Scheme 148
Scheme 148: Lift Plate and Holding Fixture Installation
| Callout | Component Name |
|---|
| 1 | DT-47811-A Transmission Lift Plate WARNING: Handle with care, the transmission assembly weighs over 90.7 kg (200 lbs). Bodily injury could occur if not handled properly. TIP: After Installation of lift plate, raise the transmission with an overhead hoist. Tighten 12 N.m (9 lb ft) Special Tools DT-47811-A Transmission Lift Plate For equivalent regional tools, refer to Special Tools . |
| 2 | DT-46625 Transmission Holding Fixture CAUTION: Refer to Fastener Caution . TIP: Adjust mounting block on fixture to match bosses on case, then tighten bolts to: Tighten 13 N.m (10 lb ft) Special Tools DT-46625 Transmission Holding Fixture For equivalent regional tools, refer to Special Tools . |
| WARNING |
|---|
| Handle with care, the transmission assembly weighs over 90.7 kg (200 lbs). Bodily injury could occur if not handled properly. |
Lift Plate and Holding Fixture Installation
Scheme 149
Scheme 149: Torque Converter Removal
| Callout | Component Name |
|---|
| 1 | Lock Pin WARNING: Lock pin must be secured into the bench fixture to hold the transmission and prevent bodily injury. TIP: Ensure the DT 3289-20 holding fixture is mounted to a bench that is properly supported and will support the weight of the transmission assembly without tipping. DT-39890 holding fixture adapter adapter and an engine stand can be used as an alternative method for supporting the transmission assembly during repairs. Special Tools DT 3289-20 Holding Fixture DT-39890 Transmission Holding Fixture Adapter For equivalent regional tools, refer to Special Tools . |
| 2 | DT 21366 Converter Holding Strap For equivalent regional tools, refer to Special Tools . |
| 3 | Dust Cover Bolts M10 x 25, model dependent (Qty: 2) |
| 4 | Dust Cover Push Pin, model dependent |
| 5 | Dust Cover, model dependent |
| 6 | Torque Converter Assembly CAUTION: Only install the lift assist handles until it stops. Do not tighten. Over tightening the lift assist handles can cause damage to the torque converter. TIP: Failure to raise the torque converter straight up could damage the torque converter clutch lip seal inside the torque converter clutch assembly. Special Tools DT 46409 Torque Converter Lifting Handles For equivalent regional tools, refer to Special Tools . |
| WARNING |
|---|
| Lock pin must be secured into the bench fixture to hold the transmission and prevent bodily injury. |
| CAUTION |
|---|
| Only install the lift assist handles until it stops. Do not tighten. Over tightening the lift assist handles can cause damage to the torque converter. |
Scheme 150
Scheme 150: Control Valve Body Cover Removal
| Callout | Component Name |
|---|
| 1 | Control Valve Body Cover Stud M6 x 30 (Qty: 2) |
| 2 | Control Valve Body Cover Bolt M6 x 30 (Qty: 12) |
| 3 | Control Valve Body Cover |
| 4 | Control Valve Body Cover Gasket TIP: Do not re-use the valve body cover gasket. |
| 5 | Control Valve Body Cover Wiring Connector Hole Seal CAUTION: Support the control solenoid valve assembly around the connector when removing the seal. Excessive pulling force can damage the internal electrical connections. |
| 6 | Shift Position Switch Connector |
| 7 | Output Speed Sensor Connector |
| 8 | Input Speed Sensor Connector |
| CAUTION |
|---|
| Support the control solenoid valve assembly around the connector when removing the seal. Excessive pulling force can damage the internal electrical connections. |
Control Valve Body Cover Removal
Scheme 151
Scheme 151: Control Solenoid (w/Body and TCM) Valve Assembly Removal
| Callout | Component Name |
|---|
| 1 | Control Valve Body Bolt M6 x 80 (Qty: 4) |
| 2 | Control Solenoid Valve Spring |
| 3 | Control Valve Body Bolt M6 x 65 (Qty: 2) |
| 4 | Control Valve Body Bolt M6 x 42 (Qty: 1) |
| 5 | Control Valve Body Bolt M6 x 95 (Qty: 3) |
| 6 | Control Valve Body Bolt M6 x 55 (Qty: 1) |
| 7 | Control Solenoid (w/Body and TCM) Valve Assembly |
| 8 | Control Solenoid Valve Assembly Filter Plate CAUTION: Use care when removing or installing the filter plate assembly. A broken or missing retaining tab may not adequately secure the filter plate to the control solenoid valve assembly, resulting in possible damage or contamination. Discard the filter plate. It is not reusable. Inspect the pressure switch manifold seals for damage. Replace the control valve assembly as necessary. |
| CAUTION |
|---|
| Use care when removing or installing the filter plate assembly. A broken or missing retaining tab may not adequately secure the filter plate to the control solenoid valve assembly, resulting in possible damage or contamination. |
Control Solenoid (w/Body and TCM) Valve Assembly Removal
Scheme 152
Scheme 152: Control Valve Body Assembly and Output Speed Sensor Removal
| Callout | Component Name |
|---|
| 1 | Control Valve Body Bolt M6 x 65 (Qty: 8) |
| 2 | Control Valve Body Bolt M6 x 55 (Qty: 2) |
| 3 | Manual Shaft Detent Assembly |
| 4 | Control Valve Body Assembly |
| 5 | A/Trans Output Speed Sensor Bolt M6 x 25 |
| 6 | A/Trans Output Speed Sensor |
| 7 | 1-2-3-4 Clutch Fluid Passage Seal TIP: The seal is not reusable. |
Control Valve Body Assembly and Output Speed Sensor Removal
Scheme 153
Scheme 153: Case Cover and 3-5-Reverse and 4-5-6 Clutch Housing Removal
| Callout | Component Name |
|---|
| 1 | A/Trans Case Cover Assembly Bolt M6 x 30 (Qty: 10) |
| 2 | A/Trans Case Cover Assembly CAUTION: Use care when pulling the input speed sensor wire harness through the case to avoid damaging the harness. |
| 3 | A/Trans Case Cover Gasket TIP: The gasket is not reusable. |
| 4 | Input Shaft Thrust Bearing Assembly TIP: The bearing may be stuck to the case cover. |
| 5 | 3-5 Rev/4-5-6 Clutch Housing Assembly |
| CAUTION |
|---|
| Use care when pulling the input speed sensor wire harness through the case to avoid damaging the harness. |
Case Cover and 3-5-Reverse and 4-5-6 Clutch Housing Removal
Scheme 154
Scheme 154: Reaction Carrier Hub and 2-6 Clutch Plate Removal
| Callout | Component Name |
|---|
| 1 | 2-6 Clutch Hub Thrust Bearing Assembly TIP: The 2-6 clutch hub thrust bearing assembly may be stuck to the reaction carrier hub assembly. |
| 2 | Reaction Sun Gear Assembly |
| 3 | 2-6 Clutch Cushion Spring |
| 4 | 2-6 Clutch Plate (Qty: 3) |
| 5 | 2-6 Clutch (w/Friction Material) Plate Assembly (Qty: 3) |
| 6 | 2-6 Clutch Backing Plate |
Reaction Carrier Hub and 2-6 Clutch Plate Removal
Scheme 155
Scheme 155: Input, Reaction, and Output Carrier Removal
| Callout | Component Name |
|---|
| 1 | Reaction (w/Input Internal Gear) Carrier Assembly |
| 2 | Input Carrier Thrust Bearing Assembly |
| 3 | Input Sun Gear Thrust Bearing Assembly |
| 4 | Input (w/Output Internal Gear) Carrier Assembly |
| 5 | Input Sun Gear |
| 6 | Output Carrier Thrust Bearing Assembly |
| 7 | Output Carrier Thrust Bearing Assembly |
| 8 | Output Carrier Assembly |
| 9 | Output Sun Gear Assembly |
| 10 | Front Differential Transfer Drive Gear Input Hub Bearing Assembly |
| 11 | Output Carrier Transfer Drive Gear Hub Assembly |
| 12 | Output Carrier Transfer Drive Gear Hub Bearing Assembly TIP: The bearing may be stuck to the support assembly. |
Input, Reaction, and Output Carrier Removal
Scheme 156
Scheme 156: Low and Reverse Clutch Plate Removal
| Callout | Component Name |
|---|
| 1 | Low and Reverse Clutch Cushion (Waved) Spring |
| 2 | Low and Reverse Clutch Apply Plate |
| 3 | Low and Reverse Clutch (w/Friction Material) Plate Assembly (Qty: 4) |
| 4 | Low and Reverse Clutch Plate (Qty: 3) |
| 5 | Low and Reverse Clutch Backing Plate |
Low and Reverse Clutch Plate Removal
Scheme 157
Scheme 157: Low and Reverse Clutch and 1-2-3-4 Clutch Plate Removal
| Callout | Component Name |
|---|
| 1 | Low and Reverse Clutch Retainer Ring |
| 2 | Low and Reverse Clutch Assembly |
| 3 | 1-2-3-4 Clutch (w/Friction Material) Plate Assembly (Qty: 2) |
| 4 | 1-2-3-4 Clutch Plate (Qty: 2) |
| 5 | 1-2-3-4 Clutch (Waved) Plate |
| 6 | 1-2-3-4 Clutch Spring Retainer Ring |
| 7 | 1-2-3-4 Clutch Spring |
| 8 | 1-2-3-4 Clutch Piston Use pliers to remove the piston. Inspect the piston seals for damage and/or wear. The piston is reusable. |
Low and Reverse Clutch and 1-2-3-4 Clutch Plate Removal
Scheme 158
Scheme 158: Torque Converter and Differential Housing, Front Differential Transfer Drive Gear, and Front Differe
| Callout | Component Name |
|---|
| 1 | Torque Converter and Differential Housing Bolt M8 x 35 (Qty: 17) |
| 2 | Torque Converter, Support and A/Trans Fluid Pump Housing Assembly |
| 3 | Torque Converter Housing Outer Seal TIP: The seal is not reusable. |
| 4 | Front Differential Drive Pinion Gear Lube Tube |
| 5 | Front Differential Drive Pinion (w/Transfer Gear) Gear Assembly |
| 6 | Front Differential Carrier Assembly |
Torque Converter and Differential Housing, Front Differential Transfer Drive Gear, and Front Differential Carrier Removal
Scheme 159
Scheme 159: Fluid Trough Removal
| Callout | Component Name |
|---|
| 1 | A/Trans Fluid Trough Bolt M6 x 25 (Qty: 1) |
| 2 | A/Trans Fluid Trough |
| 3 | A/Trans Fluid Trough (O-Ring) Seal |
| 4 | A/Trans Fluid Pump Outlet Seal Assembly TIP: The seal assembly is not reusable. |
Scheme 160
Scheme 160: Manual Shift Detent Lever with Shaft Position Switch Assembly and Park Pawl Actuator Removal
| Callout | Component Name |
|---|
| 1 | Park Pawl Actuator Bracket Bolt M6 x 25 (Qty: 2) |
| 2 | Park Pawl Actuator Bracket |
| 3 | Park Pawl Shaft |
| 4 | Park Pawl |
| 5 | Park Pawl Spring |
| 6 | Park Pawl Actuator Guide Pin |
| 7 | Park Pawl Actuator Guide |
| 8 | Manual Shift Detent Lever Pin Use a small nail puller or other suitable tool. Discard the pin. The pin is not reusable. Special Tools DT 23129 Universal Seal Remover GE 6125-1B Slide Hammer with Adapter For equivalent regional tools, refer to Special Tools . |
| 9 | Manual Shaft Detent (w/Shift Position Switch) Lever Assembly TIP: Rotate the assembly counterclockwise so the actuator rod will fit through the case opening. |
| 10 | Park Pawl Actuator Assembly |
Manual Shift Detent Lever with Shaft Position Switch Assembly and Park Pawl Actuator Removal
Scheme 161
Scheme 161: Manual Shift Shaft Seal Replacement
| Callout | Component Name |
|---|
| 1 | Manual Shift Shaft Seal Special Tools DT 45201 Cooler Line Seal Remover DT 46626 Seal Installer For equivalent regional tools, refer to Special Tools . |
Manual Shift Shaft Seal Replacement
Scheme 162
Scheme 162: Front Wheel Drive Shaft Seal Replacement - Case Side
| Callout | Component Name |
|---|
| 1 | Front Wheel Drive Shaft Oil Seal Assemble TIP: Use the flat side of J 46629-A seal installer to seat the seal to the case surface. Special Tools DT 23129 Universal Seal Remover DT 46629-A Seal Installer GE 6125-1B Slide Hammer GE 8092 Driver Handle For equivalent regional tools, refer to Special Tools . |
Front Wheel Drive Shaft Seal Replacement - Case Side
Scheme 163
Scheme 163: Front Differential Carrier Bearing Cup Replacement - Case Side
| Callout | Component Name |
|---|
| 1 | Front Differential Bearing Cup CAUTION: Support the back side of the case before installing the bearing cup. Apply a light coating of transmission fluid to the bore before pressing the cup into position. Install the bearing cup until it stops moving. Applying excessive pressure to the bearing cup once it is seated could cause damage to the case casting. CAUTION: An unseated or improperly installed bearing cup will result in premature bearing failure. Visually inspect the bearing cup to insure there is "no gap" between the case, thrust washer, and the bearing cup. Use of a feeler gauge may assist in identifying a bearing cup that is not fully seated. CAUTION: Failure to apply the lubricant will cause damage to the bolt and nut threads. CAUTION: There are first and second design front differential bearing cups. First design bearing cups are manufactured by Timken. Second design bearing cups are manufactured by NSK. Second design bearing cups require DT-45087-A cup installer. If installing second design bearing cups, second design front differential carrier bearings must be used. All four parts must be kept as a set to prevent damage to the transmission. Tighten DT-47927-2 which is part of DT-47927 cup remover until it fits snugly on the bearing cup. Adjust DT 45124 removal bridge so it sits on the torque converter housing surface just beyond the bearing cup opening. Apply the extreme pressure lubricant DT 23444-A extreme press lubricant to the puller bolt threads to prevent damage to the bolt threads during bearing cup removal. Hold the puller bridge bolt and turn the nut to remove the bearing cup. Special Tools DT 23444-A Extreme Press Lubricant - 1/4 Ounce Tube DT-45087 Bearing Cup Installer DT-45087-A Bearing Cup Installer DT 45124 Removal Bridge DT-47927 Bearing Cup Remover For equivalent regional tools, refer to Special Tools . |
| CAUTION |
|---|
| Support the back side of the case before installing the bearing cup. Apply a light coating of transmission fluid to the bore before pressing the cup into position. Install the bearing cup until it stops moving. Applying excessive pressure to the bearing cup once it is seated could cause damage to the case casting. |
| CAUTION |
|---|
| An unseated or improperly installed bearing cup will result in premature bearing failure. Visually inspect the bearing cup to insure there is "no gap" between the case, thrust washer, and the bearing cup. Use of a feeler gauge may assist in identifying a bearing cup that is not fully seated. |
| CAUTION |
|---|
| Failure to apply the lubricant will cause damage to the bolt and nut threads. |
| CAUTION |
|---|
| There are first and second design front differential bearing cups. First design bearing cups are manufactured by Timken. Second design bearing cups are manufactured by NSK. Second design bearing cups require DT-45087-A cup installer. If installing second design bearing cups, second design front differential carrier bearings must be used. All four parts must be kept as a set to prevent damage to the transmission. |
Front Differential Carrier Bearing Cup Replacement - Case Side
Scheme 164
| Callout | Component Name |
|---|
| 1 | Front Differential Drive Pinion Gear Bearing Cup CAUTION: Failure to apply the lubricant will cause damage to the bolt and nut threads. Tighten DT-45094 cup remover until it fits snugly on the bearing cup. Adjust DT 45124 removal bridge so it sits on the case surface just beyond the bearing cup opening. Apply the extreme pressure lubricant DT 23444-A extreme press lubricant to the puller bolt threads to prevent damage to the bolt threads during bearing cup removal. Hold the puller bridge nut and turn the bolt to remove the bearing cup. Special Tools DT 23444-A Extreme Press Lubricant - 1/4 Ounce Tube DT-45094 Bearing Cup Remover DT 45124 Removal Bridge For equivalent regional tools, refer to Special Tools . |
| 2 | Front Differential Drive Pinion Gear Lube Dam Special Tools DT-48055 Lube Dam Removal GE 6125-1B Slide Hammer with Adapter For equivalent regional tools, refer to Special Tools . |
| CAUTION |
|---|
| Failure to apply the lubricant will cause damage to the bolt and nut threads. |
Scheme 165
| Callout | Component Name |
|---|
| 1 | Front Differential Drive Pinion Gear Lube Dam Special Tools DT-46630 Lube Dam Installer GE 8092 Driver Handle For equivalent regional tools, refer to Special Tools . |
| 2 | Front Differential Drive Pinion Gear Bearing Cup CAUTION: Support the back side of the case before installing the bearing cup. Apply a light coating of transmission fluid to the bore before pressing the cup into position. Install the bearing cup until it stops moving. Applying excessive pressure to the bearing cup once it is seated could cause damage to the case casting. CAUTION: An unseated or improperly installed bearing cup will result in premature bearing failure. Visually inspect the bearing cup to insure there is "no gap" between the case, thrust washer, and the bearing cup. Use of a feeler gauge may assist in identifying a bearing cup that is not fully seated. Special Tools DT-45087 Bearing Cup Installer For equivalent regional tools, refer to Special Tools . |
| CAUTION |
|---|
| Support the back side of the case before installing the bearing cup. Apply a light coating of transmission fluid to the bore before pressing the cup into position. Install the bearing cup until it stops moving. Applying excessive pressure to the bearing cup once it is seated could cause damage to the case casting. |
| CAUTION |
|---|
| An unseated or improperly installed bearing cup will result in premature bearing failure. Visually inspect the bearing cup to insure there is "no gap" between the case, thrust washer, and the bearing cup. Use of a feeler gauge may assist in identifying a bearing cup that is not fully seated. |
Scheme 166
Scheme 166: Transmission Case Cleaning and Inspection
| Callout | Component Name |
|---|
| CAUTION: Do not use abrasive pads or bristle devices to clean the sealing surfaces. Abrasive pads produce a fine grit that can effect transmission function. Abrasive pads can also remove enough metal to create oil leaks. CAUTION: After cleaning the transmission components, allow to air dry. Do not use cloth or paper towels in order to dry any transmission components. Lint from the towels can cause component failure. CAUTION: Do not reuse cleaning solvents. Previously used solvents may deposit sediment which may damage the component. Preliminary Procedures Thoroughly clean the transmission case assembly, including case threads, with clean solvent. Clean gasket sealing surfaces. Remove all residual gasket material. Inspect all threaded holes. If necessary, repair any thread damage. |
| 1 | Case Cover Sealing Surface |
| 2 | Manual Shift Shaft Seal Surface TIP: Refer to Manual Shift Shaft Seal Replacement . |
| 3 | Fluid Pressure Test Plug |
| 4 | Fluid Drain Plug |
| 5 | Control Valve Body Cover Sealing Surface |
| 6 | Torque Converter Housing Sealing Surface |
| 7 | Transmission Fluid Cooler Pipe Stud M8 x 30.5 (Qty: 2) CAUTION: Refer to Fastener Caution . Tighten 12 N.m (106 lb in) |
| 8 | Transmission Case Cover Locator Pin Procedure Inspect the locating pins to be fully seated in case. |
| CAUTION |
|---|
| Do not use abrasive pads or bristle devices to clean the sealing surfaces. Abrasive pads produce a fine grit that can effect transmission function. Abrasive pads can also remove enough metal to create oil leaks. |
| CAUTION |
|---|
| After cleaning the transmission components, allow to air dry. Do not use cloth or paper towels in order to dry any transmission components. Lint from the towels can cause component failure. |
| CAUTION |
|---|
| Do not reuse cleaning solvents. Previously used solvents may deposit sediment which may damage the component. |
Transmission Case Cleaning and Inspection
Scheme 167
Scheme 167: Manual Shift Detent Lever with Shaft Position Switch Assembly and Park Pawl Actuator Installation
| Callout | Component Name |
|---|
| 1 | Park Pawl Actuator Guide |
| 2 | Park Pawl Actuator Guide Pin |
| 3 | Park Pawl |
| 4 | Park Pawl Shaft |
| 5 | Park Pawl Spring |
| 6 | Park Pawl Actuator Bracket |
| 7 | Park Pawl Actuator Bracket Bolt M6 x 25 (Qty: 2) CAUTION: Refer to Fastener Caution . Tighten 12 N.m (106 lb in). |
| 8 | Park Pawl Actuator Assembly TIP: Install the park pawl actuator assembly onto the detent lever assembly. |
| 9 | Manual Shaft Detent (w/Shift Position Switch) Lever Assembly Rotate the assembly clockwise so the actuator rod will fit through the case opening. Lubricate shaft with ATF to prevent damage to the manual shift shaft seal. |
| 10 | Manual Shift Shaft Pin CAUTION: Use J 41229 to install the manual shaft pin at the correct height in order to properly secure the manual shaft. If you install the pin too deep, the case bore may crack. Procedure Use a NEW pin to ensure proper engagement to the case. Inspect pin installed height is within 6.5-7.5 mm (0.25-0.30 in). Special Tools DT 41229 Manual Shaft Pin Installer For equivalent regional tools, refer to Special Tools . |
| CAUTION |
|---|
| Use J 41229 to install the manual shaft pin at the correct height in order to properly secure the manual shaft. If you install the pin too deep, the case bore may crack. |
Manual Shift Detent Lever with Shaft Position Switch Assembly and Park Pawl Actuator Installation
Scheme 168
Scheme 168: Fluid Trough Installation
| Callout | Component Name |
|---|
| 1 | A/Trans Fluid Pump Outlet Seal Assembly |
| 2 | A/Trans Fluid Trough (O-ring) Seal |
| 3 | A/Trans Fluid Trough |
| 4 | A/Trans Fluid Trough Bolt M6 x 25 (Qty: 1) CAUTION: Refer to Fastener Caution . Tighten 12 N.m (106 lb in). |
Fluid Trough Installation
Scheme 169
Scheme 169: Torque Converter and Differential Housing Assembly Disassemble
| Callout | Component Name |
|---|
| 1 | Front Differential Carrier Baffle Bolt M6 x 25 |
| 2 | Front Differential Carrier Baffle |
| 3 | Front Differential Transfer Drive Gear Support Bolt M8 x 25 (Qty: 9) |
| 4 | Front Differential Transfer Drive Gear Support Assembly |
| 5 | Drive Sprocket Thrust Washer |
| 6 | A/Trans Fluid Pump Bolt M6 x 25 (Qty: 3) |
| 7 | A/Trans Fluid Pump Assembly |
| 8 | Drive Link Assembly TIP: Link and sprockets will be removed as an assembly. |
| 9 | Drive Sprocket Thrust Washer TIP: Drive sprocket thrust washer may be stuck to the torque converter housing. |
| 10 | Driven Sprocket Thrust Washer |
Torque Converter and Differential Housing Assembly Disassemble
Scheme 170
Scheme 170: Front Differential Carrier Bearing Cup and Washer Replacement - Torque Converter Housing Side
| Callout | Component Name |
|---|
| Preliminary Procedures Do not install the bearing cup until after the selective washer measurement has been performed. Install the correct differential bearing washer as determined by the thrust washer measurement procedure. Refer to Front Differential Drive Pinion Gear Bearing Thrust Washer and Front Differential Bearing Washer Measurement . |
| 1 | Front Differential Bearing Thrust Washer |
| 2 | Front Differential Carrier Bearing Cup CAUTION: Support the back side of the torque converter housing before installing the bearing cup. Apply a light coating of transmission fluid to the bore before pressing the cup into position. Install the bearing cup until it stops moving. Applying excessive pressure to the bearing cup once it is seated could cause damage to the torque converter housing casting. CAUTION: An unseated or improperly installed bearing cup will result in premature bearing failure. Visually inspect the bearing cup to insure there is "no gap" between the converter housing, thrust washer, and the bearing cup. Use of a feeler gauge may assist in identifying a bearing cup that is not fully seated. CAUTION: Failure to apply the lubricant will cause damage to the bolt and nut threads. CAUTION: There are first and second design front differential bearing cups. First design bearing cups are manufactured by Timken. Second design bearing cups are manufactured by NSK. Second design bearing cups require DT-45087-A cup installer. If installing second design bearing cups, second design front differential carrier bearings must be used. All four parts must be kept as a set to prevent damage to the transmission. Procedure Tighten DT 47927-1 which is part of DT-47927 bearing cup remover until it fits snugly on the bearing cup. Adjust DT 45124 remover bridge so it sits on the torque converter housing surface just beyond the bearing cup opening. Apply the extreme pressure lubricant supplied with DT 23444-A extreme press lubricant to the puller bolt threads to prevent damage to the bolt threads during bearing cup removal. Hold the puller bridge bolt and turn the nut to remove the bearing cup. Special Tools DT 23444-A Extreme Press Lubricant - 1/4 Ounce Tube DT-45087 Bearing Cup Installer DT-45087-A Bearing Cup Installer DT 45124 Remover Bridge DT-47927 Bearing Cup Remover For equivalent regional tools, refer to Special Tools . |
| CAUTION |
|---|
| Support the back side of the torque converter housing before installing the bearing cup. Apply a light coating of transmission fluid to the bore before pressing the cup into position. Install the bearing cup until it stops moving. Applying excessive pressure to the bearing cup once it is seated could cause damage to the torque converter housing casting. |
| CAUTION |
|---|
| An unseated or improperly installed bearing cup will result in premature bearing failure. Visually inspect the bearing cup to insure there is "no gap" between the converter housing, thrust washer, and the bearing cup. Use of a feeler gauge may assist in identifying a bearing cup that is not fully seated. |
| CAUTION |
|---|
| Failure to apply the lubricant will cause damage to the bolt and nut threads. |
| CAUTION |
|---|
| There are first and second design front differential bearing cups. First design bearing cups are manufactured by Timken. Second design bearing cups are manufactured by NSK. Second design bearing cups require DT-45087-A cup installer. If installing second design bearing cups, second design front differential carrier bearings must be used. All four parts must be kept as a set to prevent damage to the transmission. |
Front Differential Carrier Bearing Cup and Washer Replacement - Torque Converter Housing Side
Scheme 171
Scheme 171: Bearing Cup, Washer and Lubricant Dam Removal
| Callout | Component Name |
|---|
| Preliminary Procedure Do not install the bearing cup until after the selective washer measurement has been performed. |
| 1 | Front Differential Drive Pinion Gear Bearing Cup CAUTION: Failure to apply the lubricant will cause damage to the bolt and nut threads. Procedure Tighten DT-45094 bearing cup remover until it fits snugly on the bearing cup. Adjust DT 45124 removal bridge so it sits on the torque converter housing surface just beyond the bearing cup opening. Apply the extreme pressure lubricant DT 23444-A extreme press lubricant to the puller bolt threads to prevent damage to the bolt threads during bearing cup removal. Hold the puller bridge bolt and turn the nut to removal the bearing cup. Special Tools DT 23444-A Extreme Press Lubricant - 1/4 Ounce Tube DT-45087 Transfer Shaft and Differential Bearing Cup Installer DT-45094 Bearing Cup Remover DT 45124 Removal Bridge DT-47927 Bearing Cup Remover For equivalent regional tools, refer to Special Tools . |
| 2 | Front Differential Drive Pinion Gear Bearing Thrust Washer |
| 3 | Front Differential Drive Pinion Gear Lube Dam Special Tools DT-48055 Lube Dam Remover GE 6125-1B Slide Hammer with Adapter or equivalent For equivalent regional tools, refer to Special Tools . |
| CAUTION |
|---|
| Failure to apply the lubricant will cause damage to the bolt and nut threads. |
Bearing Cup, Washer and Lubricant Dam Removal
Scheme 172
Scheme 172: Bearing Cup, Washer and Lubricant Dam Installation
| Callout | Component Name |
|---|
| Preliminary Procedure Do not install the bearing cup until after the selective washer measurement has been performed. |
| 1 | Front Differential Drive Pinion Gear Lube Dam Special Tools DT-46630 Lube Dam Installer GE 8092 Driver Handle For equivalent regional tools, refer to Special Tools . |
| 2 | Front Differential Drive Pinion Gear Bearing Thrust Washer TIP: Install the correct drive pinion gear bearing thrust washer as determined by the thrust washer measurement procedure. Refer to Front Differential Drive Pinion Gear Bearing Thrust Washer and Front Differential Bearing Washer Measurement . |
| 3 | Front Differential Drive Pinion Gear Bearing Cup CAUTION: Support the back side of the torque converter housing before installing the bearing cup. Apply a light coating of transmission fluid to the bore before pressing the cup into position. Install the bearing cup until it stops moving. Applying excessive pressure to the bearing cup once it is seated could cause damage to the torque converter housing casting. CAUTION: An unseated or improperly installed bearing cup will result in premature bearing failure. Visually inspect the bearing cup to insure there is "no gap" between the converter housing, thrust washer, and the bearing cup. Use of a feeler gauge may assist in identifying a bearing cup that is not fully seated. Special Tools DT-45087 Bearing Cup Installer For equivalent regional tools, refer to Special Tools . |
| CAUTION |
|---|
| Support the back side of the torque converter housing before installing the bearing cup. Apply a light coating of transmission fluid to the bore before pressing the cup into position. Install the bearing cup until it stops moving. Applying excessive pressure to the bearing cup once it is seated could cause damage to the torque converter housing casting. |
| CAUTION |
|---|
| An unseated or improperly installed bearing cup will result in premature bearing failure. Visually inspect the bearing cup to insure there is "no gap" between the converter housing, thrust washer, and the bearing cup. Use of a feeler gauge may assist in identifying a bearing cup that is not fully seated. |
Bearing Cup, Washer and Lubricant Dam Installation
Scheme 173
Scheme 173: Front Wheel Drive Shaft Seal Replacement - Torque Converter Housing Side
| Callout | Component Name |
|---|
| 1 | Torque Converter - Front Wheel Drive Shaft Oil Seal Assembly TIP: Use the open side of DT 46629-A seal installer to avoid seal lip damage and to install the seal to the proper depth. Special Tools DT 23129 Universal Seal Remover DT 46629-A Seal Installer GE 6125-1B Slide Hammer with Adapter GE 8092 Driver Handle For equivalent regional tools, refer to Special Tools . |
Front Wheel Drive Shaft Seal Replacement - Torque Converter Housing Side
Scheme 174
Scheme 174: Torque Converter Housing Cleaning and Inspection
| Callout | Component Name |
|---|
| CAUTION: After cleaning the transmission components, allow to air dry. Do not use cloth or paper towels in order to dry any transmission components. Lint from the towels can cause component failure. CAUTION: Do not reuse cleaning solvents. Previously used solvents may deposit sediment which may damage the component. CAUTION: Do not use abrasive pads or bristle devices to clean the sealing surfaces. Abrasive pads produce a fine grit that can effect transmission function. Abrasive pads can also remove enough metal to create oil leaks. Preliminary Procedure Thoroughly clean the torque converter and differential housing, including threads, with clean solvent. |
| 1 | Threaded Holes |
| 2 | Gasket Sealing Surfaces |
| CAUTION |
|---|
| After cleaning the transmission components, allow to air dry. Do not use cloth or paper towels in order to dry any transmission components. Lint from the towels can cause component failure. |
| CAUTION |
|---|
| Do not reuse cleaning solvents. Previously used solvents may deposit sediment which may damage the component. |
| CAUTION |
|---|
| Do not use abrasive pads or bristle devices to clean the sealing surfaces. Abrasive pads produce a fine grit that can effect transmission function. Abrasive pads can also remove enough metal to create oil leaks. |
Torque Converter Housing Cleaning and Inspection
Scheme 175
Scheme 175: Torque Converter Fluid Seal Replacement
| Callout | Component Name |
|---|
| 1 | Torque Converter Fluid Seal CAUTION: Support the back side of the torque converter housing while installing the seal. Install the seal until it stops moving. Applying excessive pressure to the seal once it is seated could cause damage to the torque converter housing casting. Special Tools DT 23129 Universal Seal Remover DT 49861 Seal Installer GE 6125-1B Slide Hammer with Adapter or equivalent For equivalent regional tools, refer to Special Tools . |
| CAUTION |
|---|
| Support the back side of the torque converter housing while installing the seal. Install the seal until it stops moving. Applying excessive pressure to the seal once it is seated could cause damage to the torque converter housing casting. |
Torque Converter Fluid Seal Replacement
Scheme 176
| Callout | Component Name |
|---|
| CAUTION: Do not remove the transfer drive gear bearing retaining nut. The drive gear and bearing are not serviceable. Removing the retaining nut will damage the support. Preliminary Procedure Inspect the support assembly for damage or wear to the splines, bushings, machined surfaces and threaded holes. Inspect the transfer drive gear for damage or wear. Inspect the transfer drive gear bearing assembly for proper operation. The bearing should roll smoothly and quietly. |
| 1 | Front Differential Transfer Drive Gear Support Seal Special Tools DT 23129 Universal Seal Remover GE 6125-1B Slide Hammer with Adapter or equivalent For equivalent regional tools, refer to Special Tools . |
| 2 | Front Differential Transfer Drive Gear Support Torque Converter Fluid Seal Assembly |
| CAUTION |
|---|
| Do not remove the transfer drive gear bearing retaining nut. The drive gear and bearing are not serviceable. Removing the retaining nut will damage the support. |
Scheme 177
Scheme 177: Fluid Passage Tube Removal
| Callout | Component Name |
|---|
| CAUTION: Do not remove the transfer drive gear bearing retaining nut. The drive gear and bearing are not serviceable. Removing the retaining nut will damage the support. Preliminary Procedures Inspect the support assembly for damage or wear to the splines, bushings, machined surfaces and threaded holes. Inspect the transfer drive gear for damage or wear. Inspect the transfer drive gear bearing assembly for proper operation. The bearing should roll smoothly and quietly. |
| 1 | Front Differential Transfer Drive Gear Fluid Passage Tube Bolt M6 x 15 (Qty: 2) |
| 2 | Front Differential Transfer Drive Gear Fluid Passage Tube Bolt M5 x 12 (Qty: 2) |
| 3 | Fluid Passage Tube Assembly TIP: Inspect the tubes for damage, wear or cracked welds. |
| 4 | Front Differential Transfer Drive Gear Support Fluid Passage Tube Gasket |
| 5 | Front Differential Transfer Drive Gear Support Seal |
| CAUTION |
|---|
| Do not remove the transfer drive gear bearing retaining nut. The drive gear and bearing are not serviceable. Removing the retaining nut will damage the support. |
Fluid Passage Tube Removal
Scheme 178
Scheme 178: Drive Support Seal Installation
| Callout | Component Name |
|---|
| 1 | Front Differential Transfer Drive Gear Support Seal TIP: A NEW seal must be installed. Special Tools DT-46624 Support Seal Installer For equivalent regional tools, refer to Special Tools . |
| 2 | Small Chamfer Faces Up CAUTION: To avoid damaging the seal, first place DT 46624-1 with the small chamfer end facing up and leave in place for at least 60 seconds. |
| 3 | Large Chamfer Faces Up TIP: Turn DT 46624-1 which is part of DT-46624 seal installer , over with the large chamfer end facing up for 60 seconds to ensure that the seal has been properly sized. |
| CAUTION |
|---|
| To avoid damaging the seal, first place DT 46624-1 with the small chamfer end facing up and leave in place for at least 60 seconds. |
Drive Support Seal Installation
Scheme 179
Scheme 179: Fluid Passage Tube Installation
| Callout | Component Name |
|---|
| 1 | Front Differential Transfer Drive Gear Support Fluid Passage Tube Gasket |
| 2 | Fluid Passage Tube Assembly |
| 3 | Front Differential Transfer Drive Gear Fluid Passage Tube Bolt M6 x 15 (Qty: 2) CAUTION: Refer to Fastener Caution . Tighten 12 N.m (106 lb in) |
| 4 | Front Differential Transfer Drive Gear Fluid Passage Tube Bolt M5 x 12 (Qty: 2) Tighten 7 N.m (62 lb in) |
Fluid Passage Tube Installation
Scheme 180
Scheme 180: Seal Installation
| Callout | Component Name |
|---|
| 1 | Front Differential Transfer Drive Gear Support Seal CAUTION: Ensure staking does not line up with lubrication holes or the holes may be damaged. Stop driving the seal once it bottoms out to avoid seal damage. TIP: The fluid seal assembly must be staked in place using DT-49131 seal staking tool to ensure proper seal retention. Special Tools DT-46627-A Seal Installer DT-49131 Seal Staking Tool For equivalent regional tools, refer to Special Tools . |
| 2 | Front Differential Transfer Drive Gear Support Torque Converter Fluid Seal Assembly |
| CAUTION |
|---|
| Ensure staking does not line up with lubrication holes or the holes may be damaged. Stop driving the seal once it bottoms out to avoid seal damage. |
Scheme 181
Scheme 181: Transmission Fluid Pump Cleaning and Inspection
| Callout | Component Name |
|---|
| CAUTION: After cleaning the transmission components, allow to air dry. Do not use cloth or paper towels in order to dry any transmission components. Lint from the towels can cause component failure. CAUTION: Do not reuse cleaning solvents. Previously used solvents may deposit sediment which may damage the component. Preliminary Procedure The fluid pump assembly is not serviceable. |
| 1 | Filter Neck Seal TIP: Install a NEW filter neck seal. Special Tools 28585 Snap ring Remover or equivalent For equivalent regional tools, refer to Special Tools . |
| 2 | A/Trans Fluid Filter Assembly TIP: Install a NEW fluid filter assembly. |
| 3 | Fluid Pump Drive Shaft Inspect the fluid pump drive shaft splines for damage or wear. Rotate the fluid pump drive shaft for free operation. |
| CAUTION |
|---|
| After cleaning the transmission components, allow to air dry. Do not use cloth or paper towels in order to dry any transmission components. Lint from the towels can cause component failure. |
| CAUTION |
|---|
| Do not reuse cleaning solvents. Previously used solvents may deposit sediment which may damage the component. |
Transmission Fluid Pump Cleaning and Inspection
Scheme 182
Scheme 182: Differential Thrust Washer Gauge Installation
| Callout | Component Name |
|---|
| 1 | Front Differential Carrier Assembly TIP: Install the differential assembly and the pinion gear assembly together to avoid interference with the gears during installation. |
| 2 | Front Differential Drive Pinion (w/Transfer Gear) Gear Assembly TIP: Install the differential assembly and the pinion gear assembly together to avoid interference with the gears during installation. |
| 3 | Front Differential Drive Pinion Gear Bearing Cup TIP: After placing the bearing cup on the gear, place DT 47800-2 which is part of DT-47800 selection gauge kit , onto the bearing cup. Special Tools DT-47800 Thrust Washer Selection Gauge Kit For equivalent regional tools, refer to Special Tools . |
| 4 | Front Differential Carrier Bearing Cup TIP: After placing the bearing cup on the gear, place DT 47800-1 which is part of DT-47800 selection gauge kit , onto the bearing cup. Special Tools DT-47800 Thrust Washer Selection Gauge Kit For equivalent regional tools, refer to Special Tools . |
| 5 | Torque Converter Housing Outer Seal |
| 6 | Torque Converter and Support and A/Trans Fluid Pump Housing Assembly Install 2 DT 47800-6 which is part of DT-47800 selection gauge kit , into a case threaded hole at approximately 180 degrees apart. Some alignment of DT 47800-1 and 2 which is part of DT-47800 selection gauge kit , may be required while lowering the TC housing onto the case. Install DT 47800-3 which is part of DT-47800 selection gauge kit , spacer over DT 47800-6. Special Tools DT-47800 Thrust Washer Selection Gauge Kit For equivalent regional tools, refer to Special Tools . |
Differential Thrust Washer Gauge Installation
Scheme 183
Scheme 183: Torque Sequence
| Callout | Component Name |
|---|
| 1 | Spacer Bolt M8 x 127 (Qty: 8) CAUTION: Refer to Fastener Caution . Procedure Install the remaining spacers evenly at every other bolt hole. Remove the DT 47800-6 which is part of DT-47800 selection gauge kit , guide pins and install spacer bolts in all bolt holes at spacer locations. Tighten the bolts in sequence. Tighten 30 N.m (22 lb ft) Special Tools DT-47800 Thrust Washer Selection Gauge Kit For equivalent regional tools, refer to Special Tools . |
| 2 | Front Differential Carrier Assembly CAUTION: If the bearings are not properly seated into the bearing cups, the washer selection will be inaccurate and the bearing pre-load will be set too low. Low bearing pre-load will cause premature failure of the front differential drive pinion gear. Rotate the differential assembly 10 revolutions to allow the bearings to seat into the cups. TIP: Differential rotating tool DT-47793 differential rotating tool can be used to rotate the differential from the case side. Special Tools DT-47793 Differential Rotating Tool For equivalent regional tools, refer to Special Tools . |
| CAUTION |
|---|
| If the bearings are not properly seated into the bearing cups, the washer selection will be inaccurate and the bearing pre-load will be set too low. Low bearing pre-load will cause premature failure of the front differential drive pinion gear. |
Scheme 184
Scheme 184: Differential Thrust Washer Selection
| Callout | Component Name |
|---|
| CAUTION: Improper thrust washer selection can cause insufficient taper bearing pre-load which will cause premature failure of the front differential drive pinion gear. |
| 1 | Front Differential Bearing Washer Procedure Place DT 47800-7 in the gap in DT 47800-2 which are both part of DT-47800 selection gauge kit , to determine the proper thrust washer. Choose the correct thrust washer. Refer to Taper Bearing Preload Selective Specifications . Continue trying different sizes of DT 47800-7 which is part of DT-47800 selection gauge kit , until the gauge will no longer fit into the gap. The correct thrust washer size is equal to the largest blade gauge that fits into the gap. Match the size of the correct DT 47800-7 blade which is part of DT-47800 selection gauge kit , to the color code in the thrust washer specification chart. The washer color coding is on the outside diameter of the washer. The gap in DT 47800-2 which are both part of DT-47800 selection gauge kit may not be even. Hold the top of the gauge and rotate the bottom of the gauge to even out the gap. Take two gap measurements 180 degrees apart. Average the two measurements and select the thrust washer that is closest to the average. The washer color coding is on the outside diameter of the washer. Special Tools DT-47800 Thrust Washer Selection Gauge Kit For equivalent regional tools, refer to Special Tools . |
| 2 | Front Differential Drive Pinion Gear Bearing Thrust Washer Procedure Place DT 47800-7 in the gap in DT 47800-1 which are both part of DT-47800 selection gauge kit , to determine the proper thrust washer. Choose the correct thrust washer. Refer to Taper Bearing Preload Selective Specifications . Continue trying different sizes of DT 47800-7 which is part of DT-47800 selection gauge kit , until the gauge will no longer fit into the gap. The correct thrust washer size is equal to the largest gauge that fits into the gauge. Match the size of the correct DT 47800-7 blade which is part of DT-47800 selection gauge kit to the color code in the thrust washer selection chart. The gap in DT 47800-1 which is part of DT-47800 selection gauge kit may not be even. Hold the top of the gauge and rotate the bottom of the gauge to even out the gap. Take two gap measurements 180 degrees apart. Average the two measurements and select the thrust washer that is closest to the average. The washer color coding is on the outside diameter of the washer. Special Tools DT-47800 Thrust Washer Selection Gauge Kit For equivalent regional tools, refer to Special Tools . |
| 3 | Torque Converter and Support and A/Trans Fluid Pump Housing Assembly Procedure Remove DT 47800-3 which are both part of DT-47800 selection gauge kit , bolts and spacers. Remove the torque converter housing. Remove DT 47800-1 and DT 47800-2 which are both part of DT-47800 selection gauge kit. Remove the torque converter housing seal. Remove the pinion gear and differential bearing cups. Install the bearing cups and thrust washers into the torque converter housing per the replacement procedures. Refer to Front Differential Carrier Bearing Cup and Washer Replacement - Torque Converter Housing Side , and Front Differential Drive Pinion Bearing Cup, Washer, and Lubricant Dam Replacement - Torque Converter Housing Side . TIP: DT 47800-1 and DT 47800-2 which are both part of DT-47800 selection gauge kit , may stick in the torque converter housing. Be careful not to drop the gauges. Special Tools DT-47800 Thrust Washer Selection Gauge Kit For equivalent regional tools, refer to Special Tools . |
| CAUTION |
|---|
| Improper thrust washer selection can cause insufficient taper bearing pre-load which will cause premature failure of the front differential drive pinion gear. |
Differential Thrust Washer Selection
Scheme 185
Scheme 185: Pump Assembly Installation
| Callout | Component Name |
|---|
| 1 | Driven Sprocket Thrust Washer |
| 2 | Drive Sprocket Thrust Washer |
| 3 | Install Drive Link Assembly TIP: Install as an assembly. |
| 4 | A/Trans Fluid Pump Assembly TIP: Rotating the drive sprocket and link assembly while installing the oil pump will aid in aligning the driven sprocket and oil pump drive shaft splines. |
| 5 | A/Trans Fluid Pump Bolt M6 x 25 (Qty: 3) CAUTION: Refer to Fastener Caution . Procedure: Tighten in sequence shown. Tighten 12 N.m (106 lb in). |
Pump Assembly Installation
Scheme 186
Scheme 186: Transfer Drive Gear Assembly Installation
| Callout | Component Name |
|---|
| 1 | Drive Sprocket Thrust Washer |
| 2 | Front Differential Transfer Drive Gear Support Assembly |
| 3 | Front Differential Transfer Drive Gear Support Bolt M8 x 25 (Qty: 9) CAUTION: Refer to Fastener Caution . Procedure Tighten in sequence shown. Tighten 10 N.m (89 lb in) plus 50 degrees ± 4 degrees. Special Tools: EN 45059 Angle Meter For equivalent regional tools, refer to Special Tools . |
| 4 | Front Differential Carrier Baffle |
| 5 | Front Differential Carrier Baffle Bolt M6 x 25 Tighten 12 N.m (106 lb in). |
Transfer Drive Gear Assembly Installation
Scheme 187
| Callout | Component Name |
|---|
| 1 | Front Differential Drive Pinion Gear Bearing When removing the front differential drive pinion gear bearing use DT 41816-2 step plate. Use DT 8433-1 puller bar or equivalent with bolts 2-3/8 x 3 x 24. Special Tools DT 8433-1 Puller Bar or equivalent DT 22912-B Split Plate Bearing Remover or equivalent DT 41816-2 Step Plate For equivalent regional tools, refer to Special Tools . |
Scheme 188
| Callout | Component Name |
|---|
| 1 | Front Differential Drive Pinion Gear Bearing CAUTION: Pressing against the bearing assembly can damage the bearing and cause premature bearing failure. Special Tools DT-47928 Bearing Installer For equivalent regional tools, refer to Special Tools . |
| CAUTION |
|---|
| Pressing against the bearing assembly can damage the bearing and cause premature bearing failure. |
Scheme 189
| Callout | Component Name |
|---|
| 1 | Front Differential Carrier Bearing Assembly Special Tools DT-41816 Three Legged Puller DT 41816-2 Step Plate For equivalent regional tools, refer to Special Tools . |
| 2 | Inner Race TIP: Ensure all 3 legs of the puller make contact with the inner race of the bearing. |
| 3 | Front Differential Carrier Bearing Assembly AWD differential may need longer bolts, 2-3/8 x 5 x 24 thread bolts. When removing the front differential carrier bearing assembly use DT 41816-2 step plate. Special Tools DT 8433-1 Puller Bar or equivalent DT 22912-B Split Plate Bearing Remover or equivalent DT 41816-2 Step Plate For equivalent regional tools, refer to Special Tools . |
Scheme 190
| Callout | Component Name |
|---|
| 1 | Front Differential Carrier Bearing Assembly CAUTION: Pressing against the bearing assembly can damage the bearing and cause premature bearing failure. CAUTION: There are first and second design front differential carrier bearings. First design bearings have twenty eight rollers and are manufactured by Timken. Second design bearings have 30 rollers and are manufactured by NSK. If installing second design bearings, second design front differential carrier bearing cups must be used. All four parts must be kept as a set to prevent damage to the transmission. Special Tools DT-47928 Bearing Installer For equivalent regional tools, refer to Special Tools . |
| 2 | Front Differential Carrier Bearing Assembly CAUTION: Pressing against the bearing assembly can damage the bearing and cause premature bearing failure. CAUTION: There are first and second design front differential carrier bearings. First design bearings have twenty eight rollers and are manufactured by Timken. Second design bearings have 30 rollers and are manufactured by NSK. If installing second design bearings, second design front differential carrier bearing cups must be used. All four parts must be kept as a set to prevent damage to the transmission. Special Tools DT-47928 Bearing Installer For equivalent regional tools, refer to Special Tools . |
| CAUTION |
|---|
| Pressing against the bearing assembly can damage the bearing and cause premature bearing failure. |
| CAUTION |
|---|
| There are first and second design front differential carrier bearings. First design bearings have twenty eight rollers and are manufactured by Timken. Second design bearings have 30 rollers and are manufactured by NSK. If installing second design bearings, second design front differential carrier bearing cups must be used. All four parts must be kept as a set to prevent damage to the transmission. |
| CAUTION |
|---|
| Pressing against the bearing assembly can damage the bearing and cause premature bearing failure. |
| CAUTION |
|---|
| There are first and second design front differential carrier bearings. First design bearings have twenty eight rollers and are manufactured by Timken. Second design bearings have 30 rollers and are manufactured by NSK. If installing second design bearings, second design front differential carrier bearing cups must be used. All four parts must be kept as a set to prevent damage to the transmission. |
Scheme 191
Scheme 191: Front Differential Carrier Cleaning and Inspection
| Callout | Component Name |
|---|
| CAUTION: After cleaning the transmission components, allow to air dry. Do not use cloth or paper towels in order to dry any transmission components. Lint from the towels can cause component failure. CAUTION: Do not reuse cleaning solvents. Previously used solvents may deposit sediment which may damage the component. CAUTION: Keep the thrust washers with gear it was matched to. The thrust washers are selective sizes and it is difficult to identify the proper washer thickness. Improper assembly can cause premature failure of the differential assembly. Preliminary Procedure Clean and inspect the differential assembly, pinion gears and thrust washers for scoring, wear or damage. The differential assembly is only serviced as an assembly. |
| 1 | Front Differential Pinion Gear Shaft Retainer TIP: Discard and use a new retainer. Special Tools 3/16 in (5 mm) 7 in Punch or equivalent For equivalent regional tools, refer to Special Tools . |
| 2 | Front Differential Pinion Gear Shaft |
| 3 | Front Differential Pinion Gears |
| 4 | Front Differential Carrier Thrust Washers |
| 5 | Front Differential Pinion Side Gears |
| 6 | Front Differential Side Gear Thrust Washer |
| CAUTION |
|---|
| After cleaning the transmission components, allow to air dry. Do not use cloth or paper towels in order to dry any transmission components. Lint from the towels can cause component failure. |
| CAUTION |
|---|
| Do not reuse cleaning solvents. Previously used solvents may deposit sediment which may damage the component. |
| CAUTION |
|---|
| Keep the thrust washers with gear it was matched to. The thrust washers are selective sizes and it is difficult to identify the proper washer thickness. Improper assembly can cause premature failure of the differential assembly. |
Front Differential Carrier Cleaning and Inspection
Scheme 192
Scheme 192: Front Differential Drive Pinion Gear and Carrier Installation
| Callout | Component Name |
|---|
| 1 | Front Differential Carrier Assembly TIP: Install the differential assembly and the pinion gear assembly together to avoid interference with the gears during installasion. |
| 2 | Front Differential Drive Pinion (w/Transfer Gear) Gear Assembly |
| 3 | Front Differential Drive Pinion Gear Lube Tube |
Front Differential Drive Pinion Gear and Carrier Installation
Scheme 193
Scheme 193: Torque Converter and Differential Housing Installation
| Callout | Component Name |
|---|
| 1 | Torque Converter Housing Outer Seal |
| 2 | Torque Converter and Support and A/Trans Fluid Pump Housing Assembly |
| 3 | Torque Converter and Differential Housing Bolts M8 x 35 (Qty: 17) CAUTION: Some bolt torques specifications are different. Over tightening the bolts at the 12, 15 and 17 positions in the sequence could cause damage to the case threads. CAUTION: Refer to Fastener Caution . Procedure: Tighten in sequence shown. Tighten Bolts 1-11, 13-14 and 16 to 36Y (27 lb ft) Bolts 12, 15 and 17 to 30 N.m (22 lb ft) |
| CAUTION |
|---|
| Some bolt torques specifications are different. Over tightening the bolts at the 12, 15 and 17 positions in the sequence could cause damage to the case threads. |
Torque Converter and Differential Housing Installation
Scheme 194
Scheme 194: Front Differential Carrier Preliminary Rotational Torque Measurement
| Callout | Component Name |
|---|
| 1 | Front Differential Carrier Assembly CAUTION: Low bearing pre-load will cause premature failure of the front differential drive pinion gear. CAUTION: Refer to Fastener Caution . If the turning torque is not within specifications, the transfer gear assembly and differential bearing thrust washer is incorrect and must be corrected. Refer to Front Differential Drive Pinion Gear Bearing Thrust Washer and Front Differential Bearing Washer Measurement . Use a dial or beam torque wrench with DT-47793 differential rotating tool to measure turning torque. Tighten 4-12 N.m (35-106 lb in) Special Tools DT-47793 Differential Rotating Tool For equivalent regional tools, refer to Special Tools . |
| CAUTION |
|---|
| Low bearing pre-load will cause premature failure of the front differential drive pinion gear. |
Front Differential Carrier Preliminary Rotational Torque Measurement
Scheme 195
Scheme 195: Piston and Spring Installation
| Callout | Component Name |
|---|
| 1 | 1-2-3-4 Clutch Piston TIP: DT-46623 seal protector prevents the piston seal lip from damage during installation. Apply a thin coat of ATF to the I.D. of DT-46623 seal protector to ease the installation of the piston. Special Tools DT-46623 Piston Seal Protector For equivalent regional tools, refer to Special Tools . |
| 2 | 1-2-3-4 Clutch Spring |
| 3 | 1-2-3-4 Clutch Spring Retainer Ring CAUTION: Refer to Fastener Caution . Procedure: The retainer opening should be supported by a spline tooth of the case. Install DT-46632 spring compressor and DT-48056 spring compressor bridge and retain to the case using 2 case cover assembly bolts. Turn the DT-48056 spring compressor bridge compressor bolt to compress the 1-2-3-4 Clutch Spring until the retaining ring groove is exposed. Push retainer ring into the groove. Remove DT-48056 spring compressor bridge and DT-46632 spring compressor. Air check the piston operation by applying air to the 1-2-3-4 clutch feed passage in the case. Excessive air leaks indicate damage to the clutch piston seal. Tighten 12 N.m (9 lb ft). Special Tools DT-48056 Spring Compressor Bridge DT-46632 Piston Spring Compressor For equivalent regional tools, refer to Special Tools . |
Piston and Spring Installation
Scheme 196
Scheme 196: 1-2-3-4 Clutch Plates and Low Reverse Clutch Installation
| Callout | Component Name |
|---|
| 1 | 1-2-3-4 Clutch (Waved) Plate TIP: The tab on the clutch plate faces the bottom of the case. |
| 2 | 1-2-3-4 Clutch Plate (Qty: 2) TIP: The tab on the clutch plate faces the bottom of the case. |
| 3 | 1-2-3-4 Clutch (w/Friction Material) Plate Assembly (Qty: 2) |
| 4 | Low and Reverse Clutch Assembly |
| 5 | Low and Reverse Clutch Retaining Ring TIP: The tab needs to go in groove at about 2 o'clock and snap ring opening needs to face 3 o'clock. |
1-2-3-4 Clutch Plates and Low Reverse Clutch Installation
Scheme 197
Scheme 197: Low and Reverse Clutch Plate Installation
| Callout | Component Name |
|---|
| 1 | Low and Reverse Clutch Backing Plate TIP: The tab on the clutch plate faces the bottom of the case. |
| 2 | Low and Reverse Clutch (w/Friction Material) Plate Assembly (Qty: 4) |
| 3 | Low and Reverse Clutch Plate (Qty: 3) TIP: The tab on the clutch plate faces the bottom of the case. |
| 4 | Low and Reverse Clutch Apply Plate TIP: The tab on the clutch plate faces the bottom of the case. |
| 5 | Low and Reverse Clutch Cushion (Waved) Spring TIP: The tab on the clutch plate faces the bottom of the case. |
Low and Reverse Clutch Plate Installation
Scheme 198
Scheme 198: Reaction Carrier Cleaning and Inspection
| Callout | Component Name |
|---|
| Preliminary Procedures Clean and Inspect the carrier as an assembly. If wear or damage is found disassemble to replace the affected component. |
| 1 | Input Internal Gear Retaining Ring |
| 2 | Input Internal Gear |
| 3 | Reaction Carrier Assembly |
Reaction Carrier Cleaning and Inspection
Scheme 199
Scheme 199: Output Carrier Cleaning and Inspection
| Callout | Component Name |
|---|
| Preliminary Procedures Clean and Inspect the carrier as an assembly. If wear or damage is found disassemble to replace the affected component. |
| 1 | Reaction Internal Gear Retaining Ring |
| 2 | Reaction Carrier Internal Gear |
| 3 | Output Carrier Assembly |
Output Carrier Cleaning and Inspection
Scheme 200
Scheme 200: Input, Reaction, and Output Carrier Installation
| Callout | Component Name |
|---|
| Preliminary Procedure Note location of the orientation lip on bearings. All thrust bearings can only be assembled one way. |
| 1 | Input Shaft Thrust Bearing Assembly |
| 2 | Output Carrier Transfer Drive Gear Hub Assembly |
| 3 | Front Differential Transfer Drive Gear Input Hub Bearing Assembly |
| 4 | Output Sun Gear Assembly |
| 5 | Output Carrier Assembly |
| 6 | Output Carrier Thrust Bearing Assembly |
| 7 | Output Carrier Thrust Bearing Assembly |
| 8 | Input (w/Output Internal Gear) Carrier Assembly |
| 9 | Input Sun Gear |
| 10 | Input Sun Gear Thrust Bearing Assembly |
| 11 | Input Carrier Thrust Bearing Assembly |
| 12 | Reaction (w/Input Internal Gear) Carrier Assembly |
Input, Reaction, and Output Carrier Installation
Scheme 201
Scheme 201: 2-6 Clutch Plate Installation
| Callout | Component Name |
|---|
| 1 | 2-6 Clutch Backing Plate TIP: The tab on the clutch plate faces the bottom of the case. |
| 2 | 2-6 Clutch (w/Friction Material) Plate Assembly (Qty: 3) |
| 3 | 2-6 Clutch Plate (Qty: 3) TIP: The tab on the clutch plate faces the bottom of the case. |
| 4 | 2-6 Clutch Cushion Spring |
| 5 | Reaction Sun Gear Assembly |
| 6 | 2-6 Clutch Hub Thrust Bearing Assembly TIP: Note location of the orientation lip on bearing. All thrust bearings can only be assembled one way. |
2-6 Clutch Plate Installation
Scheme 202
Scheme 202: Reluctor Wheel and Piston Removal
| Callout | Component Name |
|---|
| 1 | A/Trans Input Shaft Speed Sensor Reluctor Ring Retaining Ring CAUTION: Compress the reluctor wheel just enough to clear the retainer. Over compressing the reluctor wheel will break the alignment tab and the clutch housing. Special Tools DT-47694 Piston Spring Compressor For equivalent regional tools, refer to Special Tools . |
| 2 | A/Trans Input Shaft Speed Sensor Reluctor Wheel |
| 3 | 3-5 Reverse Clutch Piston TIP: Inspect piston seals for damage and/or wear. Piston is reusable. |
| 4 | 3-5 Reverse Clutch Spring Assembly |
| 5 | 3-5 Reverse Clutch Piston Inner Seal (Orange) |
| 6 | 3-5 Reverse Clutch Piston Inner Seal (Black) |
| 7 | 3-5 Reverse Clutch Piston Dam Seal |
| CAUTION |
|---|
| Compress the reluctor wheel just enough to clear the retainer. Over compressing the reluctor wheel will break the alignment tab and the clutch housing. |
Reluctor Wheel and Piston Removal
Scheme 203
Scheme 203: Clutch Plate Removal
| Callout | Component Name |
|---|
| 1 | 3-5 Reverse Clutch Backing Plate Retaining Ring |
| 2 | 3-5 Reverse Clutch Backing Plate |
| 3 | 3-5 Reverse Clutch (w/Friction Material) Plate Assembly (Qty: 4) |
| 4 | 3-5 Reverse Clutch Plate (Qty: 4) |
| 5 | 3-5 Reverse Clutch (Waved) Plate |
Scheme 204
Scheme 204: 4-5-6 Clutch Hub Removal
| Callout | Component Name |
|---|
| 1 | 4-5-6 Backing Plate Retaining Ring TIP: Gently push down on the backing plate to get enough clearance between the backing plate and retainer. |
| 2 | Reaction Carrier Hub Assembly TIP: The clutch plates will come out of the housing with the hub assembly. |
| 3 | 4-5-6 Clutch Backing Plate |
| 4 | 4-5-6 Clutch Plate (Qty: 6) |
| 5 | 4-5-6 Clutch (w/Friction Material) Plate Assembly (Qty: 6) |
| 6 | 4-5-6 Clutch Hub Thrust Bearing Assembly TIP: The bearing may stick to the reaction carrier hub. |
Scheme 205
Scheme 205: 4-5-6 Clutch Piston Removal
| Callout | Component Name |
|---|
| 1 | 4-5-6 Clutch Dam Retaining Ring Special Tools DT-47693 Dam Protector GE 8059 Snap Ring Pliers-Parallel Jaw or equivalent For equivalent regional tools, refer to Special Tools . |
| 2 | 4-5-6 Clutch Piston Fluid Dam Procedure: Place the 3-5-R and 4-5-6 clutch housing onto the case cover assembly. Apply shop air to the 4-5-6 clutch feed hole using a rubber tipped air gun to dislodge the dam piston and the 4-5-6 clutch piston from the clutch housing. |
| 3 | 4-5-6 Clutch Spring Assembly |
| 4 | 4-5-6 Clutch Piston |
| 5 | 4-5-6 Clutch Piston Outer Seal (Stepped) |
| 6 | 4-5-6 Clutch Piston Outer Seal (Rounded) |
| 7 | 4-5-6 Clutch Piston Inner Seal |
4-5-6 Clutch Piston Removal
Scheme 206
Scheme 206: 4-5-6 Clutch Piston Installation
| Callout | Component Name |
|---|
| 1 | 4-5-6 Clutch Piston Inner Seal |
| 2 | 4-5-6 Clutch Piston Outer Seal (Rounded) |
| 3 | 4-5-6 Clutch Piston Outer Seal (Stepped) (Orange) |
| 4 | 4-5-6 Clutch Piston TIP: DT-47859 outer seal protector prevents the piston seal lip from damage during installation. Apply a thin coat of ATF to the I.D. of DT-47859 outer seal protector to ease the installation of the piston. Special Tools DT-47859 Piston Outer Seal Protector For equivalent regional tools, refer to Special Tools . |
4-5-6 Clutch Piston Installation
Scheme 207
Scheme 207: 4-5-6 Clutch Dam Installation
| Callout | Component Name |
|---|
| 1 | 4-5-6 Clutch Spring |
| 2 | 4-5-6 Clutch Piston Fluid Dam TIP: DT 47693-1 which is part of DT-47693 dam protector prevents the dam seal lip from damage during installation. Apply a thin coat of ATF to the I.D. of DT 47693-1 which is part of DT-47693 dam protector to ease the installation of the dam. Special Tools DT-47693 Dam Protector For equivalent regional tools, refer to Special Tools . |
| 3 | 4-5-6 Clutch Dam Retaining Ring Special Tools DT 47693-2 Clutch Spring Compressor which is part of DT-47693 Dam Protector GE 8059 Snap Ring Pliers-Parallel Jaw or equivalent For equivalent regional tools, refer to Special Tools . |
4-5-6 Clutch Dam Installation
Scheme 208
Scheme 208: 4-5-6 Clutch Plates Installation
| Callout | Component Name |
|---|
| 1 | 4-5-6 Clutch Hub Thrust Bearing TIP: Note location of the orientation lip on bearing. All thrust bearings can only be assembled one way. |
| 2 | Reaction Carrier Hub Assembly CAUTION: Failure to use DT 48551 could cause damage to the hub assembly bushings which could cause premature transmission failure. Special Tools DT-48551 Reaction Hub Bushing Protector For equivalent regional tools, refer to Special Tools . |
| 3 | 4-5-6 Clutch Plate (Qty: 6) |
| 4 | 4-5-6 Clutch (w/Friction Material) Plate Assembly (Qty: 6) |
| 5 | 4-5-6 Clutch Backing Plate |
| 6 | 4-5-6 Clutch Backing Plate Retaining Ring TIP: Gently push down on the backing plate to get enough clearance between the backing plate and retainer. |
| CAUTION |
|---|
| Failure to use DT 48551 could cause damage to the hub assembly bushings which could cause premature transmission failure. |
4-5-6 Clutch Plates Installation
Scheme 209
Scheme 209: 3-5 Reverse Clutch Plates Installation
| Callout | Component Name |
|---|
| 1 | 3-5 Reverse Clutch (Waved) Plate |
| 2 | 3-5 Reverse Clutch Plate (Qty: 4) |
| 3 | 3-5 Reverse Clutch (w/Friction Material) Plate Assembly (Qty: 4) |
| 4 | 3-5 Reverse Clutch Backing Plate |
| 5 | 3-5 Reverse Clutch Backing Plate Retaining Ring |
3-5 Reverse Clutch Plates Installation
Scheme 210
Scheme 210: Piston and Reluctor Wheel Installation
| Callout | Component Name |
|---|
| 1 | 3-5 Reverse Clutch Piston Dam Seal |
| 2 | 3-5 Reverse Clutch Piston Inner Seal (Black) TIP: Apply a thin coat of ATF to the seal to ease the installation of the piston. |
| 3 | 3-5 Reverse Clutch Piston Inner Seal (Orange) TIP: Apply a thin coat of ATF to the seal to ease the installation of the piston. |
| 4 | 3-5 Reverse Clutch Spring Assembly |
| 5 | 3-5 Reverse Clutch Piston DT-46622 seal protector prevents the piston seal lip from damage during installation. Apply a thin coat of ATF to the I.D. of DT-46622 seal protector to ease the installation of the piston. Install DT-46622 seal protector onto the speed sensor reluctor wheel. Push the 3-5 Reverse Clutch piston into the reluctor wheel until it stops against J-46622 seal protector. Remove DT-46622 seal protector by separating it at the opening. Special Tools DT-46622 Piston Seal Protector For equivalent regional tools, refer to Special Tools . |
| 6 | A/Trans Input Shaft Speed Sensor Reluctor Wheel |
| 7 | A/Trans Input Shaft Speed Sensor Reluctor Wheel Retaining Ring CAUTION: Compress the reluctor wheel just enough to clear the retainer ring groove. Over compressing the reluctor wheel will break the alignment tab and the clutch housing. Special Tools DT-47694 Piston Spring Compressor For equivalent regional tools, refer to Special Tools . |
| CAUTION |
|---|
| Compress the reluctor wheel just enough to clear the retainer ring groove. Over compressing the reluctor wheel will break the alignment tab and the clutch housing. |
Piston and Reluctor Wheel Installation
Scheme 211
Scheme 211: 3-5-R and 4-5-6 Clutch Piston Air Check
| Callout | Component Name |
|---|
| 1 | Case Cover Assembly TIP: The fluid seal rings should be in place and not damaged. |
| 2 | 4-5-6 Clutch Feed Fluid Passage CAUTION: Regulate the air pressure to 40 psi maximum. High pressure could cause the piston to over travel and damage the piston seals. Procedure Apply shop air to the 4-5-6 clutch feed passage. Observe the 4-5-6 piston movement. TIP: Minimal piston movement and excessive air leaking could indicate damage to the 4-5-6 piston seals or improper assembly. |
| 3 | 3-5 Rev Clutch Feed Fluid Passage CAUTION: Regulate the air pressure to 40 psi maximum. High pressure could cause the piston to over travel and damage the piston seals. Procedure Apply shop air to the 3-5-Rev clutch feed passage. Observe the 3-5-Rev piston movement. TIP: Minimal piston movement and excessive air leaking could indicate damage to the 3-5-Rev piston seals or improper assembly. |
| CAUTION |
|---|
| Regulate the air pressure to 40 psi maximum. High pressure could cause the piston to over travel and damage the piston seals. |
| CAUTION |
|---|
| Regulate the air pressure to 40 psi maximum. High pressure could cause the piston to over travel and damage the piston seals. |
3-5-R and 4-5-6 Clutch Piston Air Check
Scheme 212
Scheme 212: 3-5-Reverse and 4-5-6 Clutch Housing Installation
| Callout | Component Name |
|---|
| 1 | 3-5 Reverse and 4-5-6 Clutch Assembly TIP: Rotate the assembly back and forth to align the 3-5 reverse clutch plates with the reaction sun gear housing. |
3-5-Reverse and 4-5-6 Clutch Housing Installation
Scheme 213
| Callout | Component Name |
|---|
| 1 | A/Trans Input Speed Sensor Bolt M6 x 25 |
| 2 | A/Trans Input Speed Sensor |
| 3 | A/Trans Input Speed Sensor Seal TIP: Discard the seal. |
| 4 | 3-5 Reverse and 4-5-6 Clutch Fluid Seal Ring TIP: Discard the seals. |
Scheme 214
Scheme 214: Low and Reverse Clutch Piston Removal
| Callout | Component Name |
|---|
| 1 | Low and Reverse Clutch Spring Retaining Ring |
| 2 | Low and Reverse Clutch Spring |
| 3 | Low and Reverse Clutch Piston Assembly TIP: Inspect piston seals for damage and/or wear. Piston is reusable. |
Low and Reverse Clutch Piston Removal
Scheme 215
Scheme 215: 2-6 Clutch Piston Removal
| Callout | Component Name |
|---|
| 1 | 2-6 Clutch Spring Retaining Ring Special Tools DT-46632 Spring Compressor For equivalent regional tools, refer to Special Tools . |
| 2 | 2-6 Clutch Spring Assembly |
| 3 | 2-6 Clutch Piston TIP: Inspect piston seals for damage and/or wear. Piston is reusable. |
2-6 Clutch Piston Removal
Scheme 216
Scheme 216: Clean and Inspect
| Callout | Component Name |
|---|
| CAUTION: After cleaning the transmission components, allow to air dry. Do not use cloth or paper towels in order to dry any transmission components. Lint from the towels can cause component failure. CAUTION: Do not reuse cleaning solvents. Previously used solvents may deposit sediment which may damage the component. Preliminary Procedures Thoroughly clean the case cover assembly, including threads, with clean solvent. Clean gasket sealing surfaces. Remove all residual gasket material. Inspect all threaded holes. If necessary, repair any thread damage. |
| 1 | Gasket Sealing Surface |
| 2 | Fluid Passages |
| 3 | Piston Bores |
| 4 | Cover to Case Passages |
| 5 | A/Trans Input Speed Sensor Assembly Bore |
| 6 | Cover Casting |
| 7 | Passage Cup Plugs |
| 8 | Input Shaft Support Bolts CAUTION: Refer to Fastener Caution . Procedure Tightened bolts in sequence. Tighten 12 N.m (106 lb in). |
| CAUTION |
|---|
| After cleaning the transmission components, allow to air dry. Do not use cloth or paper towels in order to dry any transmission components. Lint from the towels can cause component failure. |
| CAUTION |
|---|
| Do not reuse cleaning solvents. Previously used solvents may deposit sediment which may damage the component. |
Scheme 217
Scheme 217: Fluid Seal Ring Installation
| Callout | Component Name |
|---|
| 1 | 3-5 Reverse and 4-5-6 Clutch Fluid Seal Ring Procedure Place DT 46620-3 which is part of DT-46620 seal installer over the case cover hub and adjust it so that only the bottom seal ring is exposed. Place a NEW fluid seal ring onto DT 46620-3 which is part of DT-46620 seal installer. Use DT 46620-2 which is part of DT-46620 seal installer to push the fluid seal ring down over DT 46620-3 which is part of DT-46620 seal installer into the hub ring groove. Repeat the above steps to install all 4 seal rings, adjusting DT 46620-3 which is part of DT-46620 seal installer to the appropriate ring groove. Special Tools DT-46620 Seal Installer For equivalent regional tools, refer to Special Tools . |
| 2 | Small Chamfer Up CAUTION: Do not force the seal installer down over the seals as this will roll and damage the seals. The large chamfer is designed to fit over the over stretched seal. Use a hand to help shrink the seal if the seal installer is difficult to install over the seal rings. Procedure Install DT 46620-1 which is part of DT-46620 seal installer with the large chamfer end down over the fluid seal rings and leave DT 46620-1 which is part of DT-46620 seal installer on the seals for at least 60 seconds. |
| 3 | Large Chamfer Up Procedure Install DT 46620-1 which is part of DT-46620 seal installer with the small chamfer end facing down for at least 60 seconds. This will properly size the bottom seal ring. Leaving DT 46620-1 which is part of DT-46620 seal installer on the fluid seal rings for an extended period of time could cause a fluid leak on the initial clutch piston circuit until the seal rings warm up and expand to the proper dimension. |
| CAUTION |
|---|
| Do not force the seal installer down over the seals as this will roll and damage the seals. The large chamfer is designed to fit over the over stretched seal. Use a hand to help shrink the seal if the seal installer is difficult to install over the seal rings. |
Fluid Seal Ring Installation
Scheme 218
Scheme 218: 2-6 Clutch Piston Installation
| Callout | Component Name |
|---|
| 1 | 2-6 Clutch Piston Procedure DT-46621 seal protector prevents the piston seal lip from damage over the retaining ring groove during installation. Apply a thin coat of ATF to the O.D. of DT-46621 seal protector to ease the installation of the piston. Special Tools DT-46621 Seal Protector For equivalent regional tools, refer to Special Tools . |
| 2 | 2-6 Clutch Spring Assembly |
| 3 | 2-6 Clutch Spring Assembly Procedure Install the retaining ring with the opening positioned to the top of the case cover. Place the retainer ring inside DT-46632 spring compressor prior to placing DT-46632 spring compressor onto the spring. Special Tools DT-46632 Spring Compressor For equivalent regional tools, refer to Special Tools . |
2-6 Clutch Piston Installation
Scheme 219
Scheme 219: Low and Reverse Clutch Piston Installation
| Callout | Component Name |
|---|
| 1 | Low and Reverse Clutch Piston Assembly Procedure Install the L/R piston with the air bleed positioned at the alignment feature on the cover, using DT-46628-1 seal protector. This will orient the piston fingers with the openings in the case. DT-46628-1 seal protector prevents the piston seal lip from damage during installation. Apply a thin coat of ATF to the I.D. of DT-46628-1 seal protector to ease the installation of the piston. Special Tools DT-46628-1 Piston Seal Protector For equivalent regional tools, refer to Special Tools . |
| 2 | Low and Reverse Clutch Spring |
| 3 | Low and Reverse Clutch Spring Retaining Ring TIP: Do not align the retainer opening with other retaining ring openings. Special Tools DT-46628-2 Spring Compressor For equivalent regional tools, refer to Special Tools . |
Low and Reverse Clutch Piston Installation
Scheme 220
Scheme 220: 2-6 and Low-Reverse Piston Function Inspection
| Callout | Component Name |
|---|
| 1 | Case Cover Assembly TIP: The fluid seal rings should be in place and not damaged. |
| 2 | 2-6 Clutch Feed Passage CAUTION: Regulate the air pressure to 40 psi maximum. High pressure could cause the piston to over travel and damage the piston seals. Procedure Apply shop air to the 2-6 clutch feed. Observe the 2-6 piston movement. TIP: Minimal piston movement and excessive air leaking could indicate damage to the 2-6 piston seals or improper assembly. |
| 3 | Low and Reverse Clutch Feed Passage CAUTION: Regulate the air pressure to 40 psi maximum. High pressure could cause the piston to over travel and damage the piston seals. Procedure Apply shop air to the Low and Reverse clutch feed. Observe the Low and Reverse piston movement. TIP: Minimal piston movement and excessive air leaking could indicate damage to the Low and Reverse piston seals or improper assembly. |
| CAUTION |
|---|
| Regulate the air pressure to 40 psi maximum. High pressure could cause the piston to over travel and damage the piston seals. |
| CAUTION |
|---|
| Regulate the air pressure to 40 psi maximum. High pressure could cause the piston to over travel and damage the piston seals. |
2-6 and Low-Reverse Piston Function Inspection
Scheme 221
Scheme 221: Input Speed Sensor Installation
| Callout | Component Name |
|---|
| 1 | Input Speed Sensor Seal |
| 2 | A/Trans Input Speed Sensor Assembly |
| 3 | A/Trans Input Speed Sensor Bolt M6 x 25 CAUTION: Refer to Fastener Caution . Procedure Apply threadlocker or equivalent to the input speed sensor bolt. Refer to Adhesives, Fluids, Lubricants, and Sealers . TIP: The seal is coated with a dry lubricant. If the coating is missing, lubricate the seal with automatic transmission fluid prior to installation. Tighten 9 N.m (7 lb ft) |
Input Speed Sensor Installation
Scheme 222
Scheme 222: Case Cover Assembly Installation
| Callout | Component Name |
|---|
| 1 | Input Shaft Thrust Bearing TIP: Note location of the orientation lip on bearing. All thrust bearings can only be assembled one way. |
| 2 | A/Trans Case Cover Gasket |
| 3 | Input Speed Sensor Wire Harness TIP: Route the input speed sensor wire harness through the case passage. |
| 4 | A/Trans Case Cover Assembly Procedure Use guide pins to install the case cover assembly to prevent damage to the input shaft thrust bearing. Pull the input speed sensor wire harness through the case passage while lowering the cover assembly onto the case. Special Tools 39068 Guide Pins For equivalent regional tools, refer to Special Tools . |
| 5 | A/Trans Case Cover Assembly Bolt M6 x 30 (Qty: 10) CAUTION: Refer to Fastener Caution . Procedure Tighten in sequence shown. Tighten 12 N.m (106 lb in) |
Case Cover Assembly Installation
Scheme 223
Scheme 223: Front Differential Carrier Final Rotational Torque Measurement
| Callout | Component Name |
|---|
| 1 | Front Differential Carrier Assembly CAUTION: Low bearing pre-load will cause premature failure of the front differential drive pinion gear. CAUTION: Refer to Fastener Caution . If the turning torque is not within specifications, the transfer gear assembly and differential bearing thrust washer is incorrect and must be corrected. Refer to Front Differential Drive Pinion Gear Bearing Thrust Washer and Front Differential Bearing Washer Measurement . Use a dial or beam torque wrench with DT-47793 differential rotating tool to measure turning torque. Tighten 14-22 N.m (10-16 lb ft) Special Tools DT-47793 Differential Rotating Tool For equivalent regional tools, refer to Special Tools . |
| CAUTION |
|---|
| Low bearing pre-load will cause premature failure of the front differential drive pinion gear. |
Front Differential Carrier Final Rotational Torque Measurement
Scheme 224
Scheme 224: Control Valve Body Assembly Disassemble
| Callout | Component Name |
|---|
| 1 | Control Valve Body Bolt M6 x 65 (Qty: 5) |
| 2 | Control Valve Body Bolt M6 x 35 (Qty: 3) |
| 3 | Control Valve Channel Upper Plate Assembly TIP: Inspect the upper channel plate bolt pass through holes for damage or brinelling. Any damage near the PCS feed hole will cause incorrect pressure switch operation. Replace as necessary. |
| 4 | Control Valve Body Bolt M6 x 55 (Qty: 2) |
| 5 | Control Valve Body Bolt M6 x 55 (Qty: 1) |
| 6 | Control Valve Channel Plate Assembly |
| 7 | Control Valve Body Ball Check Valve (Qty: 9) |
| 8 | Control Valve Upper Body Assembly |
| 9 | Control Valve Lower Body Spacer Plate Assembly TIP: Discard the spacer plate assembly. |
| 10 | Control Valve Lower Body Assembly |
Control Valve Body Assembly Disassemble
Scheme 225
Scheme 225: Control Valve Lower Body Assembly Cleaning and Inspection
| Callout | Component Name |
|---|
| WARNING: Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal injury could result. CAUTION: After cleaning the transmission components, allow to air dry. Do not use cloth or paper towels in order to dry any transmission components. Lint from the towels can cause component failure. CAUTION: Do not reuse cleaning solvents. Previously used solvents may deposit sediment which may damage the component. Preliminary Procedure Clean and inspect all valve components and the valve body. The control valve lower body is replaceable only as an assembly. |
| 1 | 3-5 Reverse Clutch Boost Valve Train |
| 2 | Accumulator Feed Limit Valve Train |
| 3 | 4-5-6 Clutch Boost Valve Train |
| 4 | 4-5-6 Clutch Accumulator Piston Assembly |
| 5 | 1-2-3-4 Clutch Boost Valve Train |
| 6 | 1-2-3-4 Clutch Regulator Valve Train |
| 7 | Control Valve Body Locating Pins (Qty: 2) TIP: Inspect Valve Body locating pins for proper installed height of 4.25 mm (0.17 in). |
| WARNING |
|---|
| Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal injury could result. |
| CAUTION |
|---|
| After cleaning the transmission components, allow to air dry. Do not use cloth or paper towels in order to dry any transmission components. Lint from the towels can cause component failure. |
| CAUTION |
|---|
| Do not reuse cleaning solvents. Previously used solvents may deposit sediment which may damage the component. |
Control Valve Lower Body Assembly Cleaning and Inspection
Scheme 226
Scheme 226: Control Valve Upper Body Assembly Cleaning and Inspection
| Callout | Component Name |
|---|
| WARNING: Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal injury could result. CAUTION: After cleaning the transmission components, allow to air dry. Do not use cloth or paper towels in order to dry any transmission components. Lint from the towels can cause component failure. CAUTION: Do not reuse cleaning solvents. Previously used solvents may deposit sediment which may damage the component. Preliminary Procedure Clean and inspect all valve components and the valve body. The control valve upper body is replaceable only as an assembly. |
| 1 | 1st Reverse and 4-5-6 Clutch Regulator Valve Train |
| 2 | TCC Regulator Apply Valve Train |
| 3 | 2-6 Clutch Regulator Valve Train |
| 4 | 3-5 Reverse Clutch Regulator Valve Train |
| 5 | Pressure Regulator Valve Train |
| 6 | Isolator Valve Train |
| 7 | TCC Control Valve Train |
| 8 | Clutch Select Solenoid #3 Valve Train |
| 9 | Clutch Select Solenoid #2 Valve Train |
| 10 | Manual Valve |
| WARNING |
|---|
| Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal injury could result. |
| CAUTION |
|---|
| After cleaning the transmission components, allow to air dry. Do not use cloth or paper towels in order to dry any transmission components. Lint from the towels can cause component failure. |
| CAUTION |
|---|
| Do not reuse cleaning solvents. Previously used solvents may deposit sediment which may damage the component. |
Control Valve Upper Body Assembly Cleaning and Inspection
Scheme 227
Scheme 227: Control Valve Channel Plate Cleaning and Inspection
| Callout | Component Name |
|---|
| CAUTION: After cleaning the transmission components, allow to air dry. Do not use cloth or paper towels in order to dry any transmission components. Lint from the towels can cause component failure. CAUTION: Do not reuse cleaning solvents. Previously used solvents may deposit sediment which may damage the component. |
| 1 | Control Valve Body Spacer Plate Retainer (Qty: 2) |
| 2 | Control Valve Upper Body Spacer Plate Assembly |
| 3 | Actuator Feed Accumulator Spring (Qty: 3) |
| 4 | Actuator Feed Accumulator Piston (Qty: 3) |
| 5 | Control Valve Body Locating Pin (Qty: 2) TIP: Inspect locating pins for proper installed height of 4.25 mm (0.17 in). |
| CAUTION |
|---|
| After cleaning the transmission components, allow to air dry. Do not use cloth or paper towels in order to dry any transmission components. Lint from the towels can cause component failure. |
| CAUTION |
|---|
| Do not reuse cleaning solvents. Previously used solvents may deposit sediment which may damage the component. |
Control Valve Channel Plate Cleaning and Inspection
Scheme 228
Scheme 228: Lower and Upper Body Assemble
| Callout | Component Name |
|---|
| 1 | Control Valve Lower Body Spacer Plate Assembly CAUTION: Do not use the old spacer plate. Install a NEW spacer plate. Reusing an old spacer plate may cause internal transmission leaks and transmission damage. TIP: Inspect the upper channel plate bolt through holes for damage or brinelling. Any damage around the PCS switch feed holes could cause leakage around the PCS switch seals. Replace as necessary. |
| 2 | Control Valve Upper Body Assembly |
| 3 | Control Valve Body Ball Check Valve (Qty: 9) CAUTION: Do not use any type of grease or other material to hold the check ball valves in place during assembly. Grease will cause the valves to not operate properly, resulting in damage to the transmission. |
| 4 | Control Valve Channel Plate Assembly |
| 5 | Control Valve Body Bolt 6 x 55 (Qty: 1) CAUTION: Refer to Fastener Caution . Tighten 12 N.m (9 lb ft) |
| CAUTION |
|---|
| Do not use the old spacer plate. Install a NEW spacer plate. Reusing an old spacer plate may cause internal transmission leaks and transmission damage. |
| CAUTION |
|---|
| Do not use any type of grease or other material to hold the check ball valves in place during assembly. Grease will cause the valves to not operate properly, resulting in damage to the transmission. |
Lower and Upper Body Assemble
Scheme 229
Scheme 229: Channel Plate and Upper Channel Plate Assemble
| Callout | Component Name |
|---|
| 1 | Control Valve Channel Upper Plate Assembly TIP: Inspect the upper channel plate bolt pass through holes for damage or burnelling. Any damage near the PCS feed holes could cause leaking around the PCS switch seal. Replace as necessary. |
| 2 | Control Valve Body Bolt M6 x 35 (Qty: 3) CAUTION: Refer to Fastener Caution . Procedure Hand tighten for alignment, then tighten in sequence, after all bolts are installed. Tighten 12 N.m (9 lb ft) |
| 3 | Control Valve Body Bolt M6 x 65 (Qty: 5) Procedure Tighten in sequence. Tighten 12 N.m (9 lb ft) |
| 4 | Control Valve Body Bolt M6 x 55 (Qty: 2) Procedure Tighten in sequence. Tighten 12 N.m (9 lb ft) |
Channel Plate and Upper Channel Plate Assemble
Scheme 230
Scheme 230: Output Speed Sensor and Valve Body Installation
| Callout | Component Name |
|---|
| 1 | 1-2-3-4 Clutch Fluid Passage Seal |
| 2 | A/Trans Output Speed Sensor Assembly |
| 3 | A/Trans Output Speed Sensor Assembly Bolt M6 x 25 CAUTION: Refer to Fastener Caution . Tighten 12 N.m (9 lb ft) |
| 4 | Control Valve Body Assembly |
| 5 | Manual Valve Align the manual valve to the detent lever assembly. Removing the manual shaft assembly pin will aid in aligning the manual valve to the detent lever. Install the manual shaft pin after the valve body assembly is installed using DT 41229 pin installer , if it was not installed previously. Refer to Manual Shift Detent Lever with Shaft Position Switch Assembly and Park Pawl Actuator Removal . Special Tools DT 41229 Manual Shaft Pin Installer For equivalent regional tools, refer to Special Tools . |
Output Speed Sensor and Valve Body Installation
Scheme 231
Scheme 231: Control Valve Body Bolts Installation
| Callout | Component Name |
|---|
| 1 | Manual Shaft Detent Assembly TIP: Ensure proper alignment of the detent assembly to the detent lever assembly with position switch while tightening the bolt. The detent assembly can move and hit the valve body assembly that could cause improper engagement with the detent lever assembly. |
| 2 | Control Valve Body Bolt M6 x 65 (Qty: 8) CAUTION: Refer to Fastener Caution . Procedure Tighten in sequence. Tighten 12 N.m (9 lb ft). |
| 3 | Control Valve Body Bolt M6 x 55 (Qty: 2) Procedure Tighten in sequence. Tighten 12 N.m (9 lb ft). |
Control Valve Body Bolts Installation
Scheme 232
Scheme 232: Filter Plate Installation
| Callout | Component Name |
|---|
| 1 | Control Solenoid Valve Assembly Filter Plate CAUTION: Use care when removing or installing the filter plate assembly. A broken or missing retaining tab may not adequately secure the filter plate to the control solenoid valve assembly, resulting in possible damage or contamination. TIP: Install a NEW filter plate to prevent fluid leaks past the oil seals. |
| CAUTION |
|---|
| Use care when removing or installing the filter plate assembly. A broken or missing retaining tab may not adequately secure the filter plate to the control solenoid valve assembly, resulting in possible damage or contamination. |
Filter Plate Installation
Scheme 233
Scheme 233: Control Solenoid (w/Body and TCM) Valve Assembly Installation
| Callout | Component Name |
|---|
| CAUTION: Refer to Fastener Caution . Preliminary Procedure Install all bolts before tightening, then tighten in sequence to 12 N.m (9 lb ft). |
| 1 | Control Solenoid (w/Body and TCM) Valve Assembly CAUTION: Do not drop the control solenoid with body and transmission control module (TCM) valve assembly. Internal damage can occur if the control solenoid with body and TCM valve assembly is dropped. DO NOT reuse the control solenoid with body and TCM valve assembly if it is dropped. |
| 2 | Control Solenoid Valve Spring If the control solenoid spring is missing or improperly installed, the TCM may overheat causing the TCM to shut down. The transmission will default to 3rd or 5th gear. Insert tab of spring into slot on spacer plate, then rotate into position. |
| 3 | Control Valve Body Bolt M6 x 80 (Qty: 4) |
| 4 | Control Valve Body Bolt M6 x 55 (Qty: 1) |
| 5 | Control Valve Body Bolt M6 x 95 (Qty: 3) |
| 6 | Control Valve Body Bolt M6 x 42 (Qty: 1) |
| 7 | Control Valve Body Bolt M6 x 65 (Qty: 2) |
| CAUTION |
|---|
| Do not drop the control solenoid with body and transmission control module (TCM) valve assembly. Internal damage can occur if the control solenoid with body and TCM valve assembly is dropped. DO NOT reuse the control solenoid with body and TCM valve assembly if it is dropped. |
Control Solenoid (w/Body and TCM) Valve Assembly Installation
Scheme 234
Scheme 234: Wire Routing and Connector Locations
| Callout | Component Name |
|---|
| Preliminary Procedure Route all wires as shown. |
| 1 | Shift Position Switch Connector |
| 2 | Output Speed Sensor Connector |
| 3 | Input Speed Sensor Connector |
Wire Routing and Connector Locations
Scheme 235
Scheme 235: Control Valve Body Cover Installation
| Callout | Component Name |
|---|
| 1 | Control Valve Body Cover Wiring Connector Hole Seal TIP: Holes in the seal must face down. |
| 2 | Control Valve Body Cover Assembly Gasket |
| 3 | Control Valve Body Cover Assembly |
| 4 | Control Valve Body Cover Bolt M6 x 30 (Qty: 12) CAUTION: Refer to Fastener Caution . Procedure Tighten in sequence. Tighten 12 N.m (9 lb ft). |
| 5 | Control Valve Body Cover Stud M6 x 30 (Qty: 2) Procedure Tighten in sequence. Tighten 12 N.m (9 lb ft). |
Control Valve Body Cover Installation
Scheme 236
Scheme 236: Torque Converter Installation
| Callout | Component Name |
|---|
| 1 | Torque Converter Assembly CAUTION: Lower the torque converter straight down. Failure to lower the torque converter straight down could damage the torque converter clutch lip seal inside the torque converter clutch assembly. Special Tools DT 46409 Torque Converter Lifting Handles For equivalent regional tools, refer to Special Tools . |
| 2 | DT 21366 Converter Holding Strap WARNING: The torque converter must be held to the torque converter housing by a retaining device such as shipping brackets. Without the retaining device, the torque converter may slide forward, disengaging the oil pump, or may fall completely out of the transmission causing personal injury and/or property damage. |
| 3 | Dust Cover - Model Dependant |
| 4 | Dust Cover Push Pin - Model Dependant (Qty: 2) |
| 5 | Dust Cover Bolt - Model Dependant CAUTION: Refer to Fastener Caution . Tighten 75 N.m (37 lb ft) |
| CAUTION |
|---|
| Lower the torque converter straight down. Failure to lower the torque converter straight down could damage the torque converter clutch lip seal inside the torque converter clutch assembly. |
| WARNING |
|---|
| The torque converter must be held to the torque converter housing by a retaining device such as shipping brackets. Without the retaining device, the torque converter may slide forward, disengaging the oil pump, or may fall completely out of the transmission causing personal injury and/or property damage. |
Torque Converter Installation
Scheme 237
Scheme 237: Lift Plate and Holding Fixture Removal
| Callout | Component Name |
|---|
| 1 | DT 46625 Transmission Holding Fixture TIP: Raise the transmission in order to remove the holding fixture. For equivalent regional tools, refer to Special Tools . |
| 2 | DT-47811-A Lift Plate TIP: Lower the transmission assembly onto the transmission jack in order to remove the lift plate. For equivalent regional tools, refer to Special Tools . |
Lift Plate and Holding Fixture Removal
