Part 1

Transmission














Special Tool(s)

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
^ obstructed vent and fluid passages
^ cracks or warpage





3. Inspect the extension housing for cracks, burrs or warpage.





4. Inspect case bearing for damage. Install a new component as necessary. Follow Steps 5-8 if replacing the case bearing. If not replacing the case bearing, proceed to Step 9.





5. Using the special tool, remove the case bearing.
^ Use an oil stone to remove any nicks or burrs in the bearing case bore.





6. Assemble the special tools.





7. CAUTION: Make sure bearing seal ring is facing the drive handle.

Install the bearing on the special tools.





8. Using the special tool, tap case bearing into case bearing bore.





9. WARNING: Make sure the lock pin on bench-mounted holding fixture is secure. Failure to follow these instructions can result in personal injury.

Using the special tool, install the transmission into the bench with the converter housing facing up.





10. Using the special tool, install the manual control lever shaft seal and lubricate it with petroleum jelly.





11. Install the intermediate servo piston and spring.
^ Lubricate the servo bore with clean automatic transmission fluid.





12. Using the special tool, install the retaining ring.





13. Install the overdrive band servo piston and spring.
^ Lubricate the servo bore with clean automatic transmission fluid.





14. Using the special tools, install the retaining ring.





15. Install the parking lever rod





16. Install the manual control lever.





17. Assemble the manual valve inner lever and parking lever actuating rod as shown.





18. CAUTION: Align the flats on the manual valve inner lever with the flats on the manual control lever shaft.

Install the manual control lever shaft.





19. Install the manual valve inner lever onto the manual shaft and loosely install the nut.





20. 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.

Install the manual control lever shaft spring pin.
^ Tap the manual control lever shaft spring pin into the transmission case.





21. CAUTION: To avoid damage, do not allow the wrench to strike the manual valve inner lever pin.

Tighten the nut.





22. CAUTION: The tabs on the output shaft thrust washer (No. 11) point into the case. Make sure the thrust washer is correctly seated.

Install the output shaft thrust washer (No. 11).
^ Coat the output shaft thrust washer with petroleum jelly.





23. Install the park gear on the output shaft.





24. Install the output shaft and park gear.





25. CAUTION: Make sure band is resting on the two anchor pins in the case.

Install the low/reverse band over the low/reverse brake drum.





26. Install the low/reverse brake drum.
^ Rotate the low/reverse brake drum clockwise to install.





27. NOTE: The reverse band actuating lever must fit into the notches in the band.

Install the reverse band actuating lever into the reverse band.





28. Install the reverse band actuating lever shaft into the case and into the reverse band actuating lever.





29. Install the No. 10 needle bearing into the case.





30. CAUTION: Do not damage the seal against the case during assembly.

Install the output shaft ring gear, hub and seal.





31. CAUTION: Always install a new output shaft retaining ring.

Install a new output shaft retaining ring.





32. NOTE: Install the output shaft sleeve with the cone facing up. This sleeve will snap into place when correctly installed.

Install the output shaft sleeve.





33. Install low/reverse planetary carrier needle bearing (No. 9) onto the output shaft ring gear and hub assembly.





34. CAUTION: Make sure the needle bearings stay in place.

Install the low/reverse planetary assembly.





35. CAUTION: The low/reverse brake drum must be pulled forward to install the low/reverse planet retaining ring.

Install the retaining ring.