Part 2
TransmissionAssembly (Steps 36-89)
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.
41. NOTE: Use the intermediate band adjusting screw as a temporary alignment guide.
NOTE: The intermediate and front band anchor struts and band adjustment screws are the same.
Install the intermediate band anchor strut and the intermediate band adjustment screw.
42. Install the No. 4 selected intermediate brake drum thrust washer on the center support.
^ Coat the intermediate brake drum thrust washer with petroleum jelly.
43. CAUTION: Do not apply pressure to the center support while installing. Damage to sealing rings may result.
NOTE: Align the center support screw hole with correct case hole.
Install the center support.
1 Position the center support into the intermediate brake and direct clutch drum.
2 Temporarily insert the input shaft and gently wiggle it until the center support is seated against the case shoulder, then remove the input shaft.
44. NOTE: Install the center support retaining ring with the tapered side facing up.
NOTE: Make sure the notch opening is not obstructed by the center support retaining ring.
Install the center support retaining ring.
1 Position the center support retaining ring with the tapered side facing up.
2 Install the center support retaining ring so that the notch opening is not obstructed.
45. Install the center support locknut and cage.
46. Loosely install the center support-to-case cap screw.
47. CAUTION: Carefully route the turbine shaft speed (TSS) sensor connector and wiring harness through the opening in the case. Do not damage the wiring.
NOTE: Route TSS sensor electrical connector and wiring through transmission case opening.
Install the TSS sensor.
1 Install the TSS sensor.
2 Install the TSS sensor screw.
^ Tighten to 10 Nm (89 lb-inch).
48. NOTE: Use only the No. 3 center shaft thrust bearing.
NOTE: The No. 3 center shaft thrust bearing has no notches on the outer race.
Install the No. 3 center shaft thrust bearing.
49. CAUTION: Do not bend the trigger wheel.
Install the overdrive planetary and one-way clutch assembly.
50. NOTE: The trigger wheel triggering window should pass over the thin blade of the special tool. If it does not, a new overdrive planetary carrier and trigger wheel must be installed.
Using the special tool, check the TSS sensor air gap.
1 Place the thin blade of the special tool over the TSS sensor.
2 Rotate the trigger wheel and repeat checks for all windows.
51. NOTE: The trigger wheel triggering window should not pass over the thick blade of the special tool. If it does, a new overdrive planetary carrier and trigger wheel must be installed.
Using the special tool, check the TSS sensor air gap.
1 Place the thick blade of the special tool over the TSS sensor.
2 Rotate the trigger wheel and repeat checks for all windows.
52. NOTE: Align the clutch plates and front adapter gear.
Install the front brake drum and coast clutch drum assembly.
53. Install the front servo band lever and front band lever-to-case bracket into the transmission case.
54. NOTE: The front band lever shaft is longer than the intermediate band actuating lever shaft.
Install the front band actuating lever shaft through the front servo band lever.
55. Install the front band apply strut.
56. NOTE: If the front band is reused, it must be installed in its original position.
Install the front band over the front brake and coast clutch drum.
57. NOTE: Use the band adjustment screw as a temporary alignment guide.
Install the front band anchor strut.
58. Install the front band adjusting screw.
59. NOTE: Make sure that the pump body is seated against the thrust washer and the front brake and coast clutch drum. The pump body must be below the level of the case gasket surface.
NOTE: The tabs on the washer go into the pump face.
Carry out the front end play check procedure as follows:
^ Coat the No. 1 fluid pump inlet thrust washer with petroleum jelly.
^ Install the No. 1 fluid pump inlet thrust washer on the rear of the fluid pump and place the pump into position in the case.
60. NOTE: The special tool must rest on the gasket surface.
Measure the front end play clearance.
1 Place the special tool across the case.
2 Insert the special tool and extend the micrometer probe until it contacts the fluid pump face.
^ Read the measurement and subtract the special tool thickness 17.78 mm (0.70 inch). This is dimension A.
^ Repeat the measurement at the opposite side of the transmission case. This is dimension B.
^ Add dimensions A and B together and divide by 2. This is front end clearance dimension C.
61. NOTE: If the average front end clearance is below the specification, choose a thinner washer. If the average is above the specification, choose a thicker washer.
NOTE: The front end play specification is 0.18-0.70 mm (0.007-0.028 inch).
Use dimension C and the chart below to select the correct thickness fluid pump inlet thrust washer (No. 1).
Front End Play Selective Thrust Washer No. 1:
62. NOTE: Make sure that the pump body is seated against the thrust washer and the front brake and coast clutch drum. The pump body must be below the level of the case gasket surface.
NOTE: The tabs on the washer go into the pump face.
Remove the pump and install the No. 1 thrust washer onto the pump. After installing selected front pump thrust washer No. 1, repeat the front end play check. Make sure the end play is correct, then remove the pump for assembly.
63. Install a new O-ring seal in the fluid pump drive gear.
64. NOTE: Lubricate the special tool with multi-purpose grease.
Install the fluid pump drive gear on the special tool to seat the O-ring seal. Remove the tool.
65. CAUTION: The chamber on the inside edge of the small gear must be up when in the pump housing gear pocket. The dimple on the larger gear must be down when in the pump housing gear pocket. Incorrect installation can result in transmission damage.
Install the pump gears into the fluid pump housing. Apply multi-purpose grease to the pump gear to prevent scoring at start-up.
66. NOTE: Make sure the holes in the plate line up with the holes in the pump.
Install the fluid pump adapter plate.
67. NOTE: Do not allow the pump gears to come out of the pump housing pocket.
NOTE: The notch on the outside of the adapter plate will be at the 9 o'clock position relative to the converter housing.
Install the fluid pump on the converter housing.
^ Hold the fluid pump adapter plate against the pump housing. Turn the pump and adapter plate over and place on the converter housing.
68. Loosely install the fluid pump screws.
69. CAUTION: The special tools must be used to correctly align the fluid pump to the fluid adapter plate. This will prevent seal leakage, gear noise, broken gears and bushing failure.
Align the fluid pump to the fluid pump adapter plate and select the gauge from the special tool that is the snuggest fit when placed over the fluid pump.
70. Thread the gauge into the special tool and slide the tool over the fluid pump until it bottoms out in the fluid pump gear pocket.
71. Tighten the fluid pump screws in a star pattern and remove the pump alignment handle.
^ Tighten to 26 Nm (19 lb-ft).
72. Install a new fluid pump seal ring.
^ Coat the fluid pump seal ring with petroleum jelly.
73. NOTE: Make sure the fluid pump seal ring is installed on the housing and pump assembly.
Install a new fluid pump gasket.
^ Hold the fluid pump gasket in place with petroleum jelly.
74. CAUTION: Be careful not to overstretch the seal ring past the seal ring groove or damage to the seal will occur.
Using the special tools, install the fluid pump seal ring.
75. NOTE: Verify correct seal installation. Make sure seal grooves are clean and free of burrs.
Verify that the seal is installed correctly.
76. CAUTION: Failure to correctly size the seal will damage the seal when the torque converter is installed.
Using the special tool, size the seal to the correct size. Leave the special tool on the seal for 2 minutes to obtain the correct seal size.
77. Install the selected No. 1 fluid pump thrust washer.
^ Coat the fluid pump thrust washer with petroleum jelly.
78. Install the special tools into the transmission case.
79. NOTE: The splines on the ends of the input shaft are not the same length. The shorter splines go into the assembly.
Install the input shaft.
80. NOTE: Make sure that the No. 1 fluid pump inlet thrust washer selective thrust washer, fluid pump gasket and the fluid pump-to-case O-ring seal remain in the correct position throughout this step.
Install the fluid pump and converter housing onto the case.
81. NOTE: Lubricate the O-ring seals on the converter housing screws.
Remove the special tools. Install the new converter housing-to-case screws. Tighten the screws in a star pattern.
^ Tighten to 47 Nm (35 lb-ft).
82. Remove the input shaft.
83. WARNING: Always verify that the lockpin on the bench-mounted holding fixture is correctly secured to help prevent unexpected component rotation. Failure to follow this instruction may result in serious personal injury.
Rotate the transmission assembly so the fluid pan rails are facing up.
84. Assemble the front servo assembly.
1 Install the front servo cover O-ring seal on the front servo cover. Coat the front servo cover O-ring seal with petroleum jelly.
2 Install the front servo piston into the front servo cover.
3 Install the front servo piston spring on the front servo piston.
85. CAUTION: Do not damage the front servo-to-case O-ring seal during installation.
CAUTION: Do not press the front servo cover and O-ring seal past the relief hole in the case or O-ring seal damage can occur.
Using the special tool, install the front servo assembly into the case and install the front servo cover retaining ring.
86. Assemble the intermediate servo assembly.
1 Install the intermediate servo cover O-ring seal on the intermediate servo cover. Coat the intermediate servo cover O-ring seal with petroleum jelly.
2 Install the intermediate servo piston into the intermediate servo cover.
3 Install the intermediate servo piston spring on the intermediate servo piston.
87. CAUTION: Do not damage servo cover-to-case O-ring seal during installation.
CAUTION: Do not press the intermediate servo cover and O-ring seal past the relief hole in the case or O-ring seal damage can occur.
Using the special tool, install the intermediate servo assembly into the case and install the intermediate servo cover retaining ring.
88. NOTE: Do not allow front band adjustment screw to back out. The band strut may fall out of position.
NOTE: Install, but do not tighten, a new locknut on the band adjustment screw. Apply petroleum jelly to the locknut seal.
Install a new locknut on the band adjustment screw.
89. NOTE: The front servo must be installed prior to band adjustment.
NOTE: The wrench will click at the specified torque.
Using the special tool, tighten the front band adjustment screw.
^ Tighten to 14 Nm (10 lb-ft).
^ Then, back off the front band adjustment screw exactly 2 turns and hold that position.
