Required Tools | |||
---|---|---|---|
Tool | Part Number | Part Description | Qty |
A | 138-7573 | Link Bracket | 1 |
138-7575 | Link Bracket | 2 | |
B | 1P-0520 | Driver Gp | 1 |
C | 188-1456 | Metric Eyebolt | 1 |
D | 138-7575 | Link Bracket | 2 |
E | 138-7575 | Link Bracket | 3 |
F | 1P-0520 | Driver Gp | 1 |
8T-5096 | Dial Indicator Gp | 1 | |
G | 1P-1863 | Retaining Ring Pliers | 1 |
Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts. Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement.
Note: Apply oil to all of the bearings before assembly.
- Check the condition of the O-ring seals that are used in the torque converter and torque converter housing. If any of the seals are damaged, use new parts for replacement.
Show/hide table
Illustration 1 g00674989 - Install five O-ring seals (96) and three plugs (97).
Show/hide table
Illustration 2 g00674987 - Install block (95) and four bolts (94).
Show/hide table
Illustration 3 g00674986 - Install ring (93) and two bearings (92) to idler gear assembly (91).
Show/hide table
Illustration 4 g00675821 - Install idler gear assembly (91).
Show/hide table
Illustration 5 g00675822 - Install idler gear shaft (90).
- Install bolt (89) and the washer.
Show/hide table
Illustration 6 g00674982 - Install O-ring seal (88) to cover (87).
Show/hide table
Illustration 7 g00675823 - Install three bolts (86) and cover 87.
Show/hide table
Illustration 8 g00675717 - Use the proper equipment to handle bearing cup (85).
- Lower the temperature of bearing cup (85).
- Install bearing cup (85) into the housing.
Show/hide table
Illustration 9 g00675718 - Use the proper equipment to handle bearing (83).
- Heat bearing (83) to a maximum temperature of
135 °C (275 °F) . - Install bearing (83) onto gear assembly (77).
Show/hide table
Illustration 10 g00674959 - Install plate (82) onto adapter (80).
- Install retaining ring (81).
Show/hide table
Illustration 11 g00674957 - Install adapter assembly (80) into gear assembly (77).
- Install retaining ring (79).
Show/hide table
Illustration 12 g00675719 - Use the proper equipment to handle bearing (78).
- Heat bearing (78) to a maximum temperature of
135 °C (275 °F) . - Install bearing (78) onto gear assembly (77).
Note: Allow the bearing and the gear assembly to reach a uniform temperature.
- Use a hammer and a suitable punch to reset the bearing around the inside race of the bearing. This will ensure that the bearing is seated correctly.
Show/hide table
Illustration 13 g00675721 - Install gear assembly (77) and entire shim pack (84).
- If both pump drives were removed, repeat Steps 10 through 24 for the remaining pump drive.
Show/hide table
Illustration 14 g00716568 - Lower temperature of bearing cup (75). Install bearing cup (75) into adapter (73). Ensure that the bearing cup (75) is seated.
Show/hide table
Illustration 15 g00716572 Note: DO NOT install the seals to the adapters at this time.
- Use two persons to install adapters (73) and (77) on the torque converter housing. The weight of adapter (73) is
30 kg (65 lb) . - Install seven bolts (72) and six bolts (78). The torque for bolts (72) and (78) is
240 ± 40 N·m (177 ± 30 lb ft) . - When possible, rotate either the torque converter or the outer housing to ensure that the bearings are properly seated.
Show/hide table
Illustration 16 g00675824 - Use Tooling (F) to check bearing end play. The bearing end play must be
0.15 ± 0.05 mm (.006 ± .002 inch) . Remove shims (84) to attain the correct bearing end play. - Remove the pump adapters from the torque converter housing.
Show/hide table
Illustration 17 g00674954 - Use Tooling (B) to install seal (76) into adapter (73).
- Lightly lubricate seal (76) with oil.
Show/hide table
Illustration 18 g00674953 - Install two O-ring seals (74) on adapter (73).
- Lubricate the O-ring seals (74) prior to assembly.
- Install two O-ring seals and one lip seal on the remaining adapter.
Show/hide table
Illustration 19 g00716572 - Install the correct amount of shims (84) to the torque converter housing. The correct shim thickness was determined in the above steps.
- Use two persons to install adapters (73) and (77) on the torque converter housing. The weight of adapter (73) is
30 kg (65 lb) . - Install seven bolts (72) and six bolts (78). The torque for bolts (72) and (78) is
240 ± 40 N·m (177 ± 30 lb ft) . - When possible, rotate either the torque converter or the outer housing to ensure that the bearings are properly seated.
- Use Tooling (F) to recheck the bearing end play. If necessary, repeat the above procedure.
Show/hide table
Illustration 20 g00674791 - Install seal (71) onto piston (70).
Show/hide table
Illustration 21 g00674790 - Install piston (70).
Show/hide table
Illustration 22 g00674788 Show/hide tableIllustration 23 g00674750 - Install two wear plates (68) and two friction discs (69).
Show/hide table
Illustration 24 g00674748 - Install plate (67) and retaining ring (66).
Show/hide table
Illustration 25 g00674744 Show/hide tableIllustration 26 g00674747 - Install clutch adapter (65) and hub (63) to turbine (64).
- Install 24 bolts (62). The torque for bolts (62) is
105 ± 15 N·m (77 ± 11 lb ft) .Show/hide tableIllustration 27 g00674727 - Install bearing (61).
Show/hide table
Illustration 28 g00674725 - Install O-ring seal (59) and two plugs (60).
Show/hide table
Illustration 29 g00675696 - Use the appropriate equipment to turn the housing assembly onto the opposite side, as shown.
- Install turbine assembly (64) into housing assembly.
Show/hide table
Illustration 30 g00675769 - Install the ring and the plate below bearing (58).
- Install bearing (58).
Show/hide table
Illustration 31 g00675437 - Use the proper equipment to handle bearing (57).
- Heat bearing (57) to a maximum temperature of
135 °C (275 °F) . - Install bearing (57) onto the outer shaft.
Note: Allow the bearing and the shaft to reach a uniform temperature.
- Use a hammer and a punch to reset the bearing around the inside race of the bearing. This will ensure that the bearing is seated correctly.
- Use the proper equipment to handle seal carrier (56).
Note: Allow the ring and the shaft to reach a uniform temperature.
- Heat seal carrier (56) to a maximum temperature of
135 °C (275 °F) . - Install seal carrier (56) onto the outer shaft.
Show/hide table
Illustration 32 g00675571 - Use a hammer and a suitable punch to install pin (55).
Show/hide table
Illustration 33 g00674523 - Install seal (52).
- Install two seals (53).
- Install retaining ring (54).
Show/hide table
Illustration 34 g00674522 - Install seal (51) to sleeve (50).
Show/hide table
Illustration 35 g00674521 - Install sleeve (50) and eight bolts (49). The torque for bolts (49) is
30 ± 5 N·m (22 ± 4 lb ft) .Show/hide tableIllustration 36 g00674520 - Use the proper equipment to handle race (48).
- Lower the temperature of race (48).
- Install race (48) in drive gear (47).
Show/hide table
Illustration 37 g00674519 - Install drive gear (47) onto housing assembly (45).
- Install 12 bolts (46). The torque for bolts (46) is
105 ± 15 N·m (77 ± 11 lb ft) .Show/hide tableIllustration 38 g00674514 - Install Tooling (E) to housing assembly (45).
- Attach a suitable hoist and lifting slings to housing assembly (45).
- Use a suitable lifting device to install housing assembly (45) to outer shaft assembly. The weight of housing assembly (45) is
45 kg (100 lb) .Show/hide tableIllustration 39 g00674516 - Install seal (44) onto piston (43).
Show/hide table
Illustration 40 g00674512 - Install piston (43).
Show/hide table
Illustration 41 g00674510 - Install two friction discs (42) and one wear plate.
Show/hide table
Illustration 42 g00674508 - Install plate (41).
- Install two bolts (22) on the underside of plate (41).
Show/hide table
Illustration 43 g00674506 - Install 12 bolts (38) and impeller (36) to adapter assembly (39). The torque for bolts (38) is
105 ± 15 N·m (77 ± 11 lb ft) .Show/hide tableIllustration 44 g00674505 - Use the proper equipment to handle race (37).
- Lower the temperature of race (37).
- Install race (37) in impeller (36).
Show/hide table
Illustration 45 g00674507 - Install the ring and the plate below bearing (40).
- Install bearing (40).
- Install the plate above bearing (40).
Show/hide table
Illustration 46 g00674504 - Use two persons to install the impeller (36) onto the shaft assembly. The weight of impeller (36) is
29 kg (65 lb) .Show/hide tableIllustration 47 g00674503 - Install retaining ring (35).
Show/hide table
Illustration 48 g00674501 - Install the ring and the plate below bearing (34).
- Install bearing (34).
Show/hide table
Illustration 49 g00674499 - Install spacer (33).
Show/hide table
Illustration 50 g00674498 - Install race (32) and retaining ring (31).
Note: Inspect the splines on the stator. If the splines were damaged during disassembly, replace the stator with a new part.
Show/hide tableIllustration 51 g00675434 Typical Example - Use proper equipment to handle stator (24).
- Heat stator (24) to a maximum temperature of
121 °C (250 °F) for one hour. - Install stator (24) onto cam (30).
- Install retaining ring (29).
Show/hide table
Illustration 52 g00675433 - Install plate (28) and retaining ring (27) onto stator (24). Repeat this procedure for the opposite side.
Show/hide table
Illustration 53 g00673889 - Install 13 springs (25) and 13 rollers (26).
- Install springs (25) in the deepest part of the groove. Assemble the springs so that the maximum number of loops face toward the outside of the cam.
- Install rollers (26) in the narrowest part of the groove.
Show/hide table
Illustration 54 g00673888 - Install stator (24) to carrier assembly (23).
Show/hide table
Illustration 55 g00673887 - Carefully rotate carrier assembly into the upright position. The springs and the rollers will hold the stator in place.
- Install Tooling (D) to carrier assembly (23).
- Attach a suitable lifting device and slings to carrier assembly (23).
- Use a suitable lifting device to install carrier assembly (23) to the torque converter housing. The weight of carrier assembly (23) is
132 kg (290 lb) .Show/hide tableIllustration 56 g00673885 - Install 36 bolts (21). The torque for bolts (21) is
60 ± 7 N·m (45 ± 5 lb ft) .Show/hide tableIllustration 57 g06372634 - Install orifice plug (21A).
Show/hide table
Illustration 58 g00675572 - Use the proper equipment to handle seal carrier (20).
- Heat seal carrier (20) to a maximum temperature of
135 °C (275 °F) . - Install seal carrier (20) onto inner shaft (18).
- Use the proper equipment to handle bearing (19).
- Heat bearing (19) to a maximum temperature of
135 °C (275 °F) . - Install bearing (19) onto inner shaft (18).
Note: Allow the bearing and the shaft to reach a uniform temperature.
- Use a hammer and a suitable punch to reset the bearing around the inside race of the bearing. This will ensure that the bearing is seated correctly.
Show/hide table
Illustration 59 g00673883 - Install Tooling (C) to shaft assembly (18).
- Attach a suitable lifting device and a suitable lifting sling to Tooling (C).
- Use the suitable lifting device to install shaft assembly (18). The weight of shaft assembly (18) is
17 kg (38 lb) .Show/hide tableIllustration 60 g00673879 - Carefully position the torque converter onto the side, as shown.
Show/hide table
Illustration 61 g00673881 - Install washer (17), retainer (16), and two bolts (15). The torque for bolts (15) is
105 ± 15 N·m (77 ± 11 lb ft) .Show/hide tableIllustration 62 g00673880 - Install cover (14) and six bolts (13). The torque for bolts (13) is
60 ± 7 N·m (44 ± 5 lb ft) .Show/hide tableIllustration 63 g00660849 - Position the torque converter upright.
- Install gasket (10).
- Install O-ring seals (11) and (12).
Show/hide table
Illustration 64 g00660847 - Use Tooling (B) to install seal (9) into retainer (8).
Show/hide table
Illustration 65 g00660846 - Install retainer (8) and eight bolts (7). The torque for bolts (7) is
60 ± 7 N·m (45 ± 5 lb ft) .Note: It is necessary to install the torque converter into the torque converter housing prior to installation of the idler gear.
Show/hide tableIllustration 66 g00665414 - Install Tooling (A) to the torque converter housing.
- Attach a suitable lifting device and lifting chains to Tooling (A), as shown.
- Use the suitable lifting device to install the torque converter housing to the torque converter. The weight of the torque converter housing is
270 kg (600 lb) .Show/hide tableIllustration 67 g00665412 - Install eleven bolts (6) and the washers.
Show/hide table
Illustration 68 g00665121 - Install yoke (5).
- Install O-ring seal (4).
Show/hide table
Illustration 69 g00665406 - Install bolt (2) and retainer (3). The torque for bolt (2) is
240 ± 25 N·m (175 ± 20 lb ft) .Show/hide tableIllustration 70 g00660841 - Install speed sensor (1).
End By:
- Install the transmission oil pump. Refer to Disassembly and Assembly, "Transmission Oil Pump - Install" for the machine that is being serviced.
- Install the torque converter outlet relief valve. Refer to Disassembly and Assembly, "Relief Valve (Torque Converter Outlet) - Install" for the machine that is being serviced.
- Install the modulating valve for the torque converter impeller clutch. Refer to Disassembly and Assembly, "Modulating Valve (Torque Converter Impeller Clutch) - Install" for the machine that is being serviced.
- Install the modulating valve for the torque converter lockup clutch. Refer to Disassembly and Assembly, "Modulating Valve (Torque Converter Lockup Clutch) - Install" for the machine that is being serviced.
- Install the torque converter. Refer to Disassembly and Assembly, "Torque Converter - Install" for the machine that is being serviced.