Transmission Reassembly
- Install drive plate, with spacers, to crankshaft. Install front spacer, .127" (3.2 mm) thick, with beveled edge facing drive plate, then install drive plate. Install rear spacer, .056" (1.4 mm) thick, with cupped edge facing converter.
- Install thrust bearing and races, then install rear planetary ring gear to transmission housing. Install cushion plate and steel and lined plates to transmission housing. Install thrust bearing by coating race with petroleum jelly and sticking to ring gear.
- Align notch and tab of thrust washer and planetary gear, coat thrust washer with petroleum jelly and stick to planetary gear. Align disc flukes. Install rear planetary gear and thrust plate.
- Make sure planetary ring gear is fully seated, then measure brake "3" clearance. Clearance should be .395-.445" (10.04-11.30 mm).
- Install thrust washer, planetary gear, brake reaction plate, snap ring and center support to transmission housing. Refer to Figure , for plate installation sequence and Fig 1 , for thrust bearing and bearing race installation.
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- Install center support bolts, make sure oil holes in center support are aligned with oil holes in transmission housing and tighten center support bolts. After center support bolt installation, make sure planetary sun gear is easy to turn in a clockwise direction and hard to turn in a counterclockwise direction.
- Install clutch "2", bearing race and output shaft to transmission housing. Refer to Figure . Install a thrust bearing and race over output shaft. Align the flukes of the rear clutch discs and mesh them with the front clutch hub. Install front clutch assembly into case (over output shaft).
- After clutch "1" installation, lay a straightedge across clutch drum and transmission housing. Measure distance from straightedge to clutch drum. Distance should be the same as distance measured during disassembly. Standard distance is .024-.063" (.6-1.6 mm).
- Install thrust bearing and race to clutch "1" shaft. Insert bearing race into front support. Install "O" ring to transmission housing. See Fig 2 . Coat thrust washer with petroleum jelly and set into front support with lip side to front support.
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- Install front support to transmission housing. Make sure there is no clearance between surfaces of support and case when pressing down. If there is clearance, front support is not correctly installed. Make sure there is thrust play on input shaft and tighten bolts diagonally a little at a time.
- After front support installation, check clutch "1" shaft for ease of rotation and that end play is .0094-.0378" (.24-.96 mm). Check output shaft for ease of rotation and that end play is .012-.060" (.31-1.53 mm).
- Place transmission so valve body side is down and install bearing race, thrust bearing, input shaft and drive sprocket to front of transmission housing. Install chain and driven sprocket, then secure driven sprocket with snap ring. Measure clearance between snap ring and driven sprocket. Clearance should be .0043-.027" (.11-.69 mm).
- Install bearing race to input shaft, then install oil pump over input shaft. Refer to Figure . Install throttle pressure tube, then install reverse line pressure tube to front of transmission housing. Using NEW "O" rings, install oil pump delivery tube and oil pump suction to front of transmission housing. See Fig 3 .
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- Assemble NEW collar to manual valve lever. Install manual valve lever. While holding detent ball with plate, install manual valve shaft. Drive in slotted spring pin (always use NEW pin). After assembly, turn spacer 90 degrees and stake.
- Install park pawl, pivot pin and spring in case. Install park pawl bracket on case, making sure collar on control rod is toward front of transmission. Make sure planetary gear output shaft is locked when manual valve lever is in "P" range.
- Turn transmission over so valve body side is up. Install accumulator springs and pistons, fully seating pistons by hand. Install accumulator gasket (straight side of gasket nearest housing), then install accumulator cover. Refer to Figure .
- Install steel balls into valve body on transmission side. See Fig 4 . Make sure vibrating stopper is still in place and install upper valve body gasket. Refer to for gasket installation sequence. Also make sure cut back plug lock pin has not fallen out.
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- Install valve body plate, lower gasket and valve body. When installing valve body, make sure oil pump suction pipe is fully seated in transmission housing. Install oil strainer and gasket to valve body.
- Attach rod to manual valve lever and to manual valve (in front valve body), then install front valve body to transmission housing. Install front valve body cover and gasket. Place a waved washer, then a plain washer on throttle lever shaft.
- Insert throttle lever shaft into transmission, then install a plain washer, throttle lever, washers and nut. Check throttle lever thrust clearance. If clearance is greater than .020" (.5 mm), install additional washers to outside of lever. Install oil pressure tubes. See Fig 5 . Install oil pan and gasket.
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- Place transmission housing-to-converter housing gasket on transmission housing (coated with sealant). Install NEW "O" rings into transmission housing-to-converter housing oil passages. Attach converter housing-to-transmission housing.
- Install output shaft sleeve with speedometer drive gear and balls to transmission output shaft. Secure sleeve with snap ring. Install extension housing and gasket to transmission housing. Attach transmission rear mount to rear of transmission housing.
- Install speedometer driven gear, neutral start switch, oil filler tube and control rod to transmission. When installing neutral start switch, align switch shaft groove to neutral base line. See Fig 6 . Install torque converter.
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