a fixed yoke, install the output flange.
1 Install the flange.
2 Install a new bolt.

Slip yoke transmissions





25. If removed, install a new output shaft bushing using the special tool.





26. Install a new output shaft seal using the special tool.

All transmissions





27. Install the No. 16 bearing and race.





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





29. Install the reverse carrier and hub assembly.





30. Install the low/reverse clutch plates.
- Start with a steel plate on the bottom, follewed by a friction plate.
- Alternatly 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.


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





Install a new snap ring. Make sure the snap ring opening is in the one o'clock position, between two teeth on the case.
^ 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.





32. Using the special tools, install the forward geartrain as an assembly.