Oil Pump, Second Coast and Second Brake Assembly
OIL PUMP, SECOND COAST AND SECOND BRAKE ASSEMBLY
- Tools Required
- KM-698 Spring Compressor
- KM-674 Oil Seal Installer
Disassembly Procedure
1. Remove the thrust washer.
WARNING: USE CAUTION WHEN REMOVING SNAP RINGS OR PERSONAL INJURY MAY RESULT.
2. Carefully remove the snap ring.
3. Remove the coast clutch pressure plate.
4. Remove the coast clutch disc pack.
5. Position spring compressor KM-698 on the clutch piston return spring. Using a press, compress the spring, then remove the snap ring from the groove.
6. Remove the snap ring and the clutch piston return spring.
WARNING: USE CAUTION WHEN REMOVING COMPONENTS WITH COMPRESSED AIR OR PERSONAL INJURY MAY RESULT.
Notice: If the piston does not come out completely, use needle nose pliers to remove.
7. Apply 57 psi (396 kPa) of compressed air into the oil passage shown to remove the second coast piston.
8. Remove the second coast piston.
9. Remove and discard the second coast piston O-rings.
Notice: Check the steel and friction plates for wear or damage. Replace if necessary.
Notice: New clutch plates should be soaked in TOTAL FLUID HX for two hours before being assembled.
10. Inspect the coast clutch steel and friction plates.
WARNING: USE CAUTION WHEN REMOVING SNAP RINGS OR PERSONAL INJURY MAY RESULT.
11. Carefully remove the snap ring.
12. Remove the second brake upper flange.
13. Remove the second brake clutch pack.
14. Remove second brake piston return spring.
WARNING: USE CAUTION WHEN REMOVING COMPONENTS WITH COMPRESSED AIR OR PERSONAL INJURY MAY RESULT.
Notice: If the piston does not come out completely, use needle-nose pliers to remove.
15. Apply 57 psi (396 kPa) of compressed air into the oil passage shown to remove the second brake piston.
16. Remove the second brake piston.
17. Remove and discard the second brake piston O-rings.
Notice: Check the steel and friction plates for wear or damage. Replace as necessary.
Notice: New clutch plates should be soaked in TOTAL FLUID HX for two hours before being assembled.
18. Inspect the second brake flange, steel and friction plates.
19. Remove the stator support to oil pump body bolts.
Notice: Replace the oil pump plate if the gear face contact surface is scratched or worn.
20. Remove the oil pump plate.
21. Remove and discard the oil pump body O-ring.
22. Measure the clearance between the pump driven gear and the oil pump body. If not as specified, replace the gears.
Table
23. Measure the clearance between the pump drive gear and the oil pump body boss. If not as specified, replace the oil pump body and gears.
Table
24. Measure the clearance between the pump drive gear, driven gear and the oil pump body. If not as specified, replace the oil pump body and gears.
Table
Notice: Check the pump driven gear and drive gear for wear or damage. Replace as necessary.
25. Remove the pump driven gear and pump drive gear.
Notice: Be careful not to damage the oil pump body bushing.
26. Remove and discard the oil pump seal.
27. Inspect the oil pump body bushing.
- Using a dial indicator, measure the inner diameter of the oil pump body bushing. Measure the bushing at three different places and calculate the average. If it is greater than the maximum, replace the oil pump body.
Table
28. Inspect the stator support shaft bushing.
- Using a dial indicator, measure the inner diameter of the stator support shaft bushing. Measure the bushing at three different places and calculate the average. If it is greater than the maximum, replace the stator support.
Table
Assembly Procedure
1. Clean the components using a clean, high-quality parts cleaning solvent and use compressed air to dry all parts. Inspect all parts for damage or wear.
Notice: Apply automatic transmission fluid to the inner surface of the oil pump body.
Notice: Apply Transjel Assembly Lubricant J-36850 or equivalent to the oil lip seal.
Notice: The seal should be flush with the outer edge of the oil pump body.
2. Install a new oil pump seal using oil seal installer KM-674.
3. Install the pump driven gear and pump drive gear.
- Align the marks on the gears.
- Apply TOTAL FLUID HX into the gear cavity
Notice: Align the oil pump plate hole with the dowel pin in the oil pump body.
4. Install the oil pump plate.
Caution: Tighten the bolts evenly and gradually.
5. Install the stator support.
- Align the stator support with each bolt hole in the oil pump body and temporarily tighten the bolts evenly and gradually.
- Tighten the M5 bolts to 53 - 62 inch lbs. (6 - 7 Nm) and the M6 bolts to 89 - 124 inch lbs. (10 - 14 Nm).
6. Check the pump drive gear rotation.
- Install the pump assembly into the torque converter to verify smooth operation.
7. Install new second brake piston O-rings.
Notice: Apply TOTAL FLUID HX to the new second brake piston O-rings and the stator support seal area.
Notice: Seat the piston by pushing evenly around the circumference of the piston, being careful not to damage the outer seal.
8. Install the second brake piston.
9. Install the second brake piston return spring.
Notice: The flanges are thicker than the steels.
10. Install the second brake clutch pack.
- The installation order is: flange-friction-steel-friction-steel-friction.
Notice: The flanges are thicker than the steels.
11. Install the second brake top flange.
Notice: Be sure the snap ring end gap is not aligned with one of the stator support cutouts.
12. Install the snap ring.
WARNING: USE CAUTION WHEN CHECKING COMPONENTS WITH COMPRESSED AIR OR PERSONAL INJURY MAY RESULT.
13. Check the second brake clutch operation.
- Install a dial indicator.
- Apply 57 psi (396 kPa) of compressed air into the oil passage shown and measure the second brake clutch piston stroke. The piston stroke is 0.045 - 0.073 inch (1.14 - 1.860 mm). The clutch should make a solid apply sound, with no whistle or sign of leaks.
14. Install new second coast piston O-rings.
Notice: Apply TOTAL FLUID HX to the new second coast piston O-rings and the stator support seal area.
Notice: Seat the piston by pushing evenly around the circumference of the piston, being careful not to damage the outer seal.
15. Install the second coast piston.
16. Install the second coast piston return spring. Position spring compressor KM-698 on the clutch piston return spring. Using a press, compress the spring, then install the snap ring in the groove.
17. Install the coast clutch disc pack.
- The installation order is: steel-friction-steel-friction.
18. Install the coast clutch pressure plate.
19. Install the snap ring.
Caution: Make sure the lugs of the thrust washer align with the second coast piston return spring.
20. Install the thrust washer.
WARNING: USE CAUTION WHEN CHECKING COMPONENTS WITH COMPRESSED AIR OR PERSONAL INJURY MAY RESULT.
21. Check the second coast clutch operation.
- Install a dial indicator.
- Apply 57 psi (396 kPa), of compressed air into the oil passage and measure the second coast clutch piston stroke. The piston stroke is 0.029 - 0.056 inch (0.760 - 1.440 mm). The clutch should make a solid apply sound, with no whistle or sign of leaks.