Part 1

Transmission

Disassembled Views

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:
- Stripped bolt hole threads

- Gasket and mating surfaces for burrs or nicks

- Obstructions to vent and fluid passages

- Cracks or warping

Rear Wheel Drive (RWD) vehicles

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

Four-Wheel Drive (4WD) vehicles

4. Inspect the extension housing for cracks, burrs or warping.

All vehicles

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

6. 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.

NOTE: Inspect the intermediate and Overdrive (O/D) servo bores for excessive wear. Repair as required.

Using the Transmission Holding Fixture, install the transmission onto the bench with the converter housing facing up.

7. Using the Shift Shaft Fluid Seal Installer, install the manual control lever shaft seal and lubricate it with petroleum jelly.

8. Install the park lever rod.

9. Install the manual valve inner lever.

10. Assemble the manual valve inner lever and park lever actuating rod.

11. NOTE: Align the flats on the manual valve inner lever with the flats on the manual control lever shaft.

Install the manual control lever shaft.

12. Install the manual valve inner lever onto the manual shaft and loosely install the inner nut.

13. NOTICE: 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.

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

Tighten the inner nut.

- Tighten to 48 Nm (35 lb-ft).

15. NOTICE: The tabs on the output shaft thrust washer (No. 11) point into the case. Make sure the thrust washer is correctly seated or damage may occur.

Install the output shaft thrust washer (No. 11).

- Coat the output shaft thrust washer with petroleum jelly.

16. Install the park gear on the output shaft.

17. Install the output shaft and park gear.

18. Install the low/reverse brake drum.
- Rotate the low/reverse brake drum clockwise to install.

19. NOTE: Make sure band is resting on the 2 anchor pins in the case.

Install the low/reverse band over the reverse drum.

20. NOTE: The reverse band actuating lever must fit into the notches in the band.

Install the reverse band actuating lever into the reverse band.

21. Install the reverse band actuating lever shaft into the case and into the reverse band actuating lever.

22. Install the No. 10 needle bearing into the case.

23. NOTICE: Do not damage the seal against the case during assembly.

Install the output shaft ring gear, hub and seal.

24. NOTICE: Always install a new output shaft retaining ring, otherwise transmission damage can occur.

Install a new output shaft retaining ring.

25. NOTE: Install the output shaft sleeve with the cone facing up. This sleeve will snap into place when correctly installed.

Install the output shaft sleeve.

26. Install low/reverse planetary carrier needle bearing (No. 9) onto the output shaft ring gear and hub assembly.

27. NOTICE: Make sure the needle bearings stay in place or damage may occur.

Install the low/reverse planetary assembly.

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

Install the retaining ring.

29. Install the No. 8 thrust bearing.

30. Install the spacer on the input shell, using petroleum jelly to hold it in place.

31. Install the input shell and sun gear assembly.

32. NOTE: The No. 13 bearing must be correctly seated in the forward planet assembly so the sun gear can be installed correctly.

Install the forward planetary assembly.

33. Install the No. 7 forward planet thrust bearing into the forward ring gear and hub assembly. Use petroleum jelly to hold the bearing in place.

34. Install the No. 6B forward clutch thrust washer onto the forward ring gear hub.

35. Install the forward ring gear and hub as an assembly.

36. Install the No. 6A forward ring gear hub thrust bearing into the forward ring gear and hub.

37. Install the forward clutch cylinder.

38. Install the No. 5 thrust bearing.

39. NOTE: Inspect the intermediate servo bore for excessive wear. Repair as required.

Install the intermediate servo piston and spring.

- Lubricate the servo bore with transmission fluid.

40. Using the Servo Cover Compressor, install the retaining ring.

41. Install the direct clutch drum.

42. Using a Depth Micrometer with an appropriate length extension, measure from the top of the Gauge Bar to the center support ledge in the case at 4 places 90 degrees apart.
- Add the 4 measurements, divide by 4 and record as dimension A.

43. NOTICE: The torque specifications are critical for this procedure. Failure to use the correct torque specifications may cause transmission damage.

Install the Cushion Spring Compressor.

1. Install the Cushion Spring Compressor and the bolts using the 2 pump screw locations at approximately 6 and 12 o'clock positions.
- Tighten to 15 Nm (133 lb-in).

2. Tighten the center screw.
- Tighten to 1.13 Nm (10 lb-in).

44. NOTE: Align the disc holes on the Cushion Spring Compressor with the slot in the Gauge Bar for correct measurement.

Measure the distance with the Depth Micrometer from the top of the Gauge Bar to the drum bearing surface through the hole in the disc and record as dimension B. Repeat the measurement 180 degrees on the opposite side of the Gauge Bar and record as dimension C.

45. Add dimension B to C, divide by 2 and record as dimension D.

46. Subtract A from D and record as dimension E.

47. Select the bearing from the following chart, using dimension E.

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

NOTE: If the intermediate band is reused, it must be installed in the same position as it was when removed.

NOTE: The new intermediate band is dark in color. This is a normal condition of the band. Hairline cracks in the band are also considered normal. Do not install a new band based solely on the color.

Install the intermediate band.

49. NOTICE: To avoid a fall out condition of the strut from the screw during assembly and function, the small U-shaped notch should be toward the band and the large U-shaped notch toward the main control side.

Install the intermediate band anchor strut.

1. Band/case side of anchor (small U notch).

2. Main control side of anchor (large U notch).

50. NOTICE: If the strut is installed incorrectly, transmission damage will occur.

Make sure that the intermediate band anchor strut is installed in the correct orientation to the case and adjustment screw.

51. Loosely install the adjustment screw.

52. Install the intermediate band apply strut.

53. NOTICE: If the strut is installed incorrectly, transmission damage will occur.

Make sure that the intermediate band apply strut is installed in the correct orientation to the case and piston rod.

54. Install the selected No. 4 thrust washer on the direct clutch drum.
- Coat the thrust washer with petroleum jelly.

55. NOTE: Align the center support screw hole with correct case hole.

Install the center support.

56. Install the center support locknut and cage.

57. Loosely install the center support screw.

58. NOTICE: Install the center support retaining ring with the tapered side facing up or damage may occur.

NOTICE: Make sure the notch opening is not obstructed by the center support retaining ring or damage may occur.

Install the center support retaining ring.

1. Make sure the center support retaining ring is installed with the tapered side facing up.

2. Make sure the opening of the center support retaining ring is positioned correctly.

59. Install the center shaft thrust bearing (No. 3).

60. Install the O/D ring gear, O/D One-Way Clutch (OWC) and center shaft assembly.