Disassembly And Assembly: Assembly

The work area, counter surfaces and tools must be thoroughly cleaned before attempting to assemble the 948TE transmission. All of the sub assemblies should be disassembled, cleaned, and assembled with new sealing components where applicable. The transmission housing should be clean and oil free before beginning this procedure. The B, C, D, and E-clutches should be properly measured and adjusted prior to assembling the transmission. If the transmission was contaminated with metallic material, all of the thrust bearings and roller bearing should be replaced. The bearing in the output gear support assembly is not serviceable. The output gear support assembly should be replaced if metal debris is present.

WARNING:

Always wear safety glasses when cleaning, disassembling and assembling the transmission/transaxle. Contents of the transmission/transaxle can become projectiles (e.g., springs, snap-rings, as well as metal and other debris). Failure to wear safety glasses may result in severe personal injury.

Place the transmission housing on a clean work surface with the open interior upward.
Place wooden blocks under the transmission to stabilize it for assembly.

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Install the split roller bearing (1) in position on the input shaft support.

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Install the outer seal-rings (1) in the grooves in the input shaft support.

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Install the inner seal-ring (1) in the grooves in the input shaft support.

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NOTE:
The seal lip will be facing upward when the piston is oriented as shown in the photo.
Install the outer seal (2) on the C-clutch piston (1).

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NOTE:
The seal lip will be facing upward when the piston is oriented as shown in the photo.
Install the inner seal (2) on the C-clutch piston (1).

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Lubricate the C-clutch piston seals with clean transmission fluid and install the C-clutch piston (1) in the transmission housing.

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Place the C-clutch belleville spring (1) in position on the C-clutch piston (2).

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Place the special tool (special tool #10504, Compressor, Spring) (1) over the C-clutch belleville spring (3).
Position the transmission housing on a suitable arbor press using wooden blocks for support.

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Place tool (special tool #8228, Installer, Bearing) (3) over the input shaft support (tool 8901 with 10428 legs can also be used), compress the belleville spring to gain access to the snap-ring (1) groove.

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Install the snap-ring, stepped side down, with the snap ring ends (1) aligned with machined pocket in the case (2) to hold the C-clutch belleville spring in the transmission housing.
Remove the transmission housing from the arbor press and position it on a clean work bench. Position wood blocks under transmission to stabilize it for assembly.

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NOTE:
Diesel and 1.4L Fire engine clutch pack shown, 2.4L MultiAir engines will have one less friction disc (3) and steel plate (4).
Install one C-clutch steel plate (4), then install the friction discs (3) alternately separated with steel plates (4) into the transmission housing on top of the C-clutch piston.

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Install the C-clutch reaction plate (1) with raised bosses upward on top of the C-clutch disc and plate pack.

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Install the select fit snap-ring, aligning the snap ring ends (2) with the anti-rotation tab of the reaction plate (1).
NOTE:
Perform C-clutch measurements to verify that the correct selective snap ring is installed

Refer to CLUTCH, C .

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Perform D-clutch measurements to verify that the correct selective reaction plate (2) is selected. Refer to CLUTCH, D .
Install the correct thickness selective reaction plate (2).
Starting with a friction plate (1), alternately install the friction (1) and steel plates (3) into the case.

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Install the input shaft rear support selective thrust washer (1).

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Install the thrust bearing (1) onto the input shaft rear support.

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Align the teeth of the friction discs for the D- and C-clutches (1, 2) to facilitate the installation of the annulus gear 2, D and C clutch hubs, and input shaft assembly.

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Place the thrust bearing (1) in position on the C-clutch hub (2).

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Place the Annulus gear 2, D-clutch hub (1) in position on the C-clutch hub (2).

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Insert the sun gear 1 (1) into annulus gear 2 (2), D and C-clutch hub (3).

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Turn the annulus gear 2, D and C-clutch hub over and place it on tool (special tool #9611, Plug, Differential End) (2) to hold the sun gear in position.

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Using a suitable snap-ring pliers (1), install the snap-ring (2) to hold the sun gear 1 to the annulus gear 2, D and C-clutch hub.

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Insert the number 7 thrust bearing (1) in the C-clutch hub, it should have a snap fit.

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Install NEW seal-rings (1) in the grooves (2) on the input shaft (3).

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Insert the input shaft into the B-clutch (1) hub.
Using a suitable snap-ring pliers (3), install the snap-ring (2) to hold the input shaft/dog clutch A to the B-clutch (1) hub.
Install the annulus gear 2, D and C-clutch hub on the input shaft and B-clutch assembly.

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While not allowing the input shaft to slip inward, wriggle the annulus gear 2, D and C-clutch hubs and input shaft assembly (1) until they engage the D and C-clutch discs. If the input shaft slips inward, one or more B-clutch discs can come disengaged from the C-clutch hub, impeding proper installation.
NOTE:
A solid audible clunk will be heard if installed correctly.

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Place the D-clutch belleville spring (1) in position on the transmission housing (2).

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Install NEW O-ring seal (2) in the D-clutch piston retainer (1).

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Install NEW outer lip seal (2) in the D-clutch piston (1).

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Install NEW inner lip seal (1) in the D-clutch piston (2).

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Lubricate the D-clutch piston seals with clean transmission fluid and install the piston (2) in the retainer (1).

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Place the D-clutch piston (2) and retainer (1) assembly in the transmission housing over the D-clutch belleville spring. The fingers on the D-clutch piston (2) rest against the upper D-clutch steel plate.
Position the transmission housing on a suitable arbor press using wooden blocks for support.

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Using Tool (special tool #8901A, Pressing Tool) (with the pressure scale removed) (1) and legs (special tool #10428, Adapter, Pressing Tool), compress the D-clutch piston retainer against the belleville spring to gain access to the snap-ring groove in the transmission housing.
Install the snap-ring to hold the D-clutch piston retainer (2) into the transmission housing.
Remove the transmission housing from the arbor press and place the transmission housing on the clean work surface. Use wood blocks to stabilize the transmission.
Insert the pinion gear carrier 1 and 2 into the annulus gear 2, D and C-clutch hub and input shaft assembly.

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Install the NEW O-ring seal (1) into the pinion gear carrier 1 and 2.

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Install the annulus gear 3 (1) into the pinion gear carrier 1 and 2.
.

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Install the snap-ring (1) to hold the annulus gear 3 (2) in the pinion gear carrier 1 and 2.

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Place the thrust bearing (1) in position under the annulus gear 1 hub (2).

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Install the annulus gear 1 hub (1) into the pinion gear carrier 1 and 2 (2).

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Place the thrust bearing (1) onto the annulus gear 1 hub (2).

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Install the transfer gear bearing preload shim (1).

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Using tool (special tool #6888, Installer, Seal) (2), and handle (special tool #C-4171, Driver Handle, Universal) (3) install the transfer gear bearing cone (1) onto the transmission housing.

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Position the park rod (2) into the park rod guide (1).

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Position the park rod guide (1) into the housing and tighten the park rod guide bolt (2) to the proper specification. Refer to TECHNICAL SPECIFICATIONS .

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Position the park pawl (2) into the park rod guide.
Install the reaction pin (1) through the park pawl (2) and into the case.
Install the park pawl (2) return spring (3).

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Install the pinion gear carrier 3 and annulus gear 4 (1) into the annulus gear 3 (2).

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Install a NEW thrust spacer (1) on the underside of the pinion gear carrier 4 (2).

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Install a NEW thrust spacer (1) on the topside of the pinion gear carrier 4 (2).

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Install the pinion gear carrier 4 (1) into the annulus gear 4.

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Install the sun gear 3 and 4 and Dog Clutch-F (1) in the pinion gear carrier 4.

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Install the roller type thrust bearing (1) onto the sun gear 3 and 4 and Dog Clutch-F (2).
NOTE:
If a new transfer gear or transmission housing are being used, measurements must be performed to determine correct thickness for the bearing preload shims

Refer to STANDARD PROCEDURES .

If the bearings and races are replaced the factory installed preload shims do not require replacement.

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If necessary, replace the bearings and races on the transfer gear.
Install the transfer gear (1) into the transmission housing.

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Install the output gear support (1) onto the pinion gear carrier 4 (2).

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Install the E-clutch hub and shaft (1) in the output gear support (2).

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Install the thrust bearing (1) on the E-clutch (2) assembly.

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NOTE:
Before installing the E-clutch, use a suitable screwdriver to align the grooves in the friction discs.
Wriggle the E-clutch (1) until all of the friction discs are fully engaged on the E-clutch hub and shaft.
NOTE:
When the E-clutch (1) is fully seated the gap (2) will be very small between the E-clutch retainer and the output gear support.

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NOTE:
If a new differential (1) or transmission housing are being used, measurements must be performed to determine correct thickness for the bearing preload shims. If the bearings and races are replaced the factory installed preload shims do not require replacement. Refer to STANDARD PROCEDURES .
If necessary, replace the bearings and races on the differential.
Install the differential assembly (1) into the transmission housing.
Install the transmission bellhousing. Refer to BELLHOUSING, REMOVAL AND INSTALLATION .