Part 2

Transmission















Disassembled Views

Transmission Disassembled View (Part 1):

NOTE: Clutch plate quantity is model dependant based on engine displacement. Refer to Clutch Plate Quantity chart in the Specifications information.


31. Rotate the transmission to the vertical position and install the slip plane washer.





32. Position a new output shaft seal on the Rear Seal Installer 4X2.





33. Using the Rear Seal Installer 4X2, install the output shaft seal.





34. Install the output shaft flange and the extension housing flange seal.





35. Loosely install a new output shaft flange retaining nut.





36. Install the Dial Indicator Gauge with Holding Fixture on the transmission case and position the plunger on the output shaft flange.





37. NOTE: Loosely install the flange nut or an inaccurate reading may be recorded.

Using the Dial Indicator Gauge with Holding Fixture, lift up on the output shaft flange and record the reading. The reading should be within 0.6-0.9 mm (0.024-0.035 in).

- If the reading is not within specification, remove the center support and install a different (either thinner or thicker) selective shim on the T7 thrust bearing.





38. Place the manual control lever in the PARK position and tighten the output shaft flange nut.
- Tighten to 80 Nm (59 lb-ft).

- After installing the new output shaft flange nut, stake the slots to prevent it from coming loose.





39. Rotate the transmission in the vertical position with the torque converter housing facing up and install the T6 bearing.





40. Install the direct (B) clutch assembly.





41. Install the T5 roller bearing on the direct (B) clutch assembly.





42. Install the forward (A)/overdrive (E) clutch assembly.





43. Install the selective shim.





44. If the front pump was not disassembled and assembled, install a new front pump O-ring seal and lubricate it with petroleum jelly.





45. Install a new front pump seal on the Fluid Pump Seal Installer.





46. Using the Fluid Pump Seal Installer, install the front pump seal.





47. Install the Transmission Fluid Pump Remover on the front pump.





48. Lubricate the transmission case pump bore with petroleum jelly. Using the Transmission Fluid Pump Remover, position the pump assembly in the case and rotate the pump to insert the pump splines into the front planetary sun gear. Rotate the pump to align the pump-to-case bolts and push the pump into the case.





49. Install 13 new front pump-to-case bolts and washers. Tighten in a crisscross pattern.
- Tighten to 10 Nm (89 lb-in).





50. Install the Transmission End Play Gauge on the input shaft to measure the end play.
- Tighten the wing nut.





51. Install the Dial Indicator Gauge with Holding Fixture on the Transmission End Play Gauge.
- Push down on the Transmission End Play Gauge and zero the Dial Indicator Gauge.

- Lift up on the Transmission End Play Gauge and record the measurement on the Dial Indicator Gauge. The measurement should be between 0.2-0.4 mm (0.008-0.015 in). If the measurement is not within specification, install a new selective front pump shim.

- Measure the original shim, install a thinner or a thicker shim to achieve the correct measurement.





52. Rotate the transmission in the horizontal position with the main control area facing up and install 4 new center support feed tubes.

1. Black feed tubes

2. Green feed tube

3. Blue feed tube





53. NOTE: Make sure the transmission fluid filter seal has been removed. If it has not, use a suitable pick and remove the seal.

NOTE: Add 0.118L (4 oz) of clean transmission fluid to prime the pump.

Install the front pump adapter seal and prime the fluid pump.





54. Install the thermal bypass valve into the case.





55. Align the guide pins in the alignment holes in the transmission case and position the main control assembly in place.

1. Alignment holes

2. Guide pins





56. NOTE: The main control will not lay flush on the case, this is a normal condition with the rubber feed tubes, the bolts will pull the mechatronic assembly down.

Slightly lift the main control assembly and align the manual valve in the manual valve linkage and position the main control in place.





57. Install the 11 main control assembly bolts and tighten in the sequence shown.
- Tighten to 8 Nm (71 lb-in).





58. With the release tab up and unlocked, push the outer shell of the bulkhead electrical connector into the transmission. Make sure the bulkhead connector is fully seated into the molded leadframe.





59. Press down on the tab and lock the outer shell of the bulkhead electrical connector in place. Make sure the locking tab is securely locked.





60. Install a new transmission fluid filter.





61. NOTE: The fluid pan gasket can be reused if not damaged.

Install a new transmission fluid pan gasket if required.





62. Install the transmission fluid pan and transmission fluid pan bolts. Tighten in a crisscross pattern.
- Tighten to 12 Nm (106 lb-in).





63. Using the Torque Converter Handle, install the torque converter.