Overhaul (Assembly)

Transmission








Special Tool(s)





Material





























Disassembled Views

4x4 vehicles





1. Using the special tool, install the rear bearing spacer.





2. Install the rear bearing spacer snap ring.

All vehicles
3. Place the transmission in the vertical position.





4. Install the shim on the end of the output shaft.





5. Install the planet carrier hub and output shaft assembly.





6. Install the silver shim on the planet carrier hub and output shaft assembly.





7. Position the park pawl pin into the case.





8. Position the park pawl into the case and push the park pawl pin in to hold the park pawl and spring In positron.





9. Install the park pawl pin bolt.

All vehicles





10. Install the roller bearing in the bottom of the carrier.





11. Install the roller bearing race in the bottom of the carrier.





12. Snap the top and the bottom roller bearings onto the sun gear.





13. NOTE: When installing the sun gear, make sure that the taper edge is facing up toward the torque converter housing.

Install the sun gear into the planet assembly.





14. Install the low/reverse sun gear.





15. Install the low/reverse bearing race.





16. Install the planet carrier.





17. Install the low/reverse clutch plates, starting with the pressure plate and alternating between the friction and steel plates, and ending with the wave spring plate on the top.





18. If not done previously, install the roller bearing onto the center support.





19. NOTE: Make sure that when installing the center support the feed holes on the center support are lined up with the feed holes in the case.

Install the center support into the case.





20. Using the special tool, install the center support snap ring. Tap the snap ring into the case to make sure that it is seated into the case.





21. NOTE: Rotate case 180 degrees.

Using the special tool, lift up on the output shaft and record the reading. The reading should be within the specification.
^ End play specification is 0.15 - 0.35 mm (0.006 - 0.013 inches)
^ If the end play is not within specification, install a new transmission.





22. Install the roller bearing if not previously installed on the direct clutch drum.





23. Install the direct clutch drum.





24. Install the roller bearing on the direct clutch assembly.





25. Install the forward and overdrive clutch assembly.





26. Install the pump washer.





27. Install the special tool into the case.





28. Using the special tools, install the front pump.





29. NOTE: Make sure that the fluid filter seal has been removed, if it has not been removed, use a suitable pick to remove the seal.

Make sure that the pump is correctly aligned with the case.





30. Loosely install the new front pump bolts with next/ xx/her





31. Install the remaining front pump bolt. Tighten the bolts in a crisscross pattern.





32. Install the special tool onto the input shaft to measure end play.
^ Tighten the wing nut.





33. Install the remaining special tool.
^ Push down on the special tool and zero out the dial indicator.
^ Lift up on the special tool and record the measurement 0.2 - 0.4 mm (0.008 - 0.015 inches). If the measurement is not within specification install a new transmission.





34. Install the park rod actuating plate.





35. Position a new manual control lever seal in place.





36. Using the special tool, install a new manual control lever shaft seal.





37. Position the manual lever and park rod in place.
^ Push down on the park pawl and slide the park rod in place.





38. Install the manual lever in the case.
1 Slide the manual lever in the case.
2 Position the spacer in place while sliding the manual lever into the spacer.
3 Position the manual valve inner lever while sliding the manual lever and lining up the roll pin hole.
4 Install the roll pin.





39. Install the four rubber feed tubes for the center support.





40. Install the rubber adapter.





41. NOTE: The mechatronic assembly will not lay flush on the case, this is normal, the retaining bolts will pull the mechatronic assembly down.

Loosely install the ten mechatronic bolts.





42. Tighten the bolts in the sequence shown.





43. Install new O-rings on the outer shell of the bulkhead electrical connector.





44. CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.

With the release tab up, push the outer shell of the bulkhead electrical connector into the transmission.





45. Press down on the tab and lock the outer shell of the bulkhead electrical connector in place.





46. Install a new fluid pan and tighten the bolts in a crisscross pattern.





47. Install the torque converter.

4x4 vehicles





48. Position a new output shaft seal in place.





49. Using the special tool, install the output shaft seal.





50. Install the extension housing and the 11 bolts.

4x2 vehicles





51. Position the output shaft seal in place.





52. Using the special tool, install the output shaft seal.





53. Install the rear transmission mount bracket.
^ Tighten to 65 Nm (48 ft. lbs.)
54. Install the anti-click washer over the output shaft.





55. Install the output shaft flange.





56. Install a new output shaft flange nut.
^ After installing the new nut, it must be staked at the slots to prevent it from coming loose.
^ Tighten to 120 Nm (89 ft. lbs.)