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Assembly Tools Required: Turbine Shaft Holder T88C-77000-KH Converter Seal Replacer T88C-77000-BH 1. Align the bearing cover with guide bolts. Press the bearing cover into the torque converter housing. 2. Tighten the torque converter bearing cover bolts to 11-14 Nm (8-10 lb-ft). 3. Install the idler gear and output gear as an assembly by lightly tapping them in with a hammer. 4. Install the output gear bearing housing onto the torque converter housing. 5. Align the groove on the idler shaft with the mark on the bearing housing. 6. Install the output gear bearing housing bolts and tighten to 19-26 Nm (14-19 lb-ft). 7. Tap a new roll pin into the bearing housing using a 5/32-inch pin punch and hammer. 8. Install the parking pawl and shaft. 9. Install the shaft spring and snap clip. 10. Install the parking pawl actuator support with new bolts. Tighten the parking pawl actuator bolts to 11-14 Nm (8-10 lb-ft). 11. Install the detent lever and return spring. 12. Install the parking assist lever. 13. Install the detent lever holder and bolt. Tighten the detent lever holder bolt to 8-11 Nm (69-95 lb-in). 14. Install the manual shaft. 15. Install the detent plate, washer, and nut securing the manual shaft. Tighten the manual shaft nut to 41-55 Nm (30-41 lb-ft). 16. Install the differential assembly. 17. Install the output shell to the output gear. 18. Apply a thin coat of silicone sealant to the contact surfaces of the torque converter housing and transaxle housing.

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CAUTION: The torque converter must be replaced if a transmission failure resulted in large amounts of metal or fiber contamination in the fluid. The torque converter is a hydraulic device that couples the engine crankshaft to the transmission. The torque converter consists of an outer shell with an internal turbine (1), a stator (3), an overrunning clutch, an impeller (2), and an electronically applied converter clutch. The converter clutch provides reduced engine speed and greater fuel economy when engaged. Clutch engagement also provides reduced transmission fluid temperatures. The converter clutch engages in third through fifth gears. The torque converter hub drives the transmission oil (fluid) pump. See Fig. 267. A turbine damper (6) has been added for some applications to help improve vehicle noise, vibration, and harshness (NVH) characteristics. The torque converter is a sealed, welded unit that is not repairable and is serviced as an assembly. IMPELLER

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NOTICE: Whenever a transmission has been disassembled to install new parts, the transmission fluid cooler tubes must be cleaned and backflushed using a suitable torque converter/fluid cooler cleaner. A new Oil-To-Air (OTA) transmission fluid cooler must also be installed. When internal wear or damage has occurred in the transmission, metal particles, clutch plate material or band material may have been carried into the torque converter and fluid cooler. These contaminants are a major cause of recurring transmission concerns and must be removed from the system before the transmission is put back into service. NOTE: After the transmission is removed for a major overhaul, it is important to completely clean all transmission components, including torque converter, cooler inlet tube, main control valve body, clutches and all coasting booster valve shuttle balls after any transmission service that generates contamination. These contaminants are a major cause for recurring transmission concerns and must be removed from the system before the transmission is returned to service. The cleaning of foreign material from the direct clutch check ball is often omitted. This omission can lead to a repeat servicing of the transmission. A new Oil-To-Air (OTA) transmission fluid cooler must be installed under the following condition. For additional information, refer to Section 307-02. Evidence of broken transmission components or transmission fluid contamination found due to the following transmission or converter failure modes: Major metallic failure Multiple clutches or clutch plate failure Sufficient component wear which results in metallic contamination 1. Disconnect the battery ground cable. For additional information, refer to Section 414-01. 2. WARNING: Before servicing a vehicle equipped with a fire suppression system, depower the system by following the procedure in Section 419-03. Failure to follow the instructions may result in serious personal injury. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02. 3. NOTE: Only if transmission disassembly or replacement is required, drain the transmission fluid. For additional information, refer to Fluid Pan, Gasket and Filter in this section. Drain the transmission fluid. Loosen the transmission fluid pan bolts and allow the transmission fluid to drain. After transmission fluid has drained remove the bolts and the pan and drain the remaining transmission fluid that is in the pan. 4. Install the transmission fluid pan and the old transmission fluid pan gasket. 1. Position the transmission fluid pan gasket. 2. Position the transmission fluid pan. 5. NOTE: To maintain the initial driveshaft balance, mark the rear driveshaft yoke and the axle pinion flange so they can be installed in their original positions. Mark the rear driveshaft yoke and the axle pinion flange and remove the 4 bolts.

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All vehicles 5. Remove the radiator. For additional information, refer to Section 303-03A. 6. If equipped, remove the A/C condenser core. For additional information, refer to Section 412-03. 7. If equipped, disconnect the climate control vacuum connector. All except supercharged vehicles 8. Remove the bolts and position the power steering reservoir aside. All vehicles 9. Disconnect the exhaust manifold to exhaust gas recirculation (EGR) valve tube lower fitting and remove the tube. 10. Disconnect the generator electrical connections and remove the generator. 11. NOTE: Battery removed for clarity. Disconnect the 38-pin, 42-pin and 16-pin electrical connectors. 12. Disconnect the electrical connector and remove the connector from the bracket. 13. Remove the bolts and the connector bracket cover. 14. Remove the 38-pin connector from the bracket. 15. Disconnect the starter relay electrical connections and position the cables aside. 16. Remove the bolts and connector bracket. 17. Compress the holding tabs and disconnect the heater hoses from the heater core. 18. Raise and support the vehicle. For additional information, refer to Section 100-02. 19. If equipped, remove the skid plate. 1. Remove the bolts. 2. Remove the skid plate. 20. Remove the A/C compressor, if equipped. For additional information, refer toSection 412-03. 21. Remove the drain plug and drain the engine oil. All except supercharged vehicles 22. Remove the starter motor. For additional information, refer to Section 303-06. 23. If equipped, install the A/C line (muffler) bracket. Manual transmission vehicles 24. Remove the clutch disc and pressure plate. For additional information, refer to Section 308-01. Automatic transmission vehicles 25. Remove the transmission fluid cooler tubes from the block mounted clip. 26. Remove the bolts and the flexplate inspection cover. 27. Remove the cylinder block opening cover. 28. Remove the torque converter-to-flexplate nuts. Discard the nuts. 29. NOTE: The upper two transmission-bolts will be removed later. Remove the lower five transmission-to-engine bolts. 30. Remove the nut and the transmission oil filler tube.

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NOTE: Thoroughly clean the exterior of the transmission and dry it with compressed air. 1. NOTE: Position the transmission in Bench Mounted Holding Fixure in its normal upright position. Install Bench Mounted Holding Fixure on the transmission case. Position a drain pan under the transmission. 2. CAUTION: The torque converter (7902) is heavy. Be careful not to drop it. Remove the torque converter. Drain the fluid from the torque converter. 3. Remove the oil pump shaft (7B328). 4. Remove and discard the converter turbine shaft seal. 5. Install Turbine Shaft Holder. 6. Remove the fluid level indicator (7A020) and oil filler tube (7A228). 1. Remove the fluid filler tube bolts. 2. Remove the fluid level indicator and oil filler tube. 7. Remove the turbine shaft speed (TSS) sensor. 1. Remove the TSS sensor bolt. 2. Remove the TSS sensor. 8. Remove the vehicle speed sensor (VSS). 1. Remove the bolt. 2. Remove the VSS.