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Section 7 (Automatic Transmission - DPS6/DCT250): Assembly: Transmission

WARNING: This page is about a different variant/trim than selected.
SPECIAL TOOL/GENERAL EQUIPMENT DESCRIPTION

G08064294
 204-594 
Forcing screw
G08064317
 205-118  (T77F-4222-A)
Differential bearing cap installer
G08064067
 205-153  (T80T-4000-W)
Handle
G09551584
 205-425 
Installer, Differential Carrier Seal LH
TKIT-1999-F/FLM/LT
G08064159
 307-580 
Holding Fixture
TKIT-2006UF-FLM
TKIT-2006UF-ROW
G08064204
 307-670 
Remover/Installer, Shift Lever Seal
TKIT-2010D-FLM
TKIT-2010D-ROW
G08064068
 307-671 
Installer, Axle Seal
TKIT-2010D-FLM
TKIT-2010D-ROW
G08064102
 307-672 
Installer, Input Guide and Seal
TKIT-2010D-FLM
TKIT-2010D-ROW
G08064104
 307-674 
Installer, Outer Input Seal
TKIT-2010D-FLM
TKIT-2010D-ROW
G08064259
 307-680 
Table, Assembly (DPS6)
TKIT-2010D-FLM
TKIT-2010D-ROW
G08064339
 307-681 
Differential Bearing Preload Tool
TKIT-2010D-FLM
TKIT-2010D-ROW
G08064340
 308-164  (T88C-77000-JF)
Shim Selection Set
Feeler Gauge
Hot Air Gun
Punch
MATERIALS SPECIFICATIONS

Name Specification
Gasket Maker
TA-16		 WSK-M2G348-A5
  1. multimedia:A supplement to the article is available.
    multimedia:A supplement to the article is available.
    G08409240
  2. Install the hollow input shaft on the inner input shaft.
    G07979799
  3. NOTE: Make sure that the synchronizers are in the neutral position.

    Install the output shaft assembly in the special tool.

    Use Special Service Tool: 307-680 Table, Assembly (DPS6)  .

    G08064292
  4. Install the input shaft assembly in the special tool.

    Use Special Service Tool: 307-680 Table, Assembly (DPS6)  .

    G08064345
  5. Install the output shaft assembly in the special tool.

    Use Special Service Tool: 307-680 Table, Assembly (DPS6)  .

    G08064346
  6. NOTE: After installing the assembly table place the gear assembly in the upright position.

    Install the input and output shaft assemblies in the special tool.

    Use Special Service Tool: 307-680 Table, Assembly (DPS6)  .

    G08064289
  7. Remove Special Service Tool: 307-680 Table, Assembly (DPS6)  .
    G08064348
  8. Install the 4th/reverse gear shift fork.
    G07979808
  9. Install the 2nd/6th gear shift fork and linkage.
    G07979809
  10. NOTE: Make sure the shift drums are in the neutral position.

    Install shift drum 2.

    G07979810
  11. NOTE: Make sure the shift drums are in the neutral position.

    Install shift drum 1 and the 3rd gear linkage.

    G07979811
  12. Install the 1st/5th gear shift fork.
    G07979812
  13. Install the 3rd gear shift fork.
    G07979813
  14. Install the shift fork rods.
    G07979814
  15. NOTE: This step only applies to transmissions built before April-2013.

    Install the oil spout.

    G07979788
  16. NOTE: Make sure that the bearing retainers are correctly located.

    Install the special tool.

    Use Special Service Tool: 307-680 Table, Assembly (DPS6)  .

    G08064357
  17. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs, or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.

    Make sure that the mating faces are clean and free of foreign material.

    G09551609
  18. Align the special tools with the bolt holes in the transmission case and install the transmission case.
    G07979817
  19. Install new bearing retainer bolts.

    Torque  :

    Stage 1: 89 lb.in (10 Nm)

    Stage 2: 24 lb.ft (32 Nm)

    G09551611
  20. Install the special tool.

    Use Special Service Tool: 307-580 Holding Fixture  .

    G07979783
  21. Remove Special Service Tool: 307-680 Table, Assembly (DPS6)  .
    G07979781
  22. Install the magnet.
    G07979780
  23. Install the small clock gears.
    G07979822
  24. Install the large clock gears.
    G07979823
  25. Install the park pawl.
    G07979777
  26. NOTE: Make sure that the pawl pin is aligned to the actuation shaft guide.

    Install the park pawl actuator shaft assembly.

    G07979776
  27. Install the differential.
    G07979440
  28. NOTE: The following 8 steps are only required when replacing the differential housing bearings.

    Install the differential bearing cup on the bearing.

    G07979442
  29. Install the special tools on the transmission case.

    Use Special Service Tool: 307-681 Differential Bearing Preload Tool  ., 308-164 (T88C-77000-JF) Shim Selection Set  .

    G08064369
  30. Install the clutch housing on the special tool.

    Use Special Service Tool: 307-681 Differential Bearing Preload Tool  .

    Torque  : 159 lb.in (18 Nm)

    G08064370
  31. Rotate the special tool to seat the bearing cup.

    Use Special Service Tool: 307-681 Differential Bearing Preload Tool  .

    G08064371
  32. Tighten the bolt on the special tool.

    Use Special Service Tool: 307-681 Differential Bearing Preload Tool  .

    G07979446
  33. Using a feeler gauge, measure record the clearance at the 3 locations shown in illustration below. Average the 3 measurements.

    Use the General Equipment: Feeler Gauge

    G07979447
  34. Remove the special tools.
  35. NOTE: The shim size is the average of the 3 measurements.
    NOTE: Using the average of the recorded measurements, select the appropriate shim from the shim selection chart in the specifications information.

    Use the Differential Shim Selection Chart in specifications to select the correct shim. Install the selected shim into the clutch housing.

    Refer to: SPECIFICATIONS .

    G08064374
  36. Using the special tools install the differential bearing cup in the clutch housing.

    Use Special Service Tool: 204-594 Forcing screw  ., 205-118 (T77F-4222-A) Differential bearing cap installer  ., 307-671 Installer, Axle Seal  .

    G08064375
  37. Apply a 1 mm bead of silicone to the transmission case.

    Material  : Gasket Maker/TA-16 (WSK-M2G348-A5)

    G07979827
  38. NOTE: Make sure that a new component is installed.

    Install a new input shaft bearing.

    Use Special Service Tool: 204-594 Forcing screw  ., 205-118 (T77F-4222-A) Differential bearing cap installer  ., 205-425 Installer, Differential Carrier Seal LH  .

    G08064376
  39. Install the input shaft bearing retainer and new bolts.

    Torque  : 97 lb.in (11 Nm)

    G09551630
  40. NOTE: Take extra care not to overheat the bearing.

    Using a heat gun, heat the input shaft inner bearing race.

    Use the General Equipment: Hot Air Gun

    G09551631
  41. NOTE: Be sure that the park pawl detent is NOT already installed when installing the clutch housing on the transmission case. If the transmission was disassembled for a repair that did not require complete transmission disassembly, the park pawl detent must be removed before installing the clutch housing or damage to the park pawl actuator shaft will occur.

    Install the clutch housing on the transmission case.

    G09551632
  42. Tap the clutch housing down onto the transmission case.

    Use Special Service Tool: 307-672 Installer, Input Guide and Seal  .

    G09551633
  43. NOTE: Fastener quantity varies with application.

    Install the transmission case bolts.

    Torque  : 20 lb.ft (27 Nm)

    G09551509
  44. NOTE: Fastener quantity varies with application.

    Install the transmission case bolts.

    Torque  : 20 lb.ft (27 Nm)

    G09551508
  45. Using a brass punch, gently tap in the park plunger into the transmission case. Install the park plunger plug.

    Use the General Equipment: Punch

    Torque  : 32 lb.ft (43 Nm)

    G08064383
  46. NOTE: Make sure that the component is clean and free of foreign material.

    Using the special tool, install a new shift lever seal.

    Install Special Service Tool: 307-670 Remover/Installer, Shift Lever Seal  .

    Torque  : 133 lb.in (15 Nm)

    G08064209
  47. NOTE: Make sure that a new component is installed.

    Install a new manual lever and install a new bolt.

    Torque  : 19 lb.ft (26 Nm)

    G07979837
  48. Using a punch, install a new clutch housing plug. Install the plug so it is level with the chamfer of the outer diameter of the plug hole.
    G09551439
  49. NOTE: Make sure that a new component is installed.

    Install a new input shaft snap ring.

    G07979838
  50. Using the special tools, install a new input shaft case seal.

    Use Special Service Tool: 307-672 Installer, Input Guide and Seal  .

    G08064386
  51. Using the special tools, install a new hollow input shaft seal.

    Use Special Service Tool: 307-674 Installer, Outer Input Seal  .

    G07979865
  52. NOTE: Make sure that the bolt heads are not protruding above the housing surface.

    Install the guide tube and the bolts.

    Torque  : 71 lb.in (8 Nm)

    G08064107
  53. Install the following items:
    1. Install the clutch actuator.

      Refer to: CLUTCH ACTUATOR .

    2. Install the clutch and damper unit.

      Refer to: CLUTCH AND DAMPER UNIT .

    3. Install the clutch actuator motor.

      Refer to: CLUTCH ACTUATOR MOTOR .

    4. Install the ISS  sensor.

      Refer to: INPUT SHAFT SPEED (ISS) SENSOR .

    5. Install the OSS  sensor.

      Refer to: OUTPUT SHAFT SPEED (OSS) SENSOR .

    6. Install the TR  sensor.

      Refer to: TRANSMISSION RANGE (TR) SENSOR .

    7. Install the TCM  .

      Refer to: TRANSMISSION CONTROL MODULE (TCM) .

  54. Install the transmission wiring harness.
    G08064261
  55. Inspect the LH  halfshaft seal surface for damage or debris.
    G08064070
  56. Using the special tools, install a new LH  halfshaft seal.

    Install Special Service Tool: 205-153 (T80T-4000-W) Handle  ., 307-671 Installer, Axle Seal  .

    G08064071
  57. Inspect the RH  halfshaft seal surface for damage or debris.
    G08064075
  58. Using the special tools, install a new RH  halfshaft seal.

    Install Special Service Tool: 205-153 (T80T-4000-W) Handle  ., 307-671 Installer, Axle Seal  .

    G08064076
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