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Installing Second Coast Brake Band:

37. Install second coast brake band.

Installing Second Coast Brake Band Retaining Pin:

38. Install pin in second coast brake band. Then install retaining ring on pin.

Installing Forward-Direct Clutch Thrust Bearing And Race:

39. Install thrust bearing and race in forward-direct clutch. Coat bearing/race with petroleum jelly to hold them in place.
40. Verify forward-direct clutch thrust bearing size.
- Race outer diameter is 48.9 mm (1.925 inch) and inside diameter is 26.0 mm (1.024 inch).
- Bearing outer diameter is 46.7 mm (1.839 inch) and inside diameter is 26.0 mm (1.024 inch).

Installing Planetary Ring Gear Race:

41. Coat front planetary ring gear race with petroleum jelly and install it in ring gear.
42. Verify ring gear race size. Outer diameter is 47.0 mm (1.850 inch) and inside diameter is 26.5 mm (1.045 inch).

Aligning Forward-Direct Clutch Splines:

43. Align forward-direct clutch disc splines with screwdriver.

Installing Front Planetary Ring Gear:

44. Align and install front planetary ring gear in forward-direct clutch.

Installing Ring Gear Bearing And Race:

45. Coat bearing and race with petroleum jelly and install them in ring gear. Verify bearing/race size.
- Bearing outer diameter is 47.7 mm (IL.878 inch) and inside diameter is 32.6 mm (1.283 inch).
- Race outer diameter is 53.6 mm (2.110, inch) and inside diameter is 30.6 mm (1.205 inch).

Installing Front Planetary And Forward-Direct Clutch Assembly:

46. Install assembled planetary gear/forward-direct clutch.

Checking Input Drum-To-Direct Clutch Drum Clearance:

47. Check clearance between sun gear input drum and direct clutch drum. Clearance should be 9.8 - 11.8 mm (0.386 - 0.465 inch). If clearance is incorrect, planetary gear/forward-direct clutch assembly is not seated or is improperly assembled. Remove, and correct if necessary.
48. Coat thrust bearing and race assembly with petroleum jelly and install it on clutch shaft. Bearing faces up and toward case front as shown. Verify bearing/race size. Bearing and race outer diameter is 47.8 mm (1.882 inch) and inside diameter is 33.6 mm (1.301 inch).

Assembling Second Coast Brake Piston:

49. Assemble second coast brake piston components.
50. Install assembled second coast brake piston in case. Verify that the piston rod contacts the second coast brake band.
51. Install replacement seals on second coast brake piston cover and install cover in case.

Installing Second Coast Brake Piston Snap Ring:

52. Install second coast brake piston snap ring with snap ring plier tool.

Marking Brake Piston Rod:

53. Check second coast brake piston stroke as follows:
a. Install a small wire tie strap around the second coast brake piston rod tight against the transmission case.

Checking Second Coast Brake Piston Stroke:

b. Apply 57 - 114 psi air pressure through piston feed hole and check stroke length with Gauge Tool 7552.
c. Stroke length should be 1.5 - 3.0 mm (0.059 - 0.118 inch).
d. If stroke length is incorrect, piston, cover or snap ring is not seated. Reassemble and check stroke again if necessary.

Installing Overdrive Support Thrust Race And Washer:

54. Coat thrust race and tabbed washer with petroleum jelly and install them on overdrive support. Verify race size. Race outer diameter is 50.9 mm (2.004 inch) and inside diameter is 36.2 mm (1.426 inch).

Installing Overdrive Support:

55. Install overdrive support in case. Use two long bolts to help align and guide support into position.

Installing Overdrive Support Snap Ring:

56. Install overdrive support snap ring with Snap Ring Plier Tool 7540. Chamfered of snap ring faces up and toward case front. Snap ring ends must be aligned with case (opening with ring ends approximately 24 mm (0.94 inch) from center line of case opening.

Installing Overdrive Support Bolts:

57. Install and tighten overdrive support bolts to 25 Nm (19 ft. lbs.) torque.

Checking Output Shaft End Play:

58. Check output shaft end play with dial indicator. End play should be 0.27 - 0.86 mm (0.0106 - 0.0339 inch).
59. If output shaft end play is incorrect, one or more of installed components is not seated. Reassemble as necessary and check end play again.

Installing Overdrive Brake Clutch Pack:

60. Install overdrive brake clutch pack. Install thickest clutch plate first. Rounded edge of plate faces up. Install first disc followed by another plate until four discs and three plates are installed.

Installing Overdrive Brake Snap Ring:

61. Install stepped ring retainer plate with flat side facing disc. Then install brake pack snap ring.
62. Check overdrive brake piston stroke as follows:
a. Mount dial indicator on case using Miller Tool C-3339 and a suitable bolt threaded into the transmission case.
b. Verify that the dial indicator is mounted solidly and square to the direction of the piston travel.
c. Apply 57 - 114 psi air pressure through piston apply port and note piston stroke on dial indicator. Stroke length should be: 1.40 - 1.70 mm (0.055 - 0.0699 inch).
d. If stroke is incorrect, brake pack or piston is installed incorrectly. Check and correct as necessary and measure piston stroke again.
e. Remove the dial indicator set-up from the transmission.

Installing Overdrive Support Thrust Bearing And Races:

63. Coat overdrive lower race, thrust bearing and upper race with petroleum jelly and install them in overdrive support. Be sure races and bearing are assembled and installed as shown.
64. Verify bearing/race sizes before proceeding. Bearing race sizes are:
- Outer diameter of lower race is 47.8 mm (1.882 inch) and inside diameter is 34.3 mm (1.350 inch).
- Outer diameter of bearing is 47.7 mm (1.878 inch) and inside diameter is 32.7 mm (1.287 inch).
- Outer diameter of upper race is 47.8 mm (1.882 inch) and inside diameter is 30.7 mm (1.209 inch).

Installing Overdrive Planetary Ring Gear:

65. Install overdrive planetary ring gear in support.

Installing Ring Gear Thrust Bearing And Race:

66. Coat ring gear thrust race and thrust bearing assembly with petroleum jelly and install them in gear.
67. Verify bearing/race size before proceeding.
- Outer diameter of ring gear race-bearing is 47.8 mm (1.882 inch) and inside diameter is 24.2 mm (0.953 inch).
- Outer diameter of bearing is 46.8 mm (1.844 inch) and inside diameter is 26.0 mm (1.024 inch).

Installing Planetary Thrust Race:

68. Coat tabbed thrust race with petroleum jelly and install it on planetary gear. Race outer diameter is 41.8 mm (1.646 inch) and inside diameter is 27.1 mm (1.067 inch).

Installing Overdrive Planetary And Clutch Assembly:

69. Install assembled overdrive planetary gear and clutch.

Installing Overdrive Planetary And Clutch Assembly:

70. Coat thrust bearing and race assembly with petroleum jelly and install it on clutch input shaft. Bearing and race outer diameter is 50.2 mm (1.976 inch) and inside diameter is 28.9 mm (1.138 inch).

Installing Oil Pump Thrust Race:

71. Coat thrust bearing race with petroleum jelly and install it in oil pump. Bearing race outer diameter is 47.2 mm (1.858 inch) and inside diameter is 28.1 mm (1.106 inch).
72. Lubricate and install replacement O-ring on oil pump body.
73. Install oil pump in case. Align pump and case bolt holes and carefully ease pump into place.

CAUTION: Do not use force to seat the pump. The seal rings on the stator shaft could be damaged if they bind or stick to the direct clutch drum.

74. Tighten oil pump bolts to 22 Nm (16 ft. lbs.) torque.
75. Verify input shaft rotation. Shaft should rotate smoothly and not bind.

Installing Transmission Throttle Cable:

76. Lubricate and install new O-ring on transmission throttle cable adapter and install cable in case.

Clutch And Brake Feed Hole Locations:

77. Check clutch and brake operation. Operate clutches and brakes with compressed air applied through feed holes in case. Listen for clutch and brake application. If you do not, hear a clutch or brake apply, disassemble transmission and repair fault before proceeding. It is necessary to block the overdrive clutch accumulator feed hole No. 8 in order to check direct clutch operation.

Accumulator Piston And Spring Installation:

78. Lubricate and install new O-rings on accumulator pistons.
79. Assemble and install accumulator pistons and springs.

Installing Check Ball Body And Spring:

80. Install new check ball body and spring.

Aligning Manual Valve, Shift Sector And Detent Spring:

81. Position valve body on case.
82. Install detent spring.
83. Align manual valve, detent spring and shift sector.

Connecting Transmission Throttle Cable:

84. Connect transmission throttle cable to throttle valve cam.
85. Install and tighten valve body-to-case bolts to 10 Nm (7 ft. lbs.) torque.

Connecting Valve Body Solenoid Wires:

86. Connect valve body solenoid wires to solenoids.
87. Install new O-ring on solenoid harness adapter and secure adapter to case.

Installing Valve Body Oil Tubes:

88. Install valve body oil tubes. Tap tubes into place with a plastic mallet. Be sure the flanged tube ends and straight tube ends are installed as shown.
89. Install new gaskets on oil screen and install screen on valve body. Tighten screen bolts to 10Nm (7 ft. lbs.) torque.
90. Install magnet in oil pan. Be sure that magnet doesn't interfere with valve body oil tubes.
91. Apply Threebond"R" Liquid Gasket TB1281, P/N 83504038, to sealing surface of oil pan. Sealer bead should be at least 3 mm (1/8 inch) wide. Install pan on case and tighten pan bolts to 7 Nm (65 inch lbs.) torque.

Installing Transmission Speed Sensor Rotor And Key:

92. Install transmission speed sensor rotor and key on output shaft.

Installing Spacer And Speedometer Drive Gear:

93. Install spacer and speedometer drive gear on output shaft. Then install retaining snap ring.

Applying Sealer To Case Rear Flange:

94. Apply bead of Threebond"R" Liquid. Gasket TB1281, P/N 83504038, to sealing surface at rear of case.
95. Install adapter housing on transmission. Tighten adapter bolts to 34 Nm (25 ft. lbs.) torque.

Installing Transmission Speed Sensor:

96. Install transmission speed sensor. Tighten sensor bolt to 7.4 Nm (65 inch lbs.) torque and connect sensor wire harness connector.

Installing Converter Housing:

97. Install converter housing. Tighten 12 mm diameter housing bolts to 57 Nm (42 ft. lbs.) torque. Tighten 10 mm diameter housing bolts to 34 Nm (25 ft. lbs.) torque.
98. Install transmission shift lever on manual valve shaft. Do not install lever attaching nut at this time.
99. Move transmission shift lever fully rearward. Then move lever two detent positions forward.

Park/Neutral Position Switch Installation/Adjustment:

100. Mount park/neutral position switch on manual valve shaft and tighten switch adjusting bolt just enough to keep switch from moving.
101. Install park/neutral position switch tabbed washer and retaining nut. Tighten nut to 6.9 Nm (61 inch lbs.) torque, but do not bend any of the washer tabs against the nut at this time.
102. Align park/neutral position switch standard line with groove or flat on manual shaft.
103. Tighten park/neutral position switch adjusting bolt to 13 Nm (9 ft. lbs.) torque.
104. Install transmission shift lever on manual valve shaft. Tighten lever attaching nut to 16 Nm (12 ft. lbs.) torque.

Installing Cable/Harness Clamps:

105. Install retaining clamp for wire harness and throttle cable.

Oil Pump Components AW-4 Automatic Transmission:

106. Install torque converter.
107. Verify that converter is seated by measuring distance between converter housing flange and one of the converter mounting pads. Use straightedge and vernier calipers to measure distance. On 6-cyl. transmissions, distance should be 16.5 mm (0.650 inch).
108. Secure converter in transmission with C-clamp or metal strapping. Do this before mounting transmission on jack or moving transmission under vehicle.
109. Install lower half of transmission fill tube (install upper half after transmission is in vehicle).

CAUTION: The transmission cooler and lines must be reverse flushed if overhaul corrected a malfunction that generated sludge, metal particles, or clutch friction material. The torque converter should also be replaced if contaminated by the same malfunction. Debris and residue not flushed from the cooler and lines will flow back into the transmission and converter. The result will be a repeat failure and shop comeback.