Part 3 of 3

Transmission Assembly (Continued Steps 101-136)

Loosely install the four M6 x 45 mm screws.





101. NOTE: The main control valve body screws will be tightened in later steps.

Loosely install the two M6 x 35 mm screws.





102. NOTE: The main control valve body screw will be tightened in later steps.

Loosely install the M6 x 30 mm screw.





103. Remove the special tools.








104. NOTE: The main control valve body screws will be tightened in later steps.

Loosely install the sixteen M6 x 40 mm screws.
105. Tighten the screws in the sequence shown.





106. Rotate the manual lever into the NEUTRAL position, then install the manual control valve detent lever spring.
1. Position the manual control valve detent lever spring on the main control valve body.
2. Install the screw.





107. Install the low/reverse band servo cover and reverse servo separator plate cover gasket.
1. Position the low/reverse band servo cover and low/reverse servo separator plate cover gasket on the transmission case.
2. Loosely install the screws.





108. Tighten the screws in the sequence shown.





109. Connect the solenoid electrical connectors.
1. Connect shift solenoids SSA, SSB, SSC and SSD electrical connectors.
2. Connect the torque converter clutch (TCC) solenoid electrical connector.
3. Connect the electronic pressure control (EPC) solenoid electrical connector.





110. CAUTION: Excessive pressure may break the locating pins.

Install the wiring loom protector and guide.
^ Align the pins in the holes of the solenoid clamps and gently push down.





111. CAUTION: Make sure that both fluid pan filter O-ring seals are correctly installed on the fluid pan filter prior to installation.

Install the fluid pan filter O-ring seals.
^ Coat the fluid pan filter O-ring seals with clean automatic transmission fluid.





112. Install the transmission fluid filter.





113. Install the transmission fluid pan and transmission fluid pan gasket.
^ Loosely install the screws.





114. Tighten the transmission fluid pan screws.
^ Tighten the transmission fluid pan screws in a crisscross sequence.





115. Remove the transmission from the bench and place on a flat surface.





116. Remove the special tools from the transmission case.





117. NOTE: Use petroleum jelly to hold the gasket in place.

Install a new extension housing gasket.





118. NOTE: The guide cup is press-fit into the extension housing and is not serviced separately.

Install the parking pawl assembly.
1. Install the parking pawl shaft into the extension housing.
2. Install the parking pawl.
3. Install the parking pawl return spring.





119. CAUTION: Make sure the parking lever actuating rod is correctly seated into the transmission case parking rod guide cup.

Install the extension housing.
1. Install the extension housing and gasket.
2. Install the screws.
3. Install the stud(s).

4x2 vehicles





120. CAUTION: The lube hole in the bushing must be aligned with the lube groove in the extension housing.

NOTE: Install the extension housing bushing only if removed in disassembly.

NOTE: Remove any burrs from the extension housing counterbore.

Align the lube hole with the lube groove in the extension housing. This groove is located at the 3 o'clock position when viewed from the rear.





121. CAUTION: Tool will bottom when bushing is in the correct position.

Using the special tool, install the extension housing bushing.





122. Position a new extension housing seal with drain hole in the 6 o'clock position.





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

All vehicles





124. Install the digital transmission range (TR) sensor.
1. Position the digital TR sensor on the transmission.
2. Loosely install the screws.
3. Rotate the manual lever to the NEUTRAL position (two detents rearward).





125. CAUTION: Tightening one screw before tightening the other can cause the sensor to bind or become damaged.

NOTE: The manual lever must be in the NEUTRAL position.

Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence.





126. Install the manual control lever.
1. Install the lever.
2. Install the nut.





127. If equipped, install the transmission servo heat shield and nut.





128. NOTE: Inspect the O-ring seal for damage. Install a new component if damaged.

Install the output shaft speed (OSS) sensor.
1. Install the sensor.
2. Install the screw.





129. NOTE: Inspect the O-ring seal for damage. Install a new component if damaged.

Install the intermediate shaft speed sensor.
1. Install the intermediate shaft speed sensor.
2. Install the intermediate shaft speed sensor screw.





130. CAUTION: The splines of the input shaft are not the same length on both ends. The shaft end with the shorter splines goes into the fluid pump.

Install the input shaft.





131. Using the special tool, check that the fluid pump gear seal ring is seated.





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

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

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

Lubricate the converter hub with clean automatic transmission fluid.





133. WARNING: The torque converter can fall out if the transmission is tipped. Failure to follow these instructions can result in personal injury.

Use the special tools to install the torque converter by pushing and rotating.





134. Make sure the torque converter is installed to specification.





135. Lubricate the torque converter pilot hub with multi-purpose grease.





136. Install the special tool on the case.