Remove and discard the bottom pan oil filter, as shown in Figure 36. While holding it in position, turn the assembly over and place it back on the foot press as shown in Figure 94. Ensure that orifice cup plugs and ball capsules are in place and functional. Install the proper pump cover to converter housing retaining bolts in their proper locations as shown in Figure 68, and hand tighten only. Note: These tools are mandatory to prevent damage to the 2nd clutch piston seals. Install the number 7 checkball spring 302 in the location shown in Figure 169. Install the seven converter housing to case bolts, as shown in Figure 192.
Install output shaft bearing thrust washer onto the output shaft, as shown in Figure 209. Remove and discard the extension housing gasket, as shown in Figure 32. Turn the assembly over and install the thrust washer, as shown in Figure 114, Retain the thrust washer with small amount of Trans-Jel®. Set the completed converter housing and pump assembly aside for the final assembly process. Using Figure 74 as a guide dis-assemble the direct and reverse clutch housing.
We have provided you with an illustration to identify the location of the nine different clutch packs, the four mechanical sprag clutches and a component application chart in Figures 2 and 3. The direct clutch housing 404 also serves as the reverse clutch piston and has a molded seal as shown in Figure 75. This is the coast clutch pack travel, and travel shoud be as follows: 0. Install thrust bearing 559 onto output shaft, as shown in Figure 158, and retain with small amount of Trans-Jel®. Measure the clearance between the rotor and the straight edge, as shown in Figure 61. Remove and discard bottom oil pan gasket, as shown in Figure 35.
Upshifts and downshifts all occur automatically, except 5th gear is prohibited. Remove the lip seal protectors. Install the coast clutch backing plate into the coast clutch housing, as shown in Figure 90. This manual is a companion manual to the 4T65-E Blue assembly and disassembly manual and is most helpful during a rebuild. Remove the J-45135 lip seal protector.
Changing of the gear ratios and application of the converter clutch is controlled automatically. Remove the valve body assembly from the case as shown in Figure 39, and set aside for the component rebuild section. Install oil pump slide seal support 217 into slide, as shown in Figure 64, and retain with a small amount of Trans-Jel®. For clarity this manual will address the disassembly and assembly procedures for the 8L90 and is intended for use by the professional technician. Upshifts and downshifts all occur automatically, except 4th and 5th is prohibited. Ensure that internal wiring harness is not rubbing on any part of the oil pan, as you put it on the case. Inspect the direct clutch piston ball capsule for proper operation, as shown in Figure 73.
However, words commonly associated with the specific transaxle or transmission function have been defined in a Glossary rather than within the text of this book. Note: Lined side must be installed facing up as shown in Figure 126. The fluid should trickle from the plugs opening. Manual Fourth can be selected at any vehicle speed but will downshift into 4th gear only if vehicle speed is low enough not to over-rev the engine. Remove the lip seal protectors.
Inspect the low sprag assembly for proper hold and freewheel operation See Figure 128. Remove the J-45136 lip seal protector. Remove the center support assembly from the case, as shown in Figure 52, and set aside for the component rebuild section. R N - Neutral position enables the engine to start and operate without driving the vehicle. Torque all four of the accumulator housings to 11 Nm 8 ft. Place forward clutch housing on a foot press and install J-45134 seal ptotector on forward clutch housing, as shown in Figure 86. Install the seven extension housing bolts, as shown in Figure 209.
You may also continue purchasing additional items from our auctions or eBay store. Install the reverse clutch backing plate on top of the last inside spline plate, as shown in Figure 82. Remove the oil filter spacer, if used, and store in a safe place for transmission re-assembly See Figure 36. Also, the pressure control solenoid is turned off which will increase line pressure to the maximum. This transmission manual contains service and identification; troubleshooting, transmission removal and installation information, transmission disassemble and assembly information, transmission valve body and clutch drum components, pressure charts and torque specifications. Using a universal spring compressor or a foot press, compress the bellville spring and install the snap ring See Figures 77 and 78.
Note: Once again, ensure that manual valve moves freely. The Hydra-matic 5L40-E is a fully automatic, five forward speed, rear wheel drive, fully electronic controlled transmission, with a maximum torque rating of 360 Nm. Technicians or other persons not having automatic transaxle or transmission know-how may find this publication somewhat technically complex if additional instruction is not provided. Install the intermediate sprag thrust bearing, as shown in Figure 112 with the lip facing up, on top of the thrust washer. Inspect all converter housing and pump parts thoroughly and replace as necessary. Dis-assemble the rear valve body assembly using Figure 165 as a guide. The finished assembly should look like illustration in Figure 66.
Remove input speed sensor retaining bolt and input speed sensor, as shown in Figure 42. Remove and discard the extension housing driveshaft yoke seal, as shown in Figure 31 15. Note: Lined side must be installed facing up as shown in Figure 119. All accumulator housings are the same. Install dial indicator on top of forward clutch backing plate, as shown in Figure 96, and zero the dial indicator. Dis-assemble the forward sprag assembly using Figure 99 as a guide. Install the J-45130-3 re-sizing tool, as shown in Figure 97.