Part 3
TransmissionAssembly (Steps 62-118)
62. Install the overdrive brake drum and coast clutch drum assembly.
63. Install the overdrive band servo piston and spring.
^ Lubricate the servo bore with clean automatic transmission fluid.
64. Using the special tool, install the retaining ring.
65. NOTE: If the overdrive band is reused, it must be installed in the same position as when removed.
NOTE: Make sure that the overdrive band apply strut is aligned with the band notch.
NOTE: The new overdrive band is dark in color. This is a normal condition of the band. Hairline cracks in the band are also considered normal. Do not install a new band based solely on the color.
Install the overdrive band.
66. CAUTION: To avoid a fall out condition of the strut from the screw during assembly and function, the small U-shaped notch should be toward the band and the large U-shaped notch toward the main control side.
Install the overdrive anchor strut.
1 Band/case side of anchor (small U notch).
2 Main control side of anchor (large U notch).
67. CAUTION: If the strut is installed incorrectly, transmission damage will occur.
Check to make sure that the overdrive band anchor strut is installed in the correct orientation to the case and adjustment screw.
68. Loosely install the screw.
69. Install the overdrive apply strut.
70. CAUTION: If the strut is installed incorrectly, transmission damage will occur.
Check to make sure that the overdrive band apply strut is installed in the correct orientation to the case and piston rod.
71. CAUTION: The torque specifications are critical for this procedure. Failure to use the correct torque specifications may cause transmission damage.
Install the special tool.
1 Install the special tool and the bolts using the 2 pump screw locations at approximately 6 and 12 o'clock positions.
^ Tighten to 15 Nm (11 lb-ft).
2 Tighten the center screw.
^ Tighten to 1.13 Nm (10 lb-inch).
72. NOTE: Align the disc holes on special tool with the slot in gauge bar for correct measurement.
Measure the distance from the top of the gauge bar to the drum bearing surface through the hole in the disc and record as dimension A. Repeat the measurement 180 degrees on the opposite side of the special tool and record as dimension B.
73. Add dimension A to B, divide by 2 and record as dimension C.
74. Subtract the thickness of the gauge bar 17.78 mm (0.70 inch) from dimension C and record as dimension D.
75. Select the No. 1 thrust bearing from the following chart using dimension D.
76. Install the selected No. 1 fluid pump input thrust washer.
^ Coat the fluid pump input thrust washer with petroleum jelly.
77. Install the special tools into the transmission case.
78. Install the pump gasket.
79. CAUTION: Make sure that the fluid pump inlet thrust washer (No. 1), selective thrust washer, fluid pump gasket and the fluid pump-to-case O-ring seal remain in the correct position throughout this step or damage may occur.
Install the fluid pump.
80. CAUTION: The special tools must be used to correctly align the pump with the adapter plate to reduce gear noise, bushing failure and leakage.
Using the special tool, align the fluid pump to the adapter plate.
81. Install 6 screws. Tighten the screws in a star pattern.
^ Tighten to 22 Nm (16 lb-ft).
82. Remove special tool 307-399 and install the 2 remaining screws.
^ Tighten to 22 Nm (16 lb-ft).
83. CAUTION: Do not allow overdrive band adjustment screw to back out. 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.
84. CAUTION: The overdrive servo must be installed prior to band adjustment or damage may occur.
Using the special tool, tighten the overdrive band adjustment screw.
^ Tighten to 13 Nm (10 lb-ft).
^ Then back off the screw exactly 2 turns and hold that position.
85. Tighten the overdrive band locknut.
1 Hold the overdrive band adjustment screw stationary.
2 Tighten the overdrive band locknut.
^ Tighten to 54 Nm (40 lb-ft).
86. CAUTION: Do not allow the intermediate band adjusting screw to back out. 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.
87. CAUTION: The intermediate servo must be installed prior to band adjustment or damage may occur.
Using the special tool, tighten the intermediate band adjustment screw.
^ Tighten to 13 Nm (10 lb-ft).
^ Then back off the screw exactly 2 turns and hold that position.
88. 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).
89. Tighten the center support screw.
^ Tighten to 11 Nm (8 lb-ft).
90. Using the special tools, carry out the air pressure test procedure.
91. Install the special tools into the transmission case.
92. Using the special tools, install the main control valve body and loosely install the main control valve body screws.
1 Install the short main control valve body screw.
2 Install the screw with the larger head.
3 Install the remaining main control valve body screws.
93. Remove the special tools and loosely install the main control valve body screw.
94. Tighten the main control valve body screws in the sequence shown.
^ Tighten to 10 Nm (89 lb-inch).
95. With the manual lever in the NEUTRAL position, install the manual valve detent spring.
^ Tighten to 10 Nm (89 lb-inch).
96. Install new O-ring seals on the transmission control solenoid body harness connector. Lubricate the O-ring seals with clean transmission fluid.
97. CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not damaged. If damaged, transmission leak may occur.
Install the transmission control solenoid body. Tighten the transmission control solenoid body screws in the sequence shown.
^ Tighten to 8 Nm (71 lb-inch).
98. Install the reverse servo. Tighten the bolts in the sequence shown in 2 stages.
^ Stage 1: Tighten bolts to 5 Nm (44 lb-inch).
^ Stage 2: Tighten bolts to 11 Nm (8 lb-ft).
99. CAUTION: Lubricate the transmission fluid filter seals with clean transmission fluid or they may be damaged.
NOTE: Make sure that the transmission fluid filter seals are correctly seated on the transmission fluid filter.
Lubricate the transmission fluid filter seals and install the transmission fluid filter.
^ Tighten to 10 Nm (89 lb-inch).
100. NOTE: The transmission fluid pan gasket is reusable. Clean and inspect for damage. If not damaged, the transmission fluid pan gasket should be reused.
Install the transmission fluid pan and transmission fluid gasket and loosely install the transmission fluid pan screws.
101. Tighten the 16 transmission fluid pan screws in a crisscross sequence.
^ Tighten to 11 Nm (8 lb-ft).
102. Install the parking pawl assembly and gasket.
1 Install the parking pawl shaft.
2 Install the parking pawl return spring.
3 Install the parking pawl.
4 Install a new gasket.
RWD
103. Install the extension housing.
^ Tighten to 30 Nm (22 lb-ft).
104. Using the special tool, install the extension housing seal.
4WD
105. Install the extension housing.
^ Tighten to 30 Nm (22 lb-ft).
106. Using the special tool, install the extension housing seal.
107. CAUTION: The digital transmission range (TR) sensor must fit flush against the boss on the case to prevent damage to the sensor.
Install the digital transmission range (TR) sensor and loosely install the screws.
108. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged.
NOTE: The manual lever must be in the NEUTRAL position.
Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence.
^ Tighten to 8 Nm (71 lb-inch).
109. Install the outer manual lever.
^ Tighten to 48 Nm (35 lb-ft).
110. CAUTION: The splines of the input shaft are not the same length on both ends. Install shaft end with the shorter splines goes into the fluid pump or damage may occur.
Install the input shaft.
111. Using the special tool, make sure that the fluid pump gear seal ring is fully seated.
112. Remove the special tool.
113. CAUTION: Do not damage the fluid pump gear O-ring seal when installing torque converter.
CAUTION: Make sure the converter hub is fully engaged in the pump support and gear and rotates freely. Do not damage the hub seal.
CAUTION: If the torque converter slides out, the hub seal may be damaged.
Lubricate the converter hub with clean automatic transmission fluid.
114. WARNING: Secure the torque converter in the transmission during removal or installation. The torque converter is heavy and may result in injury if it falls out of the transmission. Failure to follow this instruction may result in serious personal injury.
Using the special tools, install the torque converter by pushing and rotating.
115. Lubricate the torque converter pilot hub with multi-purpose grease.
116. Using one of the speed sensor holes, fill the transmission with 8.5L (9 qt) of automatic transmission fluid.
117. NOTE: Inspect O-ring seals for damage. Install new seals if damaged. Lubricate the O-ring seals with petroleum jelly to prevent damage to the O-ring seals.
Install the sensors.
^ Tighten to 14 Nm (10 lb-ft).
118. Install the special tool.
