Steps 1 - 40

Special Tools And Equipment Part 1 Of 4:

Special Tools And Equipment Part 2 Of 4:

Special Tools And Equipment Part 3 Of 4:

Special Tools And Equipment Part 4 Of 4:

Special Tool(s)





Material

NOTE: The bearing type pump is shown, the seal type pump is similar. Use this procedure for transmissions equipped with a bearing or seal type converter housing fluid pump.

All vehicles
1. Thoroughly clean the transmission case and extension housing in solvent and blow dry with compressed air.





2. Inspect the transmission case for the following:
1. Stripped bolt hole threads.
2. Gasket and mating surfaces for burrs or nicks.
3. Obstructions to vent and fluid passages.
^ Cracks or warpage.





3. Inspect the extension housing for cracks, burrs or warpage.





4. Inspect the case bearing for damage. If damage to the case bearing is indicated, install a new case.





5. Install the special tool on the rear of the transmission case.





6. Attach the fixture arm of the special tool as shown.





7. WARNING: Make sure the lock pin on the special tool is secure. Failure to follow these instructions may result in personal injury.

Install transmission into the special tool.
^ Rotate the transmission so that the fluid pan rail is facing up.





8. Using the special tool, install the manual control lever shaft seal.
^ Lubricate the manual control lever shaft seal with petroleum jelly.





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





10. Install the manual control lever shaft.





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

NOTE: Align the manual control lever shaft alignment groove with the manual control lever shaft spring pin bore in the transmission case.

Install the manual control lever shaft spring pin.
^ Tap the manual control lever shaft spring pin into the transmission case.





12. CAUTION: Align the flats on the manual valve inner lever with the flats on the manual control lever shaft.

Install the manual valve inner lever and parking lever actuating rod on to the manual control lever shaft.





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

Install the manual valve inner lever nut on the manual control lever shaft and tighten.





14. CAUTION: The tabs on the output shaft thrust washer (No. 11) point into the case. Make sure the thrust washer is correctly seated.

Install the output shaft thrust washer (No. 11).
^ Coat the output shaft thrust washer with petroleum jelly.





15. Install the park gear.





16. Install the low/reverse brake drum.
^ Rotate the low/reverse brake drum clockwise to install.





17. If not already installed during subassembly, install the No. 10B needle bearing onto the output shaft ring gear and hub assembly.
^ Coat the needle bearing with petroleum jelly.





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





19. Install the output shaft ring gear and output shaft hub.





20. CAUTION: Always install a new output shaft retaining ring.

Install a new output shaft retaining ring.





21. NOTE: Install the output shaft sleeve with the cone facing up.

Install the output shaft sleeve.





22. Install low/reverse planetary carrier needle bearings.
1. Install low/reverse planetary carrier needle bearing (No. 8) on the front face of the low/reverse planetary.
2. Install low/reverse planetary carrier needle bearing (No. 9) on the rear face of the low/reverse planetary.
^ Coat the low/reverse planetary carrier needle bearing (No. 8) and low/reverse planetary carrier needle bearing (No. 9) with petroleum jelly.





23. CAUTION: Make sure needle bearings stay in place.

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





24. CAUTION: The low/reverse brake drum must be pulled forward to install the low/reverse planet retaining ring.

Install the low/reverse retaining ring into the low/reverse brake drum groove.





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

Install the low/reverse band over the low/reverse brake drum.





26. Temporarily install the low/reverse band servo piston and rod to hold the low/reverse band in position.





27. Install the previously assembled forward geartrain assembly.

28. WARNING: Make sure the lock pin on the special tool is secure. Failure to follow these instructions may result in personal injury.

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





29. Select the intermediate brake drum thrust bearing (No. 4) as follows:
1. Install the special tool on the case assembly shoulder.
2. Set the special tool on top as shown.





30. Calculate the thrust bearing thickness.
^ Extend the micrometer probe until it contacts the intermediate brake drum thrust bearing surface. Record the reading. This is dimension A.





31. Place the micrometer on the opposite side of the special tool and repeat the measurement. This is dimension B.
32. Add dimension A and B. divide the total of A and B by 2. Then subtract the special tool thickness 17.78 mm (0.700 inch). Record this reading as dimension C.





33. Place the special tool across the center support. Place the micrometer on the top of the special tool.
^ Extend the micrometer probe until it makes contact with the center support thrust bearing surface. Record this reading as dimension D.





34. Place the special tool on the opposite side of the special tool.
^ Extend the micrometer probe until it makes contact with the center support thrust bearing surface. Record this reading as dimension F.





35. Add dimensions D and F. divide the total of D and F by 2. Subtract the special tool thickness 17.78 mm (0.700 inch) dimension E. The result is dimension G.





36. Add dimensions C and G. this total is dimension H. Use the following chart to select the correct No. 4 thrust bearing. Reference end play is 0.20 - 0.54 mm (0.008 - 0.021 inch).





37. Install the intermediate servo actuating lever.





38. NOTE: The intermediate band lever shaft is shorter than the front band lever shaft.

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





39. Install the intermediate band apply strut on the intermediate servo actuating lever.





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

Install the intermediate band.