Transmission

1. If bearing (7025) was removed, position replacement bearing on Bushing Installer T61L-7657-A and install in bushing bore through the front of the case (7005).

2. Thread Impact Slide Hammer T50T-100-A into bushing installer through the back of the case. Install the bearing.
   
   
   
   

3. With transmission in the vertical position, coat case rear bearing (7F242) with petroleum jelly and install the No. 9 case rear bearing on the transmission case boss.
   
   
   
   

4. Install output shaft (7060), ring gear (7A153) and direct clutch as an assembly.
   
   
   
   

5. Install retaining ring that supports reverse band.
   
   
   
   

6. Install the reverse band. Ensure reverse band is seated on anchor pins.
   
   
   
   

   NOTE: Forward planetary assembly and planetary gear support assembly cannot be installed unless the notch cut in the planetary gear support assembly is aligned with the overdrive band anchor pin (7F295). Top of planetary gear support assembly should be below snap ring groove.

7. Install forward planetary assembly and planetary gear support assembly as a unit.

   Align notch in planetary gear support assembly with overdrive band anchor pin.

   Rotate the output shaft, if necessary, to align the planet carrier splines with the direct clutch hub splines.

   NOTE: Forward planetary assembly and planetary gear support assembly cannot be installed unless notch cut in planetary gear support assembly is aligned with overdrive band anchor pin .

   
   
   
   
   

8. Install the case to planet support spring (7F277) using a screwdriver to position.
   
   
   
   

9. Install center planet support retaining ring. Reference retainer ring end tab to anchor pin location.
   
   
   
   

10. Install forward clutch sun gear, No. 5 thrust bearing (7C096), reverse sun gear and shell and No. 4 needle bearing.
    
    
    
    

11. Install intermediate stub shaft.
    
    
    
    

12. Install forward clutch hub and No. 3 forward clutch hub front bearing (7F231).
    
    
    
    

13. Install forward clutch assembly.
    
    
    
    

    NOTE: Wiggle the output shaft while engaging the reverse clutch splines. Make sure the reverse clutch cylinder lugs are completely seated in the notches of the reverse clutch gear and shell (7A019).

14. Install reverse clutch cylinder assembly.
    
    
    
    

15. Install overdrive band (7F196) over reverse clutch assembly and position the pocket of the overdrive band against overdrive band anchor pin. Install overdrive servo piston return spring (7F201) and overdrive servo piston assembly. Verify tip of piston assembly engages the pocket of overdrive band. Using Servo Piston Remover/Replacer Tool T92P-70023-A, install piston assembly into the case and compress overdrive servo piston return spring.
    
    
    
    
    
    
    
    

16. Make sure band anchor and tip of the piston assembly are properly positioned against band pockets. Tighten tool forcing screw until piston is below retaining ring groove and install retaining ring, remove tool.
    
    
    
    

17. Install intermediate clutch as follows:
    1. Clutch pressure plate (7B066) is the thickest. Install this first with chamfer side down.
    2. Clutch plates.
    3. Perform Intermediate Clutch Selective Steel Plate Procedure.
       
       
       
       

Intermediate Clutch Selective Steel Plate Procedure

1. With proper intermediate plates selected and installed, perform end clearance check for No. 1 thrust washer using the same tools.
   
   
   
   

   NOTE: Maintain downward pressure on clutch pack while measuring depth.

2. Measure the intermediate clutch clearance using Depth Micrometer D80P- 4201-A or equivalent and Gauge Bar T80L-77003-A.

   Set the gauge bar across the pump case mounting surfaces. The depth at the intermediate clutch separator plate is:

   • 42.4-42.0mm (1.670-1.654 inch)

   Check the clearance again 180 degrees opposite to ensure the average depth is within tolerance.

   If the depth is not within tolerance, the following size selective steel plates are available:
   
   

   Selective Steel Plates
   1.80-1.7mm (0.071-0.067 inch)
   2.05-1.95mm (0.081-0.077 inch)
   2.31-2.20mm (0.091-0.087 inch)
   2.56-2.46mm (0.101-0.097 inch)

   
   

   Install correct plate and check clearance.

Transmission Selective Thrust Washer Procedure

1. Position the Depth Micrometer D80P-4201-A or equivalent on Gauge Bar T80L-77003-A so that the depth is measured at the reverse clutch drum thrust face. Check the end play 180 degrees opposite to determine the average depth. Reference selective thrust washers chart under Specifications in this section.
   
   
   
   

2. Install No. 1 thrust washer (7D014) on pump body using petroleum jelly to hold in place.
   
   
   
   

3. Install oil pump gasket (7A136). Make sure oil pump gasket is positioned and case passages are covered.

4. To maintain pump-to-case alignment, use a fabricated M8-1.25mm bolt (head removed) as a guide. Install in the 12 o'clock position using petroleum jelly on pump-to-case seal surfaces to aid pump installation.
   
   
   
   

5. To aid assembly, grasp input shaft and wiggle shaft while pressing down on pump.
   
   
   
   

6. Remove alignment bolt and install pump-to-case bolts. Alternate bolt tightening to "draw" the pump fully into the case. Tighten to 20-26 Nm (15-19 lb-ft).

   Place transmission in the horizontal position.
   
   
   
   

7. Install parking pawl (7A441) and parking pawl return spring (7D070). Slide parking pawl shaft (7D071) into case through parking pawl.
   
   
   
   

8. Install output shaft speed sensor (OSS). Tighten bolt to 7-10 Nm (5-7 lb-ft).
   
   
   
   

9. Install manual control lever oil seal (7B498) using Shift Lever Seal Replacer T74P-77498-A.
   
   
   
   

10. Install EPC solenoid.
    
    
    
    

11. Install new extension housing gasket (7086) and extension housing (7A039). Tighten bolts to 25-30 Nm (18-22 lb-ft).

12. Install extension housing seal.
    
    
    
    

13. Position manual valve detent lever (7A115) and parking lever actuating rod (7A232) into case. Parking lever actuating rod must be positioned over parking pawl.
    
    
    
    

14. Slide manual control lever (7A256) into case and position through detent. Install nut and tighten to 26-37 Nm (20-27 lb-ft).

15. Install manual lever shaft retaining pin (7B210).

16. Install oil screen into case (head first).
    
    
    
    

17. Install reverse band servo spring (7D031), reverse band servo piston and rod (7D189). To determine the correct length of the reverse servo piston, proceed as follows:
    1. Lubricate the reverse piston seal to facilitate assembly and to prevent damage to the seal.
    2. Install the reverse servo piston and return spring. Do not install the piston cover or retaining ring.
    3. Install Servo Piston Selection Tool T80L-77030-A. Tighten the band apply bolt on Servo Piston Selection Tool T80L-77030-A to 5.6 Nm (50 lb-in).
       
       
       
       
    4. Attach Dial Indicator with Bracketry TOOL-4201-C or equivalent and position the indicator stem on the flat portion of the piston. Zero the dial indicator.
       
       
       
       
    5. Thread the bolt out of the selector tool until the piston stops against the bottom of the tool.
    6. Read the amount of piston travel on the dial indicator.
       • If the travel is 2.845-6.020mm (0.112-0.237 inch), the piston length is within specification.
       • If the travel is not within specification, selective pistons are available in the following lengths:
         • ID
         • 74.56mm (2.936 inch) 1 groove
         • 75.92mm (2.989 inch) 2 grooves
         • 77.29mm (3.043 inch) 3 grooves
         • Length of rod measured from piston surface to end of rod.
         • Select the proper rod to bring the servo piston travel within specification.
    7. Lubricate the cover seal to facilitate assembly and to prevent damage to the seal.
    8. Remove the servo selection tool and dial indicator.

18. Tighten screw on Servo Piston Remover/Replacer T92P-70023-A to allow enough clearance to install retaining ring.
    
    
    
    

19. Install the components for 2-3 accumulator in the following order:

    NOTE: Retainer is secured by main control.

    • Upper accumulator seal (7F250).
    • Lower accumulator seal (7F249).
    • Accumulator piston (7F251).
    • Accumulator piston spring (7F285).
    • Accumulator spring retainer (7B264).
    
    
    
    
    

20. Install the components for 1-2 accumulator in the following order:
    • Accumulator piston seal (7F248).
    • Lower accumulator seal.
    • Accumulator piston.
    • Accumulator outer spring.
    • Cover and seal assembly.
    • Accumulator piston retaining ring (7384).
    
    
    
    
    
    

    Item	Part Number	Description
    1	7F248	Accumulator Piston Seal
    2	7F251	Accumulator Piston
    3	7F249	Lower Accumulator Seal
    4	7G267	1-2 Accumulator Outer Spring
    5	7G300	Cover and Seal Assy
    6	7384	Accumulator Piston Retaining Ring

    
    
    
    
    

    NOTE: Tab on connector is secured by main control.

21. Align and install wiring connector into case. Inspect O-ring and replace if required.
    
    
    
    

22. Position main control valve body (7A100) using the two alignment bolts as a guide.

23. Install the EPC solenoid bracket. Loosely install one long 6mm bolt.
    
    
    
    

24. Loosely install 11 long and 12 short bolts.

25. Install manual control valve detent lever spring (7A261) and one bolt.
    
    
    
    

26. Tighten the main control valve body bolts in two steps as follows:
    • Tighten the 25 retaining bolts to case to 9-11 Nm (80-100 lb-in).
    • Retighten the following bolts to the specification indicated and in sequence as indicated by the illustration:
      • 2 M8X1.25X46mm guide pin bolts to 22-26 Nm (190-230 lb-in).
      • 4 M6X1.0X18mm cover plate bolts to 9-11 Nm (80-100 lb-in).
      • 12 M6X1.0X52mm cover plate bolts to 11-15 Nm (100-130 lb-in)

27. Connect wiring connectors to transmission oil temperature sensor (TOT sensor) (7H141), shift solenoids (7G484) and EPC solenoid.
    
    
    
    

28. Install new filter and grommet.
    
    
    
    

29. Install MLP sensor on manual control lever and two shims, then loosely install bolts.
    
    
    
    

    NOTE: PARK is the last detent when the manual control lever is full forward. Return two detents toward output shaft for NEUTRAL.

30. Position manual control lever in NEUTRAL.

    Insert Gear Position Sensor Adjuster T93P-70010-A into slots. Align all three slots on manual lever position sensor with three tabs on tool.
    
    
    
    

31. Tighten MLP sensor bolts to 9-11 Nm (80-100 lb-in).

32. Install new oil pan to case gasket (7A191) and transmission oil pan (7A194). Tighten all bolts to 7-10 Nm (5-7 lb-ft).