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Home >> Ford >> 2001 >> Explorer Chassis >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transmission - Overhaul - 5R55E >> Transmission Reassembly >> Transmission Assembly

Transmission Assembly

  1. Thoroughly clean the transmission case and extension housing in solvent and blow dry with compressed air.
  2. Inspect the transmission case for the following:
    1. Stripped bolt hole threads.
    2. Gasket and mating surfaces for burrs or nicks.
    3. Obstructions to vent and fluid passages.
      • Cracks or warpage.
    Fig 1: Inspecting Transmission Case
    G02046110
  3. Inspect the extension housing for cracks, burrs or warpage.
    Fig 2: Inspecting Extension Housing
    G02046111
  4. Inspect case bearing for damage. Install new components as needed. Follow steps  6 ,  7 and  8 if replacing the case bearing. If not replacing the case bearing, proceed to Step  8 .
    Fig 3: Inspecting Case Bearing For Damage
    G02046112
  5. Using the special tool, remove the case bearing.
    • Use an oil stone to remove any nicks or burrs in the bearing case bore.
    Fig 4: Removing Case Bearing
    G02046113
  6. Inspect the rear case inner race for burrs, nicks and scoring. If any damage has been found, a new case must be installed.
    Fig 5: Inspecting Rear Case Inner Race
    G02046114
    7. CAUTION: Make sure the bearing seal ring is facing the drive handle.
    Fig 6: Installing New Case Bearing
    G02046115
  7. Install a new case bearing.
    1. Assemble the special tool.
    2. Position new case bearing onto special tool.
  8. Using the special tool, tap case bearing into case bearing bore.
    Fig 7: Taping Case Bearing Into Case Bearing Bore
    G02046116
  9. Install the special tool on the rear of the transmission case.
    Fig 8: Installing Special Tool (307-262) Onto Rear Of Transmission Case
    G02046117
  10. Attach the fixture arm of the special tool as shown.
    Fig 9: Attaching Fixture Arm
    G02046118
    11. WARNING: Make sure the lock pin on the special tool is secure. Failure to follow these instructions may result in personal injury.
    Fig 10: Rotating Transmission
    G02046119
  11. Install transmission into the special tool.
    • Rotate the transmission so that the fluid pan rail is facing up.
  12. Using the special tool, install the manual control lever shaft seal.
    • Lubricate the manual control lever shaft seal with petroleum jelly.
    Fig 11: Installing Manual Control Lever Shaft Seal
    G02046120
  13. Assemble the manual valve inner lever and parking lever actuating rod as shown.
    Fig 12: Assembling Manual Valve Inner Lever & Parking Lever Actuating Rod
    G02046121
  14. Install the manual control lever shaft.
    Fig 13: Installing Manual Control Lever Shaft
    G02046122
    15. CAUTION: Use care not to damage the fluid pan rail surface when installing the retaining pin.
    NOTE: Align the manual control lever shaft alignment groove with the manual control lever shaft spring pin bore in the transmission case.
    Fig 14: Installing Manual Control Lever Shaft Spring Pin
    G02046123
  15. Install the manual control lever shaft spring pin.
    • Tap the manual control lever shaft spring pin into the transmission case.
    16. CAUTION: Align the flats on the manual valve inner lever with the flats on the manual control lever shaft.
    Fig 15: Installing Manual Valve Inner Lever & Parking Lever Actuating Rod
    G02046124
  16. Install the manual valve inner lever and parking lever actuating rod on to the manual control lever shaft.
    17. CAUTION: To avoid damage, do not allow the wrench to strike the manual valve inner lever pin.
    Fig 16: Installing Manual Valve Inner Lever Nut Onto Manual Control Lever Shaft
    G02046125
  17. Install the manual valve inner lever nut on the manual control lever shaft and tighten.
    18. CAUTION: The tabs on the output shaft thrust washer (No. 11) point into the case. Make sure the thrust washer is correctly seated.
    Fig 17: Installing No. 11 Output Shaft Thrust Washer
    G02046126
  18. Install the output shaft thrust washer (No. 11).
    • Coat the output shaft thrust washer with petroleum jelly.
  19. Install the park gear.
    Fig 18: Installing Park Gear
    G02046127
  20. Install the low/reverse brake drum.
    • Rotate the low/reverse brake drum clockwise to install.
    Fig 19: Installing Low/Reverse Brake Drum
    G02046128
  21. If not already installed during subassembly, install the No. 10B needle bearing onto the output shaft ring gear and hub assembly.
    • Coat the needle bearing with petroleum jelly.
    Fig 20: Installing No. 10B Needle Bearing
    G02046129
  22. Install the output shaft through the output shaft park gear.
    Fig 21: Installing Output Shaft
    G02046130
  23. Install the output shaft ring gear and output shaft hub.
    Fig 22: Installing Output Shaft Ring Gear & Output Shaft Hub
    G02046131
    24. CAUTION: Always install a new output shaft retaining ring.
    Fig 23: Installing New Output Shaft Retaining Ring
    G02046132
  24. Install a new output shaft retaining ring.
    25. NOTE: Install the output shaft sleeve with the cone facing up.
    Fig 24: Installing Output Shaft Sleeve
    G02046133
  25. Install the output shaft sleeve.
  26. Install low/reverse planetary carrier needle bearings.
    1. Install low/reverse planetary carrier needle bearing (No. 8) on the front face of the low/reverse planetary.
    2. Install low/reverse planetary carrier needle bearing (No. 9) on the rear face of the low/reverse planetary.
    • Coat the low/reverse planet carrier needle bearing (No. 8) and low/reverse planetary carrier needle bearing (No. 9) with petroleum jelly.
    Fig 25: Installing Low/Reverse Planetary Carrier Needle Bearings
    G02046134
    27. CAUTION: Make sure needle bearings stay in place.
    Fig 26: Installing Low/Reverse Planetary Assembly With No. 8 & No. 9 Low/Reverse Planetary Carrier Needle Bearings
    G02046135
  27. Install the low/reverse planetary assembly with No. 8 and No. 9 low/reverse planetary carrier needle bearings into the output shaft ring gear.
    28. CAUTION: The low/reverse brake drum must be pulled forward to install the low/reverse planet retaining ring.
    Fig 27: Installing Low/Reverse Retaining Ring
    G02046136
  28. Install the low/reverse retaining ring into the low/reverse brake drum groove.
    29. CAUTION: Make sure band is resting on the two anchor pins in the case.
    Fig 28: Installing Low/Reverse Band
    G02046137
  29. Install the low/reverse band over the low/reverse brake drum.
  30. Temporarily install the low/reverse band servo piston and rod to hold the low/reverse band in position.
    Fig 29: Temporarily Installing Low/Reverse Band Servo Piston & Rod
    G02046138
  31. Install the previously assembled forward geartrain assembly.
    Fig 30: Installing Assembled Forward Geartrain Assembly
    G02046139
    32. WARNING: Make sure the lock pin on the special tool is secure. Failure to follow these instructions may result in personal injury.
  32. Rotate transmission assembly so that the converter housing surface is facing up.
  33. Select the intermediate brake drum thrust bearing (No. 4) as follows:
    1. Install the special tool on case assembly shoulder.
    2. Set the special tool on top as shown.
    Fig 31: Selecting No. 4 Intermediate Brake Drum Thrust Bearing
    G02046140
  34. Calculate the thrust bearing thickness.
    • Extend the micrometer probe until it contacts the intermediate brake drum thrust bearing surface. Record the reading. This is dimension A.
    Fig 32: Calculating Thrust Bearing Thickness
    G02046141
  35. Place the micrometer on the opposite side of the special tool and repeat measurement. This is dimension B.
    Fig 33: Measuring Dimension B
    G02046142
  36. Add dimension A and B, divide the total of A and B by 2. Then subtract the special tool thickness 17.78 mm (0.700 in). Record this reading as dimension C.
  37. Place the special tool across the center support. Place the micrometer on the top of the special tool.
    • Extend the micrometer probe until it makes contact with the center support thrust bearing surface. Record this reading as dimension D.
    Fig 34: Measuring Dimension D
    G02046143
  38. Place the special tool on the opposite side of the special tool.
    • Extend the micrometer probe until it makes contact with the center support thrust bearing surface. Record this reading as dimension F.
    Fig 35: Measuring Dimension F
    G02046144
  39. Add dimensions D and F. Divide the total of D and F by two. Subtract the special tool thickness 17.78 mm (0.700 in) dimension E. The result is dimension G.
    Fig 36: Calculating Dimension G
    G02046145
  40. Add dimensions C and G. This total is dimension H. Use the following chart to select the correct No. 4 thrust bearing. Reference end play is 0.20-0.54 mm (0.008-0.021 in).
    Fig 37: No. 4 Thrust Bearing Chart
    G02046146
  41. Install the intermediate servo actuating lever.
    Fig 38: Installing Intermediate Servo Actuating Lever
    G02046147
    42. NOTE: The intermediate band lever shaft is shorter than the front band lever shaft.
    Fig 39: Installing Intermediate Band Actuating Lever Shaft
    G02046148
  42. Install the intermediate band actuating lever shaft through the intermediate servo actuating lever.
  43. Install the intermediate band apply strut on the intermediate servo actuating lever.
    Fig 40: Installing Intermediate Band Apply Strut
    G02046149
    44. NOTE: Make sure that the intermediate apply strut is aligned with the band notch.
    Fig 41: Installing Intermediate Band
    G02046150
  44. Install the intermediate band.
    45. NOTE: Use the intermediate band adjusting screw as a temporary alignment guide.
    NOTE: The intermediate and front band anchor struts and band adjustment screws are the same.
    Fig 42: Installing Intermediate Band Anchor Strut & Adjustment Screw
    G02046151
  45. Install the intermediate band anchor strut and the intermediate band adjustment screw.
  46. Install the selected intermediate brake drum thrust washer (No. 4) on the center support.
    • Coat the intermediate brake drum thrust washer with petroleum jelly.
    Fig 43: Installing Selected No. 4 Intermediate Brake Drum Thrust Washer
    G02046152
    47. CAUTION: Do not apply pressure to the center support while installing. Damage to sealing rings can result. Make sure the rear planetary support is seated.
    NOTE: Align the center support screw hole with correct case hole.
    Fig 44: Installing Center Support
    G02046153
  47. Install the center support.
    1. Position the center support into the intermediate brake and direct clutch drum.
    2. Temporarily insert input shaft and gently wiggle it until the center support is seated against the case shoulder, then remove the input shaft.
    48. CAUTION: Install the center support retaining ring with the tapered side facing up.
    CAUTION: Make sure the notch opening is not obstructed by the center support retaining ring.
    Fig 45: Installing Center Support Retaining Ring
    G02046154
  48. Install the center support retaining ring.
    1. Position center support retaining ring with the tapered side facing up.
    2. Install the center support retaining ring so that the notch opening is not obstructed.
  49. Install the center support locknut and cage.
    Fig 46: Installing Center Support Locknut & Cage
    G02046155
  50. Install the center support-to-case capscrew.
    Fig 47: Installing Center Support-To-Case Capscrew
    G02046156
    51. CAUTION: Carefully route the turbine shaft speed (TSS) sensor connector and wiring harness through the opening in the case. Do not damage the wiring.
    NOTE: Route TSS sensor electrical connector and wiring through transmission case opening.
    Fig 48: Installing Turbine Shaft Speed (TSS) Sensor
    G02046157
  51. Install the Turbine Shaft Speed (TSS) sensor.
    1. Install the TSS sensor.
    2. Install TSS sensor screw.
    52. CAUTION: Use only the center shaft thrust bearing (No. 3).
    NOTE: The center shaft thrust bearing (No. 3) has no notches on the outer race.
    Fig 49: Installing No. 3 Center Shaft Thrust Bearing
    G02046158
  52. Install the center shaft thrust bearing (No. 3).
    53. CAUTION: Do not bend the trigger wheel.
    Fig 50: Installing Overdrive Planetary & One-Way Clutch Assembly
    G02046159
  53. Install the overdrive planetary and one-way clutch assembly.
    54. CAUTION: The trigger wheel triggering window should pass over the thin blade of the special tool. If it does not, a new overdrive planetary carrier and trigger wheel must be installed.
    Fig 51: Checking TSS Sensor Air Gap
    G02046160
  54. Using the special tool, check TSS sensor air gap.
    1. Place the thin blade of the special tool over the TSS sensor.
    2. Rotate the trigger wheel and repeat checks for all windows.
    55. CAUTION: The trigger wheel triggering window should not pass over the thick blade of the special tool. If it does not, a new overdrive planetary carrier and trigger wheel must be installed.
    Fig 52: Checking TSS Sensor Air Gap
    G02046161
  55. Using the special tool, check TSS sensor air gap.
    1. Place the thick blade of the special tool over the TSS sensor.
    2. Rotate the trigger wheel and repeat checks for all windows.
    56. NOTE: Align the clutch plates and front adapter gear.
    Fig 53: Installing Front Brake Drum & Coast Clutch Drum Assembly
    G02046162
  56. Install the front brake drum and coast clutch drum assembly.
  57. Install the front servo band lever and front band lever-to-case bracket into the transmission case.
    Fig 54: Installing Front Servo Band Lever & Front Band Lever-To-Case Bracket
    G02046163
    58. NOTE: The front band lever shaft is longer than the intermediate band actuating lever shaft.
    Fig 55: Installing Front Band Actuating Lever Shaft
    G02046164
  58. Install the front band actuating lever shaft through the front servo band lever.
  59. Install the front band apply strut.
    Fig 56: Installing Front Band Apply Strut
    G02046165
    60. NOTE: If the front band is reused, it must be installed in the same position as when removed.
    Fig 57: Installing Front Band
    G02046166
  60. Install the front band over the front brake and coast clutch drum.
    61. NOTE: Use the band adjustment screw as a temporary alignment guide.
    Fig 58: Installing Front Band Anchor Strut
    G02046167
  61. Install the front band anchor strut.
  62. Install the front band adjusting screw.
    Fig 59: Installing Front Band Adjusting Screw
    G02046168
    63. CAUTION: Make sure that the pump body is seated against the thrust washer and the front brake and coast clutch drum. The pump body must be below the level of the case gasket surface.
    CAUTION: The tabs on the washer go into the pump face.
    Fig 60: Performing Front End Play Check Procedure
    G02046169
  63. Perform front end play check procedure as follows:
    • Coat the fluid pump inlet thrust washer (No. 1) with petroleum jelly.
    • Install the fluid pump inlet thrust washer (No. 1) on the rear of the fluid pump and place pump into position in case.
    64. CAUTION: The special tool must rest on the gasket surface.
    Fig 61: Measuring Front End Play Clearance
    G02046170
  64. Measure the front end play clearance.
    1. Place special tool across the case.
    2. Insert the special tool and extend the micrometer probe until it contacts the fluid pump face.
    • Read the measurement and subtract special tool thickness 17.78 mm (0.700 in). This is dimension A.
    • Repeat the measurement at the opposite side of the transmission case. This is dimension B.
    • Add dimensions A and B together and divide by two. This is front end clearance dimension C.
    65. CAUTION: If the average front end clearance is below the specification, choose a thinner washer. If the average is above the specification, choose a thicker washer.
    NOTE: The front end play specification is 0.18-0.70 mm (0.007-0.028 in).
    Fig 62: Front End Play Selective No. 1 Thrust Washer Chart
    G02046171
  65. Use dimension C and the chart below to select the correct thickness fluid pump inlet thrust washer (No. 1).
    66. CAUTION: Make sure that the pump body is seated against the thrust washer and the front brake and coast clutch drum. The pump body must be below the level of the case gasket surface.
    CAUTION: The tabs on the washer go into the pump face.
    Fig 63: Installing No. 1 Thrust Washer
    G02046172
  66. Remove pump and install No. 1 thrust washer onto pump. After installing selected front pump thrust washer No. 1, repeat front end play check. Make sure end play is correct, then remove pump for assembly.
  67. Install a new O-ring seal in fluid pump drive gear.
    Fig 64: Installing New Fluid Pump Drive Gear O-Ring Seal
    G02046173
    68. CAUTION: Lubricate the special tool with multi-purpose grease.
    Fig 65: Installing Fluid Pump Drive Gear Onto Special Tool To Seat O-Ring Seal
    G02046174
  68. Install the fluid pump drive gear on special tool to seat the O-ring seal. Remove the tool.
    69. CAUTION: The chamber on the inside edge of the small gear must be up when in the pump housing gear pocket. The dimple on the larger gear must be down when in the pump housing gear pocket.
    Fig 66: Installing Pump Gears Into Fluid Pump Housing
    G02046175
  69. Install the pump gears into the fluid pump housing. Apply multi-purpose grease to pump gear to prevent scoring at start-up.
    70. CAUTION: Make sure the holes in the plate line up with the holes in the pump.
    Fig 67: Installing Fluid Pump Adapter Plate
    G02046176
  70. Install the fluid pump adapter plate.
    71. CAUTION: Do not allow the pump gears to come out of the pump housing pocket.
    NOTE: The notch on the outside of the adapter plate will be at the 9 o'clock position relative to the converter housing.
    Fig 68: Installing Fluid Pump Onto Converter Housing
    G02046177
  71. Install the fluid pump on the converter housing.
    • Hold the fluid pump adapter plate against the pump housing. Turn the pump and adapter plate over and place on the converter housing.
  72. Loosely install the fluid pump screws.
    Fig 69: Installing Fluid Pump Screws
    G02046178
    73. CAUTION: The special tools must be used to correctly align the fluid pump to the fluid adapter plate. This will prevent seal leakage, gear noise, broken gears and bushing failure.
    Fig 70: Aligning Fluid Pump To Fluid Pump Adapter Plate
    G02046179
  73. Align the fluid pump to the fluid pump adapter plate and select the gauge from the special tool that is the snuggest fit when placed over the fluid pump.
  74. Thread the gauge into special tool and slide the tool over the fluid pump until it bottoms out in the fluid pump gear pocket.
    Fig 71: Installing Fluid Pump Alignment Tool
    G02046180
  75. Tighten the fluid pump bolts in a star pattern and remove the pump alignment handle.
    Fig 72: Tightening Fluid Pump Bolts
    G02046181
  76. Install a new fluid pump seal ring.
    • Coat the fluid pump seal ring with petroleum jelly.
    Fig 73: Installing New Fluid Pump Seal Ring
    G02046182
    77. NOTE: Make sure the fluid pump seal ring is installed on the housing and pump assembly.
    Fig 74: Installing New Fluid Pump Gasket
    G02046183
  77. Install a new fluid pump gasket.
    • Hold the fluid pump gasket in place with petroleum jelly.
    78. CAUTION: Verify correct seal installation. Make sure seal grooves are clean and free of burrs.
    Fig 75: Installing Front Pump Support Seal
    G02046184
  78. Install the front pump support seal.
  79. Install the selected No. 1 fluid pump thrust washer.
    • Coat the fluid pump thrust washer with petroleum jelly.
    Fig 76: Installing Selected No. 1 Fluid Pump Thrust Washer
    G02046185
  80. Install the special tools into the transmission case.
    Fig 77: Installing Special Alignment Tools (307-331) Into Transmission Case
    G02046186
    81. CAUTION: The splines on the ends of the input shaft are not the same length. The shorter splines go into the assembly.
    Fig 78: Installing Input Shaft
    G02046187
  81. Install the input shaft.
    82. CAUTION: Make sure that the fluid pump inlet thrust washer (No. 1) selective thrust washer, fluid pump gasket, and the fluid pump-to-case O-ring seal remain in the correct position throughout this step.
    Fig 79: Installing Fluid Pump & Converter Housing Onto Case
    G02046188
  82. Install the fluid pump and converter housing onto the case.
    83. NOTE: Lubricate O-ring seals on converter housing screws.
    Fig 80: Installing New Converter Housing-To-Case Screws
    G02046189
  83. Remove the special tools. Install the new converter housing-to-case screws. Tighten the screws in a star pattern.
  84. Remove the input shaft.
    Fig 81: Removing Input Shaft
    G02046190
    85. WARNING: Make sure the lock pin on the special tool is secure. Failure to follow these instructions may result in personal injury.
  85. Rotate the transmission assembly so the fluid pan rails are facing up.
  86. Assemble the front servo assembly.
    1. Install the front servo cover O-ring seal on the front servo cover. Coat the front servo cover O-ring seal with petroleum jelly.
    2. Install front servo piston into the front servo cover.
    3. Install the front servo piston spring on the front servo piston.
    Fig 82: Assembling Front Servo Assembly
    G02046191
    87. CAUTION: Do not damage the front servo-to-case O-ring seal during installation.
    CAUTION: Do not press the front servo cover and O-ring past the relief hole in the case or O-ring seal damage can occur.
    Fig 83: Installing Front Servo Assembly
    G02046192
  87. Using the special tool, install the front servo assembly into the case and install the front servo cover retaining ring.
  88. Assemble the intermediate servo assembly.
    1. Install the intermediate servo cover O-ring seal on intermediate the servo cover. Coat the intermediate servo cover O-ring seal with petroleum jelly.
    2. Install the intermediate servo piston into the intermediate servo cover.
    3. Install the intermediate servo piston spring on the intermediate servo piston.
    Fig 84: Assembling Intermediate Servo Assembly
    G02046193
    89. CAUTION: Do not damage servo cover-to-case O-ring seal during installation.
    CAUTION: Do not press the intermediate servo cover and O-ring seal past the relief hole in the case or O-ring seal damage can occur.
    Fig 85: Installing Intermediate Servo Assembly
    G02046194
  89. Using the special tool, install the intermediate servo assembly into the case and install the intermediate servo cover retaining ring.
    90. CAUTION: Do not allow front band adjustment screw to back out. Band strut can fall out of position.
    CAUTION: Install, but do not tighten, a new locknut on the band adjustment screw. Apply petroleum jelly to the locknut seal.
    Fig 86: Installing New Band Adjustment Screw Locknut
    G02046195
  90. Install new locknut on the band adjustment screw.
    91. CAUTION: The front servo must be installed prior to band adjustment.
    NOTE: The wrench will click at the specified torque.
    Fig 87: Tightening Front Band Adjustment Screw
    G02046196
  91. Tighten front band adjustment screw using the special tool and back off front band adjustment screw exactly two (2) turns and hold that position.
  92. Tighten the front band locknut.
    1. Hold the front band adjustment screw stationary.
    2. Tighten the front band locknut.
    Fig 88: Tightening Front Band Locknut
    G02046197
    93. CAUTION: Do not allow intermediate band adjusting screw to back out. Band strut could fall out of position.
    CAUTION: Install, but do not tighten, a new locknut on the band adjustment screw. Apply petroleum jelly to the locknut seal.
    Fig 89: Installing Band Adjustment Screw Nut
    G02046198
  93. Install new nut on the band adjustment screw.
    94. CAUTION: The intermediate servo must be installed prior to band adjustment.
    NOTE: The wrench will click at the specified torque.
    Fig 90: Tightening Intermediate Band Adjusting Screw
    G02046199
  94. Tighten intermediate band adjusting screw using the special tool and back off intermediate band adjusting screw exactly two (2) turns and hold that position.
  95. Tighten the intermediate band locknut.
    1. Hold the intermediate band adjustment screw stationary.
    2. Tighten the intermediate band locknut.
    Fig 91: Tightening Intermediate Band Locknut
    G02046200
    96. CAUTION: Install new O-ring seals on the 16-pin electrical connector. Coat the O-ring seals with petroleum jelly.
    NOTE: Make sure that the tab is in the lock position.
    Fig 92: Positioning Transmission Case (16-Pin) Electrical Connector Into Case Bore
    G02046201
  96. Position the transmission case (16-pin) electrical connector into the case bore.
    • Press the transmission case (16-pin) electrical connector through the case until a click is heard.
    97. CAUTION: Do not overstretch the retaining spring.
    Fig 93: Installing 16-Pin Electrical Connector Retaining Spring
    G02046202
  97. Install the 16-pin electrical connector retaining spring.
    98. CAUTION: Align the slot on the turbine shaft speed (TSS) sensor electrical connector with the slot in the 16-pin electrical connector.
    Fig 94: Installing TSS Sensor Electrical Connector
    G02046203
  98. Install the TSS sensor electrical connector into the transmission case (16-pin) electrical connector.
    1. Connect the TSS sensor electrical connector.
    2. Insert the TSS sensor electrical connector wires into the retaining slot in the 16-pin electrical connector.
  99. Install the special tools into the transmission case.
    Fig 95: Installing Special Tools (307-333) Into Transmission Case
    G02046204
    100. CAUTION: Make sure main control valve body gasket is aligned.
    CAUTION: Make sure that the manual valve is correctly aligned with the manual valve inner pin when the main control valve body is installed.
    Fig 96: Positioning Main Control Valve Body Into Transmission Case
    G02046205
  100. Position the main control valve body into the transmission case.
    101. NOTE: The screws will be tightened in later steps.
    Fig 97: Installing Four M6 x 45 mm Screws
    G02046206
  101. Loosely install the four M6 x 45 mm screws.
    102. NOTE: The main control valve body screws will be tightened in later steps.
    Fig 98: Installing Two M6 x 35 mm Screws
    G02046207
  102. Loosely install the two M6 x 35 mm screws.
    103. NOTE: The main control valve body screw will be tightened in later steps.
    Fig 99: Install M6 x 30 mm Screw
    G02046208
  103. Loosely install the M6 x 30 mm screw.
  104. Remove the special tools.
    Fig 100: Removing Special Tools
    G02046209
    105. NOTE: The main control valve body screws will be tightened in later steps.
    Fig 101: Install Sixteen M6 x 40 mm Screws
    G02046210
  105. Loosely install the sixteen M6 x 40 mm screws.
  106. Tighten the screws in the sequence shown.
    107. Fig 102: Screws Tightening Sequence
    G02046211
  107. Rotate the manual lever into the NEUTRAL position, then install the manual control valve detent lever spring.
    1. Position the manual control valve detent lever spring on the main control valve body.
    2. Install the screw.
    Fig 103: Installing Manual Control Valve Detent Lever Spring
    G02046212
  108. Install the low/reverse band servo cover and reverse servo separator plate cover gasket.
    1. Position the low/reverse band servo cover and low/reverse servo separator plate cover gasket on the transmission case.
    2. Loosely install the screws.
    Fig 104: Installing Low/Reverse Band Servo Cover & Reverse Servo Separator Plate Cover Gasket
    G02046213
  109. Tighten the screws in the sequence shown.
    Fig 105: Tightening Servo Separator Plate Cover Screws Sequence
    G02046214
  110. Connect the solenoid electrical connectors.
    1. Connect shift solenoids SSA, SSB, SSC and SSD electrical connectors.
    2. Connect the torque converter clutch (TCC) solenoid electrical connector.
    3. Connect the electronic pressure control (EPC) solenoid electrical connector.
    Fig 106: Connecting Solenoid Electrical Connectors
    G02046215
    111. CAUTION: Excessive pressure may break the locating pins.
    Fig 107: Installing Wiring Loom Protector & Guide
    G02046216
  111. Install wiring loom protector and guide.
    • Align the pins in the holes of the solenoid clamps and gently push down.
    112. CAUTION: Make sure that both fluid pan filter O-ring seals are correctly installed on the fluid pan filter prior to installation.
    Fig 108: Installing Fluid Pan Filter O-Ring Seals
    G02046217
  112. Install the fluid pan filter O-ring seals.
    • Coat the fluid pan filter O-ring seals with clean automatic transmission fluid.
  113. Install the transmission fluid filter.
    Fig 109: Installing Transmission Fluid Filter
    G02046218
  114. Install the transmission fluid pan and transmission fluid pan gasket.
    • Loosely install the screws.
    Fig 110: Installing Transmission Fluid Pan
    G02046219
  115. Tighten the transmission fluid pan screws.
    • Tighten the transmission fluid pan screws in a crisscross sequence.
    Fig 111: Tightening Transmission Fluid Pan Screws
    G02046220
  116. Remove the transmission from the bench and place on a flat surface.
    Fig 112: Removing Transmission From Bench
    G02046221
  117. Remove the special tools from the transmission case.
    Fig 113: Removing Special Tools From Transmission Case
    G02046222
    118. NOTE: Use petroleum jelly to hold the gasket in place.
    Fig 114: Installing New Extension Housing Gasket
    G02046223
  118. Install a new extension housing gasket.
    119. NOTE: The guide cup is press-fit into the extension housing and is not serviced separately.
    Fig 115: Installing Parking Pawl Assembly
    G02046224
  119. Install the parking pawl assembly.
    1. Install the parking pawl shaft into the extension housing.
    2. Install the parking pawl.
    3. Install the parking pawl return spring.
    120. CAUTION: Make sure the parking lever actuating rod is correctly seated into the transmission case parking rod guide cup.
    Fig 116: Installing Extension Housing
    G02046225
  120. Install the extension housing.
    1. Install the extension housing and gasket.
    2. Install the screws.
    3. Install the stud(s).
    121. CAUTION: The lube hole in the bushing must be aligned with the lube groove in the extension housing.
    NOTE: Install the extension housing bushing only if removed in disassembly.
    NOTE: Remove any burrs from the extension housing counterbore.
    Fig 117: Aligning Lube Hole & Lube Groove In Extension Housing
    G02046226
  121. Align lube hole with the lube groove in extension housing. This groove is located at the 3 o'clock position when viewed from the rear.
    122. CAUTION: Tool will bottom when bushing is in the correct position.
    Fig 118: Installing Extension Housing Bushing
    G02046227
  122. Using the special tool, install the extension housing bushing.
  123. Position new extension housing seal with drain hole in the 6 o'clock position.
    Fig 119: Positioning New Extension Housing Seal
    G02046228
  124. Using the special tool, install a new extension housing seal.
    Fig 120: Installing New Extension Housing Seal
    G02046229
  125. Install the digital transmission range (TR) sensor.
    1. Position the digital TR sensor on the transmission.
    2. Loosely install the screws.
    3. Rotate manual lever to neutral position (two detents rearward).
    Fig 121: Installing Digital Transmission Range (TR) Sensor
    G02046230
    126. CAUTION: Tightening one screw before tightening the other can cause the sensor to bind or become damaged.
    NOTE: The manual lever must be in the neutral position.
    Fig 122: Aligning Digital TR Sensor & Tighten Screws
    G02046231
  126. Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence.
  127. Install the manual control lever.
    1. Install the lever.
    2. Install the nut.
    Fig 123: Installing Manual Control Lever
    G02046232
  128. If equipped, install transmission servo heat shield and nut.
    Fig 124: Installing Transmission Servo Heat Shield & Nut
    G02046233
    129. NOTE: Inspect the O-ring seal for damage. Install a new component if damaged.
    Fig 125: Installing Output Shaft Speed (OSS) Sensor
    G02046234
  129. If equipped, install the output shaft speed (OSS) sensor.
    1. Install the sensor.
    2. Install the screw.
    130. NOTE: Inspect the O-ring seal for damage. Install a new component if damaged.
    Fig 126: Installing Intermediate Shaft Speed (ISS) Sensor
    G02046235
  130. Install the intermediate shaft speed (ISS) sensor.
    1. Install the sensor.
    2. Install the screw.
    131. CAUTION: The splines of the input shaft are not the same length on both ends. The shaft end with the shorter splines goes into the fluid pump.
    Fig 127: Installing Input Shaft
    G02046236
  131. Install the input shaft.
  132. Using the special tool, check that the fluid pump gear seal ring is seated.
    Fig 128: Checking Fluid Pump Gear Seal Ring Is Installation
    G02046237
    133. CAUTION: Do not damage the fluid pump gear O-ring seal when installing the torque converter.
    CAUTION: Make sure the converter hub is fully engaged in the front pump support and gear, and it rotates freely. Do not damage the hub seal.
    CAUTION: If the torque converter slides out, the hub seal can be damaged.
    Fig 129: Lubricating Converter Hub
    G02046238
  133. Lubricate the converter hub with clean automatic transmission fluid.
    134. WARNING: The torque converter can fall out if the transmission is tipped. Failure to follow these instructions can result in personal injury.
    Fig 130: Installing Torque Converter
    G02046239
  134. Use the special tools to install the torque converter by pushing and rotating.
  135. Make sure the torque converter is installed to specification.
    Fig 131: Torque Converter Installed Specification
    G02046240
  136. Lubricate the torque converter pilot hub with multi-purpose grease.
    Fig 132: Lubricating Torque Converter Pilot Hub
    G02046241
  137. Before installing transmission, make sure that the transmission cooling system is properly installed.
  138. Install the special tool on case.
    Fig 133: Installing Special Tool (307-346) On Case
    G02046242
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