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Section 2 (Automatic Transmission): Assembly: Transmission

WARNING: This page is about a different variant/trim than selected.
SPECIAL TOOL(S)

G04696520
 Adjustment Set, Transmission Band
307-S022 (T71P-77370-A)
G04696521
 Holding Fixture, Transmission
307-003 (T57L-500-B)
G04696522
 Depth Micrometer
303-D026 (D80P-4201-A) or equivalent
G04696523
 Alignment Gauge, TR Sensor
307-351 (T97L-70010-A)
G04696524
 Installer, Transmission Extension Housing Oil Seal
307-038 (T74P-77052-A)
G04696525
 Sizer, Piston Seal
307-338 (T95L-70010-G)
G04696526
 Alignment Set, Fluid Pump
307-S039 (T74P-77103-X)
G04696527
 Aligner, Fluid Pump Handle
307-431
G04696528
 Aligner, Fluid Pump Pilot
307-432
G04696529
 Gauge Bar
307-400
G04696530
 Compressor, Servo Cover
307-402
G04696531
 Installer, Shift Shaft Fluid Seal
307-050 (T74P-77498-A)
G04696532
 Handle, Torque Converter
307-091 (T81P-7902-C)
G04696533
 Compressor, Cushion Spring
307-401
G04696534
 Aligner, Valve Body
307-334 (T95L-70010-C)
G04696535
 Alignment Pins, Transmission Pump
307-399
G04696536
 Aligner, Flex Plate
307-403
G04696537
 Air Test Plate
307-433-01, 307-433-2, 307-433-3
G04696538
 Installer, Drive Pinion flange
205-479
G04696539
 Installer, Output Shaft Flange
307-404
MATERIAL

Item Specification
MERCON® V Automatic Transmission Fluid XT-5-QM MERCON® V
Multi-Purpose Grease XG-4 and/or XL-5 ESB-M1C93-B
Fig 1: Exploded View Of Automatic Transmission Components (1 Of 3)
G04696540
Fig 2: Exploded View Of Automatic Transmission Components (2 Of 3)
G04696541
Fig 3: Exploded View Of Automatic Transmission Components (3 Of 3)
G04696542
Fig 4: Automatic Transmission Components Description Chart (1 Of 3)
G04696543
Fig 5: Automatic Transmission Components Description Chart (2 Of 3)
G04696544
Fig 6: Automatic Transmission Components Description Chart (3 Of 3)
G04696545
  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:
    • Stripped bolt hole threads.
    • Gasket and mating surfaces for burrs or nicks.
    • Obstructions to vent and fluid passages.
    • Cracks or warpage.
      Fig 7: Locating Transmission Case
      G04696546
  3. Inspect the extension housing for cracks, burrs or warpage.
    Fig 8: Locating Extension Housing
    G04696547
  4. Inspect the case bearing for damage. If damage to the case bearing is indicated, install a new case.
    Fig 9: Locating Case Bearing
    G04696548
    WARNING: Make sure the lock pin on bench-mounted holding fixture is secure. Failure to follow these instructions may result in personal injury.
  5. Using the special tool, install the transmission into the bench with the converter housing facing up.
    Fig 10: Identifying Transmission Into Bench
    G04696549
  6. Using the special tool, install the manual control lever shaft seal and lubricate it with petroleum jelly.
    Fig 11: Identifying Special Tool
    G04696550
  7. Install the parking lever rod.
    Fig 12: Locating Parking Lever Actuating Rod
    G04696551
  8. Install the manual control lever.
    Fig 13: Locating Manual Control Valve Lever
    G04696552
  9. Assemble the manual valve inner lever and parking lever actuating rod as shown.
    Fig 14: Locating Parking Lever Actuating Rod
    G04696553
    CAUTION: Align the flats on the manual valve inner lever with the flats on the manual control lever shaft.
  10. Install the manual control lever shaft.
    Fig 15: Locating Manual Control Lever Shaft
    G04696554
  11. Install the manual valve inner lever onto the manual shaft and loosely install the nut.
    Fig 16: Locating Manual Valve Inner Lever And Mounting Nut
    G04696555
    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.
  12. Install the manual control lever shaft spring pin.
    • Tap the manual control lever shaft spring pin into the transmission case.
      Fig 17: Locating Manual Control Lever Shaft Spring Pin
      G04696556
    CAUTION: To avoid damage, do not allow the wrench to strike the manual valve inner lever pin.
  13. Tighten the nut.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 18: Tightening Nut
      G04696557
    CAUTION: The tabs on the output shaft thrust washer (No. 11) point into the case. Make sure the thrust washer is correctly seated.
  14. Install the output shaft thrust washer (No. 11).
    • Coat the output shaft thrust washer with petroleum jelly.
      Fig 19: Locating Output Shaft Thrust Washer
      G04696558
  15. Install the park gear on the output shaft.
    Fig 20: Locating Park Gear On Output Shaft
    G04696559
  16. Install the output shaft and park gear.
    Fig 21: Locating Output Shaft And Park Gear
    G04696560
  17. Install the low/reverse brake drum.
    • Rotate the low/reverse brake drum clockwise to install.
      Fig 22: Locating Low/Reverse Brake Drum
      G04696561
    CAUTION: Make sure band is resting on the 2 anchor pins in the case.
  18. Install the low/reverse band over the reverse drum.
    Fig 23: Locating Low/Reverse Band
    G04696562
    NOTE: The reverse band actuating lever must fit into the notches in the band.
  19. Install the reverse band actuating lever into the reverse band.
    Fig 24: Locating Reverse Band Actuating Lever
    G04696563
  20. Install the reverse band actuating lever shaft into the case and into the reverse band actuating lever.
    Fig 25: Locating Reverse Band Actuating Lever Shaft
    G04696564
  21. Install the No. 10 needle bearing into the case.
    Fig 26: Locating Needle Bearing
    G04696565
    CAUTION: Do not damage the seal against the case during assembly.
  22. Install the output shaft ring gear, hub and seal.
    Fig 27: Locating Output Shaft Ring Gear
    G04696566
    CAUTION: Always install a new output shaft retaining ring.
  23. Install a new output shaft retaining ring.
    Fig 28: Locating Output Shaft Retaining Ring
    G04696567
    NOTE: Install the output shaft sleeve with the cone facing up. This sleeve will snap into place when correctly installed.
  24. Install the output shaft sleeve.
    Fig 29: Locating Output Shaft Sleeve
    G04696568
  25. Install low/reverse planetary carrier needle bearing (No. 9) onto the output shaft ring gear and hub assembly.
    Fig 30: Locating Thrust Bearing
    G04696569
    CAUTION: Make sure the needle bearings stay in place.
  26. Install the low/reverse planetary assembly.
    Fig 31: Locating Low/Reverse Planetary Assembly
    G04696570
    CAUTION: The low/reverse brake drum must be pulled forward to install the low/reverse planet retaining ring.
  27. Install the retaining ring.
    Fig 32: Locating Retaining Ring
    G04696571
  28. Install the No. 8 thrust bearing.
    Fig 33: Locating Thrust Bearing
    G04696572
  29. Install the spacer on the input shell, using petroleum jelly to hold it in place.
    Fig 34: Locating Spacer On Input Shell
    G04696573
  30. Install the input shell and sun gear assembly.
    Fig 35: Locating Input Shell And Sun Gear Assembly
    G04696574
    NOTE: The No. 13 bearing must be correctly seated in the forward planet assembly so the sun gear can be installed correctly.
  31. Install the forward planetary assembly.
    Fig 36: Locating Forward Planetary Assembly
    G04696575
  32. Install the No. 7 forward planet thrust bearing into the forward ring gear and hub assembly. Use petroleum jelly to hold the bearing in place.
    Fig 37: Locating Forward Planet Thrust Bearing
    G04696576
  33. Install the No. 6B forward clutch thrust washer onto the forward ring gear hub.
    Fig 38: Locating Forward Clutch Thrust Washer
    G04696577
  34. Install the forward ring gear and hub as an assembly.
    Fig 39: Locating Forward Ring Gear And Hub
    G04696578
  35. Install the No. 6A forward ring gear hub thrust bearing into the forward ring gear and hub.
    Fig 40: Locating Forward Ring Gear Hub Thrust Bearing
    G04696579
  36. Install the forward clutch cylinder.
    Fig 41: Locating Forward Clutch Cylinder
    G04696580
  37. Install the No. 5 thrust bearing.
    Fig 42: Locating Thrust Bearing
    G04696581
  38. Install the intermediate servo piston and spring
    • Lubricate the servo bore with clean automatic transmission fluid.
      Fig 43: Locating Intermediate Servo Piston And Spring
      G04696582
  39. Using the special tool, install the retaining ring.
    Fig 44: Locating Retaining Ring
    G04696583
  40. Install the direct clutch drum.
    Fig 45: Locating Direct Clutch Drum
    G04696584
  41. Using a depth micrometer with an appropriate length extension, measure from the top of the gauge bar to center support ledge in case at 4 places 90 degrees apart.
    • Add the 4 measurements, divide by 4, and record as dimension A.
      Fig 46: Identifying Special Tool
      G04696585
    CAUTION: The torque specifications are critical for this procedure. Failure to use the correct torque specifications may cause transmission damage.
  42. Install the special tool.
    1. Install the special tool and the bolts using the 2 pump screw locations at approximately 6 and 12 o'clock positions.
      • Tighten to 15 Nm (11 lb-ft).
    2. Tighten the center screw.
      • Tighten to 1.13 Nm (10 lb-in).
        Fig 47: Identifying Special Tool
        G04696586
    NOTE: Align the disc holes on special tool with the slot in gauge bar for correct measurement.
  43. Measure the distance from the top of the gauge bar to the drum bearing surface through the hole in the disc and record as dimension B. Repeat the measurement 180 degrees on the opposite side of the special tool and record as dimension C.
    Fig 48: Aligning Disc Holes On Special Tool
    G04696587
  44. Add dimension B to C, divide by 2, and record as dimension D.
  45. Subtract A from D and record as dimension E.
  46. Select bearing from the following chart, using dimension E.
    BEARING THICKNESS CHART

    Dimension E Service Part Number (7D014) Bearing Thickness Identification (Notches)
    1.69-1.87 mm (0.066-0.074 in) XW4Z-CA 2.65-2.80 mm (0.104-0.110 in) None
    1.88-2.04 mm (0.073-0.080 in) XW4X-DA 2.83-2.98 mm (0.111-0.116 in) One
    2.05-2.22 mm (0.081- 0.088 in) XW4Z-EA 3.01-3.16 mm (0.118-0.124 in) Two
    2.23-2.43 mm (0.088-0.096 in) XW4Z-FA 3.21-3.36 mm (0.126-0.132 in) Three
    NOTE: Make sure that the intermediate band apply strut is aligned with the band notch.
    NOTE: If the intermediate band is reused, it must be installed in the same position as when removed.
    NOTE: The new intermediate band is dark in color. This is a normal condition of the band. Hairline cracks in the band are also considered normal. Do not install a new band based solely on the color.
  47. Install the intermediate band.
    Fig 49: Locating Intermediate Band
    G04696588
    CAUTION: To avoid a "fall-out" condition of the strut from the screw during assembly and function, the small "U" shaped notch should be toward the band/case side and the large "U" shaped notch toward the main control side.
  48. Install the intermediate band anchor strut.
    1. Band/case side of the anchor (small U notch).
    2. Main control side of the anchor (large U notch).
      Fig 50: Identifying Intermediate Band Anchor Strut
      G04696589
    CAUTION: If the strut is installed incorrectly, transmission damage will occur.
  49. Check to make sure that the intermediate band anchor strut is installed in the correct orientation to the case and adjustment screw.
    Fig 51: Identifying Intermediate Band Anchor Strut Position
    G04696590
  50. Loosely install the screw.
    Fig 52: Locating Screw
    G04696591
  51. Install the intermediate band apply strut.
    Fig 53: Locating Intermediate Band Applying Strut
    G04696592
    CAUTION: If the strut is installed incorrectly, transmission damage will occur.
  52. Check to make sure that the intermediate band apply strut is installed in the correct orientation to the case and piston rod.
    Fig 54: Identifying Intermediate Band Applying Strut Position
    G04696593
  53. Install the selected No. 4 thrust washer on the direct clutch drum.
    • Coat the thrust washer with petroleum jelly.
      Fig 55: Locating Intermediate Brake Drum Thrust Washer
      G04696594
    NOTE: Align the center support screw hole with correct case hole.
  54. Install the center support.
    Fig 56: Locating Center Support
    G04696595
  55. Install the center support locknut and cage.
    Fig 57: Locating Center Support Locknut And Cage
    G04696596
  56. Loosely install the screw.
    Fig 58: Locating Center Support Screw
    G04696597
    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.
  57. Install the center support retaining ring.
    1. Make sure the center support retaining ring is installed with the tapered side facing up.
    2. Make sure the opening of the center support retaining ring is positioned correctly.
      Fig 59: Identifying Center Support Retaining Ring
      G04696598
  58. Install the center shaft thrust bearing (No. 3).
    Fig 60: Locating Center Shaft Thrust Bearing
    G04696599
  59. Install the Overdrive ring gear, Overdrive one-way clutch and center shaft assembly.
    Fig 61: Locating Overdrive Ring Gear
    G04696600
    CAUTION: Do not bend the trigger wheel. Make sure that the No. 2 thrust bearing is in this assembly.
  60. Install the planetary gear Overdrive carrier.
    Fig 62: Locating Planetary Gear Overdrive Carrier
    G04696601
  61. Install the Overdrive brake drum and coast clutch drum assembly.
    Fig 63: Locating Overdrive Brake And Coast Clutch Drum
    G04696602
  62. Install the Overdrive band servo piston and spring.
    • Lubricate the servo bore with clean automatic transmission fluid.
      Fig 64: Locating Overdrive Band Servo Piston
      G04696603
  63. Using the special tools, install the retaining ring.
    Fig 65: Identifying Special Tools On Retaining Ring
    G04696604
    NOTE: If the Overdrive band is reused, it must be installed in the same position as when removed.
    NOTE: Make sure that the Overdrive band apply strut is aligned with the band notch.
    NOTE: The new Overdrive band is dark in color. This is a normal condition of the band. Hairline cracks in the band are also considered normal. Do not install a new band based solely on the color.
  64. Install the Overdrive band.
    Fig 66: Locating Overdrive Band
    G04696605
    CAUTION: To avoid a "fall-out" condition of the strut from the screw during assembly and function, the small "U" shaped notch should be toward the band/case side and the large "U" shaped notch toward the main control side.
  65. Install the Overdrive band anchor strut.
    1. Band/case side of the anchor (small U notch).
    2. Main control side of the anchor (large U notch).
      Fig 67: Identifying Overdrive Band Anchor Strut
      G04696606
    CAUTION: If the strut is installed incorrectly, transmission damage will occur.
  66. Check to make sure that the intermediate band anchor strut is installed in the correct orientation to the case and adjustment screw.
    Fig 68: Identifying Intermediate Band Anchor Strut Position
    G04696607
  67. Loosely install the screw.
    Fig 69: Locating Screw
    G04696608
  68. Install the Overdrive apply strut.
    Fig 70: Identifying Overdrive Apply Strut
    G04696609
    CAUTION: If the strut is installed incorrectly, transmission damage will occur.
  69. Check to make sure that the Overdrive band apply strut is installed in the correct orientation to the case and piston rod.
    Fig 71: Identifying Overdrive Band Applying Strut Position
    G04696610
    CAUTION: The torque specifications are critical for this procedure. Failure to use the correct torque specifications may cause transmission damage.
  70. Install the special tool.
    1. Install the special tool and the bolts using the 2 pump screw locations at approximately 6 and 12 o'clock positions.
      • Tighten to 15 Nm (11 lb-ft).
    2. Tighten the center screw.
      • Tighten to 1 Nm (9 lb-in).
        Fig 72: Identifying Special Tool
        G04696611
    NOTE: Align the disc holes on special tool with the slot in gauge bar for correct measurement.
  71. Measure the distance from the top of the gauge bar to the drum bearing surface through the hole in the disc and record as dimension A. Repeat the measurement 180 degrees on the opposite side of the special tool and record as dimension B.
    Fig 73: Aligning Disc Holes On Special Tool
    G04696612
  72. Add dimension A to B, divide by 2, and record as dimension C.
  73. Subtract the thickness of the gauge bar 17.78 mm (0.70 in) from dimension C and record as dimension D.
  74. Select the No. 1 thrust bearing from the following chart using dimension D.
    BEARING THICKNESS CHART

    Dimension D Service Part Number (7D014) Bearing Thickness Identification (Color/ID)
    38.05-38.13 mm (1.498-1.501 in) F7TZ-TA 1.55-1.60 mm (0.061-0.063 in) White
    38.14-38.28 mm (1.50-1.51 in) F7TZ-MA 1.75-1.80 mm (0.069-0.071 in) Green
    38.29-38.42 mm (1.507-1.513 in) F7TZ-NA 1.85-1.90 mm (0.073-0.075 in) Red
    38.43-38.61 mm (1.51-1.52 in) F7TZ-RA 2.05-2.10 mm (0.081-0.083 in) Black
    38.62-38.74 mm (1.52-1.53 in) F7TZ-SA 2.15-2.20 mm (0.095-0.097 in) Yellow
  75. Install the selected No. 1 fluid pump input thrust washer.
    • Coat the fluid pump input thrust washer with petroleum jelly.
      Fig 74: Locating Fluid Pump Input Thrust Washer
      G04696613
  76. Install the special tools into the transmission case.
    Fig 75: Identifying Special Tools Into Transmission Case
    G04696614
  77. Install the pump gasket.
    Fig 76: Locating Pump Gasket
    G04696615
    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.
  78. Install the fluid pump.
    Fig 77: Identifying Special Tools
    G04696616
    CAUTION: The special tools must be used to correctly align the pump with the adapter plate to reduce gear noise, bushing failure and leakage.
  79. Using the special tool, align the fluid pump to the adapter plate.
    Fig 78: Identifying Special Tool
    G04696617
  80. Install screws. Tighten the screws in a star pattern.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 79: Locating Screws
      G04696618
  81. Remove the special tools and install the 2 remaining screws.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 80: Locating Remaining Screws
      G04696619
    CAUTION: Do not allow Overdrive band adjustment 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.
  82. Install a new locknut on the band adjustment screw.
    Fig 81: Identifying Locknut On Band Adjustment Screw
    G04696620
    CAUTION: The Overdrive servo must be installed prior to band adjustment.
  83. Using the special tool, tighten the Overdrive band adjustment screw.
    • Tighten to 14 Nm (10 lb-ft).
    • Then back off the screw exactly 1.5 turns and hold that position.
      Fig 82: Identifying Special Tool On Overdrive Band Adjustment Screw
      G04696621
  84. Tighten the Overdrive band locknut.
    1. Hold the Overdrive band adjustment screw stationary.
    2. Tighten the Overdrive band locknut.
      • Tighten to 54 Nm (40 lb-ft).
        Fig 83: Identifying Overdrive Band Locknut
        G04696622
    CAUTION: Do not allow the 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.
  85. Install new nut on the band adjustment screw.
    Fig 84: Locating Locknut On Band Adjustment Screw
    G04696623
    CAUTION: The intermediate servo must be installed prior to band adjustment.
  86. Using the special tool, tighten the intermediate band adjustment screw.
    • Tighten to 14 Nm (10 lb-ft).
    • Then back off the screw exactly 1.5 turns and hold that position.
      Fig 85: Identifying Tightening Intermediate Band Adjustment Screw
      G04696624
  87. Tighten the intermediate band locknut.
    1. Hold the intermediate band adjustment screw stationary.
    2. Tighten the intermediate band locknut.
      • Tighten to 54 Nm (40 lb-ft).
        Fig 86: Identifying Intermediate Band Locknut
        G04696625
  88. Tighten the center support screw.
    • Tighten to 11 Nm (8 lb-ft).
      Fig 87: Locating Center Support Screw
      G04696626
  89. Using the special tools, carry out the air pressure test procedure. For additional information, refer to SPECIAL TESTING PROCEDURES  in this article.
    Fig 88: Identifying Special Tool
    G04696627
  90. Install the special tools into the transmission case.
    Fig 89: Identifying Special Tools
    G04696628
  91. Using the special tools, install the main control valve body and loosely install the screws.
    1. Install the short screw.
    2. Install the screw with the larger head.
    3. Install the remaining screws.
      Fig 90: Identifying Special Tools On Main Control Valve Body
      G04696629
  92. Remove the special tools, and loosely install the screw.
    Fig 91: Locating Screw
    G04696630
  93. Tighten the screws in the sequence shown.
    • Tighten to 10 Nm (89 lb-in).
      Fig 92: Identifying Screws Tightening Sequence
      G04696631
  94. With the manual lever in the NEUTRAL position, install the manual valve detent spring.
    • Tighten to 10 Nm (89 lb-in).
      Fig 93: Locating Manual Lever In NEUTRAL Position
      G04696632
  95. Install new O-ring seals on the solenoid body connector. Lubricate the O-ring seals with clean automatic transmission fluid.
    Fig 94: Identifying O-Ring Seals
    G04696633
    CAUTION: Inspect the transmission case bore to make sure it is free of foreign material and not damaged. If damaged, transmission leak may occur.
  96. Install the solenoid body. Tighten the screws in sequence shown.
    • Tighten to 8 Nm (71 lb-in).
      Fig 95: Identifying Screws Tightening Sequence
      G04696634
  97. Install the reverse servo. Tighten the bolts in the sequence shown in 2 stages.
    • Stage 1: Tighten to 5 Nm (44 lb-in).
    • Stage 2: Tighten to 11 Nm (8 lb-ft).
      Fig 96: Identifying Tightening Sequence For Reverse Servo Bolts
      G04696635
    CAUTION: Lubricate the fluid filter seals with clean automatic transmission fluid or they may be damaged.
    NOTE: Make sure that the fluid filter seals are correctly seated on the filter.
  98. Lubricate the seals and install the transmission fluid filter.
    • Tighten to 10 Nm (89 lb-in).
      Fig 97: Locating Transmission Fluid Filter
      G04696636
    NOTE: The transmission fluid pan gasket is reusable. Clean and inspect for damage. If not damaged, the gasket should be reused.
  99. Install the transmission fluid pan and gasket and loosely install the screws.
    Fig 98: Identifying Transmission Fluid Pan Bolts
    G03948629
  100. Tighten the 16 screws in a crisscross sequence.
    • Tighten to 11 Nm (8 lb-ft).
      Fig 99: Identifying Transmission Fluid Pan Bolts
      G03948629
  101. Install the parking pawl assembly and gasket.
    1. Install the parking pawl shaft.
    2. Install the parking pawl return spring.
    3. Install the parking pawl.
    4. Install a new gasket.
      Fig 100: Identifying Parking Pawl Return Spring
      G04696639
  102. Install the extension housing.
    • Tighten to 30 Nm (22 lb-ft).
      Fig 101: Locating Extension Housing And Mounting Screws
      G04696640
  103. Using the special tool, install the extension housing seal.
    Fig 102: Identifying Special Tool Into Extension Housing Seal
    G04696641
  104. Using the special tools, install the output shaft flange.
    Fig 103: Identifying Special Tools Into Output Shaft Flange
    G04696642
  105. Install a new nut.
    • Tighten to 131 Nm (97 lb-ft).
      Fig 104: Locating Nut
      G04696643
    CAUTION: The digital TR sensor must fit flush against the boss on the case to prevent damage to the sensor.
  106. Install the digital TR sensor and loosely install the screws.
    Fig 105: Locating Transmission Range Sensor
    G04696644
    CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or become damaged.
    NOTE: The manual lever must be in the NEUTRAL position.
  107. Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence.
    • Tighten 8 Nm (71 lb-in).
      Fig 106: Identifying Special Tool
      G04696645
    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.
  108. Install the input shaft.
    Fig 107: Locating Input Shaft
    G04696646
  109. Using the special tool, make sure that the fluid pump gear seal ring is fully seated.
    Fig 108: Identifying Special Tool On Fluid Pump Gear Seal
    G04696647
  110. Remove the special tool.
    Fig 109: Identifying Special Tool
    G04696648
    CAUTION: Do not damage the fluid pump gear O-ring seal when installing torque converter.
    CAUTION: Make sure the converter hub is fully engaged in the pump support and gear and rotates freely. Do not damage the hub seal.
    CAUTION: If the torque converter slides out, the hub seal may be damaged.
  111. Lubricate the converter hub with clean automatic transmission fluid.
    Fig 110: Lubricating Converter Hub
    G04696649
    WARNING: The torque converter can fall out if the transmission is tipped. Failure to follow these instructions may cause personal injury.
  112. Using the special tools, install the torque converter by pushing and rotating.
    Fig 111: Identifying Special Tools On Torque Converter
    G04696650
  113. Lubricate the torque converter pilot hub with multi-purpose grease.
    Fig 112: Lubricating Torque Converter Pilot Hub With Multi-Purpose Grease
    G04696651
    CAUTION: The special tool must be used to correctly align the adapter plate to the converter or transmission damage could occur.
    In order to correctly install the special service tool, it must be installed using 1 round and 1 oblong hole. Using 2 oblong holes will cause damage to the transmission.
    NOTE: Position the adapter plate on the torque converter and identify the position of the orange or green paint daub on the converter face.
  114. If the vehicle is equipped, use the special tool to install the torque converter flex plate adapter assembly and 8 nuts.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 113: Identifying Special Tool
      G04696652
  115. Remove the special tool and install the remaining torque converter flex plate adapter nuts.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 114: Locating Torque Converter Adapter Plate
      G04696653
  116. Using one of the speed sensor holes, fill the transmission with 8.5L (9 qts) of automatic transmission fluid.
    Fig 115: Locating Speed Sensor Holes
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    NOTE: Inspect O-ring seals for damage. Install new O-ring seals if damaged. Lubricate the O-ring seals with petroleum jelly to prevent damage to the O-ring seals.
  117. Install the sensors.
    • Tighten to 14 Nm (10 lb-ft).
      Fig 116: Locating O-Ring Seals
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