Part 2
Transmission Steps 36 - 7436. NOTE: Position the seal in the housing with the drain hole at the 6 o'clock position.
Using the special tool, install a new extension housing seal.
37. Install the speed sensors.
1 Install the turbine shaft speed (TSS) sensor and bracket.
2 Install the TSS sensor bolt.
- Tighten to 11 Nm (8 lb-ft).
3 Install the output shaft speed (OSS) sensor.
4 Install the OSS sensor bolt.
- Tighten to 12 Nm (9 lb-ft).
38. Using the special tool, install the manual control lever seal.
39. NOTE: Lubricate the electronic pressure control (EPC) solenoid O-rings with clean transmission fluid.
Lubricate the EPC solenoid and install it into the case.
40. Install the manual valve detent lever and parking lever actuating rod.
41. Install the manual control lever shaft.
1 Slide the manual control shaft into the case.
2 Install the manual control lever shaft inner nut.
- Tighten to 31 Nm (23 lb-ft).
3 Install the manual lever shaft retaining pin.
42. Install the 1-2 accumulator piston assembly.
1 Install the 1-2 accumulator spring.
2 Install the 1-2 accumulator.
3 Install the inner and outer 1-2 accumulator springs.
4 Install the 1-2 accumulator cover and seal.
43. Install the 1-2 accumulator springs and install the accumulator piston retaining ring.
44. NOTE: This is not an ordinary installation procedure and does not compensate for band wear. When a new piston and rod assembly becomes necessary or when a new reverse band has been installed, the reverse piston and rod length must be adjusted.
NOTE: Lubricate the reverse piston seal to facilitate assembly and prevent damage to the seal.
Install the reverse servo piston and return spring.
45. Install the special tool.
^ Tighten the bolt to 5.6 Nm (50 lb-in).
46. Install the special tool.
^ Position the indicator stem on the flat portion of the reverse servo piston and zero the dial indicator.
47. Loosen the bolt until the piston stops against the tool.
48. Verify the amount of piston travel on the dial indicator is within specification.
49. If piston travel is not within specification, select and install the correct servo assembly to bring the servo piston travel within specification.
1 One groove.
2 Two grooves.
3 Three grooves.
50. Remove the special tools.
51. Install the reverse servo assembly.
1 Install the rod.
2 Install the piston assembly.
3 Install the reverse servo piston cover and seal.
52. Using the special tool, install the reverse servo retaining ring.
1 Compress the reverse band servo.
2 Install the reverse band servo retaining ring.
53. Install the 2-3 accumulator assembly.
1 Install the accumulator piston.
2 Install the accumulator piston spring.
3 Install the accumulator spring retainer.
54. Using the special tools apply regulated air pressure to the test ports. Verify that the components are applied and released.
^ Tighten to 10 Nm (89 lb-in).
55. NOTE: The tab on the electrical connector is secured by the main control valve body.
Install the electrical connector into the case.
56. NOTE: The alignment bolts are valve body assembly bolts and are in the valve body.
Align the main control valve body alignment bolts and position the main control valve body.
57. NOTE: The main control valve body bolts will be tightened in later steps.
Loosely install the 11 long main control valve body bolts.
58. NOTE: The main control valve body bolts will be tightened in later steps.
Loosely install the 12 short main control valve body bolts.
59. Position the EPC solenoid bracket and loosely install the bolt.
60. Install the manual control valve detent lever spring and loosely install the bolt.
61. Tighten the bolts in the sequence shown.
^ Tighten to 10 Nm (89 lb-in).
62. Inspect the lead frame for damage.
^ Using the special tool, check all lead frame solenoid connections. The gauge should fit tightly and not fall out after being inserted.
^ If the special tool passes through any lead frame connector pins or does not feel like it makes a good contact, install a new lead frame.
63. Connect the molded lead frame to the solenoids.
^ Connect the bulkhead inter-connector by pressing it in place by hand and fully seating the connector in place.
^ Connect the EPC solenoid by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots.
^ Connect the TCC by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots.
^ Connect the shift solenoid SSA and SSB by pressing it in place by hand and fully seating the connector in place. Make sure that the terminals pass fully through the connector slots.
64. Install the fluid filter and seal assembly.
65. Position the pan magnet onto the fluid pan.
66. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the transmission fluid pan gasket should be reused.
Install the transmission fluid pan and gasket.
1 Position the transmission fluid pan with the gasket in place.
2 Install the bolts.
- Tighten to 14 Nm (10 lb-ft).
67. Install the digital TR sensor and loosely install the bolts.
68. Using the special tool, align the digital TR sensor slots. The tool is designed to fit snug.
69. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged.
Tighten the digital TR sensor bolts.
^ Tighten to 9 Nm (80 lb-in).
70. Install the manual control lever.
1 Position the manual control lever.
2 Install a new manual control lever nut.
- Tighten to 33 Nm (24 lb-ft).
71. If equipped, install the transmission vent tube.
72. Lightly lubricate the converter hub with clean automatic transmission fluid.
73. WARNING: Secure the torque converter in the transmission during removal or installation. The torque converter is heavy and may result in injury if it falls out of the transmission. Failure to follow this instruction may result in serious personal injury.
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.
Using special tools, install the torque converter.
74. Lubricate the torque converter pilot hub with multi-purpose grease.
