Operation CHARM: Car repair manuals for everyone.

Steps 1-50




Transmission

































Assembly

All vehicles

1. Clean and inspect the transmission case for damage or excessive wear. Inspect the bearing, bushing and splined surfaces for damage. Inspect the vent tube to be sure it is not restricted. Install new components as necessary.

Vehicles equipped with PTO

2. Clean the PTO cover. Install the PTO gasket and cover. Install the 6 PTO cover bolts.
- Tighten to 20 Nm (177 lb-in).





All vehicles

3. NOTE: There are 2 different types of vent tubes. Both tubes are installed by sliding it on the vent fitting.

Install the vent tube.





4. Install a new manual shaft seal.





5. NOTICE: The bearings must be installed in the transmission case by pressing on the thicker (marked) side of the bearing. When installing the bearing on the Rear Bearing Remover/Installer (307-648/3 and 307-648/4), make sure that the thicker (marked) side of the bearing faces the step on the Rear Bearing Remover/Installer (307-648/3 and 307-648/4). Failure to press on the thicker (marked) side can result in damage to the bearing.

NOTE: 307-648/4 shown, 307-648/3 similar.

Install new bearings on the Rear Bearing Remover/Installer with the thicker (marked) side of the bearing facing the step on the Rear Bearing Remover/Installer.

1. Thicker (marked) side of the bearing

2. Markings

3. Thinner (unmarked) side of the bearing

4. Rear Bearing Installer step





6. NOTICE: The Rear Bearing Remover/Installer 307-648/3 is used to install the inside bearing and the Rear Bearing Remover/Installer 307-648/4 is used to install the outside bearing. If the Rear Bearing Remover/Installer 307-648/3 and Rear Bearing Remover/Installer 307-648/4 are not used on the correct bearings, damage to the transmission can occur.

Install new bearings on the Rear Bearing Remover/Installer with the thicker (marked) side of the bearing facing the Rear Bearing Remover/Installer. Using the Rear Bearing Remover/Installer and the Forcing Screw, install the inner and outer output shaft bearing.





7. Rotate the transmission upright and install the low/reverse clutch piston assembly in the transmission case.





8. Install the longest clutch feed tube in the low/reverse feed tube port to align the low/reverse piston assembly. Install the low/reverse cylinder alignment bolt. Remove the feed tube.

1. Long feed tube

2. Low/reverse clutch piston assembly bolt

- Tighten to 11 Nm (97 lb-in).





9. Install the output shaft thrust bearing.





10. Install the output shaft.





11. NOTE: Fixed flange/4WD shown, slip yoke similar.

Rotate the transmission to access the output shaft and install the thrust washer, the thrust bearing and loosely install the output shaft nut

1. Thrust washer

2. Thrust bearing

3. Output shaft nut





12. Install the rear planetary gearset thrust bearing.





13. Position the center support up side down on a bench. Install the rear planetary carrier onto the center support. Install the low/reverse (1,R) clutch assembly onto the rear planetary carrier so that it rests on the One-Way Clutch (OWC).

1. Center support

2. Rear planetary carrier

3. Low/reverse (1,R) clutch

4. OWC





14. NOTE: Do NOT measure from the top of the lugs on the apply ring.

NOTE: The low/reverse clutch measurement in specifications is a measurement of the clutch height and is NOT the clutch clearance.

Using a suitable depth gauge, measure the distance from the piston contact surface of the apply ring to the center support surface in 3 different places. Average the 3 measurements and record as the low/reverse clutch measurement.





15. Compare the low/reverse (1,R) clutch measurement to the low/reverse (1,R) clutch measurement specification. For additional information, refer to specifications. If the low/reverse (1,R) clearance is out of specification, install a new low/reverse (1,R) clutch assembly.

16. Lubricate the low/reverse (1,R) clutch in clean transmission fluid.

1. Apply plate

2. Steel plates

3. Clutch plates





17. Position the transmission in the upright position and install the low/reverse (1,R) apply plate and clutch assembly.





18. NOTE: The anti-clunk clip is NOT installed in this step.

NOTE: Make sure the outer One-Way Clutch (OWC) splines are aligned as shown or the anti-clunk clip will not fit into the transmission case.

Install the rear planetary gearset with the outer OWC splines aligned so the anti-clunk clip can be installed correctly.
Inspect the OWC to be sure it is aligned correctly for installation of the anti clunk spring. The anti clunk spring should rest against both a spline of the OWC and an inner spline of the transmission case.

1. OWC spline

2. Transmission case spline





19. Install the No. 3 sun gear with the beveled end facing down and install the No. 3 sun gear thrust bearing.

1. No. 3 sun gear

2. No. 3 sun gear thrust bearing





20. Install the thrust washer on the No. 2 sun gear. Use petroleum jelly if needed to hold the thrust washer to the sun gear and install the No. 2 sun gear in the rear planetary gearset with the thrust washer facing down.





21. Install the No. 2 sun gear thrust bearing on top of the No. 2 sun gear.





22. Install the End Play Gauge on the transmission case.





23. NOTICE: Make sure to zero the dial indicator on the transmission case and not the rear planetary gearset or inaccurate measurements can be recorded causing damage to the transmission.

Position a suitable depth dial indicator on the End Play Gauge with the plunger positioned on the top of the transmission case step that the center support rests on. Zero the dial indicator.





24. Gently lift the plunger of the dial indicator off the transmission case step, slide the dial indicator over and drop the plunger onto the No. 2 sun gear thrust bearing. Record this distance as measurement A.





25. With measurement A recorded, calculate the selective shim thickness and find the part number.

1. Zero

2. Measurement A

- NOTE: The distance on the center support from the transmission case surface to the No. 2 sun gear thrust bearing surface equals 8.55 mm (0.336 in). 8.55 mm (0.336 in) is subtracted from measurement A to compensate for the offset of the center support.

Subtract 8.55 mm (0.336 in) from measurement A to get the clearance for the rear shim. Compare the clearance of the rear shim to the Rear Selective Shim Part Number Chart in Specifications to get the correct selective shim dimension and part number. The target clearance with the correct rear shim installed should be between 0.8-1.1 mm (0.031-0.043 in).





26. Install the rear selective shim on top of the thrust bearing.





27. NOTE: When installing the center support, make sure the alignment lugs are lined up with the slots in the transmission case and the feed hole is facing down.

NOTE: Inspect the alignment lugs to be sure they are installed in the center support and are not loose. If the alignment lugs are loose, use petroleum jelly to hold them in place when installing the center support.

Install the center support assembly.





28. WARNING: Use caution when unloading the beveled retaining ring. Failure to follow this instruction may result in serious personal injury.

NOTICE: Be sure the beveled retaining ring is installed with the beveled end facing up or the beveled retaining ring can come loose and damage to the transmission can occur.

Place the beveled retaining ring in the torque converter housing. Using the Center Support Snap Ring Pliers, compress the beveled retaining ring in the torque converter housing and install the beveled retaining ring with the beveled retaining ring gap in the 12 o'clock position and the beveled side facing up.





29. Using a suitable tool, tap on the center support snap ring to make sure it is seated in the groove.





30. Install direct (3,5,R)/intermediate (2,6) clutch thrust bearing.





31. Install the direct (3,5,R)/intermediate (2,6) clutch hub in the intermediate (2,6) clutch.





32. Install the intermediate clutch feed tube.





33. NOTICE: Be sure to turn the shop air supply down to 276 kPa (40 psi) or damage to the clutch seals can occur.

Install the C-Clutch Air Plate and apply 276 kPa (40 psi) of shop air to the C-Clutch Air Plate.





34. Remove the direct (3,5,R)/intermediate (2,6) clutch hub.





35. Using the Transmission Holding Fixture and the Clutch Pack End Play Gauge, install the direct (3,5,R)/intermediate (2,6) clutch hub in the forward/overdrive clutch assembly.





36. Install the direct (3,5,R) clutch wave spring , clutch assembly and pressure plate in the forward/overdrive clutch assembly. Install the direct (3,5,R) clutch snap ring.

1. Direct (3,5,R) clutch wave spring

2. Clutch assembly

3. Pressure plate

4. Snap ring





37. Install the Pump Remover/Installer Bracket on the forward/overdrive clutch assembly with the pin installed in the center hole and support it with a Heavy Duty Floor Crane.





38. Using the Heavy Duty Floor Crane and the Pump Remover/Installer Bracket, gently install the forward/overdrive clutch assembly in the transmission case. Make sure the forward/overdrive clutch assembly is seated all the way by making sure it rests slightly above the rib of the transmission case as shown.





39. Remove the C-Clutch Air Plate.





40. Install the anti-clunk clip.





41. NOTE: Non-Power Take-Off (PTO) pump shown with 307-657/3, PTO pump with 307-659/2 similar.

Position the pump assembly on 2 blocks of wood or a suitable stand and remove the Non-PTO Pump Seal Installer or PTO Pump Seal Installer/Sizer.





42. Position the End Play Gauge on the pump with it centered to the center of the stator support. Using a suitable depth gauge, measure the distance from the top of the End Play Gauge to the front shim surface in 2 places, 180 degrees apart. Average the 2 measurements and record as measurement A.





43. NOTE: Apply pressure to the End Play Gauge to hold it flush against the stator support when measuring to the deck surface.

Using a suitable depth gauge, measure the distance from the top of the End Play Gauge to the deck surface in 2 places, 180 degrees apart. Average the 2 measurements and record as measurement B.





44. Subtract measurement A from measurement B and record as measurement C.

45. Position the End Play Gauge on the transmission case pump deck surface. Using a suitable depth gauge, measure the distance from the top of the End Play Gauge to the selective shim surface on the No. 1 sun gear. Subtract the height of the End Play Gauge 12.7 mm (0.5 in) from the measurement and record as measurement D. Remove the End Play Gauge.





46. Subtract measurement C from measurement D and record that distance as the front selective shim thickness. Compare the thickness of the center support shim to the Front Selective Shim Part Number Chart in Specifications to get the correct front selective shim part number. The target clearance with the correct front shim installed should be between 0.15-0.45 mm (0.006-0.018 in).

47. Install the selective shim on top of the No. 1 sun gear. Make sure the selective shim is positioned correctly in the No. 1 sun gear groove.





48. Install the Pump Remover/Installer Bracket on the pump with the pin in the top hole.





49. Using the Heavy Duty Floor Crane and the Pump Remover/Installer Bracket, gently position the pump in the transmission case with the feed tube surface facing the bottom of the transmission.





50. Align the bolt holes and loosely install 2 bolts. Using a suitable tool, gently tap the pump until it is seated on the deck surface of the transmission case.