SECTION 7C2 - ON-VEHICLE SERVICE & UNIT REPAIR

CAUTION

When fasteners are removed, always reinstall

them at the same location from which they

were removed. If a fastener needs to be

replaced, use the correct part number fastener

for that application. If the correct part number

fastener is not available, a fastener of equal

size and strength (or stronger) may be used.

Fasteners that are not reused, and those

requiring thread locking compound, will be

called out. The correct torque values must be

used when installing fasteners that require

torque. If the above conditions are not

followed, parts or system damage could

result.

Sprag Unit

Second Clutch

3-4 Accumulator Piston

Reverse Clutch Piston and Center Suppor t

Overrun Clutch and Turbine Shaft

4L30-E Parts List

On-Vehicle Ser vice

Selector Lever

Mode Switch

Transmission (With T ransfer Case)

Solenoid Valve (Main Case Valve Body)

Solenoid Valve (Adapter Case Valve Body)

Unit Repair

Transmission (4L30-E)

Converter Housing and Oil Pump Assembly

Oil Pump

Main Case Valve Body

Adapter Case Valve Body

Third Clutch and Sprag Unit

Third Clutch

SELECTOR LEVER

2. Selector Lever Assembly

1) Disconnect shift lock cable from the selector lever

assembly side.

2) Disconnect wiring harness connectors.

3) Disconnect shift control rod from the selector

lever assembly side.

Shift lock cable

4) Remove selector lever assembly.

INSPECTION

1) Make sure that when the shifter control lever is

shifted from “P” to “L”, a “clicking” can be felt at

each shift position. Make sure that the gear

corresponds to that of the position plate indicator.

2) Check to see if the shifter lever can be shifted as

shown.

ON-VEHICLE SERVICE

REMOVAL

Preparation:

Disconnect negative (–) battery cable.

1. Front Console

Disconnect wiring harness connectors.

745LW001

256RV012

255LW007

INSTALLATION

To install, follow the removal steps in the reverse order,

noting the following points;

Adjustment of select lever and control rod

(1) Place the vehicle on a level surface.

NOTE:

If the vehicle is not on a level surface, the shift select

cable set positions will vary with the movement of

the engine. To prevent possible misadjustment of the

cable, the vehicle must be placed on a level surface.

(2) Install the shift control rod (1) to the transmission

select lever (2), and then place the lever in the “N”

position.

(3) Set select lever in the “N” position.

(4) Push select lever forward and secure it (using a

rubber band (3), etc.) so that pin comes into contact

with the wall of detent plate.

(5) Install the shift control rod (1) to the selector lever

arm (4).

Nut Torque N·m (kg·m / lb·ft)

32 (3.3 / 24)

NOTE:

Do not apply to threaded portions.

(6) After adjustment, make sure that the selector lever

operates normally, and that each selector position is

properly indicated. (The red mark shows through the

window.)

Adjustment of shift lock cable

1) Set IGN key in “LOCK” position and selector lever

in “P” position.

2) Adjust cable screw cap on selector lever side to

provide a gap (slack for cable) of 1 ~ 2mm

between rod on steering lock side and stopper.

Adjust cap as follows:

1Pull screw cap in arrow direction to remove

inner cable slack.

5mm

256RW014

256RW015

2With cable kept as 1, adjust gap between nut

(1) and bracket to 5mm (0.2in).

3Lock inner cable by turning nut (2) while

holding nut (1) in place.

Lock Nut Torque N·m (kg·cm / lb·in)

4 (39 / 35)

NOTE:

Clean the rod threads and do not apply oil to them.

3) Check the shift lock operation:

1Selector lever shall not move out of “P”

position with ignition key in “Lock” position.

2Selector lever can be moved out of “P”

position with ignition key in “ON” position

only when brake pedal is depressed.

3Ignition key can be turned to “LOCK” position

only when selector lever is in “P” position

(key can be pulled out).

If 1and 3fail, readjust cable. If 2fails, readjust

connector wiring and brake pedal switch.

MODE SWITCH

REMOVAL

Preparation:

•Disconnect negative (–) battery cable.

1. Place selector lever in neutral.

2. Disconnect battery ground cable.

3. Remove mode switch cover (1).

4. Disconnect selector lever (2) from the mode switch.

5 Disconnect transmission harness from the mode

switch connector (3).

6 Remove bracket with mode switch connector from

the transmission case.

7. Remove mode switch connector (3) from the bracket

(4).

8. Remove two mode switch bolts and nut then remove

mode switch(5).

210RW008

INSTALLATION

To install, follow the removal steps in the reverse order,

noting the following points;

1. Mode Switch Bolt Torque N·m (kg·cm / lb·in)

13 (130 / 113)

Selector Lever Nut Torque N·m (kg·m / lb·ft)

23 (2.3 / 17)

2. Mode switch setting procedure

Perform either of the following adjustment

procedures:

Procedure1

a. Place selector lever in neutral.

b. Remove selector lever from the mode switch.

c. Remove the mode switch cover.

d. Loosen the two 10 mm screws.

e. Rotate the mode switch until the slot in the mode

switch housing aligns with the selector shaft

bushing, and insert a 3/32 in. (2.4 mm) drill bit or

punch (1) into the slot.

f. Tighten the screws to 13 N·m (113 lb·in).

g. After completing adjustment, snap the mode

switch cover into place.

h. Reinstall the selector lever.

Procedure2

a. Place selector lever in neutral.

b. Disconnect transmission harness connector from

mode switch connector.

c. Remove mode switch connector with bracket

from the transmission case.

d. Connect multimeter (resistance mode) to

terminals 1(E) and 4(H) on mode switch

connector.

e. Loosen two mounting screws.

f. Rotate mode switch slightly in both directions to

determine the range (approx. 5 degrees) of

electrical contact.

g. Position mode switch in middle of contact range.

h. Tighten two mounting screws.

I. Remove multimeter and install mode switch

harness connector with bracket to the

transmission case.

j. Connect transmission harness connector to mode

switch connector.

249RW001

Mode switch connector

5 (D) 8 (A)

6 (C)

3 (G) 4 (H)

7 (B)

2 (F)

1 (E)

F07RW003

TRANSMISSION (WITH TRANSFER CASE)

240LW002

Removal Steps

1. Exhaust pipe

2. Rear propeller shaft

3. Fuel pipe

4. ATF oil cooler pipe

5. Heat protector

6. Harness connector

7. Starter

8. Flywheel under cover

9. Flywheel-Torque converter bolt

10. Rear mount nut

11. 3rd crossmember

12. Engine-transmission bolt

13. Transmission assembly

Installation Steps

To install, follow the removal steps in the

reverse order.

REMOVAL

Preparation:

•Remove engine hood.

•Disconnect negative (–) battery cable.

1. Exhaust Pipe

1) Remove catalytic converter, center pipe and left

front pipe.

2) Disconnect O2sensor connector from the

transmission harness connector.

2) Disconnect rear propeller shaft transmission side.

2. Rear Propeller Shaft

1) Disconnect shift control rod from the selector

lever assembly side.

3. Fuel Pipe

Disconnect two fuel pipe clamp bracket from the

transmission case eight side.

4. ATF Oil Cooler Pipe

1) Disconnect ATF oil cooler pipe from transmission

side.

2) Remove oil pipe clamp bracket from torque

converter case.

3) Loosen oil pipe clamp bolt at the engine mount

side.

256LW004

401LW001

141LW001

253LW002

5. Heat Protector

6. Harness Connector

1) Disconnect transmission harness connectors from

transmission side connectors.

2) Disconnect harness clamp from transmission case

side.

7. Starter

8. Flywheel Under Cover

Remove flywheel under covers (3 pieces) from

transmission case.

9. Flywheel – Torque Converter Bolt

Remove flywheel torque converter fixing bolts (6

pieces) by turning crankshaft.

10. Rear Mount Nut

1) Support transmission with a jack.

2) Remove two rear mount nuts from the rear

mount.

11. 3rd Crossmember

Remove eight 3rd crossmember bolts.

12. Engine-Transmission Bolt

1) Hoist engine with a chain block.

2) Remove engine-transmission bolts

13. Transmission Assembly

815LW001

210LW001

210LW002

INSTALLATION

To install, follow the removal steps in the reverse order,

noting the following points;

13. Transmission Assembly

Slowly raise transmission jack until front of the

transmission is aligned with rear of the engine.

12. Engine-Transmission Bolt

Tighten engine-transmission bolts, to the specified

torque (see next page).

11. 3rd Crossmember

3rd Crossmember Bolt Torque N·m (kg·m / lb·ft)

50 (5.1 / 37)

10 Rear Mount Nut

Rear Mount Nut Torque N·m (kg·m / lb·ft)

41 (4.2 / 30)

9. Flywheel-Torque Converter Bolt

1) Align the flywheel-torque converter bolt boss with

the starter portion of the converter housing by

turning torque converter.

2) Install new flywheel-torque converter bolts (6

pieces) by turning crankshaft.

NOTE:

Do not reuse the flywheel-torque converter bolt.

Flywheel-Torque Converter

Bolt Torque N·m (kg·m / lb·ft)

55 (5.6 / 41)

8. Flywheel Under Cover

Flywheel Under Cover

Bolt Torque N·m (kg·cm / lb·in)

8 (80 / 69)

7. Starter

Starter Bolt Torque N·m (kg·m / lb·ft)

40 (4.1 / 30)

6. Harness Connector

1) Connect transmission harness connectors to

transmission side.

2) Connect harness clamp to transmission harness

clamp bracket.

210LW002

(6places)

Cylinder block

T/M case

Bracket;fuel pipe

Clip;breather hose

Cylinder block

T/M case

Under cover

Crank case

21 27 2.5

76(7.7/56)

8(0.8/69lb in)

8(0.8/69lb in) 40(4.1/30)

76(7.7/56)

Torque : N•m(kg•m/lb ft)

Length : mm

32 20

Cylinder block

T/M case

21 27 1.2

Cylinder block

T/M case

21 27

Cylinder block

T/M case

17 27

Cylinder block

T/M case

25 30

Crank case

T/M case

25 20 T/M case

0.9 20

Under cover

T/M case

0.9 20

Under cover

0.9 11

Engine-Transmission Bolt Torque

F07RW041

5. Heat Protector

Heater Protector Bolt Torque N·m (kg·cm / lb·in)

6 (60 / 52)

4. ATF Oil Cooler Pipe

1) Install ATF oil cooler pipe to transmission.

ATF Oil Cooler Pipe Nut Torque N·m (kg·m / lb·ft)

54 (5.5 / 40)

2) Install oil pipe clamp bracket to torque converter

case.

3) Tighten oil pipe clamp bolt at engine mount side.

3. Fuel Pipe

Connect fuel pipe bracket to transmission side.

2. Rear Propeller Shaft

Connect shift control rod to the selector lever assembly.

Propeller Shaft Bolt Torque N·m (kg·m / lb·ft)

63 (6.4 / 46)

1. Exhaust Pipe

Exhaust Pipe Bolt Torque N·m (kg·m / lb·ft)

Exh. pipe to exh. manifold 67 (6.8 / 49)

Exh. pipe flange bolt 43 (4.4 / 32)

Connect O2sensor connector to transmission harness

connector.

815LW001

253LW002

141LW001

SOLENOID VALVE

(MAIN CASE VALVE BODY)

REMOVAL

Preparation:

• Disconnect negative (–) battery cable.

• Drain fluid.

Refer to “SERVICING” of the SERVICE

INFORMATION (Section 7C).

•Remove exhaust pipe and disconnect oxygen

sensor connector.

•Support transmission case with a jack and remove

third crossmember.

1. Main Case Oil Pan

Remove sixteen 10 mm screws, main case oil pan,

magnet, and gasket.

2. Oil Filter

Remove three 13 mm screws, oil filter.

3. Wiring Harness

Disconnect wiring harness from band control

solenoid, shift solenoids. Pull only on connectors, not

on wiring harness.

4. Spring Pin

Remove spring pin for shift solenoid A, shift solenoid

B, and band control solenoid respectively, using

suitable pliers taking care not to damage solenoids.

5. Solenoids

Remove shift solenoid A, shift solenoid B, band

control solenoid, and gaskets from main case valve

body. Do not pull on wiring harness. Remove

solenoids by grasping the metal tip.

210RW010

244RW003

INSTALLATION

To install, follow the removal steps in the reverse order,

noting the following points;

5. Solenoids

Install 1shift solenoid A, shift solenoid B, band control

solenoid with new gaskets to main case valve body

respectively.

4. Spring Pin

Carefully install spring pin with hammer to avoid

damage to valve body etc.

3. Wiring Harness

Connect wiring harness to solenoids.

2. Oil Filter

Install oil filter with new gasket, three 13 mm screws.

Oil Filter Bolt Torque N·m (kg·m / lb·ft)

20 (2.0 / 15)

1. Main Case Oil Pan

Install magnet, main case oil pan with new gasket,

sixteen 10 mm screws

Main Case Oil Pan Bolt Torque N·m (kg·cm / lb·in)

11 (110 / 96)

• Install third crossmember and rear mount nuts.

Rear Mount Nut Torque N·m (kg·m / lb·ft)

41 (4.2 / 30)

Third Crossmember Bolt Torque N·m (kg·m / lb·ft)

50 (5.1 / 37)

• Install exhaust pipe and connect oxygen sensor

connector.

Exhaust Pipe Flange Bolt Torque N·m (kg·m / lb·ft)

43 (4.4 / 32)

• Refill the transmission with new ATF DEXRON-III.

Refer to “SERVICING” of the SERVICE

INFORMATION (Section 7C).

•Connect negative (–) battery cable.

243RW004

SOLENOID VALVE

(ADAPTER CASE VALVE BODY)

REMOVAL

Preparation:

• Disconnect negative (–) battery cable.

• Drain fluid.

Refer to “SERVICING” of the SERVICE

INFORMATION (Section 7C).

•Remove exhaust pipe and disconnect oxygen

sensor connector.

1. Adapter Case Oil Pan

Remove twelve 10 mm screws, adapter case oil pan,

and gasket.

2. Wiring Harness

Disconnect wiring harness from force motor solenoid,

converter clutch solenoid. Pull only on connectors,

not on wiring harness.

3. Solenoid

•Remove 11 mm bolt and converter clutch solenoid

with two O-rings.

•Remove 11 mm bolt, retainer, and force motor

solenoid.

INSTALLATION

To install, follow the removal steps in the reverse order,

noting the following points;

3. Solenoids

1) Install force motor solenoid, retainer, and 11 mm

bolt to adapter case valve body.

Retainer Bolt Torque N·m (kg·cm / lb·in)

10 (100 / 87)

210RW011

210RW009

2) Install converter clutch solenoid with two O-rings.

3) Tighten 11 mm converter clutch solenoid bolt to

adapter case valve body.

Converter Clutch Solenoid

Bolt Torque N·m (kg·cm / lb·in)

10 (100 / 87)

2. Wiring Harness

Connect wiring harness assembly to solenoids.

1. Adapter Case Oil Pan

Install adapter case oil pan, new gasket, and twelve

10 mm screws.

Adapter Case Oil Pan

Bolt Torque N·m (kg·cm / lb·in)

11 (110 / 96)

• Install exhaust pipe and connect oxygen sensor

connector.

Exhaust Pipe Flange Bolt Torque N·m (kg·m / lb·ft)

43 (4.4 / 32)

• Refill the transmission with new ATF DEXRON-III.

Refer to “SERVICING” of the SERVICE

INFORMATION (Section 7C).

•Connect negative (–) battery cable.

UNIT REPAIR

TRANSMISSION (4L30-E)

2. O-ring

1. Torque converter

3. Mode switch

and transmission

harness

6. Adapter case

valve body

5. Wiring harness

4. Adapter case

oil pan

8. Oil filter

7. Main case oil pan

12.Main

case

valve

body

9. Manual detent

11. Servo cover

10. Wiring harness

240LW003

DISASSEMBLY

During the disassembly and reassembly of the following

components, perform the following:

•Wash each part thoroughly and blow air through

each oil passage and groove to eliminate blockage.

•Seal rings, roll pins and gaskets should be replaced

with new parts.

•When assembling the components, apply DEXRON-

III Automatic transmission fluid to each seal, rotating

part and sliding part.

•Do not dip those parts having a facing, such as drive

plate for clutch or brake, in the cleaner when washing

it with solvent.

Also, always wash it with new ATF two or three times

after cleaning with solvent.

1. Torque Converter

1) Drain fluid from torque converter.

2) Attach holding fixture to the transmission and set

it on holding fixture base.

Holding fixture: 5-8840-2278-0 (J-8763-02)

Fixture base: 5-8840-0003-0 (J-3289-20)

NOTE:

Do not overtighten the tool, as case damage may

result.

2. O-Ring

Remove O-ring from turbine shaft.

3. Mode Switch

1) Remove two 10mm screws, cover and mode

switch.

4. Adapter Case Oil Pan

1) Remove twelve 10mm screws, adapter oil pan,

and gasket.

5. Wiring Harness

1) Disconnect electrical connections from solenoids.

Pull on connectors only, not on wiring harness.

6. Adapter Case Valve Body

1) Remove seven 13mm screws, adapter case valve

body assembly, transfer plate and two gaskets.

2) Remove wiring harness and 5 pin connector.

7. Main Case Oil Pan

Remove sixteen 10mm screws, main oil pan, magnet,

and gasket.

8. Oil Filter

Remove three 13mm screws, oil filter.

9. Manual Detent

Remove two 13mm screws, roller & spring and

manual detent.

5-8840-0003-0 5-8840-2278-0

420RW019

10. Wiring Harness

1) Disconnect harness assembly from band apply

solenoid, shift solenoids and main case 4 pin

connector.

2) Remove 4 pin connector.

11. Servo Cover

Remove four 13mm screws, servo cover and gasket.

12. Main Case Valve Body and Ground Wire

1) Remove seven 13mm valve body screws.

2) Remove ground wire from main case.

3) Remove main valve body assembly with manual

valve link and transfer plate.

NOTE:

Note the position of link, with the long end into valve

short end, into range selector lever.

3) Remove gasket transfer plate from main case.

4) Remove two check balls from main case.

13. Servo Piston

1) Turn transmission to vertical position to drain

fluid. Return back to horizontal position when

drained.

2) Install servo piston spring compressor with offset

to the rear of case.

3) Compress servo piston assembly.

4) Remove servo piston retaining ring.

5) Slowly release servo piston assembly.

6) Remove tool.

7) Remove servo piston assembly, return spring,

and servo apply rod.

Servo piston spring compressor: 5-8840-0501-0

(J-23075)

14. Speed Sensor

1) Rotate transmission to horizontal position, pan

side down.

2) Remove one 10mm screw, and speed sensor with

O-ring.

15. Extension Housing and Flange

1) Remove seven 8mm hexagon socket head screws,

extension assembly, and gasket.

2) Remove retaining ring.

NOTE:

Use extra long nose pliers.

3) Remove flange nut.

4) Remove flange and O-ring.

5) Remove speed wheel.

6) Remove wheel parking lock (with seal ring).

15.Wheel parking lock

Seal ring

15.Speed wheel

15.Retaining ring

15.Extension housing

15.Flange

15.Flange nut

14.Speed sensor

241LW001

16. Converter Housing and Oil Pump Assembly

1) Rotate transmission to vertical position, converter

housing up.

2) Loosen, but not remove, five 13 mm inner screws

if oil pump disassembly required.

3) Remove seven outer screws.

4) Remove converter housing and oil pump

assembly.

5) Remove gasket.

6) Remove selective thrust washer.

17. Fourth Clutch Retainer

Remove fourth clutch retainer.

18. Turbine Shaft and Clutch Plates

Grasp turbine shaft and lift out the overrun clutch

housing assembly and fourth clutch plates.

19. Thrust Bearing Assembly

Remove thrust bearing assembly.

20. Overdrive Internal Gear

Remove overdrive internal gear.

21. Thrust Washer

Remove thrust washer.

22. Adapter Case and Center Support Assembly

1) Remove adapter case and center support

assembly (with fourth clutch piston).

2) Remove seal ring.

3) Remove selective thrust washer and two O-ring

seals from main case.

23. Fourth Clutch Spring Retainer

1) Compress the fourth clutch spring retainer and

springs.

2) Release snap ring from groove.

3) Remove clutch compressor and snap ring.

4) Remove retainer and spring assembly.

Compressor: 5-8840-0195-0 (J-23327) and

5-8840-2263-0 (J-23327-90)

24. Fourth Clutch Piston

1) Insert two converter housing/main case screws to

hold adapter case while pulling out fourth clutch

piston.

2) Remove fourth clutch piston assembly.

3) Remove converter housing/main case screws.

25. Second and Third Clutch Assemblies

1) Grasp intermediate shaft, twist and pull out the

second and third clutch drum assemblies with

reverse clutch plates while holding onto output

shaft.

2) Separate 2nd and 3rd clutch assemblies.

3) Remove thrust washer.

4) Remove reverse clutch plates and reverse clutch

pressure plate.

26. Planetary Carrier Assembly

1) Remove bearing and washer.

2) Remove planetary carrier assembly.

3) Remove thrust bearing.

27. Reaction Sun Gear

1) Remove reaction sun gear

2) Remove needle bearing.

28. Brake Drum

Remove brake drum.

29. Brake Band

1) Remove brake band.

2) Remove thrust bearing.

30. Parking Lock and Selector Lever Assembly

1) Rotate case to horizontal position, valve body side

facing up.

2) Remove spring pin, using cutting pliers.

NOTE:

Insert wire in the center of the spring pin to prevent

it from collapsing during removal. Be aware of pin

height. Protect machined face of main case.

3) Remove parking lock and range selector lever 17

mm nut.

4) Remove parking lock and range selector lever and

actuator assembly.

5) Remove selector shaft.

NOTE:

Inspect the shaft for burrs before removing to

prevent damaging seal. If necessary, remove burrs by

lightly sanding with an oilstone.

REASSEMBLY

30. Parking Lock and Selector Lever Assembly

1) Inspect selector shaft seal, replace if necessary.

NOTE:

Use a seal installer when replacing the seal.

2) Install selector shaft.

NOTE:

Spring pin groove must be positioned inside the

case.

3) Install spring pin. Be sure the selector shaft can

move freely.

Do not push the pin flush with the case surface.

Leave enough height for removal.

4) Install actuator assembly.

5) Install parking lock and range selector lever and

new 17 mm nut.

Selector Lever Nut Torque N·m (kg·m / lb·ft)

22 (2.2 / 16)

29. Brake Band

1) Rotate main case to vertical position, extension

end facing down.

2) Install brake band assembly.

NOTE:

Be sure to align servo pin area with the servo hole.

3) Install thrust bearing.

NOTE:

The case bushing acts as a guide for the thrust

bearing.

28. Brake Drum

Install brake drum.

27. Reaction Sun Gear

1) Install reaction sun gear.

2) Install needle bearing.

26. Planetary Carrier Assembly

1) Inspect planetary carrier assembly for wear and

damage, if necessary renew.

2) Measure pinion end play clearance (A)with a

feeler gage.

Planetary Carrier Pinion End Play (A) mm (in)

Standard 0.13 – 0.89 (0.005 – 0.035)

If clearance is outside specified valve, replace

planetary carrier assembly.

3) Install the thrust bearing on the output shaft.

NOTE:

Use petroleum jelly to hold the thrust bearing in

place.

4) Align planetary pinions. Each planetary pinion is

marked with double points to indicate the master

tooth space and exactly opposite with a single

point to indicate the master tooth. The markings

on the planetary carrier consist of double lines

which are to be lined-up with the double points

on two opposite pinions; the single lines are to be

lined-up with the single points on the other two

pinions.

5) After all four pinions are lined-up, slide on third

clutch assembly. Rotate third clutch and check

mark alignment. Considering that the ring gear

tooth between the double points of one planetary

pinion is tooth number 1, count the teeth to check

that the single points on the two adjacent pinions

are between teeth 23 and 24 of the ring gear, and

that the ring gear tooth between the double

points of the opposite pinion is tooth number 46.

If it is not so, remove, realign and try again.

6) Install planetary carrier with third clutch.

NOTE:

Do not force. When properly aligned, the parts will fit

together easily.

7) Remove the third clutch.

8) Install bearing and washer.

NOTE:

Use petroleum jelly to hold the washer and bearing

in place.

25. Second and Third Clutch Assemblies

1) Carefully align second clutch plates inner tangs.

2) Install thrust washer, tangs pointing downward,

locating tang positioned in slot on second clutch

hub.

NOTE:

Use petroleum jelly to hold thrust washer in place.

3) Install third clutch and intermediate shaft

assembly into the second clutch drum.

4) Install second and third clutch assemblies into the

main case. Twist output shaft and clutch

assemblies to insure proper fit.

5) Install pressure plate with lip side up, tang facing

valve body face.

6) Install reverse clutch plates. Start with a steel

plate and alternate with lined plates.

7) Install waved clutch plate, center tang facing valve

body side.

5-8840-2262-0

Second clutch end play measurement

1) Install the gaging tool on the case flange and

against the intermediate shaft.

2) Position the inner shaft of the gaging tool against

the thrust surface of the second clutch hub.

3) Tighten thumb screw. Remove the tool.

4) Fit the spacer ring on the inner shaft of the tool.

5) Measure gap (“G”). Select appropriate size

washer as the chart specified.

Selective washer gaging tool: 5-8840-2262-0

(J-23085-A)

Selective Thrust Washer

DIM. “G” mm(in) Color

1.53 - 1.63 (0.060 - 0.064) YELLOW

1.72 - 1.82 (0.068 - 0.072) RED

1.91 - 2.01 (0.075 - 0.079) BLACK

2.10 - 2.20 (0.083 - 0.087) NATURAL

2.29 - 2.39 (0.090 - 0.094) GREEN

2.48 - 2.58 (0.098 - 0.102) BLUE

FOLLOWING THE PROCEDURE SHOULD

RESULT IN FINAL END-PLAY FROM

0.36mm TO 0.79 mm (.014” TO .031”)

247RW007

17. Fourth clutch retainer

18. Fourth clutch plates

18. Turbine shaft and overrun clutch

Turbine shaft

Turbine shaft oil seal ring

Overrun clutch drum

Overrun clutch piston

2. O-ring

Overrun clutch relase

spring retainer

Roller clutch

Snap ring

Sun gear

Clutch plate

Backing plate

Snap ring

carrier assembly

20. OD

internal gear

21. Thrust

washer

Diaphragm spring

Overrun roller clutch cam

24. Fourth clutch piston

23. Snap ring

23. Retainer and spring assembly

Fourth clutch piston

Piston seal Piston seal

19. Thrust

bearing

Snap ring

Ratainer and

ball assembly

23. Fourth Clutch Spring Retainer

1) Install retainer and spring assembly.

2) Install snap ring in adapter case.

3) Install compressor.

4) Compress retainer and spring assembly.

5) Seat snap ring in groove.

6) Remove compressor.

Fourth clutch spring compressor: 5-8840-0195-0

(J-23327) and 5-8840-2263-0 (J-23327-90)

22. Adapter Case and Center Support Assembly

1) Install selective washer using petroleum jelly.

2) Install two O-ring seals in main case and adapter

case/main case seal ring.

3) Install guide pins.

4) Install adapter case complete to main case.

Guide pin: 5-8840-2268-0 (J-38588)

24. Fourth Clutch Piston

1) Inspect piston seals and replace if necessary.

2) Lubricate fitter and install on fourth clutch piston.

3) Install fourth clutch piston in adapter case.

4) Remove fitter.

Fourth clutch piston fitter: 5-8840-2267-0 (J-38554)

21. Thrust Washer

Install thrust washer into adapter case, with tangs

pointing downwards.

20. Overdrive Internal Gear

19. Thrust Bearing Assembly

18. Turbine Shaft and Fourth Clutch Plates

1) Preassemble overdrive internal gear and thrust

bearing assembly onto the overrun clutch

assembly complete.

NOTE

Install bearing assembly, black side up. Use

petroleum jelly to keep assembly in place.

2) Complete overdrive carrier and internal gear

assembly into adapter case.

3) Install fourth clutch plates in the following order.

Steel, Lined, Steel, Steel, Lined, Steel. Steel plates

go in with short tang facing towards valve body

surface.

17. Fourth Clutch Retainer

Install fourth clutch retainer.

Notch facing up and positioned towards valve body

surface.

OD clutch end play measurement

1) Install the tool on the adapter case flange and

against the input shaft.

2) Position the inner shaft of the tool against the

thrust surface of the overrun clutch housing.

3) Tighten thumb screw. Remove the tool.

4) Measure gap “G”. Select appropriate size washer

as the chart specifies.

5) Set selective thrust washer aside.

Selective washer gaging tool: 5-8840-2262-0

(J-23085-A)

Selective Thrust Washer

DIM. “G” mm(in) Color

1.53 - 1.63 (0.060 - 0.064) YELLOW

1.72 - 1.82 (0.068 - 0.072) RED

1.91 - 2.01 (0.075 - 0.079) BLACK

2.10 - 2.20 (0.083 - 0.087) NATURAL

2.29 - 2.39 (0.090 - 0.094) GREEN

2.48 - 2.58 (0.098 - 0.102) BLUE

FOLLOWING THE PROCEDURE SHOULD

RESULT IN FINAL END-PLAY FROM

0.1 mm TO 0.8 mm (0.004” TO 0.03”)

16. Converter Housing and Oil Pump Assembly

1) Install outer seal ring and gasket.

2) Install selective washer.

NOTE

Use petroleum jelly to hold selective washer in place.

3) Install complete converter housing and oil pump

assembly to adapter case.

4) Fit and tighten seven outer 13 mm screws.

Converter Housing Outer

Screw Torque N·m (kg·m / lb·ft)

39 (4.0 / 29)

5) Ensure free rotation of pump using rotation tool.

Pump rotation tool: 5-8840-2273-0 (J-23082-01)

Overdrive end play measurement

1) Fit puller on turbine shaft.

2) Position axial play checking tool on converter

housing mating face.

3) Pull turbine shaft upwards with puller until first

resistance is met.

(Due to weight of overdrive complete assembly)

Maintain shaft in this position and set indicator to

zero.

4) Pull turbine shaft further upwards with puller.

Read end play shown on indicator.

Overdrive End Play mm (in)

Standard

0.1 – 0.8 (0.004 – 0.031)

5) Remove axial play checking tool and puller.

NOTE:

If end play is not correct, repeat selective washer

selection.

Turbine shaft puller: 5-8840-2271-0 (J-25022) and

5-8840-0618-0 (J-24773-1)

15. Extension Housing and Flange

1) Inspect extension housing oil seal and

bearing.Replace if necessary.

Extension housing oil seal installer: 5-8840-2282-0

(J-36797)

2) Rotate transmission to horizontal position, with

valve body side down.

3) Inspect parking wheel seal ring. Replace if

necessary.

4) Install wheel parking lock assembly.

5) Install speed wheel and snap ring.

NOTE:

Use extra long nose pliers.

6) Install gasket onto extension assembly, using a

thin coating of oil.

7) Install extension housing assembly, and align

parking pawl shaft.

8) Install actuator assembly into extension

assembly.

9) Install seven 8 mm hexagon socket head screws.

Extension Housing Bolt Torque N·m (kg·m / lb·ft)

32 (3.3 / 24)

10) Install flange and O-ring.

11) Install flange nut.

Flange Nut Torque N·m (kg·m / lb·ft)

103 (10.5 / 76)

14. Speed Sensor

1) Inspect speed sensor O-ring. Replace if necessary.

2) Install speed sensor assembly and 10 mm screws.

Speed Sensor Bolt Torque N·m (kg·cm / lb·in)

9 (90 / 78)

Main case end play measurement

1) Attach axial play checking tool on the extension

housing and set indicator to zero on output shaft.

2) Manually push output shaft upwards.

Main Case End Play mm (in)

Standard

0.36 – 0.80 (0.014 – 0.031)

3) Remove axial play checking tool.

4) If end play is not correct, repeat selective washer

selection.

15.Wheel parking lock

Seal ring

15.Speed wheel

15.Retaining ring

15.Extension housing

15.Flange

15.Flange nut

14.Speed sensor

241LW001

13. Servo Piston

1) Inspect piston seal ring. Replace if necessary.

2) Ensure brake band is correctly positioned. Rotate

output shaft if necessary.

3) Install servo piston fitter in servo bore.

4) Install apply rod, round end toward band, return

spring and piston assembly.

5) Install the tool with offset to rear of case.

6) Compress servo piston seal ring, using fitter while

tightening the tool screw.

7) Install servo piston retaining ring.

8) Remove tool.

9) Adjust the brake band by tightening the servo

adjusting screw to 4.5 N·m (46 kg·cm / 40 lb·in)

torque. Be certain the lock nut is loose, then back-

off the screw five turns exactly. Hold piston sleeve

with wrench and tighten lock nut to 18.5 N·m

(1.9 kg·m / 14 lb·ft) torque. Be certain the

adjusting screw does not turn.

Servo spring compressor: 5-8840-0501-0 (J-23075)

Servo piston fitter: 5-8840-2274-0 (J-38428)

2. O-ring

1. Torque converter

3. Mode switch

and transmission

harness

6. Adapter case

valve body

5. Wiring harness

4. Adapter case

oil pan

8. Oil filter

7. Main case oil pan

12.Main

case

valve

body

9. Manual detent

11. Servo cover

10. Wiring harness

240LW003

12. Main Case Valve Body and Ground Wire

1) Install two check balls.

2) Inspect electrical connector and seal, replace if

necessary.

3) Install electrical 4 pin connector/main case and

wiring harness.

4) Install two guide pins into main case.

Guide pin: 5-8840-0022-0 (J-25025-B)

5) Install valve body complete assembly and manual

valve link.

NOTE:

Valve must be extended as the short end of manual

valve link is connected to the range selector lever.

Long end of link goes into valve.

6) Install seven 13 mm screws.

7) Pass ground wire of adapter case wiring harness

assembly through the hole joining adapter fluid

area and main case fluid area.

8) Assemble 8.5 mm connector of ground wire under

the head of this valve body bolt and reinstall it.

Main Case Valve Body

Bolt Torque N·m (kg·m / lb·ft)

20 (2.0 / 15)

9) Remove two guide pins.

11. Servo Cover

Install servo cover gasket, cover and four 13 mm

screws.

Servo Cover Bolt Torque N·m (kg·m / lb·ft)

25 (2.5 / 18)

10. Wiring Harness

Connect harness to band control and shift solenoids.

9. Manual Detent

Install roller and spring assembly with clip.

Install two 13 mm screws.

Manual Detent Screw Torque N·m (kg·m / lb·ft)

20 (2.0 / 15)

8. Oil Filter

Install oil filter, three 13 mm screws.

Oil Filter Bolt Torque N·m (kg·m / lb·ft)

20 (2.0 / 15)

Earth harness

244RV001

7. Main Case Oil Pan

Install oil pan gasket, magnet, oil pan, sixteen 10 mm

screws.

Main Case Oil Pan Bolt Torque N·m (kg·cm / lb·in)

11 (110 / 96)

6. Adapter Case Valve Body

1) Inspect electrical connector and seal. Replace if

necessary.

Install electrical five pin connector and harness

assembly in bottom of adapter case.

Install gasket, transfer plate, gasket.

2) Install adapter case valve body complete and

seven 13 mm screws.

Adapter Case Valve Body

Bolt Torque N·m (kg·m / lb·ft)

20 (2.0 / 15)

5. Wiring Harness

1) Connect harness assembly to converter clutch

solenoid, and force motor.

4. Adapter Case Oil Pan

1) Install oil pan gasket, oil pan, twelve 10 mm

screws.

Adapter Case Oil Pan

Bolt Torque N·m (kg·cm / lb·in)

11 (110 / 96)

2) Rotate transmission, with bottom pan facing

down.

3. Mode Switch

1) Install mode switch, shield and two 10 mm

screws.

2) Adjust using setting tool.

Refer to “MODE SWITCH” in this section.

Selector Shaft Nut Torque N·m (kg·m / lb·ft)

23 (2.3 / 17)

Mode Switch Screw Torque N·m (kg·cm / lb·in)

13 (130 / 113)

2. O-Ring

Install O-ring on turbine shaft.

1. Torque Converter

1) The converter assembly must be replaced under

any of the following conditions:

a. Evidence of damage to the pump assembly

b. Metal particles are found after flushing the

cooler lines

c. External leaks in hub weld area

d. Converter Pilot broken, damaged or poor fit

into crankshaft

e. Converter hub scored or damaged

f. Internal failure in stator

g. Contamination from engine coolant

h. Excess end play

2) Install converter assembly.

Rotate transmission, bell housing up. Spin

converter to insure proper fit.

3) Fill transmission through the overfill screw, using

DEXRON-III ATF.

3542

CONVERTER HOUSING AND OIL PUMP ASSEMBLY

DISASSEMBLY

1. Converter Housing

Remove five bolts from converter housing.

2. Outer Seal Ring

3. Gasket

4. Wear Plate

5. Oil Pump Assembly

6. Oil Seal Ring

INSPECTION AND REPAIR

Visual check

If any damage, deformation or local wear is found in a

converter housing, outer seal ring, wear plate or oil seal

ring, replace it.

Disassembly Steps

1. Converter housing

2. Outer seal ring

3. Gasket

4. Wear Plate

5. Oil pump assembly

6. Oil seal ring

Reassembly Steps

To reassemble, follow the disassembly steps

in the reverse order.

241RW003

REASSEMBLY

6. Oil Seal Ring

Install oil seal ring using installer.

Oil Seal Ring Bolt Torque N·m (kg·cm / lb·in)

3 (30 / 26)

5. Oil Pump Assembly

4. Wear Plate

Install wear plate onto oil pump assembly.

3. Gasket

2. Outer Seal Ring

1. Converter Housing

1) Install converter housing onto complete oil pump

assembly. Align with two short guide pins on

outer bolt holes.

2) Loosely install five 13mm bolts.

3) Center converter housing using centering tool.

4) Tighten five inner 13mm bolts in an alternating

pattern.

Converter Housing Bolt Torque N·m (kg·m / lb·ft)

20 (2.0 / 15)

Guide pin: 5-8840-2268-0 (J-38588)

Centering tool: 5-8840-2272-0 (J-38557)

14 15 16 17

11 12 13

543

OIL PUMP

DISASSEMBLY

1. Oil Pump Drive Gear

2. Oil Pump Driven Gear

3. Pin

4. Plug

5. Spring

6. Converter Clutch Control Valve

7. Snap Ring

8. Spring Seat

9. Spring

10. Throttle Signal Accumulator Piston

11. Sleeve Pin

12. Sleeve

13. Boost Valve

14. Spring Seat

15. Valve Spring

16. Spring Seat

17. Pressure Regulator Valve

Disassembly Steps

1. Oil pump drive gear

2. Oil pump driven gear

3. Pin

4. Plug

5. Spring

6. Converter clutch control valve

7. Snap ring

8. Spring seat

9. Spring

10. Throttle signal accumulator piston

11. Sleeve pin

12. Sleeve

13. Boost valve

14. Spring seat

15. Valve spring

16. Spring seat

17. Pressure regulator valve

Reassembly Steps

To reassemble, follow the disassembly steps

in the reverse order.

INSPECTION AND REPAIR

Visual check

If any damage, deformation or local wear is found in a

snap ring, spring, spring retainer valve, gear or oil pump,

replace it.

REASSEMBLY

17. Pressure Regulator Valve

16. Spring Seat

Lubricate and preinstall pressure regulator spring

seat on valve, with the flat side against shoulder.

15. Valve Spring

14. Spring Seat

13. Boost Valve

12. Sleeve

11. Sleeve Pin

10. Throttle Signal Accumulator Piston

9. Spring

8. Spring Seat

Install throttle signal accumulator piston, spring, and

spring seat, with the flat side away from the spring

and snap ring.

7. Snap Ring

6. Converter Clutch Control Valve

5. Spring

4. Plug

3. Pin

2. Oil Pump Driven Gear

1. Oil Pump Drive Gear

813

26 25

MAIN CASE VALVE BODY

Disassembly Steps

1. Gaskets and transfer plate

2. Manual valve

3. Band control solenoid

4. Pin

5. Waved washer

6. Spring pin

7. Solenoid A

8. Retainer

9. 1-2/3-4 shift valve

10. Spring

11. Spring pin

12. Solenoid B

13. Retainer

14. 2-3 shift valve

15. Spring

16. Spring pin

17. Plug

18. Spring

19. Low pressure control valve

20. Spring pin

21. Plug

22. Band control screen assembly

23. Spring pin

24. Plug

25. 1-2 accumulator valve

26. 1-2 accumulator control valve

27. Check ball

Reassembly Steps

To reassemble, follow the disassembly steps

in the reverse order.

DISASSEMBLY

1. Gaskets and Transfer Plate

Remove two 11mm bolts from valve body.

2. Manual Valve

3. Band Control Solenoid

4. Pin

5. Waved Washer

6. Spring Pin

7. Solenoid A

Remove solenoids by grasping the metal tip. Do not

grasp the connector housing.

8. Retainer

9. 1-2/3-4 Shift Valve

10. Spring

11. Spring Pin

12. Solenoid B

Remove solenoids by grasping the metal tip. Do not

grasp the connector housing.

13. Retainer

14. 2-3 Shift Valve

15. Spring

16. Spring Pin

17. Plug

18. Spring

19. Low Pressure Control Valve

20. Spring Pin

21. Plug

22. Band Control Screen Assembly

23. Spring Pin

24. Plug

25. 1-2 Accumulator Valve

26. 1-2 Accumulator Control Valve

27. Check Ball

Remove 1 check ball from valve body.

INSPECTION AND REPAIR

Inspect for the following and replace any damaged or

worn parts:

•Damage or wear to each valve.

•Damage in oil passeges.

•Cracks or damage to valve body.

•Valve operations.

•Spring fatigue.

REASSEMBLY

27. Check Ball

Install 1 check ball to valve body

26. 1-2 Accumulator Control Valve

25. 1-2 Accumulator Valve

24. Plug

23. Spring Pin

22. Band Control Screen Assembly

21. Plug

20. Spring Pin

19. Low Pressure Control Valve

18. Spring

17. Plug

16. Spring Pin

15. Spring

14. 2-3 Shift Valve

13. Retainer

12. Solenoid B

11. Spring Pin

10. Spring

9. 1-2/3-4 Shift Valve

8. Retainer

7. Solenoid A

6. Spring Pin

5. Waved Washer

4. Pin

3. Band Control Solenoid

2. Manual Valve

1. Gaskets and Transfer Plate

1) Install gasket (valve body/transfer plate) and

transfer plate, using two guide pins.

2) Install two 11mm bolts.

Valve Body Bolt Torque N·m (kg·cm / lb·in)

13 (130 / 113)

3) Install gasket (transfer plate/main case).

Guide pins: 5-8840-2270-0 (J-3387-2)

ADAPTER CASE VALVE BODY

DISASSEMBLY

1. Converter Clutch Solenoid

1) Remove 11mm bolt from valve body.

2) Remove converter control solenoid assembly with

two O-ring.

2. Retainer

Remove 11mm bolt and retainer from valve body.

3. Force Motor Solenoid

4. Retainer

5. Plug

6. 3/4 Accumulator Valve

7. 3/4 Accumulator Control Valve

Disassembly Steps

1. Converter clutch solenoid

2. Retainer

3. Force motor solenoid

4. Retainer

5. Plug

6. 3/4 accumulator valve

7. 3/4 accumulator control valve

8. Spring

9. Retaining ring

10. Feed limit valve

11. Plug retainer

12. O-ring

13. Plug

14. Force motor screen assembly

15. Adapter case valve body

Reassembly Steps

To reassemble, follow the disassembly steps

in the reverse order.

243RW001

8. Spring

9. Retaining Ring

10. Feed Limit Valve

11. Plug Retainer

12. O-ring

13. Plug

14. Force Motor Screen Assembly

Use 5mm bolt to pull plug.

INSPECTION AND REPAIR

Inspect for the following and replace any damaged or

worn parts:

•Damage or wear to each valve.

•Damage in oil passeges.

•Cracks or damage to valve body.

•Valve operations.

•Spring fatigue

REASSEMBLY

14. Force Motor Screen Assembly

13. Plug

12. O-ring

11. Plug Retainer

10. Feed Limit Valve

9. Retaining Ring

8. Spring

7. 3/4 Accumulator Control Valve

6. 3/4 Accumulator Valve

5. Plug

4. Retainer

3. Force Motor Solenoid

2. Retainer

1) Place solenoid terminals pointing towards mating

face.

2) Install retainer and bolt.

Retainer Bolt Torque N·m (kg·cm / lb·in)

10 (100 / 87)

1. Converter Clutch Solenoid

1) Install converter clutch solenoid assembly with

two O-rings to valve body.

2) Install bolt.

Bolt Torque N·m (kg·cm / lb·in)

10 (100 / 87)

854312

THIRD CLUTCH AND SPRAG UNIT

DISASSEMBLY

1. Retaining Ring

1) Place the third clutch housing and intermediate

shaft assembly upright, using the overdrive

internal gear as a support.

2) Locate the end of the sprag retaining ring.

Compress near the end, using a screwdriver

through the side slot and slide one tool blade

between ring and housing to hold the ring clear of

the groove.

3) Repeat with a second tool blade near the other

end of the retaining ring.

4) Repeat with a third tool blade opposite the first

two.

5) Repeat with two further blades equally spaced

apart.

Third clutch retaining ring compressor:5-8840-2258-0

(J-38450)

Disassembly Steps

1. Retaining ring

2. Input sun gear assembly

3. Retaining washer

4. Bearing

5. Thrust washer

6. Clutch plates

7. Third clutch drum

Reassembly Steps

To reassemble, follow the disassembly steps

in the reverse order.

248RW001

2. Input Sun Gear Assembly

Pull the input sun gear assembly unit until the sprag

retaining ring clears the ring groove.

3. Retaining Washer

4. Bearing

5. Thrust Washer

6. Clutch Plates

7. Third Clutch Drum

INSPECTION AND REPAIR

Visual check

If any damage, deformation or local wear is found in a

bearing, thrust washer, clutch plates or third clutch drum,

replace it.

REASSEMBLY

7. Third Clutch Drum

6. Clutch Plates

1) Place third clutch housing and intermediate shaft

assembly upright, using the overdrive internal

gear as a support.

2) Install third clutch spring cushion plate, bevel face

down.

3) Install third clutch plates into clutch housing.

Start with the steel clutch plate and alternate with

lined plates.

5. Thrust Washer

4. Bearing

3. Retaining Washer

2. Input Sun Gear Assembly

1. Retaining Ring

1) Fully engage the sprag assembly hub splines into

the third clutch inner tangs.

Simultaneously rotate the outer sprag race to

engage into the third clutch housing.

2) Install a tool blade at each extremity of the

retaining ring.

3) Compress the retaining ring with a screw-driver

opposite the tool blades while pushing down on

the outer sprag race.

4) Engage retaining ring into groove.

5) Remove tool blades.

Third clutch retaining ring compressor:5-8840-2258-0

(J-38450)

Disassembly Steps

1. Retaining ring

2. Spring seat

3. Springs

4. Piston

Reassembly Steps

To reassemble, follow the disassembly steps

in the reverse order.

★; Repair kit

THIRD CLUTCH

DISASSEMBLY

1. Retaining Ring

1) Compress spring seat using the tool.

NOTE:

Do not over-stress the springs and seat. This will

cause damage to the spring seat.

2) Remove retaining ring.

3) Release the spring seat.

NOTE:

Do not let the spring seat catch in the ring groove.

Spring compressor: 5-8840-0501-0 (J-23075)

Adapter: 5-8840-2259-0 (J-23075-12)

2. Spring Seat

3. Springs

4. Piston

INSPECTION AND REPAIR

Visual check

If any damage, deformation or local wear is found in a

retaining ring, return spring, piston seals or spring seat,

replace it.

Operation check

Shake piston and listen for check ball movement. Replace

piston if check ball is missing or falls out.

REASSEMBLY

4. Piston

1) The lip of the seals must point toward the front of

the transmission. Lubricate the lip seal with

transmission fluid.

2) Install piston assembly into the third clutch drum.

Use installer to protect the outer seal during

installation.

Third clutch piston installer: 5-8840-2260-0

(J-23084)

3. Springs

2. Spring Seat

1. Retaining Ring

1) Place retaining ring onto spring seat.

2) Compress the piston springs, using the piston

spring compressor.

NOTE:

Do not over-stress the springs and seat. Do not let

the spring seat catch in the ring groove. This may

cause damage to the spring seat.

3) Install spring seat retaining ring.

4) Remove the piston spring compressor.

Spring compressor: 5-8840-0501-0 (J-23075)

Adapter: 5-8840-2259-0 (J-23075-12)

SPRAG UNIT

DISASSEMBLY

1. Sprag Outer Race

2. Sprag Assembly

Remove sprag outer race and sprag assembly from

third clutch hub and sun gear assembly.

3. Sun Gear Assembly

INSPECTION AND REPAIR

Visual check

If any damage, deformation or local wear is found in a sun

gear, sprag assembly or sprag outer race, replace it.

REASSEMBLY

3. Sun Gear Assembly

2. Sprag Assembly

Install sprag assembly onto the sun gear.

NOTE:

Flared shoulder of the sprag cage faces the sun gear.

This procedure must be followed exactly to be sure

that the sprag assembly is installed properly.

1. Sprag Outer Race

1) Install outer sprag race assembly over the sprag

cage assembly.

2) Place third clutch hub and sun gear assembly on a

flat surface, sun gear facing up. Place sprag outer

race and sprag assembly over the sun gear

assembly, push down and turn the input sun

counterclockwise at the same time.

NOTE:

Check correct rotation by holding the sun gear in

your left hand and turning the outer race. The outer

sprag race should turn freely towards you and lock

turning away from you.

Disassembly Steps

1. Retaining ring

2. Ring gear

3. Retaining ring

4. Spacer

5. Clutch plates

6. Waved washer

7. Retaining ring

8. Spring seat

9. Springs

10. Piston

11. Second clutch drum

Removal Steps

To reassemble, follow the disassembly steps

in the reverse order.

54321

10 9 8 7 6

SECOND CLUTCH

DISASSEMBLY

1. Retaining Ring

2. Ring Gear

3. Retaining Ring

4. Spacer

5. Clutch Plates

6. Waved Washer

7. Retaining Ring

Compress the spring seat.

Compressor: 5-8840-0195-0 (J-23327)

247RW001

★; Repair kit

8. Spring Seat

9. Springs

10. Piston

11. Second Clutch Drum

INSPECTION AND REPAIR

Visual check

If any damage, deformation or local wear is found in a

retaining ring, ring gear, spacer, clutch plates, piston

seals, return spring or spring seat, replace it.

Operation check

Shake piston and listen for check ball movement.

Movement indicates proper check ball operation. Replace

piston if check ball is missing or falls out.

REASSEMBLY

11. Second Clutch Drum

10. Piston

Install piston assembly into the second clutch drum.

Lubricate the lip seal with liberal amounts of

transmission fluid. Use the installer to protect the

outer piston lip seal.

NOTE:

Lip of the seals point toward front of transmission.

Second clutch piston installer:5-8840-2261-0

(J-23080-A)

9. Springs

8. Spring Seat

7. Retaining Ring

1) Install twenty-two piston springs and spring seat

on the second clutch piston. Place retaining ring

onto spring seat.

2) Use the compressor to compress the piston

springs.

Compressor: 5-8840-0195-0 (J-23327)

NOTE:

Do not let spring seat catch in ring groove.

6. Waved Plate

5. Clutch Plates

Install clutch plates. Start with a steel plate and

alternate with lined plates.

Align second clutch inner tangs.

4. Spacer

Install spacer, with the fluted end toward clutch

plates.

3. Retaining Ring

2. Ring gear

1. Retaining Ring

3-4 ACCUMULATOR PISTON

DISASSEMBLY

Disassembly steps

1. Snap ring

2. Cover

3. Spring

4. Piston

Reassembly steps

To reassemble, follow the disassembly steps in the

reverse order.

★Repair kit

1. Snap Ring

Install cover compressor on adapter case.

Compress piston cover. Remove snap ring.

Compressor: 5-8840-2277-1 (J-38559-A)

5-8840-2277-1

Adapter case

Piston cover

2. Cover

Install cover remover to center hole of cover.

Use slide hammer to remove cover.

Cover remove: 5-8840-2403-0 (J-41096)

Adapter: 5-8840-2266-0 (J-38584)

Slide hammer: 5-8840-0019-0 (J-23907)

3. Spring

4. Piston

INSPECTION AND REPAIR

Visual Check

If any damage, deformation or wear is found in a return

spring, piston or piston cover, replace it.

REASSEMBLY

4. Piston

Place the fitter into adaptor case and push the piston

into position, using suitable diameter tube.

Piston fitter: 5-8840-2264-0 (J-38553)

3. Spring

5-8840-0019-0

5-8840-2266-0 5-8840-2403-0

242LW001

Disassembly Steps

1. Retaining ring

2. Spring seat

3. Springs

4. Piston

5. Center support

6. Gasket

7. Transfer plate

8. Gasket

9. Restrictor

10. Retainer plate

11. Plug

12. Spring

13. Overrun lock out valve

Reassembly Steps

To reassemble, follow the disassembly steps

in the reverse order.

REVERSE CLUTCH PISTON AND CENTER SUPPORT

5-8840-2277-1 Adapter case

Piston cover

2. Cover

Install cover, using compressor tool.

Compressor: 5-8840-2277-1 (J-38559-A)

1. Snap ring

Install snap ring in groove.

DISASSEMBLY

1. Retaining Ring

1) Install the tool on spring seat.

2) Compress the spring seat.

Compressor: 5-8840-0195-0 (J-23327)

NOTE:

Do not over-stress the springs and seat, as this will

cause damage to the spring seat.

2. Spring Seat

3. Springs

4. Piston

5. Center Support

Remove 8 bolts from center support. Remove center

support from adapter case.

6. Gasket

7. Transfer Plate

8. Gasket

9. Restrictor

10. Retainer Plate

11. Plug

12. Spring

13. Overrun Lock Out Valve

INSPECTION AND REPAIR

Visual check

If any damage, deformation or local wear is found in a

retaining ring, return spring, spring retainer, piston or

center support, replace it.

REASSEMBLY

13. Overrun Lock Out Valve

12. Spring

Install overrun lock out valve and spring.

NOTE:

Ensure correct assembly of valve. The spring should

be located over the long small diameter end.

11. Plug

10. Retainer Plate

9. Restrictor

Place in the lube overdrive channel in the adapter

case housing.

8. Gasket

7. Transfer Plate

6. Gasket

5. Center Support

Install center support with 8 bolts.

Center Support Bolt Torque N·m (kg·m / lb·ft)

25 (2.5 / 18)

4. Piston

3. Springs

2. Spring Seat

1. Retaining Ring

1) Install twenty four springs, spring seat and

retaining ring.

2) Install the tool.

3) Compress retaining ring and springs.

4) Seat snap ring in groove.

Compressor: 5-8840-0195-0 (J-23327)

Disassembly Steps

1. Snap ring

2. Overdrive carrier assembly

3. Sun gear

4. Turbine shaft

5. Snap ring

6. Backing plate

7. Clutch plates

8. Snap ring

9. Overrun roller clutch cam

10. Roller clutch assembly

11. Overrun clutch release spring

retainer

12. Diaphragm spring

13. Piston

14. Overrun clutch drum

15. Turbine shaft seal rings

Reassembly Steps

To reassemble, follow the disassembly steps

in the reverse order.

415 14 13

12 11 10 9 8 3 765 2 1

OVERRUN CLUTCH AND TURBINE SHAFT

DISASSEMBLY

1. Snap Ring

1) Position overrun clutch assembly upright, using

the overdrive internal gear as a support.

2) Remove snap ring.

2. Overdrive Carrier Assembly

3. Sun Gear

4. Turbine Shaft

5. Snap Ring

6. Backing Plate

7. Clutch Plates

8. Snap Ring

Compress piston return spring with compressor.

Compressor: 5-8840-2275-0 (J-23327-91)

9. Overrun Roller Clutch Cam

10. Roller Clutch Assembly

11. Overrun Clutch Release Spring Retainer

12. Diaphragm Spring

13. Piston

14. Overrun Clutch Drum

15. Turbine Shaft Seal Rings

INSPECTION AND REPAIR

Overdrive carrier check

Check pinion end play with a feeler gage.

Overdrive Carrier Pinion End Play mm (in)

Standard

0.24 – 0.64 (0.0094 – 0.025)

If clearance is outside specified value, replace overdrive

carrier assemlby

REASSEMBLY

Visual check

If any damage, deformation or local wear is found in a

snap ring, diaphragm spring, or spring retainer, roller

clutch assembly, turbine shaft, piston or clutch plates,

replace it.

15. Turbine Shaft Seal Rings

Install seals with grease (petroleum jelly).

14. Overrun Clutch Drum

13. Piston

1) Install the inner installer on the drum.

2) Pre-install piston into outer installer.

3) Install overrun clutch piston assembly. Use the

outer installer while pushing piston into drum.

Installer: 5-8840-2269-0 (J-38555)

12. Diaphragm Spring

11. Overrun Clutch Release Spring Retainer

10. Roller Clutch Assembly

9. Overrun Roller Clutch Cam

8. Snap Ring

1) Place snap ring loosely on spring retainer.

2) Hold the compressor in a vise. Compress piston

return spring with compressor.

3) Set snap ring in ring groove.

Compressor: 5-8840-2275-0 (J-23327-91)

7. Clutch Plates

Install clutch plates, start with steel plate and

alternate with lined plates.

6. Backing Plate

5. Snap Ring

4. Turbine Shaft

3. Sun Gear

Overdrive sun gear, countersink pointing downwards.

2. Overdrive Carrier Assembly

Complete overdrive carrier assembly.

NOTE:

Turn the assembly in a counter-clockwise direction

only until roller clutch enters the outer race. After

assembly, rotate the assembly and listen for loose

rollers.

1. Snap ring

4L30-E PARTS LIST CASE AND ASSOCIATED PARTS

123568910 11 12

104

27 28 29

28 30 31 8

12 32

1314 15

105

TRANSMISSION

CONTROL MODULE

97 106

100

101

102

103

16 43 44 4546

35 36

39 38

4948 47

5251

606162 63 64

76 76

77 77

57 56

241LW002

1 Torque converter

2 Screw, seal ring assembly

3 Seal ring assembly, converter

housing

4 Screw, converter housing/main

case

5 Screw, converter housing/oil pump

6 Housing, converter

7 Plug, converter housing

8 Seal, O-ring

9 Wear plate, oil pump body

10 Pump assembly, oil

11 Gasket

12 Washer, thrust selective

13 Ring, snap

14 Cover, 3-4 accumulator piston

15 Seal, O-ring, 3-4 accumulator

16 Spring, 3-4 accumulator piston

17 Pin, 3-4 accumulator piston

18 Piston, 3-4 accumulator

19 Ring, 3-4, accumulator piston

20 Case, adapter

22 Connector, electrical/adapter case

27 Restrictor, oil

28 Gasket, Transfer plate/adapter

29 Plate, transfer adapter/center

support

30 Support assembly, center

31 Screw, center support

32 Ring, oil seal

33 Seal, O-ring main case

34 Fitting, cooler

35 Fitting assembly, cooler

36 Case, main

37 Breather, pipe

38 Seal, O-ring

39 Reservoir

42 Gasket, extension case

43 Extension assembly

44 Seal, O-ring/speed sensor

45 Sensor assembly, speed

46 Screw, speed sensor

47 Nut, output shaft/drive flange

48 Seal, O-ring/drive flange

49 Flange, drive

50 Seal, extension assembly

51 Bearing, needle/extension

52 Screw, extension/main case

53 Spring, parking pawl lock

54 Pawl, parking lock

55 Connector, electrical/main case

56 Actuator assembly, parking lock

57 Nut, parking lock lever

58 Link, manual valve

59 Pin, spring

60 Lever, parking lock & range

selelector

61 Shaft, selector

62 Seal, selector shaft

63 Mode switch assembly

64 Screw & conical washer assembly

65 Shield, mode switch

67 Pan, Bottom/Adapter case

68 Gasket, bottom pan/adapter case

69 Harness assembly, adapter case

70 Screw, valve body

71 Valve body assembly, adapter case

72 Gasket, adapter valve body

73 Plate, adapter valve body/transfer

74 Pan, bottom/main case

75 Gasket, bottom pan/main case

76 Gasket, screw (’97)

77 Screw, oil drain or overfill (’97)

78 Magnet, chip collector

79 Filter oil

80 Harness assembly, main case

81 Earth harness (’97)

82 Roller & spring assembly, manual

detent

84 Valve body assembly, main case

85 Ball, check

86 Gasket, main V.B./Transfer plate

87 Plate, main V.B./Transfer

88 Gasket, transfer/main case

89 Screw, transfer plate on V.B.

90 Screw, servo cover

91 Cover, servo piston

92 Gasket, cover/servo piston

93 Ring, retaining servo piston

94 Clip, servo piston

95 Nut, servo screw

96 Screw, servo piston

97 Piston, servo

98 Seal, ring/servo piston

99 Spring, cushion/servo piston

100 Seat, cushion spring

101 Sleeve, servo piston adjust

102 Rod, apply/servo piston

103 Spring, return/servo piston

104 Gasket, adapter case/transfer plate

105 Transmission control module

106 Servo piston assembly

CASE AND ASSOCIATED PARTS

PUMP ASSEMBLY

201 Gear, oil pump drive

202 Gear, oil pump driven

203 Pin, boost valve sleeve

204 Sleeve, boost valve

205 Valve, boost

206 Seat, spring/pressure regulator valve

207 Spring, pressure regulator valve

208 Valve, pressure regulator

209 Pump assembly, oil

210 Valve, converter clutch control

211 Spring, converter clutch control valve

212 Plug, converter clutch control valve

213 Pin, spring

214 Piston, throttle signal accumulator

215 Spring, throttle signal accumulator

216 Seat, spring/throttle signal accumulator

217 Ring, snap/throttle signal accumulator

206 207 206 208

203 204 205

201 202

217

216

215

214

210

211212 213

209

403

402

407

410

414

416 402

401

415

412

413

417

409

406

405

411

404

VALVE BODY ASSEMBLIES

301 Body, valve main case

302 Pin, spring

303 Solenoid assembly, on/off N.C.

304 Valve, 1-2 & 3-4 shift

305 Spring, 1-2 & 3-4 (2-3) shift

306 Retainer, valve

307 Solenoid assembly, ON/OFF N.O.

308 Valve, 2-3 shift

309 Pin, spring

310 Plug, valve bore

311 Spring, valve low pressure control

312 Valve, low pressure control

317 Ball, check

318 Valve, 1-2 accumulator control

320 Valve, 1-2 accumulator

321 Washer, waved PWM solenoid

322 Pin, solenoid PWM

323 Solenoid assembly, band control PWM

324 Screen assembly, PWM solenoid

325 Plug, screen

326 Valve, manual

318 320

309

310

321

323 325

309

322

324

326

306

317

312

302

310

308

302

303

304 305

317

301

307

305 317

311

243LW001

401 Body, valve/adapter case

402 Screw, solenoid force motor

403 Retainer, force motor

404 Solenoid, force motor

405 Plug, 3-4 accumulator

406 Retainer

407 Valve, 3-4 accumulator

409 Valve, 3-4 accumulator control

410 Spring, feed limit valve

411 Ring, retainer

412 Valve, feed limit

413 Seal, O-ring plug filter

414 Plug, screen

415 Screen assembly, force motor

416 Solenoid, torque conv. clutch on/off

N.C.

417 Plug retainer

501 Retainer, 4th clutch

502 Plate, 4th clutch (steel)

503 Plate assembly, 4th clutch (lined)

504 Retainer & ball assembly, check valve

505 Seal, O-ring/turbine shaft

506 Shaft, turbine

508 Ring, oil seal/turbine shaft

510 Housing, overrun clutch

513 Piston, overrun clutch

514 Spring, overrun clutch release

515 Retainer, release spring/overrun clutch

516 Roller assembly, overdrive clutch

517 Cam, overdrive roller clutch

518 Ring, snap/overrun clutch hub

519 Gear, overdrive sun

521 Plate, overrun clutch (steel)

522 Plate assembly, overrun clutch (lined)

523 Plate, backing/overrun clutch

524 Ring, snap/overrun clutch housing

525 Carrier assembly, overdrive complete

526 Ring, snap/turbine shaft/carrier

527 Bearing assembly, thrust

528 Gear, overdrive internal

529 Washer, thrust/internal gear/support

530 Ring, snap/adapter/4th clutch spring

531 Retainer & spring assembly, 4th clutch

532 Piston, 4th clutch

533 Seal, 4th clutch piston (inner)

534 Seal, 4th clutch piston (outer)

OVERDRIVE INTERNAL COMPONENTS

252RW003

501 502 503 504 505

514 515 516 517 518 519

530 531

532 533 534

521

520

522 523 524 525 526 527 528 529

506

508 510 513

INTERNAL COMPONENTS

608 Seal, reverse clutch piston (inner)

609 Seal, reverse clutch piston (outer)

610 Piston, reverse clutch

611 Spring, piston clutch

612 Seat, spring/reverse clutch

613 Ring, Retaining

614 Plate, waved/reverse clutch

615 Plate, reverse clutch (steel)

616 Plate assembly, reverse clutch (lined)

617 Plate, reverse clutch pressure/selective

618 Drum assembly, 2nd clutch

620 Seal, 2nd clutch piston (Inner)

621 Seal, 2nd clutch piston (Outer)

622 Piston, 2nd clutch

623 Seat, spring/2nd clutch

625 Plate, waved/2nd clutch

626 Plate, 2nd clutch (Steel)

627 Plate assembly, 2nd clutch (Lined)

628 Spacer, 2nd clutch

629 Ring, retaining

630 Gear, ring

631 Washer, thrust/2nd clutch/3rd clutch

632 Thrust washer, clutch hub

634 Drum assembly, 3rd clutch

635 Seal, 3rd clutch piston (Inner)

636 Washer, retaining

637 Seal, 3rd clutch piston (Outer)

638 Piston 3rd clutch

639 Seat, spring/3rd clutch

640 Ring, retaining

641 Plate, spring cushion/3rd clutch

642 Plate, 3rd clutch (Steel)

643 Plate assembly, 3rd clutch (Lined)

644 Washer, thrust/input sun

645 Bearing, input shaft/gear assembly

646 Gear assembly, input sun

647 Race assembly, sprag

648 Ring, retaining/sprag

649 Ring, retaining

650 Cage assembly, sprag

651 Bearing, output shaft/input sun

652 Washer, output shaft/input sun

653 Carrier assembly, planetary

658 Gear, reaction sun

659 Drum, reaction sun

664 Band assembly, brake

667 Seal, ring/wheel parking lock

668 Wheel, parking lock

672 Wheel, speedo

673 Ring, retaining

675 Bearing, thrust assembly

INTERNAL COMPONENTS

CENTER SUPPORT ASSEMBLY

701 Center support

702 Retainer plate

703 Plug, lockout

704 Spring, overrun lockout

705 Valve, overrun lockout

702

703704

705

701