Part 4

Transmission (Con't)





107. Install a new reverse pressure switch and loosely install the screws.





108. Tighten the screws in the sequence shown.





109. Install new O-ring seals on the solenoid body connector. Lubricate the O-ring seals with clean automatic transmission fluid.





110. CAUTION: Inspect the transmission case bore to make sure it is free of debris and not damaged. If damaged, transmission leak can result.

Install the solenoid body. Tighten bolts in sequence shown.





111. Install the reverse servo. Tighten the bolts in sequence shown in two stages.
^ Stage 1: Tighten bolts to 5 Nm (44 inch lbs.)
^ Stage 2: Tighten bolts to 11 Nm (8 ft. lbs.)





112. Connect the reverse pressure switch connector.





113. Install the manual valve detent spring.





114. CAUTION: Lubricate the fluid filter O-ring seals with clean automatic transmission fluid or they can be damaged.

NOTE: Make sure that the fluid filter O-ring seals are correctly seated on the filter.

Lubricate the seals and install the transmission fluid filter.





115. NOTE: The transmission fluid pan gasket is reusable. Clean and inspect for damage. If not damaged, the gasket should be reused.

Install the transmission fluid pan and gasket.





116. Tighten the screws in a crisscross sequence.





117. Install the parking pawl assembly and gasket.
1 Install the parking pawl shaft.
2 Install the parking pawl.
3 Install the parking pawl return spring.
4 Install the gasket.





118. Install the extension housing.





119. Using the special tool, install the extension housing seal.





120. Using the special tools, install the output shaft flange.





121. Install a new nut.





122. CAUTION: The digital transmission range sensor must fit flush against the boss on the case to prevent damage to the sensor.

Install the digital Transmission Range (TR) sensor and loosely install the screws.





123. CAUTION: Tightening one screw before tightening the other can cause the sensor to bind or become damaged.

NOTE: The manual lever must be in the NEUTRAL position.

Using the special tool, align the digital TR sensor and tighten the screws in an alternating sequence.





124. NOTE: Inspect O-ring seal for damage. Install new if damaged. Lubricate the O-ring seals with petroleum jelly to prevent damage to the O-ring seals.

Install the sensors.





125. CAUTION: The splices of the input shaft are not the same length on both ends. The shaft end with the shorter splices goes into the fluid pump.

Install the input shaft.





126. Using the special tool, make sure that the fluid pump gear seal ring is fully seated.





127. Remove the special tool.





128. 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 can be damaged.

Lubricate the converter hub with clean automatic transmission fluid.





129. NOTE: A new converter drain plug must be used to prevent leakage.

Install the drain plug.





130. Install the converter housing access plug.





131. WARNING: The torque converter can fall out if the transmission is tipped. Failure to follow these instructions may cause personal injury,

Using the special tools, install the torque converter by pushing and rotating.





132. Lubricate the torque converter pilot hub with multipurpose grease.





133. CAUTION: The special tool must be used to correctly align the adapter plate to the converter or transmission damage can occur.

In order to correctly install the special service tool, it must be installed using one round and one oblong hole. Using two oblong holes will cause damage to the transmission.
If the vehicle is equipped, use the special tool to install the torque converter flex plate adapter assembly and eight nuts.





134. Install two torque converter flex plate adapter nuts.





135. NOTE: Use the 5/16 inch Allen key to remove the fill plug.

Remove the fill plug.





136. Fill the transmission with 8.5L (9 quarts) of clean automatic transmission fluid.





137. CAUTION: When installing the fill plug, make sure not to cross thread the plug to prevent damage.

NOTE: Use a 5/16 inch Allen key to install the fill plug.

Install the fill plug.
138. Before installing transmission, make sure that the transmission cooling system (tube and cooler[s]) have been thoroughly flushed. If contamination cannot be removed or correct flow cannot be obtained, install a new cooler(s) and/or tubes.