Steps 81-120

Transmission













































81. NOTE: Lubricate the O-ring seals on the converter housing screws.

Remove the Torque Converter Aligners. 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. NOTICE: Do not damage the front servo-to-case O-ring seal during installation.

NOTICE: 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 Servo Cover Compressor, 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. NOTICE: Do not damage servo cover-to-case O-ring seal during installation or O-ring seal damage can occur.

NOTICE: 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 Servo Cover Compressor, 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 Transmission Band Adjustment Set, tighten the front band adjustment screw.

- Tighten to 14 Nm (124 lb-in).

- Back off the front band adjustment screw exactly 2 turns and hold that position.





90. Tighten the front band locknut.

1. Hold the front band adjustment screw stationary.

2. Tighten the front band locknut.
- Tighten to 54 Nm (40 lb-ft).





91. NOTE: Do not allow the intermediate band adjusting screw to back out. The band strut could 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 nut on the band adjustment screw.





92. NOTE: The intermediate servo must be installed prior to band adjustment.

NOTE: The wrench will click at the specified torque.

Using the Transmission Band Adjustment Set, tighten the intermediate band adjustment screw.

- Tighten to 14 Nm (124 lb-in).

- Back off the intermediate band adjustment screw exactly 2 turns and hold that position.





93. Tighten the intermediate band locknut.

1. Hold the intermediate band adjustment screw stationary.

2. Tighten the intermediate band locknut.
- Tighten to 54 Nm (40 lb-ft).





94. NOTE: Install new O-ring seals on the 16-pin electrical connector. Coat the O-ring seals with petroleum jelly.

NOTE: Make sure that the tab is in the lock position.

Position the transmission case 16-pin electrical connector into the case bore.

- Press the transmission case 16-pin electrical connector through the case until a click is heard.





95. NOTICE: Do not overstretch the retaining spring. Overstretching may damage the spring.

Install the 16-pin electrical connector retaining spring.





96. NOTE: Align the slot on the TSS sensor electrical connector with the slot in the 16-pin electrical connector.

Install the TSS sensor electrical connector into the transmission case 16-pin electrical connector.

1. Connect the TSS sensor electrical connector.

2. Insert the TSS sensor electrical connector wires into the retaining slot in the 16-pin electrical connector.





97. Tighten the center support screw.
- Tighten to 11 Nm (97 lb-in).





98. Install the Valve Body Aligners into the transmission case.





99. NOTE: Make sure main control valve body gasket is aligned.

NOTE: Make sure that the manual valve is correctly aligned with the manual valve inner pin when the main control valve body is installed.

Position the main control valve body into the transmission case.





100. NOTE: The screws will be tightened in later steps.

Loosely install the 4 M6 x 45 mm (1.771 in) screws.





101. NOTE: The main control valve body screws will be tightened in later steps.

Loosely install the 2 M6 x 35 mm (1.377 in) screws.





102. NOTE: The main control valve body screw will be tightened in later steps.

Loosely install the M6 x 30 mm (1.181 in) screw.





103. Remove the Valve Body Aligners.





104. NOTE: The main control valve body screws will be tightened in later steps.

Loosely install the 16 M6 x 40 mm (1.574 in) screws.





105. Tighten the screws in the sequence shown.
- Tighten to 10 Nm (89 lb-in).





106. Rotate the manual lever into the NEUTRAL position, then install the manual control valve detent lever spring.

1. Position the manual control valve detent lever spring on the main control valve body.

2. Install the screw.
- Tighten to 10 Nm (89 lb-in).





107. Install the low/reverse band servo cover and reverse servo separator plate cover gasket.

1. Position the low/reverse band servo cover and low/reverse servo separator plate cover gasket on the transmission case.

2. Loosely install the screws.





108. Tighten the low/reverse band servo cover screws in the sequence shown.
- Tighten to 13 Nm (115 lb-in).





109. Connect the solenoid electrical connectors.

1. Connect Shift Solenoid A (SSA), Shift Solenoid B (SSB), Shift Solenoid C (SSC) and Shift Solenoid D (SSD) electrical connectors.

2. Connect the Torque Converter Clutch (TCC) solenoid electrical connector.

3. Connect the Electronic Pressure Control (EPC) solenoid electrical connector.





110. NOTICE: Excessive pressure may break the locating pins.

Install the wiring loom protector and guide.

- Align the pins in the holes of the solenoid clamps and gently push down.





111. NOTICE: Lubricate fluid filter O-ring seals with transmission fluid or they may be damaged.

NOTE: Make sure that both fluid pan filter O-ring seals are correctly installed on the fluid pan filter prior to installation.

Lubricate and install new O-ring seals onto the transmission fluid filter.





112. Install the transmission fluid filter.

1. Position the transmission fluid filter on the main control valve body.

2. Install the transmission fluid filter screw.
- Tighten to 10 Nm (89 lb-in).





113. Position the fluid pan magnet in the transmission fluid pan.





114. NOTE: The transmission fluid pan gasket is reusable. Clean and inspect for damage, if not damaged, the gasket should be reused.

Install the transmission fluid pan.

1. Position the transmission fluid pan gasket on the transmission fluid pan.

2. Install and align the transmission fluid pan.





115. Loosely install the transmission fluid pan screws.





116. Tighten the transmission fluid pan screws in a crisscross pattern.
- Tighten to 10 Nm (89 lb-in).





117. Remove the transmission from the bench and place on a flat surface.





118. Remove the Transmission Holding Fixtures from the transmission case.





119. NOTE: Use petroleum jelly to hold the gasket in place.

Install a new extension housing gasket.





120. NOTE: The guide cup is press-fit into the extension housing and is not serviced separately.

Install the park pawl assembly.

1. Install the park pawl shaft into the extension housing.

2. Install the park pawl.

3. Install the park pawl return spring.