Required Tools | |||
Tool | Part Number | Part Description | Qty |
A | 439-3938 | Link Bracket | 3 |
H | - | Guide Stud 1/2 - 13 by 3 inch | 1 |
J | - | Guide Stud M10 X 1.5 by 203 mm | 2 |
K | 8T-5096 | Dial Indicator Gp | 1 |
5P-2390 | Gauge Tool Gp | 1 | |
L | - | Guide Stud 1/2 - 13 by 203 mm | 2 |
NOTICE |
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Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
Note: Cleanliness is an important factor. Thoroughly clean all parts before assembly 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.
- Install seal rings (86) and seal metal ring (85) onto shaft assembly (68).
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Illustration 2 g03675945 - Install adapter (84), hub (83), thrust bearing race (82), and bolts (81) to impeller (67). Tighten bolts (81) to a torque of
105 ± 14 N·m (77 ± 10 lb ft) .Show/hide tableIllustration 3 g03675918 - Lower the temperature of bushing (80). Install bushing (80 ) into carrier assembly (77).
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Illustration 4 g03675910 - Install bearing (79) to carrier assembly (77).
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Illustration 5 g03675891 - Install carrier assembly (77) and retaining ring (78) onto impeller (67).
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Illustration 6 g03676100 - Raise the temperature of bearing (76). Install bearing (76) onto support carrier (72).
- Install retaining ring (74).
- Install O-ring seal (75) and seal ring (73) onto support carrier (72).
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Illustration 7 g03675529 - Install support carrier (72) and retaining ring (71).
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Illustration 8 g03675526 - Lower the temperature of bearing outer race (70).
- Install bearing outer race (70) to drive gear (69).
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Illustration 9 g03675484 - Install drive gear (69). Install bolts (68) and the washers. Tighten bolts (68) to a torque of
50 ± 7 N·m (37 ± 5 lb ft) .Show/hide tableIllustration 10 g03675448 - Attach Tooling (A) and a suitable lifting device to impeller (67). The weight of impeller (67) is approximately
35 kg (77 lb) . Use Tooling (A) and the suitable lifting device in order to place impeller (67) onto shaft assembly (68).Show/hide tableIllustration 11 g03675275 - Install thrust bearing (66).
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Illustration 12 g03675239 - Install freewheel cam (65), plate (64), and retaining ring (63) into stator (57).
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Illustration 13 g03675234 Note: Freewheel springs (61) must be installed with maximum number of loops to the outside.
- Flip stator (57) over and install freewheel springs (61) and freewheel rollers (62). Install retaining ring (60).
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Illustration 14 g03675225 Show/hide tableImproper assembly of parts that are spring loaded can cause bodily injury.
To prevent possible injury, follow the established assembly procedure and wear protective equipment.
- Install plate (59) and retaining ring (58) into stator (57).
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Illustration 15 g03675217 - Install stator (57).
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Illustration 16 g03675185 - Install thrust bearing (56) and thrust bearing race (55).
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Illustration 17 g03675181 - Install split pins (54) and retaining ring (53) into turbine hub (52).
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Illustration 18 g03675174 - Connect turbine (51) to turbine hub (52). Install two bolts (40).
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Illustration 19 g03675130 - Install turbine hub (52) and turbine (51) as one unit. Remove bolts (40).
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Illustration 20 g03675105 - Install plate (50) and retaining ring (49).
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Illustration 21 g03675083 - Install race (48), thrust bearing (47), and thrust bearing race (46).
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Illustration 22 g03674946 Show/hide tableImproper assembly of parts that are spring loaded can cause bodily injury.
To prevent possible injury, follow the established assembly procedure and wear protective equipment.
- Install springs (45). Install cover (44) onto coupling assembly (41). Install bolts (43) and the nuts. Tighten bolts (43) to a torque of
50 ± 10 N·m (37 ± 7 lb ft) .Show/hide tableIllustration 23 g03674917 - Install dowels (42).
- Install coupling assembly (41) and bolts (40). Tighten bolts (40) to a torque of
60 ± 7 N·m (44 ± 5 lb ft) .Show/hide tableIllustration 24 g03674905 - Install backing plate (39) and friction disc (38).
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Illustration 25 g03674887 - Install splined plated (37).
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Illustration 26 g03674880 - Install seal rings (36) onto piston (34).
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Illustration 27 g03674854 Show/hide tableIllustration 28 g03676233 - Lower the temperature of bearing sleeve (35). Install bearing sleeve (35) into clutch housing assembly (30) to a Depth of (X). Depth (X) is equal to
3.60 ± 0.15 mm (0.142 ± 0.006 inch) . - Install piston (34) into clutch housing assembly (30).
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Illustration 29 g03674844 - Install ring (32) onto clutch housing assembly (30).
- Install plug (33). Install plug assemblies (31) into clutch housing assembly (30).
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Illustration 30 g03674827 - Use two people in order to install clutch housing assembly (30). The weight of clutch housing assembly (30) is approximately
26 kg (57 lb) . Install bolts (29). Tighten bolts (29) to a torque of60 ± 7 N·m (44 ± 5 lb ft) .Show/hide tableIllustration 31 g03674545 - Install retaining ring (27) in the groove of idler gear (16) .
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Illustration 32 g03676349 - Lower the temperature of bearing cup (26). Install bearing cup (26) in idler gear (16).
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Illustration 33 g03676354 - Flip idler gear (16) to the opposite side. Install bearing cup spacer (25) in idler gear (16). The notch in bearing cup spacer (25) must be aligned with retaining ring (16).
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Illustration 34 g03676357 - Lower the temperature of bearing cup (24). Install bearing cup (24) in idler gear (16).
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Illustration 35 g03674512 - Install bearing cone (23), bearing cone spacer (22), and bearing cone (21) into idler gear (16).
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Illustration 36 g03674505 - Install O-ring seal (20) onto shaft assembly (19).
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Illustration 37 g03676571 Show/hide tableIllustration 38 g03676572 - Install Tooling (H) in shaft assembly (19).
- Hold idler gear (16) in position in torque converter housing (3). Install shaft assembly (19).
- Remove Tooling (H) from shaft assembly (19).
- Install bolt (15) and the washer. Tighten bolt (15) to a torque of
120 ± 20 N·m (90 ± 15 lb ft) . - Install spring pins (17).
- Install O-ring seal (18).
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Illustration 39 g03674417 - Install relief valve body (14) and the two O-ring seals.
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Illustration 40 g03674411 - Install manifold (13) and the O-ring seal.
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Illustration 41 g03674384 - Lower the temperature of bearing cup (11). Install bearing cup (11) in torque converter housing (3).
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Illustration 42 g03676761 - Raise the temperature of bearing cones (12). Install bearing cones (12) on drive gear (10).
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Illustration 43 g03674377 - Install drive gear (10).
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Illustration 44 g03674374 - Install adapter (9) and the O-ring seal.
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Illustration 45 g03674346 - Apply the lubricant that is being sealed to O-ring seal (8). Install O-ring seal (8) and shims (7).
- Lower the temperature of bearing cup (6). Install bearing cup (6) into pump adapter (5).
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Illustration 46 g03676772 - Install Tooling (J) in torque converter housing (3).
- Install pump adapter (5) and the shims on torque converter housing (3).
- Install bolts (6) and the washers.
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Illustration 47 g03676880 Typical Example - Use Tooling (K) in order to check bearing end play. The bearing end play must be
0.15 ± 0.05 mm (0.006 ± 0.002 inch) . Add or remove shims in order to get the correct bearing end play.Note: If end play is less than
0.10 mm (0.004 inch) , add additional shims. If end play is greater than0.20 mm (0.008 inch) , remove shims.Show/hide tableIllustration 48 g03677169 - Apply the lubricant that is being sealed to O-ring seal (4). Install O-ring seal (4) on torque converter housing (3).
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Illustration 49 g03677180 - Install Tooling (L) in torque converter (28).
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Illustration 50 g03677194 - Use Tooling (A) and a suitable lifting devise in order to position torque converter housing (3) onto torque converter (28), as shown. The weight of torque converter housing (3) is approximately
120 kg (265 lb) . Install two of bolts (2) and the washers.Show/hide tableIllustration 51 g03674083 - Install the remaining bolts (2) and the washers. Tighten bolts (2) to a torque of
120 ± 20 N·m (90 ± 15 lb ft) .
Illustration 1 | g03675966 |
End By:
- Connect the torque converter to the transmission and the output transfer gears.