Tools Required

1. Install the piston seal rings (1, 2, 3) onto the 4-5 clutch piston (4).
2. Lubricate the 4-5 balance piston seal (3), the piston ID and OD, and the seal rings (1, 2) with J 36850 ®.



3. Position the 1-2-3-4, 4-5 clutch housing (2) on the work table so that the rear of the housing is facing up.
4. Install the O-ring (1) into the bottom groove on the inner hub of the 1-2-3-4, 4-5 clutch housing (2).



5. Position the 4-5 clutch piston (3) on the work table so that the rear of the piston is facing up.
6. Align the 4-5 clutch balance piston (2) so that the rubber seal is facing down.
7. Install the 4-5 clutch balance piston (2) onto the 4-5 clutch piston (3).
8. Lubricate the rubber seals on the 4-5 clutch balance piston (2) with J 36850 ®.
9. Install the 4-5 clutch piston (3), with the 4-5 clutch balance piston (2) attached, into the 1-2-3-4, 4-5 clutch housing (4).
10. Make sure the 4-5 clutch piston (3) is seated on the 1-2-3-4, 4-5 clutch housing (4).
11. Push the 4-5 clutch balance piston (2) below the retaining ring groove on the 1-2-3-4, 4-5 clutch housing (4).
12. Install the retaining ring (1) into the 1-2-3-4, 4-5 clutch housing (4).
13. Make sure the retaining ring (1) is seated completely around the 1-2-3-4, 4-5 clutch housing (4).



14. Align the 4-5 clutch piston return spring assembly (2) so that the notches of the spring assemblies are facing and aligned with the tangs of the 4-5 clutch piston (4).
15. Install the 4-5 clutch piston return spring assembly (2) into the 4-5 clutch piston (4).
16. Align the 1-2-3-4 clutch piston housing (1) so that the rear of the housing is facing up.
17. Install the 1-2-3-4 clutch piston housing (1) into the 4-5 clutch piston (4).



18. Position the 1-2-3-4, 4-5 clutch housing (8) on the base of J 24204-2  (10) so that the rear of the housing is facing up.
19. Install J 43776-1 (7) onto the shaft of J 24204-2 with the bowl down.
20. Install the retaining ring (6) onto the surface of J 43776-2 (7).
21. Install the spring (5) of J 43776 onto the shaft of J 24204-2 .
22. Install J 43776-2 (4) onto the shaft of J 24204-2 .
23. Align a notch of J 43776-2 (4) with the ball of the 1-2-3-4 clutch piston housing.
24. Install the J 24204-2 ball bearing (3) and washer (2) onto the shaft of J 24204-2 .
25. Install the J 24204-2 wing nut (1) onto the shaft of J 24204-2 .
26. Compress the 4-5 clutch piston return spring assembly until the retaining ring groove on the inner hub of the 1-2-3-4, 4-5 clutch housing (8) is visible.
27. Install the retaining ring (6) into the rotating clutch housing inner hub.
28. Make sure the retaining ring (6) is seated all around the clutch housing (8).
29. Remove all J tools except for the base of J 24204-2 .



30. Install the 1-2-3-4 clutch piston ID seal ring (1) and the 1-2-3-4 clutch piston OD seal ring (2) onto the 1-2-3-4 clutch piston (3).
31. Lubricate the seal rings with J 36850 ®.



32. Position the 1-2-3-4, 4-5 clutch housing (3) on the work table so that the rear of the housing is facing up.
33. Align the 1-2-3-4 clutch piston (2) so that the spring indents are facing up.
34. Install the 1-2-3-4 clutch piston (2) into the 1-2-3-4 clutch piston housing (4).
35. Make sure the 1-2-3-4 clutch piston (2) is seated in the 1-2-3-4 clutch piston housing (4).
36. Align the 1-2-3-4 clutch piston return spring assembly (1) so that the springs are facing and aligned with the spring pockets of 1-2-3-4 clutch piston (2).
37. Install the 1-2-3-4 clutch piston return spring assembly (1) into the 1-2-3-4 clutch piston (2).



38. Position the 1-2-3-4, 4-5 clutch housing (7) on the base of J 24204-2  (8) so that the rear of the housing is facing up.
39. Install the retaining ring (6) into the inner hub of the 1-2-3-4, 4-5 clutch housing.
40. Install J 43777  (5) onto the shaft of J 24204-2  (8).
41. Center J 43777  (5) on the 1-2-3-4 clutch piston return spring assembly.
42. Install the J 43777 extension (4) onto the shaft of J 24204-2 .
43. Install the J 24204-2 ball bearing (3) and washer (2) onto the shaft of J 24204-2 .
44. Install the J 24204-2 wing nut (1) on the shaft of J 24204-2 .
45. Compress the 1-2-3-4 clutch piston return spring assembly until the retaining ring groove on the 1-2-3-4, 4-5 clutch housing inner hub is visible.
46. Install the retaining ring (6) into the 1-2-3-4, 4-5 clutch housing inner hub.
47. Remove tools J 24204-2 and J 43777 .



48. Position the 1-2-3-4, 4-5 clutch housing (3) on the work table so that the rear of the housing is facing up.
49. Lubricate the rubber seals on the 1-2-3-4 clutch balance piston (2) with J 36850 ®.
50. Align the 1-2-3-4 clutch balance piston (2) so that the rubber seal is facing down.
51. Install the 1-2-3-4 clutch balance piston (2) between the 1-2-3-4 clutch piston and the 1-2-3-4 clutch piston housing.
52. Press the 1-2-3-4 clutch balance piston (2) into the 1-2-3-4 clutch piston housing until the 1-2-3-4 clutch balance piston is below the retaining ring groove on the 1-2-3-4 clutch piston housing.
53. Install the retaining ring (1).
54. Make sure the retaining ring (1) is seated in the groove.



55. Install 2 overlap seal rings (4) onto the turbine shaft (3).
56. Position the turbine shaft (3) on the work table so that the rear of the shaft is facing up.
57. Align the 1-2-3-4, 4-5 clutch housing (2) with the rear of the turbine shaft (3) so that the rear of the clutch housing is facing up.
58. Install the 1-2-3-4, 4-5 clutch housing (2) onto the rear of turbine shaft (3).
59. Install the retaining ring (1) onto the turbine shaft (3).
60. Make sure the retaining ring (1) is seated completely around the turbine shaft (3).



61. Starting with a 1-2-3-4 clutch steel plate, alternately install six 1-2-3-4 clutch steel plates (2) and six 1-2-3-4 clutch fiber plates (1) onto the turbine shaft (3).




Important: There are 2 designs for the turbine shaft, 1-2-3-4 clutch hub, and the 1-2-3-4 clutch hub thrust bearing. The current components are not interchangeable with the former components. When replacing any one of the components with a current P/N in a former configuration, it will require updating to the current design for all the parts.

62. Determine which turbine shaft is being used in the transmission configuration. The current design (2) will have a single or double identification mark (3) on the shaft surface. The former design (1) will have a smooth shaft surface.




Important: Special tools J 44525-3 pressure plate (3) and J 44525-2 selector tool (4) are black for easy identification, and used with the former design. Special tools J 44525-4 selector tool (7) and J 44525-5 pressure plate (8) are silver plated for easy identification, and used with the current design. Do not use the pressure plate and selector tool from the J 44525 set if they are not matched in color.

63. Align J 44525-3 pressure plate (3) or J 44525-5 pressure plate (8), depending on model, with the turbine shaft so that the countersunk holes of J 44525-3 pressure plate (3) or J 44525-5 pressure plate (8) are facing up.
64. Install J 44525-3 pressure plate (3) or J 44525-5 pressure plate (8) onto the turbine shaft.
65. Align J 44525-1 ridge plate (2) with the turbine shaft so that the inner ridge of J 44525-1 ridge plate is facing down.
66. Slide the inner ridge of J 44525 -1 ridge plate (2) into the turbine shaft retaining ring groove.
67. Align the holes in J 44525-1 ridge plate (2) with the countersunk holes of J 44525-3 pressure plate (3) or J 44525-5 pressure plate (8).

Notice: Refer to Fastener Notice in the Preface section.

68. Hand install 2 bolts (1) of J 44525 into the holes of J 44525-1 ridge plate (2).

Tighten
Tighten the bolts to 1.8 N·m (16 lb in).





Important: The shift quality of the transmission depends heavily upon selecting the correct 1-2-3-4 clutch backing plate.

69. Perform the following procedure for each tab of J 44525-2 selector tool (1) or J 44525-4 selector tool (1):

69.1.

Place the flat surface, tabbed end of J 44525-2 selector tool (1) or J 44525-4 selector tool (1) onto the top surface of J 44525-3 pressure plate (3) or J 44525-5 pressure plate (3).

Important: At most, 2 of the different tabs will fit into the retaining ring groove.

69.2.

Try to slide the tabbed end of J 44525-2 selector tool (1) or J 44525-4 selector tool (1) into the retaining ring groove on the turbine shaft.

69.3.

If a tab fits into the retaining ring groove, record the 4-digit ID number located on the stem of J 44525-2 selector tool (1) that is associated with the tab or on the tab of J 44525-4 selector tool (1). Refer to Selective Components Specifications to determine the correct backing plate.

70. Select a 1-2-3-4 clutch backing plate as follows:

•	For the former design, if no tab of J 44525-2 selector tool (1) fits into the retaining ring groove, select the 1-2-3-4 clutch backing plate with ID No. 6221 or 8521.

•	For the current design, if no tab of J 44525-4 selector tool (1) fits into the retaining ring groove, select the 1-2-3-4 clutch backing plate with ID No. 2420.

•	If one or more tabs of J 44525-2 selector tool (1) or J 44525-4 selector tool (1) fit into the retaining ring groove, select the 1-2-3-4 clutch backing plate with an ID No. corresponding to the highest number recorded in the previous step.

71. Remove J 44525 from the turbine shaft.



72. Align the selected 1-2-3-4 clutch backing plate (3) so that the beveled edge of the backing plate is facing up.
73. Install the 1-2-3-4 clutch backing plate (3) onto the turbine shaft (4).
74. Install the retaining ring (2) onto the turbine shaft (4).
75. Lift the 1-2-3-4 clutch backing plate (3) and install the spiral retaining ring (1) into the 1-2-3-4 clutch backing plate (3).




Notice: Installing the thrust bearing assembly onto the rear of the turbine shaft in the wrong direction may cause permanent damage to the transmission. The blue stripe must be visible.

Important: There are 2 designs for the turbine shaft, 1-2-3-4 clutch hub, and the 1-2-3-4 clutch hub thrust bearing. The current components are not interchangeable with the former components. When replacing any one of the components with a current P/N in a former configuration, it will require updating to the current design for all the parts.

76. Align thrust bearing assembly (2) so that the blue stripe on the thrust bearing assembly is facing away from turbine shaft (3).
77. Install the thrust bearing assembly (2) into the turbine shaft (3).
78. Make sure the blue stripe on the thrust bearing assembly is visible.
79. Center the 1-2-3-4 clutch plates (4).
80. Install the 1-2-3-4 clutch drive hub (1) over the 1-2-3-4 clutch plates (4).
81. Make sure the 1-2-3-4 clutch drive hub (1) has seated on the thrust bearing assembly (2).




Notice: Installing the thrust bearing assembly onto the rear of the 1-2-3-4 drive hub in the wrong direction may cause permanent damage to the transmission. The blue stripe must be visible.

82. Align the thrust bearing assembly (2) so that the blue stripe on the thrust bearing assembly is facing away from the 1-2-3-4 clutch drive hub (3).
83. Install the thrust bearing assembly (2) onto the rear of the 1-2-3-4 clutch drive hub (3).
84. Make sure the blue stripe on the thrust bearing assembly is visible.
85. Align the 4-5 clutch drive hub (1) so that the smaller end is facing up.
86. Install the 4-5 clutch drive hub (1).



87. Starting with a 4-5 clutch steel plate, alternately install seven 4-5 clutch steel plates (2) and six 4-5 clutch fiber plates (1) into the 1-2-3-4, 4-5 clutch housing.



88. Align the tangs of the bronze thrust washer (1) with the holes in the 4-5 clutch drive hub (2).
89. Install the bronze thrust washer (1) onto the 4-5 clutch drive hub (2).



90. Align the input sun gear (3) so that the gear teeth of the sun gear face the concave face of the input sun gear flange (2).
91. Install the input sun gear (3) into the input sun gear flange (2).
92. Make sure the splines are engaged.
93. Hold the sun gear and align the double wide splines of the input sun gear flange (2) with the double wide spaces on the 1-2-3-4, 4-5 clutch housing (4).
94. Install the input sun gear (3) with the input sun gear flange (2) into the 1-2-3-4, 4-5 clutch housing (4).
95. Install the input sun gear external retaining ring (1) into the 1-2-3-4, 4-5 clutch housing (4).
96. Make sure the retaining ring is seated all the way around the 1-2-3-4, 4-5 clutch housing.
97. Remove tools J 24204-2 and J 43777 .