Disassembly/Reassembly of Subassemblies

NOTE: Before beginning assembly, perform/inspect the following:

• All fasteners must be tightened to the torque indicated in the text. In addition to appearing in the text, the necessary torques can be found under Specifications.
• When building up subassemblies, each component part should be lubricated with clean transmission fluid. It is also good practice to lubricate the subassemblies as they are installed in the case (7005).
• Needle bearings, thrust washers and seals should be lightly coated with petroleum jelly during subassembly buildup or transmission assembly.
• Many components and surfaces in the transmission are precision machined. Careful handling during disassembly, cleaning, inspection and assembly can prevent unnecessary damage to machined surfaces.

When building up subassemblies and assembling the transmission, ALWAYS use new gaskets and seals.

Main Control Valve Body

Main Control Valve Body Disassembled View

Item	Part Number	Description
1	7A334	1-2 Shift Valvea
2	7A320	2-3 Shift Valve Springa
3	7E086	2-3 Shift Valvea
4	7F187	Valve Retaining Pluga
5	7G007	Valve Plug Retainera
6	7B200	Pressure Regulator Valveb
7	7H172	Pressure Regulator Valve Springb
8	7F194	Spring Retaining Plateb
9	7G179	Bypass Clutch Control Valvec
10	7H140	Bypass Clutch Control Valve Springc
11	7G320	Bypass Clutch Control Valve Plungerc
12	7G319	Bypass Clutch Control Plunger Sleevec
13	7E170	Control Valve Platec
14	7C388	Main Regulator Valved
15	7A270	Main Pressure Regulator Valve Springd
16	7D003	Main Pressure Booster Valved
17	7D002	Main Pressure Booster Valve Sleeved
18	7G007	Valve Plug Retainerd
19	7E195	Check Ball (8 Req'd)
20	7H171	Converter Drain Back Valve
21	7B200	Pressure Regulator Valvee
22	7H172	Pressure Regulator Valve Springe
23	7F187	Valve Retainer Pluge
24	7G007	Valve Plug Retainere
25	7H150	Capacity Modulator Valvef
26	7F267	Capacity Modulator Valve Springf
27	7F194	Spring Retaining Platef
28	7H150	Capacity Modulator Valvef
29	7F267	Capacity Modulator Valve Springf
30	7F194	Spring Retaining Platef
31	7F259	3-4 Shift Valveg
32	7F260	3-4 Shift Valve Springg
33	7F187	Valve Retainer Plugg
34	7G007	Valve Plug Retainerg
35	7H150	Capacity Modulator Valveh
36	7F267	Capacity Modulator Valve Springh
37	7F187	Valve Retainer Plugh
38	7G007	Valve Plug Retainerh
39	7F187	Valve Retainer Plugh
40	7G007	Valve Plug Retaineri
41	7B200	Pressure Regulator Valvej
42	7H172	Pressure Regulator Valve Springj
43	7F194	Spring Retaining Platej
44	97411-S	Retaining Ringk
45	7C389	Control Manual Valvek
46	7H187	Solenoid Screen

Disassembly

1. Remove retaining bolt and shift control solenoid bracket (7H186).

2. Remove shift solenoid (7G484) assembly and torque converter clutch solenoid (TCC solenoid) (7G136) by pulling straight up.

   

3. Turn main control valve body (7A100) over and remove 11 bolts retaining reinforcement plates to separator plates.

   

4. Remove separator plate and gaskets. Discard gaskets.

   

5. Note location and remove the eight coasting booster valve shuttle balls (7E195). Remove solenoid pressure supply screen.

   

6. Remove converter drain back valve.

7. Remove 11 valve body cover plate bolts and two guide pin bolts.

   

8. Remove valve body cover plate and gasket.

   

Assembly

1. Install valve body cover plate and gasket.

2. Install, in sequence per the following illustration, two guide pin bolts. Tighten to 9-11 Nm (80-100 lb-in).

3. Install, in sequence per the following illustration, 11 valve body cover retaining bolts. Tighten to 9-11 Nm (80-100 lb-in).

   

4. Install the eight coasting booster valve shuttle balls, converter drain back valve and solenoid pressure supply screen.

   

5. Install separator plate and new gaskets.

6. Install reinforcement plates. Tighten retaining bolts to 9-11 Nm (80-100 lb-in).

   

7. NOTE: TCC solenoid must be installed first.

   Inspect O-rings on solenoids for damage. Install shift solenoid and torque converter clutch solenoid.

   

8. Install shift control solenoid bracket and retaining bolt. Tighten to 9-11 Nm (80-100 lb-in).

   

Pump and Intermediate Clutch Piston

Item	Part Number	Description
1	7902	Torque Converter
2	7A248	Front Pump O-Ring
3	N605789-S100	Bolt (7 Req'd)
4	—	Front Pump Body Assembly (Part of 7A103)
5	—	Pump Inner Gerotor Gear (Part of 7A103)
6	N605787-S	Bolt (5 Req'd)
7	7D014	No. 1 Front Pump Support Thrust Washer
8	7D020	Reverse Clutch Cylinder Seal
9	7D019	Forward Clutch Cylinder Seal
10	7E005	Intermediate Clutch Piston
11	7F224	Intermediate Clutch Piston Outer Seal
12	7F225	Intermediate Clutch Piston Inner Seal
13	7A108	Front Pump Support
14	—	Pump Outer Gerotor Gear (Part of 7A103)
15	7A136	Front Pump Gasket
16	7B258	Front Pump Bushing
17	7A248	Front Pump Inner Seal
18	87650-S2	Converter Drain Plug

Disassembly

SPECIAL SERVICE TOOL(S) REQUIRED

Description	Tool Number
Front Pump Seal Replacer	T63L-77837-A
Intermediate Clutch Lip Seal Protector	T80L-77005-A

1. Remove the No. 1 front pump support thrust washer.

   

2. Using a 10mm socket, remove five front pump support bolts. Separate front pump support (7A108) and front pump body assembly.

   

3. NOTE: The reverse clutch cylinder seals (7D020) are larger than the forward clutch cylinder rings.

   Remove two reverse clutch cylinder seals and two forward clutch cylinder seals.

   

4. Remove inner and outer pump gerotor gears from front pump body assembly.

   

5. Remove spring retainer assembly by carefully dislodging the tabs.

   

6. Remove intermediate clutch piston (7E005) and intermediate clutch piston inner seal (7F225) and intermediate clutch piston outer seal (7F224).

   

7. Remove front pump O-ring and discard.

   

Assembly

1. Install the front pump seal using Front Pump Seal Replacer T63L-77837-A.

   

2. Install new intermediate clutch piston inner seal and intermediate clutch piston outer seal on intermediate clutch piston.

   

3.  CAUTION: The piston bleed hole must be located at 12 o'clock position (toward top of transmission).

   NOTE: Piston bleed hole is the only round hole in the intermediate clutch piston assembly.

   Note location of the piston bleed hole.

   

4. NOTE: Coat intermediate clutch piston outer seal and intermediate clutch piston inner seal and pump body sealing area with petroleum jelly.

   Install intermediate clutch piston in Intermediate Clutch Lip Seal Protector T80L-77005-A.

   

5. Install intermediate clutch piston in pump body and push intermediate clutch piston to the bottom of the bore by exerting even pressure.

   

6. Snap spring retainer assembly into place on pump body.

   

7. Install the inner and outer pump gerotor gears in pump body.

   The flats have steps that must face the pump body for ease of installing the torque converter (7902).

   

8. Install reverse clutch cylinder seal and forward clutch cylinder seals.

   

9. Position front pump support to front pump body assembly and install retaining bolts. Tighten to 20-26 Nm (15-19 lb-ft).

   

Intermediate Clutch Cylinder

Disassembled View

NOTE: Clutch must rotate counterclockwise when installed on drum.

Disassembly

1. Remove retaining ring.

   

2. Remove intermediate one-way clutch retainer.

   

3. Remove intermediate clutch hub by lifting and turning counterclockwise.

   

4. Carefully lift intermediate one-way clutch from reverse clutch drum (7D044).

Assembly

1. NOTE: For ease in assembly, the chamfer on the intermediate clutch hub splines should face upward.

   Install intermediate one-way clutch on reverse clutch drum.

   

2. NOTE: Clutch must rotate counterclockwise when installed on reverse clutch drum.

   Install intermediate clutch hub.

   

3. Install intermediate one-way clutch retainer.

   

4. Install retaining ring.

Reverse Clutch

Disassembled View

Item	Part Number	Description
1	7D044	Reverse Clutch Drum
2	7D256	Reverse Clutch Piston Spring Pressure Ring
3	7B070	Reverse Clutch Piston Spring
4	7B442	Reverse Clutch External Spline Plate (Steel)
5	7B066	Reverse Clutch Rear Pressure Plate
6	7G008	No. 2 Forward Clutch Bearing
7	7D483	Reverse Clutch Pressure Plate Retainer
8	7B164	Reverse Clutch Internal Spline Plates (Friction)
9	7B066	Reverse Clutch Front Pressure Plate
10	7A577	Reverse Clutch Piston Spring Ring
11	7D404	Reverse Clutch Piston Small Seal
12	7D402	Reverse Clutch Piston
13	7D403	Reverse Clutch Piston Outer Seal

SPECIAL SERVICE TOOL(S) REQUIRED

Description	Tool Number
Reverse Clutch Spring Compressor	T80L-77405-A
Clutch Spring Compressor	T65L-77515-A
Reverse Clutch Inner Seal Protector	T80L-77403-B
Reverse Clutch Outer Seal Protector	T80L-77403-A

Disassembly

1. Remove No. 2 forward clutch bearing.

   

2. Remove reverse clutch pressure plate retainer.

   

3. Remove clutch pack.

   

4. Install Reverse Clutch Spring Compressor T80L-77405-A and Clutch Spring Compressor T65L-77515-A onto reverse clutch drum. Tighten enough to compress reverse clutch piston spring (7B070). Remove reverse clutch piston spring ring.

   

5. Remove reverse clutch piston spring and reverse clutch piston spring pressure ring (7D256).

   

6. NOTE: To aid in reverse clutch piston spring removal, it may be necessary to apply air pressure to the reverse clutch drum. Block the opposite hole with a finger.

   Remove reverse clutch piston (7D402).

   

7. Remove reverse clutch piston small seal (7D404) and reverse clutch piston outer seal (7D403).

Assembly

1. NOTE: The piston check ball must be present and moving freely.

   Install new reverse clutch piston small seal and reverse clutch piston outer seal on reverse clutch piston. Direction of installation is not important because seals are square cut.

   

2. NOTE: Coat reverse clutch piston outer seal and reverse clutch piston small seal, reverse clutch drum, sealing area and seal protector with petroleum jelly.

   Install Reverse Clutch Inner Seal Protector T80L-77403-B on the clutch hub and Reverse Clutch Outer Seal Protector T80L-77403-A over the reverse clutch piston.

3. Position reverse clutch piston and push it to the bottom of the reverse clutch drum using even thumb pressure.

   

4. Install reverse clutch piston spring pressure ring and reverse clutch piston spring. The dished side of reverse clutch piston spring must face toward the reverse clutch piston.

   

5. Install reverse clutch piston spring ring (with points down) using Reverse Clutch Spring Compressor T80L-77405-A and Clutch Spring Compressor T65L-77515-A.

   

6. Install reverse clutch front pressure plate, clutch pack and reverse clutch rear pressure plate. Position the stepped side of reverse clutch front pressure plate down with flat side toward clutch pack and reverse clutch rear pressure plate flat side toward clutch pack.

   

7. Install reverse clutch pressure plate retainer and check the clearance between the reverse clutch pressure plate retainer and the reverse clutch rear pressure plate using a feeler gauge. Reverse clutch rear pressure plate should be held downward as clearance is checked using Dial Indicator with Bracketry TOOL-4201-C or equivalent.

   

The four plate assembly clearance should be 1.01-1.524mm (0.040-0.060 inch).

If clearance is not within specification, install correct size retaining ring and check clearance. Selective retaining rings are available in the following thicknesses:

SELECTIVE RETAINING RINGS

1.52-1.62mm (0.060-0.064 Inch)
1.87-1.98mm (0.074-0.078 Inch)
2.23-2.33mm (0.088-0.092 Inch)
2.59-2.69mm (0.102-0.106 Inch)

8. Check clutch for proper operation using Air Nozzle Assembly TOOL-7000-DE or equivalent. The clutch should be heard and felt to work smoothly and without leakage.

   

Forward Clutch Cylinder

Disassembled View

Item	Part Number	Description
1	7F207	Forward Clutch Cylinder and Shaft
2	7A548	Forward Clutch Piston Outer Seal
3	7A480	Forward Clutch Piston Return Spring
4	7A527	Forward Clutch Retainer Return Spring
5	7B442	Forward Clutch External Spline Plate (Steel)
6	7D483	Retaining Snap Ring
7	7B067	Forward Clutch Hub
8	7F231	No. 5 Forward Clutch Hub Front Bearing
9	7B066	Forward Clutch Pressure Plate
10	7B164	Forward Clutch Internal Spline Plates (Friction)
11	7E085	Forward Clutch Pressure Spring
12	388099-S	Retaining Snap Ring
13	7A262	Forward Clutch Piston
14	7C099	Forward Clutch Piston Inner Seal
15	7A166	No. 2 Forward Clutch Bearing
16	7B497	Input Shaft Seal

SPECIAL SERVICE TOOL(S) REQUIRED

Description	Tool Number
Direct Clutch Spring Compressor	T81P-7035-A
Forward Clutch Lip Seal Protector	T80L-77140-A
Lip Seal Protector	T68P-7D158-A

Disassembly

1. NOTE: Forward clutch hub may remain in shell during disassembly.

   Remove forward clutch hub and No. 3 forward clutch hub front bearing (7F231), if not already removed.

   

2. NOTE: To aid in handling, forward clutch assembly may be set in the extension housing (7A039) or a 51mm (2-inch) hole may be cut in a workbench.

   Remove retaining snap ring.

   

3. Remove clutch pack, forward clutch pressure plate and forward clutch pressure spring.

   

4. Compress forward clutch piston return spring using Direct Clutch Spring Compressor T81P-70235-A.

   Place into a shop arbor press and apply only enough pressure to release spring tension on the snap ring.

   Remove retaining snap ring and slowly release the press to remove spring compressor.

   

5. NOTE: Air pressure may be required to remove forward clutch piston.

   Remove forward clutch retainer return spring, forward clutch piston return spring and forward clutch piston.

   

6. Remove inner and outer forward clutch piston seals.

7. NOTE: Make sure input shaft seals are not damaged.

   NOTE: Solid input shaft seals may be replaced with scarf-cut input shaft seals for service.

   Remove input shaft seals from forward clutch cylinder and shaft (7F207).

   

8. Make sure check balls in clutch cylinder are free and clean. Check for proper seating.

   

Assembly

1. Install new inner and outer forward clutch piston seals on the forward clutch piston. Note direction of the sealing lip before installation.

   

2. NOTE: Coat piston seals and clutch drum sealing area with petroleum jelly.

   Install Forward Clutch Lip Seal Protector T80L-77140-A over clutch cylinder hub.

3. Install forward clutch piston Lip Seal Protector T68P-7D158-A.

   

4. Position seal protector and forward clutch piston in forward clutch cylinder and shaft. Push forward clutch piston to the bottom of the forward clutch cylinder and shaft using even thumb pressure. Remove seal protectors.

   

5. Install forward clutch piston return spring and forward clutch retainer return spring.

   

6. Compress forward clutch piston return spring using Direct Clutch Spring Compressor T81P-70235-A. Compress forward clutch piston only enough to allow clearance to install retaining snap ring.

   

7. Install clutch pack in the following order:

   1. Forward clutch pressure spring
   2. Clutch pack
   3. Forward clutch pressure plate

      

8. Install retaining snap ring and check the clearance between the retaining snap ring and forward clutch pressure plate using Dial Indicator with Bracketry TOOL-4201-C or equivalent.

   Forward clutch pressure plate should be held downward as the clearance is checked.

   

   

   If the clearance is not within specification, install the correct size retaining ring and recheck the clearance. Selective retaining rings are available in the following thicknesses:

SELECTIVE RETAINING RING

1.52-1.62mm (0.060-0.064 Inch)
1.87-1.98mm (0.074-0.078 Inch)
2.23-2.69mm (0.086-0.092 Inch)
2.59-2.69mm (0.102-0.106 Inch)

9. NOTE: Scarf-cut input shaft seals must be installed with mating surfaces as shown.

   Install two scarf-cut input shaft seals on the forward clutch cylinder and shaft if original seals are damaged or missing.

   

   

   The clearance should be:

   • 1.27-2.26mm (0.50-0.089 inch)

10. Install No. 3 forward clutch hub front bearing. Install forward clutch hub into forward clutch cylinder and shaft, ensure forward clutch hub is against No. 3 forward clutch hub front bearing.

    

Planetary Gear Support Assembly and Planetary One-Way Clutch

Disassembly

1. Remove planetary gear support from planetary assembly. Rotate the planetary gear support counterclockwise and lift.

   

2. Carefully remove planetary one-way clutch from planetary assembly.

   

Assembly

1. Inspect clutch outer race, inner race, band surface, pinion gears, bearings and thrust washer for roughness.

   Inspect rear planet support bushing for roughness.

   Inspect planetary one-way clutch, rollers and springs for damage.

   

   Item	Part Number	Description
   1	7A089	Planetary One-Way Clutch
   2	—	Cage (Part of 7A089)
   3	—	Spring (Part of 7A089)
   4	—	Roller (Part of 7A089)
   5	—	Cam-Type Clutch Race (Part of 7A398)
   6	7A398	Planetary Assembly
   7	7A130	Planetary Gear Support

2. Install planetary one-way clutch in planetary assembly.

3. Install planetary gear support into planetary one-way clutch by rotating the planetary gear support counterclockwise.

   Lubricate clutch races and clutch assembly with petroleum jelly to aid in assembly.

Reverse Clutch Sun Gear Assembly

Disassembly

1. Remove the No. 4 forward clutch hub bearing from reverse clutch sun gear assembly.

   

2. NOTE: The forward clutch sun gear and reverse sun gear assembly are assembled as part of the transmission assembly procedure.

   Remove forward clutch sun gear and No. 5 forward clutch sun gear bearing from reverse clutch sun gear assembly.

   

Output Shaft and Direct Clutch Cylinder

Item	Part Number	Description
1	7F236	Direct Clutch Hub
2	7F243	No. 7 Direct Clutch Inner Bearing
3	7F237	Direct Clutch Inner Bearing Washer
4	7A153	Output Shaft Ring Gear Assembly
5	7F283	Direct Clutch Cylinder
6	7F274	Output Shaft to Direct Clutch Cylinder Seal
7	7F240	No. 8 Direct Clutch Outer Bearing
8	97713-S	Retaining Snap Ring
9	7064	Snap Ring
10	7D164	Output Shaft Hub
11	7F273	Output Shaft to Case Seal
12	7060	Output Shaft

Disassembly

1. Remove snap ring retaining the output shaft hub (7D164) to output shaft ring gear assembly.

   

2. Separate output shaft (7060) from output shaft ring gear assembly.

   

3. Remove snap ring retaining output shaft hub. Slide output shaft hub off rear of output shaft.

   

4.  CAUTION: The output shaft has three grooves. The illustration shows the correct locations.

   Remove three output shaft to case seals (7F273).

   

5. Remove two output shaft to direct clutch cylinder seals (7F274) from the output shaft. Note the direction of the output shaft to direct clutch cylinder seals.

   

Direct Clutch Cylinder

Disassembled View

Item	Part Number	Description
1	7F243	No. 7 Direct Clutch Inner Bearing
2	7D483	Direct Clutch Pressure Plate Retaining Ring
3	7B066	Direct Clutch Pressure Plate
4	7B442	Direct Clutch External Spline Plate (Steel)
5	388104-S	Retaining Ring
6	7F283	Direct Clutch Cylinder
7	7A548	Direct Clutch Piston Outer Seal
8	7C099	Direct Clutch Piston Inner Seal
9	7A262	Direct Clutch Piston
10	7F235	Direct Clutch Support and Spring
11	7B164	Direct Clutch Internal Spline Plates (Friction)
12	7F237	Direct Clutch Inner Bearing Washer
13	7F236	Direct Clutch Hub

SPECIAL SERVICE TOOL(S) REQUIRED

Description	Tool Number
Clutch Spring Compressor	T65L-77515-A
Direct Clutch Inner Lip Seal Protector	T80L-77234-A
Direct Clutch Outer Lip Seal Protector	T80L-77254-A

Disassembly

1. Remove the direct clutch hub (7F236).

2. Remove No. 7 direct clutch inner bearing (7F243) and direct clutch inner bearing washer (7F237).

   

3. Remove direct clutch pressure plate retaining ring. Remove and inspect clutch pack. Note the relation of clutch plates for assembly.

   

4. Using Clutch Spring Compressor T65L-77515-A compress the direct clutch support and spring (7F235). Remove retaining ring using expanding-type snap-ring pliers.

   

5. NOTE: Use air pressure if necessary to remove direct clutch piston.

   Remove direct clutch support and spring and direct clutch piston from direct clutch cylinder.

   

6. Remove direct clutch piston inner seal and direct clutch piston outer seal from direct clutch piston. Verify presence of check ball and that it moves freely.

   

Assembly

1. NOTE: Lubricate direct clutch piston inner seal and seal protector with petroleum jelly.

   Position Direct Clutch Inner Lip Seal Protector T80L-77234-A over direct clutch cylinder.

2. Position direct clutch piston inner seal over installer tool with the sealing lip facing down.

   

3. Install direct clutch piston outer seal. Note direction of sealing lip before installation. The lip should point toward bottom of direct clutch cylinder.

   

4. NOTE: Coat inner and outer direct clutch piston seals, clutch cylinder sealing area and piston inner sealing area with petroleum jelly.

   Install direct clutch piston in Direct Clutch Outer Lip Seal Protector T80L-77254-A.

   

5. Position tool in the direct clutch cylinder and push the direct clutch piston to the bottom of the direct clutch cylinder using even thumb pressure.

   

6. Install direct clutch support and spring and retaining ring using Clutch Spring Compressor T65L-77515-A.

   

7. Install clutch pack and direct clutch pressure plate.

   

8. NOTE: Dial Indicator with Bracketry TOOL-4201-C or equivalent may also be used for clearance check.

   Install direct clutch pressure plate retaining ring. Check clearance between direct clutch pressure plate retaining ring and direct clutch pressure plate using a feeler gauge. Direct clutch pressure plate should be held downward as the clearance is checked.

   

9. The six plate assembly clearance should be 1.57-2.16mm (0.062-0.085 inch).

   If the clearance is not within limits, install the correct size retaining ring and check the clearance. Selective retaining rings are available in the following thicknesses:

   SELECTIVE RETAINING RINGS

   1.27-1.37mm (0.050-0.054 Inch)
   1.62-1.72mm (0.064-0.068 Inch)
   1.98-2.08mm (0.078-0.082 Inch)
   2.33-2.43mm (0.092-0.096 Inch)

10. Install direct clutch inner bearing washer and No. 7 direct clutch inner bearing (black side up toward direct clutch hub).

    

11. Install direct clutch hub.

    

12. Install two output shaft to direct clutch cylinder seals. Ensure output shaft to direct clutch cylinder seals are properly lapped.

    

13. Install output shaft hub. Install retaining snap ring.

    

14. NOTE: Make sure output shaft to case seals are lapped properly.

    Install three output shaft to case seals.

    

15. Install No. 8 direct clutch outer bearing on direct clutch cylinder.

    

16. NOTE: Direct clutch cylinder may be installed after output shaft ring gear is installed to output shaft hub.

    Install direct clutch cylinder on output shaft.

    

17. Install output shaft ring gear and retaining snap ring on output shaft.

    

18. Install following components as an assembly:

    • Intermediate one-way clutch
    • Reverse clutch
    • Forward clutch

19. Install reverse clutch assembly on forward clutch assembly.

    

Torque Converter Checks

Torque Converter Leakage Check

If welds on the torque converter indicate leakage, remove the torque converter and make the following check.

Assemble Rotunda Torque Converter Leak Test Kit 014-R1067 or equivalent to the torque converter. Test torque converter for leaks, following the directions supplied with the detector kit.

One-Way Clutch Check

SPECIAL SERVICE TOOL(S) REQUIRED

Description	Tool Number
Converter Clutch Holding Tool	T77L-7902-R
Converter Clutch Torquing Tool	T76L-7902-C

1. Insert the Converter Clutch Holding Tool T77L-7902-R in one of the grooves in the stator thrust washer.

   

2. Insert the Converter Clutch Torquing Tool T76L-7902-C in converter pump drive hub to engage one-way clutch inner race.

3. Attach a torque wrench to the converter clutch torquing tool. With the converter clutch holding tool held stationary, turn the torque wrench counterclockwise. The torque converter one-way clutch should lock up and hold a 13 Nm (10 lb-ft) force. The torque converter one-way clutch should rotate freely in a clockwise direction until torquing tool contacts the holding tool. Try the clutch for lockup and hold in at least five different locations around the torque converter.

4. If the clutch fails to lock up and hold a 13 Nm (10 lb-ft) torque, replace the torque converter.

   One-Way Clutch Check

   

Stator to Impeller Interference Check

1. NOTE: Front pump support may remain in front pump support and gear (7A103) during this test.

   Position the front pump support on a bench with the spline end of the shaft pointing up.

2. Mount torque converter on the front pump support with the splines on the one-way clutch inner race, engaging the mating splines of the front pump support.

   

3. Hold the front pump support stationary, and try to rotate the torque converter counterclockwise. The torque converter should rotate freely without any signs of interference or scraping within the torque converter.

4. If there is an indication of scraping, the trailing edges of the stator blades may be interfering with the leading edges of the impeller blades. In such cases, replace the torque converter.

Stator to Turbine Interference Check

1. NOTE: Front pump support may remain in front pump support and gear during this test.

   Position the torque converter on the bench, front side down.

2. Install a front pump support to engage the mating splines of the front pump support shaft.

3. Install the forward clutch cylinder and shaft, engaging the splines with the rear clutch hub (7B067).

   

4. Hold the stator shaft stationary and attempt to rotate the rear clutch hub with the forward clutch cylinder and shaft. The turbine and torque converter clutch assemblies should rotate in both directions not exceeding maximum torque of 9.5 Nm (7 lb-ft) without any signs of metallic interference or scraping noise.

5. If interference exists, the stator front thrust washer may be worn, allowing the stator to hit the turbine. In such cases, the torque converter must be replaced.

   The converter crankshaft pilot should be checked for nicks or damaged surfaces that could cause interference when installing the torque converter into the crankshaft (6303). Check the converter front impeller hub for nicks or sharp edges that would damage the pump seal.

End Play Check

SPECIAL SERVICE TOOL(S) REQUIRED

Description	Tool Number
End Play Checking Tool	T80L-7902-A

1. Insert End Play Checking Tool T80L-7902-A into the torque converter pump drive hub until it bottoms.

2. Expand the sleeve in the turbine spline by tightening the threaded inner post until the tool is securely locked in to the spline.

   

3. Attach Dial Indicator with Bracketry TOOL-4201-C to the tool. Position the indicator button on the converter pump drive hub, and set the dial face at 0 (zero).

4. Lift the tool upward as far as it will go and note the indicator reading. The indicator reading is the total end play which the turbine and stator share. Replace the torque converter if the total end play exceeds the limits indicated in the chart below.

5. Loosen the threaded inner post to free the tool and remove the tool from the torque converter. Refer to the following chart for torque converter end play specifications.

   TORQUE CONVERTER END PLAY

   Converter End Play
   New or Rebuilt Torque Converter	Used Torque Converter
   0.355-1.04mm (0.014-0.041 Inch) Max.	0.355-1.87mm (0.014-0.074 Inch) Max.