Part 2

NOTE: Use the band adjustment screw as a temporary alignment guide.





57. Install the overdrive band adjusting screw.

CAUTION:
- Make sure that the pump body is seated against the thrust washer and the overdrive brake and coast clutch drum. The pump body must be below the level of the case gasket surface.
- The tabs on the washer go into the pump lace.





58. Perform front end play check procedure as follows:
(1). Coat the oil pump inlet thrust washer (No.1) with petroleum jelly.
(2). Install the oil pump inlet thrust washer (No.1) on the rear of the oil pump and place pump into position in case.

CAUTION: The Gauge Bar tool must rest on the gasket surface.





59. Measure the front end play clearance.
(1). Place Gauge Bar T93T-77003-AH or equivalent across the case.
(2). Place depth micrometer on Gauge Bar and extend micrometer probe until it contacts the oil pump face.
(3). Read the measurement and subtract Gauge Bar thickness 17.78 mm (0.700 inch). This is dimension A.
(4). Repeat the measurement at the opposite side of the transmission case. This is dimension B.
(5). Add dimensions A and B together and divide by two. This is front end clearance dimension C.

CAUTION: If the average front end clearance is below the specification, choose a thinner washer. If the average is above the specification, choose a thicker washer.

60. Use dimension C and the chart below to select the correct thickness oil pump inlet thrust washer (No. 1).





NOTE: The front end play specification is 0.18 - 0.70 mm (0.007 - 0.028 in).

CAUTION:
- Make sure that the pump body is seated against the thrust washer and the overdrive brake and coast clutch drum. The pump body must be below the level of the case gasket surface.
- The tabs on the washer go into the pump face.





61. Remove pump and install No.1 thrust washer onto pump. After installing selected front pump thrust washer No.1, repeat front end play check. Make sure correct end play, then remove pump for assembly.





62. Install a new 0-ring in oil pump drive gear.

CAUTION: Lubricate the SST with clean transmission fluid.





63. Install oil pump drive gear on SST to seat 0-ring. Remove SST.

CAUTION: The chamber on the inside edge of the small gear must be up when in the pump housing gear pocket. The dimple on the larger gear must be down when in the pump housing gear pocket.





64. Install the pump gears into the oil pump housing. Apply grease to pump gear to prevent scoring at start up.

CAUTION: Make sure the holes in the plate line up with the holes in the pump.





65. Install the fluid pump adapter plate.

CAUTION: Do not allow the pump gears to come out of the pump housing pocket.

66. Install the oil pump on the converter housing.




(1). Hold the oil pump adapter plate against the pump housing. Turn the pump and adapter plate over and place on the converter housing.

NOTE: The notch on the outside of the adapter plate will be at the 9 o'clock position relative to the converter housing.





67. Loosely install the oil pump bolts.

CAUTION: The SST must be used to properly align the oil pump to the oil adapter plate. This will prevent seal leakage, gear noise, broken gears and bushing failure.





68. Align the oil pump to the oil pump adapter plate and select the gauge from the SST that is the snuggest fit when placed over the oil pump.





69. Thread the gauge into SST and slide the tool over the oil pump until it bottoms out in the oil pump gear pocket.





70. Tighten the Allen head screws in a star pattern and remove the pump alignment handle.





71. Install a new oil pump seal ring.
(1). Coat the oil pump seal ring with petroleum jelly.

72. Install a new oil pump gasket.




(1). Hold the oil pump gasket in place with petroleum jelly.

NOTE: Make sure the oil pump seal ring is installed on the housing and pump assembly.

CAUTION: Verify correct seal installation. Make sure seal grooves are clean and free of burrs.





73. Install the front pump support seal.





74. Install the selected No.1 oil pump thrust washer.
(1). Coat the oil pump thrust washer with petroleum jelly.





75. Install SST into the transmission case.

CAUTION: The splines on the ends of the input shaft are not the same length. The shorter splines go into the assembly.





76. Install the input shaft.

CAUTION: Make sure that the oil pump inlet thrust washer (No.1) selective thrust washer, oil pump gasket, and the oil pump-to-case 0-ring remain in the correct position throughout this step.





77. Install the oil pump and converter housing onto the





78. Remove SSTs. Install the new converter housing-to-case screws. Tighten the screws in a star pattern.

NOTE: Lubricate 0-rings on converter housing screws.





79. Remove the input shaft.

WARNING: Make sure the lock pin on bench-mounted holding fixture is secure.

80. Rotate transmission assembly so the oil pan rails are facing up.





81. Assemble the overdrive servo assembly.
(1). Install the overdrive servo cover 0-ring on overdrive servo cover. Coat the overdrive servo cover 0-ring with petroleum jelly.
(2). Install the overdrive servo piston into the overdrive servo cover.
(3). Install the overdrive servo piston spring on the overdrive servo piston.

CAUTION:
- Do not damage the overdrive servo to case 0-ring during installation.
- Do not press the overdrive servo cover and 0-ring past the relief hole in the case or 0-ring damage may occur.





82. Using the SST, install the overdrive servo assembly into the case.
(1). Install SST.
(2). Insert the overdrive servo assembly into overdrive servo bore in the transmission case.
(3). Compress overdrive servo cover and install the overdrive servo cover retaining ring.





83. Assemble the intermediate servo assembly.
(1). Install the intermediate servo cover 0-ring on intermediate servo cover. Coat the intermediate servo cover 0-ring with petroleum jelly.
(2). Install intermediate servo piston into the intermediate servo cover.
(3). Install the intermediate servo piston spring on the intermediate servo piston.

CAUTION:
- Do not damage servo cover to case 0-ring during installation.
- Do not press the intermediate servo cover and 0-ring past the relief hole in the case or 0-ring damage may occur.





84. Install the intermediate servo assembly into the case.
(1). Install SST.
(2). Insert the intermediate servo assembly into intermediate servo bore in the transmission case. Compress servo cover and install the intermediate servo cover retaining ring.

CAUTION:
- Do not allow overdrive band adjustment screw to back out. Band strut could fall out of position.
- Install, but do not tighten, a new locknut on the band adjustment screw. Apply petroleum jelly to the locknut seal.