Part 1

Transmission

Transmission, Disassembled View

NOTE: Soak all friction clutch plates in transmission fluid.

NOTE: Prior to installation, lightly lubricate all O-ring seals with transmission fluid.

NOTE: Lightly lubricate all thrust washers with petroleum jelly to hold them in place during assembly.

1. Mount the transmission case into a suitable stand.

2. If installing a new case, install the transmission fluid cooler tube nut case fittings. Coat the threads with threadlock sealant.
- Tighten to 51 Nm (38 lb-ft).

3. If removed, use the Fluid Filler Tube Installer to install the short transmission fluid inlet tube.

4. If removed, use the Output Shaft Seal/Housing Installer to install a new Teflon(R) seal retainer.
- Install 2 new Teflon(R) seals.

5. NOTE: Coat the reverse clutch piston seals with petroleum jelly.
Install the reverse clutch piston in the case until it is fully seated in the case.

6. Install the reverse clutch return spring assembly.

7. NOTICE: Do not over compress the return spring or damage to the spring will occur.

Using the Clutch Spring Compressor Aligner and the Clutch Spring Compressor, install the reverse clutch return spring snap ring.

8. NOTE: The use of petroleum jelly will hold the No. 17 thrust bearing or washer in place during assembly.
Install the No. 17 park gear thrust washer.

9. NOTICE: Be careful when installing the output shaft not to damage the seals or a transmission leak could occur.

Install the output shaft.

10. NOTICE: The Torx screw has a threadlocking compound. If the screw is removed, it must be discarded and a new screw installed.

If removed, install the park pawl abutment with a new Torx screw.
- Tighten to 25 Nm (18 lb-ft).

11. Install the park pawl.
1. Install the park pawl shaft.

2. Install the park pawl.

3. Install the park pawl return spring.

12. NOTE: Make sure the dimple on the park guide support plate is facing inward.
Install the park rod guide plate.
1. Install the park rod guide plate.

2. Install the bolts.
- Tighten to 25 Nm (18 lb-ft).

13. Install a new orifice lube plug in the rear of the case. Using a 12-mm socket, tap the orifice lube plug into the back of the transmission. Check to make sure that the orifice lube plug is fully seated into the back of the transmission.

14. Install a new extension housing gasket.

15. Install the extension housing and the transmission extension housing-to-case bolts.
- Tighten to 47 Nm (35 lb-ft).

16. Using the Shift Shaft Fluid Seal Installer, install a new manual control lever seal.

17. Install the Transmission Range (TR) sensor, park rod assembly and loosely install the bolts.

18. Install the manual control lever.

19. Install the manual control lever shaft retaining pin into the case.

20. Install a new manual control valve detent lever shaft retaining pin. Leave 2 mm (0.078 in) of the pin exposed.

21. Tighten the TR (Transmission Range) sensor bolts.
- Tighten to 10 Nm (89 lb-in).

22. Using the Transmission Extension Housing Seal Installer, install a new extension housing seal.

23. Inspect the new output shaft nut O-ring for cuts. If cut, install a new output shaft nut.

24. Using the Output Shaft Locknut Socket, install a new output shaft nut.
- Tighten to 200 Nm (148 lb-ft).

25. If equipped, install the output flange and a new output flange bolt.
- Tighten to 130 Nm (96 lb-ft).

26. Install the No. 16 bearing and race.

27. Assemble the rocker clutch and ring gear assembly.
1. Install the No. 15 hub bearing onto the ring gear hub.

2. Install the rocker clutch, low/reverse clutch pack and carrier and hub assembly into the output hub and ring gear assembly.

28. NOTE: Place the transmission in the horizontal position.
Install the rocker clutch and ring gear assembly into the transmission case.

29. NOTICE: Do not apply air pressure to move the low/reverse piston without first installing the rocker clutch snap ring, or damage to the snap ring will occur.

Install a new flat snap ring and make sure that the snap ring is fully seated in the case snap ring groove.
Install a new flat snap ring so the tang ends are in the gaps to the right and to the left of the case spline as shown.
- Check the function of the reverse clutch by applying air to the correct passage (through the case valve body worm trail) for the reverse clutch.

30. Using the Transmission Forward Clutch Assembly Installer and Adapter, install the forward geartrain as an assembly.

31. Install the intermediate clutch pressure plate.
- Position the intermediate clutch pressure plate in the case with the 3 tabs facing downward.

32. Install the intermediate clutch plates, starting with a friction plate.

33. Install the center support with the transmission in a position that will avoid damage to the center support Teflon(R) seals.

34. Loosely install the feed bolts.
1. Loosely install the Torx head forward clutch feed bolt into the case toward the rear of the case.

2. Loosely install the hex head intermediate clutch feed bolt into the case toward the front of the case.

35. Using the Retaining Ring Pliers, install the center support snap ring.
- The snap ring should be installed with the flat edge facing downward. The gap in the snap ring should be facing in the 6 o'clock position. Tap the snap ring securely into the case.

36. Tighten the feed bolts.
- Tighten to 32 Nm (24 lb-ft).

37. Install the No. 5 thrust bearing onto the center support.