Transmission

Tools Required:

• Bench Mounted Holding Fixture T57L-500-B
• Grommet Remover T84P-7341-A

NOTE: If the transmission is being removed for a major overhaul, it is important to completely clean all transmission components, including converter, cooler, cooler lines, main control valve body, governor, all clutches and all check balls after any transmission servicing that generates contamination. These contaminants are a major cause for recurring transmission troubles and must be removed from the system before the transmission is put back into service.

The cleaning of debris from the direct clutch check ball is often omitted. This omission can lead to a repeat servicing of the transmission.

For cleaning and flushing procedures for transmission components, including the direct clutch check ball, refer to Cleaning and Inspection as outlined.

Removal

1. Raise vehicle on a hoist. Refer to Section 00-02.

2. Place the drain pan under the transmission oil pan. Starting at the rear of the pan and working toward the front, loosen the retaining bolts and allow the fluid to drain. Finally remove all of the pan retaining bolts except two at the front, to allow the fluid to further drain. With fluid drained, install two bolts on the rear side of the pan to temporarily hold it in place.

3. Remove the converter drain plug access cover from the lower end of the converter housing.

4. Remove the converter-to-flywheel retaining nuts. Place a wrench on the crankshaft pulley retaining bolt to turn the converter to gain access to the nuts.

5. Place a drain pan under the converter. With the wrench on the crankshaft pulley retaining bolt, turn the converter to gain access to the converter drainplug and remove the plug. After the fluid has been drained, install the plug.

6. Disconnect the driveshaft from the rear axle and slide shaft rearward from the transmission. To maintain driveshaft balance, mark the rear driveshaft yoke and axle companion flange so the driveshaft can be installed in its original position. Refer to Section 05-01. Install a seal installation tool in the extension housing to prevent fluid leakage.

7. Disconnect the cable from the terminal on the starter motor. Remove the three retaining bolts and remove the starter motor. Disconnect the neutral start switch wires at the plug connector.

8. Remove the rear mount-to-crossmember retaining bolts and the two crossmember-to-frame retaining bolts.

9. Remove the two engine rear support-to-extension housing retaining bolts.

10. Disconnect TV linkage cable from transmission TV lever ball stud.

11. Carefully disconnect manual cable from transmission manual lever at transmission using Grommet Remover T84P-7341-A. For tool usage instructions, refer to Section 07-05.

12. Remove the two bolts retaining the bellcrank bracket to the converter housing.

    NOTE: Disconnect and remove any interfering exhaust system components.

13. Raise the transmission with a transmission jack to provide clearance to remove the crossmember. Remove the rear mount from the crossmember and remove the crossmember from the side supports.

14. Lower the transmission to gain access to the oil cooler lines.

15. Disconnect each oil line from the fittings on the transmission.

16. Disconnect the speedometer cable from the extension housing.

17. Remove the bolt that retains the transmission fluid filler tube to the cylinder block. Lift the filler tube and the dipstick from the transmission.

18. Secure the transmission to the jack with a chain.

19. Remove the converter housing-to-cylinder block retaining bolts.

20. Carefully move the transmission and converter assembly away from the engine and, at the same time, lower the jack to clear the underside of the vehicle.

21. Remove the converter and mount the transmission in Bench Mounted Holding Fixture T57L-500-B.

Installation

1. Tighten converter drain plug to 11-38 Nm (8-28 lb-ft).

    CAUTION: Lubricate pilot with chassis grease.

2. Position the converter on the transmission, ensuring the converter drive flats are fully engaged in the pump gear by rotating the converter.

3. With the converter properly installed, place the transmission on the jack. Secure the transmission to the jack with a chain.

4. Rotate the converter until the studs and drain plug are in alignment with the holes in the flywheel.

5. Align the orange balancing marks on converter stud and flywheel bolt hole if balancing marks are present.

   NOTE: Before installing the torque converter to the flywheel retaining nut, a check should be made to ensure that the converter is properly seated. The converter should move freely with respect to the flywheel. Grasp the stud. Movement back and forth should result in a metallic clank noise if the converter is properly seated. If the converter will not move, the transmission must be removed and the converter repositioned so that the impeller hub is properly engaged in the pump gear.

6. Move the converter and transmission assembly forward into position, using care not to damage the flywheel and the converter pilot. The converter face must rest squarely against the flywheel. This indicates that the converter pilot is not binding in the engine crankshaft.

7. Install transmission housing-to-engine retaining bolts. Tighten to 55-68 Nm (40-50 lb-ft).

8. Remove the safety chain from around the transmission.

9. Install a new O-ring on the lower end of the transmission filler tube. Insert the tube in the transmission case and secure the tube to the engine with the retaining bolt.

10. Connect the speedometer cable to the extension housing.

11. Connect the oil cooler lines to the RH side of transmission case. Tighten lines to 16-24 Nm (12-18 lb-ft).

12. Position the crossmember on the side supports. Position the rear mount on the crossmember and install the retaining bolt and nut.

13. Secure the engine rear support to the extension housing and tighten the bolts to specification. Refer to Group 03 for Specifications.

14. If removed, install any exhaust system components.

15. Lower the transmission and remove the jack.

16. Secure the crossmember to the side supports with the retaining bolts and tighten to 95-136 Nm (70-100 lb-ft).

17. Connect the TV linkage to the transmission TV lever. Connect the manual linkage rod to the manual lever at the transmission.

18. Connect TV linkage rod or cable to transmission TV lever ball stud.

19. Connect manual linkage rod to manual lever at transmission using the Grommet Replacer T84P-7341-B. For tool usage instructions, refer to Section 07-05.

20. Install converter-to-flywheel retaining nuts. Tighten to 27-46 Nm (20-34 lb-ft).

21. Install the converter housing access cover and secure it with the retaining bolts. Tighten to 16-22 Nm (12-16 lb-ft).

22. Secure the starter motor in place with the retaining bolts. Connect the cable to the terminal on the starter. Connect the neutral start switch harness at the transmission.

23. Connect the driveshaft to the rear axle. Install the driveshaft so the index marks, made during removal, are correctly aligned.

    NOTE: Lubricate the yoke splines with Premium Long Life Grease C1AZ-19590-E (ESA-M1C75-B) or equivalent. Refer to Section 05-01.

24. Lower vehicle and fill the transmission to the correct level with Synthetic MERCON® Multi-Purpose Automatic Transmission Fluid E6AZ-19582-B (ESR-M2C163-A2) or equivalent. Start the engine and shift the transmission to all ranges, then check the fluid level. Refer to Transmission Fluid Level Check.

25. Adjust the manual shift linkage as required. Refer to Section 07-05

26. Adjust TV linkage, as outlined.