Part 1
TransmissionAssembly (Steps 1-36)
Special Tool(s) (Part 1):
Special Tool(s) (Part 2):
Special Tool(s) (Part 3):
Material:
Transmission, Disassembled View - Early Build Vehicles (Part 1):
Transmission, Disassembled View - Early Build Vehicles (Part 2):
Transmission, Disassembled View - Early Build Vehicles (Part 3):
Transmission, Disassembled View - Early Build Vehicles (Part 4):
Transmission, Disassembled View - Early Build Vehicles (Part 5):
Transmission, Disassembled View - Early Build Vehicles (Part 6):
Transmission, Disassembled View - Early Build Vehicles (Part 7):
Transmission, Disassembled View - Early Build Vehicles (Part 8):
Transmission, Disassembled View - Early Build Vehicles (Part 9):
Transmission, Disassembled View - Early Build Vehicles (Part 10):
Transmission, Disassembled View - Early Build Vehicles (Part 11):
Transmission, Disassembled View - Late Build Vehicles (Part 1):
Transmission, Disassembled View - Late Build Vehicles (Part 2):
Transmission, Disassembled View - Late Build Vehicles (Part 3):
Transmission, Disassembled View - Late Build Vehicles (Part 4):
Transmission, Disassembled View - Late Build Vehicles (Part 5):
Transmission, Disassembled View - Late Build Vehicles (Part 6):
Transmission, Disassembled View - Late Build Vehicles (Part 7):
Transmission, Disassembled View - Late Build Vehicles (Part 7):
Transmission, Disassembled View - Late Build Vehicles (Part 8):
Transmission, Disassembled View - Late Build Vehicles (Part 9):
Early Build Vehicles With Externally Mounted Remote Filter
CAUTION: Early build vehicles, those equipped with an externally mounted remote filter, are also equipped with a different design sump filter and bottom pan. Always pair the sump filter with the correct bottom pan design, to avoid cavitation, filter cracking and transmission damage.
Late Build Vehicles Without Remote Filter and With Serviceable High Efficiency Sump Filter (HESF)
CAUTION: Late build vehicles replace the remote filter with a serviceable high efficiency sump filter (HESF), which requires a wider and deeper bottom transmission fluid pan. Always pair the sump filter with the correct bottom transmission fluid pan design, to avoid cavitation, transmission fluid filter cracking and transmission damage.
NOTE: Soak all friction clutch plates in clean transmission fluid.
NOTE: Prior to installation, lightly lubricate all O-ring seals with clean 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 installing a new case, install the transmission fluid cooler tube nut case fittings. Coat the threads with Threadlock(R) sealant.
^ Tighten to 51 Nm (38 ft. lbs.).
3. If removed, use the special tool to install the short transmission fluid inlet tube.
4. If removed, use the special tool to install a new Teflon(R) seal retainer.
^ Install 2 new Teflon(R) seals.
5. 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.
6. Install the reverse clutch return spring assembly.
7. CAUTION: Do not over compress the return spring or damage to the spring will occur.
Using the special tools, install the reverse clutch return spring snap ring.
8. 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.
9. CAUTION: Be careful when installing the output shaft not to damage the seals or a transmission leak could occur.
Install the output shaft.
10. CAUTION: The Torx(R) 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(R) screw.
^ Tighten to 25 Nm (18 ft. lbs.).
11. Install the parking pawl.
1. Install the parking pawl shaft.
2. Install the parking pawl.
3. Install the parking pawl return spring.
12. 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.
^ Tighten to 25 Nm (18 ft. lbs.).
13. Install a new orifice lube plug in the rear of the case. Using a 12-mm 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.
14. Install a new extension housing gasket.
15. Install the extension housing.
^ Tighten to 47 Nm (35 ft. lbs.).
16. Using the special tool, install a new manual control lever seal.
17. Install the transmission range (TR) position sensor, park rod assembly and loosely install the bolts.
18. Install the manual control lever.
19. Install the roll pin into the case.
20. Install a new roll pin. Leave 2 mm (0.08 inch) of the pin exposed.
21. Tighten the TR position sensor bolts.
^ Tighten to 10 Nm (89 inch lbs.).
22. If equipped with a fixed flange, use the special tool to install a new extension housing seal.
23. If equipped with a fixed flange, inspect the new output shaft nut O-ring for cuts. new nut must be installed.
24. If equipped with a fixed flange, use the special tool to install a new output shaft nut.
^ Tighten to 200 Nm (148 ft. lbs.).
25. If equipped with a fixed flange, install the output flange and a new bolt.
^ Tighten to 130 Nm (96 ft. lbs.).
26. If equipped with a slip yoke, use the special tool to install a new extension housing seal.
27. Install the No. 16 bearing and race.
Early build vehicles
28. Install the output hub and ring gear assembly 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, followed by a friction plate.
^ Alternately stack the remaining steel and friction plates.
31. Install the pressure plate (low/reverse one-way clutch [OWC]) on the last friction plate, with THIS SIDE UP facing upward and with the partial tooth located between 10 o'clock and 2 o'clock.
1. For gasoline engine vehicles, install the 12 strut OWC.
2. For diesel engine vehicles, install the 6 strut OWC.
Late build vehicles
32. Assemble the rocker clutch and ring gear assembly.
1. Install the No. 15 hub bearing onto the ring gear hub.
2. Install the rocker clutch, low/reverse clutch pack and carrier and hub assembly into the output hub and ring gear assembly.
33. NOTE: Place the transmission in the horizontal position.
Install the rocker clutch and ring gear assembly into the transmission case.
All vehicles
34. CAUTION: Do not apply air pressure to move the low/reverse piston without first installing the friction plates and the snap ring, or damage to the snap ring will occur.
Install a new flat snap ring and make sure that the snap ring is fully seated in the case snap ring groove.
Install a new flat snap ring so the tang ends are in the gaps to the right and to the left of the case spline as shown.
^ 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.
35. Install the anti-clunk spring.
36. Verify the anti-clunk spring is correctly seated.
1. Place a straight edge across the machined surface of the transmission case.
2. An air gap should be between the anti-clunk spring and the straight edge.
