948TE Automatic Transmission (Service Information): Assembly

The work area, counter surfaces and tools must be thoroughly cleaned before attempting to assemble the transmission. All of the sub assemblies should be disassembled, cleaned, and assembled with new sealing components where applicable. The transmission housing should be clean and oil free before beginning this procedure. The B, C, D, and E-clutches should be properly measured and adjusted prior to assembling the transmission. If the transmission was contaminated with metallic material, all of the thrust bearings and roller bearing should be replaced. The bearing in the output gear support assembly is not serviceable. The output gear support assembly should be replaced if metal debris is present.

WARNING:

Always wear safety glasses when cleaning, disassembling and assembling the transmission/transaxle. Contents of the transmission/transaxle can become projectiles (e.g., springs, snap-rings, as well as metal and other debris). Failure to wear safety glasses may result in severe personal injury.

Place the transmission housing on a clean work surface with the open interior upward.
Place wooden blocks under the transmission to stabilize it for assembly.

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Install the split roller bearing (1) in position on the input shaft support.

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Install the outer seal-rings (1) in the lands in the input shaft support.

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Install the inner seal-rings (1) in the lands in the input shaft support.

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NOTE:
The seal lip will be facing upward when the piston is oriented as shown in the illustration.
Install the inner seal (2) on the C-clutch piston (1).

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NOTE:
The seal lip will be facing upward when the piston is oriented as shown in the illustration.
Install the outer seal (2) on the C-clutch piston (1).

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Lubricate the C-clutch piston seals with clean transmission fluid and install the C-clutch piston (1) in the transmission housing.

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Place the fingers of the C-clutch belleville spring (1) within the notches of the C-clutch piston (2).

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Place the (special tool #10504, Compressor, Spring) (1) over the C-clutch belleville spring (2) at the bottom of the transmission housing (3).
Position the transmission housing on a suitable arbor press using wooden blocks for support.

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Place tool (special tool #8228, Installer, Bearing) (3) over the input shaft support (tool 8901 with 10428 legs can also be used), compress the belleville spring to gain access to the snap-ring (1) groove.

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Install the snap-ring (1), stepped side down, to hold the C-clutch belleville spring in the transmission housing.

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The C-clutch piston snap ring ends (1) must be in the machined pocket of the housing as shown in the illustration.
Remove the transmission housing from the arbor press and position it on a clean work bench. Position wood blocks under transmission to stabilize it for assembly.

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NOTE:
Diesel and V-6 gas engine clutch pack shown, 4 cylinder gas engines will have one less friction disc (3) and steel plate (4).
Install the C-clutch steel plates (4) and friction discs (3).

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Install the C-clutch reaction plate (1) with raised bosses upward on top of the C-clutch disc and plate pack.

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Install the selective snap-ring in the groove in the transmission housing, abut the snap ring ends (2) to the anti- rotation protrusion (1) of the reaction plate.
NOTE:
Perform C-clutch measurements to verify that the correct selective snap ring is installed

Refer to ADJUSTMENTS .

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NOTE:
Perform D-clutch measurements to verify that the correct selective reaction plate (2) is installed

Refer to ADJUSTMENTS .
Install the correct thickness D-clutch selective reaction plate (2).
Starting with a friction plate (1), alternately install the friction (1) and steel plates (3) in to the case.

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Install the input shaft rear support selective thrust washer (1).

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Install the thrust bearing (1) onto the input shaft rear support.

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Align the teeth of the friction discs for the D- and C-clutches (1, 2) to facilitate the installation of the annulus gear 2, D and C clutch hubs, and input shaft assembly.
NOTE:
Before final assembly of the annulus gear 2, D and C-clutch hub and input shaft, measure the B-clutch to verify that proper selective reaction plate was installed. Refer to ADJUSTMENTS .

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Place the thrust bearing (1) in position on the C-clutch hub (2).

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Place the Annulus gear 2, D-clutch hub (1) in position on the C-clutch hub (2).

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Insert the sun gear 1 (1) into annulus gear 2 (2), D and C-clutch hub (3).

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Turn the annulus gear 2, D and C-clutch hub (1) over and place it on tool (special tool #9611, Plug, Differential End) (2) to hold the sun gear in position.

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Using a suitable snap-ring pliers (1), install the snap-ring (2) to hold the sun gear 1 to the annulus gear 2, D and C-clutch hub.

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Install the thrust washer. The thrust washer is a light press fit.

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Install NEW seal-rings (1) in the lands (2) on the input shaft (3).

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Insert the input shaft into the B-clutch (1) hub.
Using a suitable snap-ring pliers (3), install the snap-ring (2) to hold the input shaft/dog clutch A to the B-clutch (1) hub.
Install the annulus gear 2, D and C-clutch hub on the input shaft and B-clutch assembly.

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While not allowing the input shaft to slip inward, wriggle the annulus gear 2, D and C-clutch hubs and input shaft assembly (1) until they engage the D and C-clutch discs. If the input shaft slips inward, the B-clutch will come out of its retainer impeding proper installation.
NOTE:
A solid audible clunk will be heard if installed correctly.

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Place the belleville spring (1) in position on the transmission housing (2).

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Install NEW O-ring seal (2) in the D-clutch piston retainer (1).

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Install NEW outer lip seal (2) in the D-clutch piston (1).

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Install NEW inner lip seal (1) in the D-clutch piston (2).

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Install the D-clutch piston (2) in the retainer (1).

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Place the D-clutch piston (2) and retainer (1) assembly in the transmission housing over the D-clutch belleville spring. The fingers on the D-clutch piston rest against the D-clutch selective reaction plate.

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Position the transmission housing on a suitable arbor pressure using wooden blocks for support.
Using Tool (special tool #8901A, Pressing Tool) (with the pressure scale removed) (1) and legs (special tool #10428, Adapter, Pressing Tool), compress the belleville spring to gain access to the snap-ring groove in the transmission housing.
Install the snap-ring to hold the D-clutch piston retainer (2) into the transmission housing.
Remove the transmission housing from the arbor press and place the transmission housing on the clean work surface. Use wood blocks to stabilize the transmission.

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Insert the carrier gear 1 and 2 (1) annulus gear 2, D-clutch hub and input shaft assembly onto the annulus gear 2, D and C-clutch hub and input shaft assembly.

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Install the NEW O-ring seal (1) into the carrier gear 1 and 2.

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Install the annulus gear 3 (1) into the carrier gear 1 and 2.

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Install the snap-ring (1) to hold the annulus gear 3 (2) in the carrier gear 1 and 2.

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Place the thrust bearing (1) in position under the annulus gear 1 planetary hub (2).

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Install the annulus gear 1 planetary hub (1) into the carrier gear 1 and 2 (2).

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Place the trust bearing (1) onto the annulus gear 1 planetary hub (2).

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Using tool (special tool #6888, Installer, Seal) (2), and handle (special tool #C-4171, Driver Handle, Universal) (3) install the transfer gear bearing cone (1) onto the transmission housing.

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Install the annulus gear 4 (1) in the annulus gear 3 (2).

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Install a NEW thrust spacer (1) on the underside of the gear 4 planetary pinion carrier (2).

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Install a NEW thrust spacer (1) on the topside of the gear 4 planetary pinion carrier (2).

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Install the gear 4 planetary pinion carrier (1) into the annulus gear 4.

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Install the sun gear 3 and 4 and Dog Clutch-F (1) in the gear 4 planetary pinion carrier.

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Install the roller type thrust bearing (1) onto the sun gear 3 and 4 and Dog Clutch-F (2).
NOTE:
If a new transfer gear or transmission housing are being used, measurements must be performed to determine correct thickness for the bearing preload shims

Refer to STANDARD PROCEDURES .

If the bearings and races are replaced the factory installed preload shims do not require replacement.
If necessary, replace the bearings and races on the transfer gear.
Install the transfer gear into the transmission housing.

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Install the output gear support (1) into the gear 4 planetary pinion carrier (2).

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Install the E-clutch hub and shaft (1) in the output gear support (2).

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Install the thrust bearing (1) on the E-clutch (2) hub.

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NOTE:
Before installing the E-clutch, use a suitable screwdriver to align the grooves in the friction discs.

Wriggle the E-clutch (1) until all of the friction discs are fully engaged on the E-clutch hub and shaft.

NOTE:
The gap (2) between the E-clutch retainer and the output gear support will be very small once the E-clutch is fully seated (1).

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NOTE:
If a new differential (1) or transmission housing are being used, measurements must be performed to determine correct thickness for the bearing preload shims. If the bearings and races are replaced the factory installed preload shims do not require replacement. Refer to STANDARD PROCEDURES .
If necessary, replace the bearings and races on the differential (1).
Install the differential assembly (1) into the transmission housing.

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Install a NEW seal (1) in the port in the transmission housing.

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Install a NEW gasket (1) on the sealing surface of the transmission housing (2).
If necessary, replace the output seal using (special tool #2064700210, Installer, Quill Shaft Outer Seal) and the impeller hub seal.

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Guide the bellhousing (1) downward over the input and output shafts and onto the transmission housing (2).

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Rotate the output gear clockwise to assure guide pin (1) alignment.

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Rotate the output gear support (1) through the window (2) behind the valve body until the guide pin engages the receptacle hole in the bellhousing.
Engage the guide pins in the transmission housing into the receptacle holes in the bellhousing to assure proper alignment.
Install several bolts to hold the bell housing to the transmission housing. Tighten the bolts hand tight.
Position the transmission on the bench with the bellhousing facing outward.

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Install the bolts (1) with NEW seal washers to hold the bellhousing to the output gear support and tighten to the proper torque specifications. Refer to TORQUE SPECIFICATIONS .

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Install the bolts (1) to hold the bellhousing to the transmission housing and tighten to the proper torque specifications. Refer to TORQUE SPECIFICATIONS .

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Install NEW O-rings on both ends of the fluid transfer tubes.
Install the fluid transfer tubes (1) in the transmission housing.
Place the valve body with the internal harness near the transmission.

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Insert the speed sensors (1) into the transmission with the wire harness connected.

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Install the speed sensor screw (1) to hold the speed sensors to the transmission housing and tighten to the proper torque specifications. Refer to TORQUE SPECIFICATIONS .

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Place the Transmission Range Sensor (TRS) (1) in position on the transmission with the wire harness connected.

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Install the TRS screw (1) to hold the TRS to the transmission housing and tighten to the proper torque specifications. Refer to TORQUE SPECIFICATIONS .
Align the valve body with the fluid transfer tubes.

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Guide the manual lever cam (1) into the slot (2) on the manual valve.
Firmly press the valve body inward until the O-rings on the fluid transfer adapters engage into receptacle holes on the valve body.

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Install the valve body bolts (1) to hold the valve body to the transmission housing and tighten to the proper torque specifications. Refer to TORQUE SPECIFICATIONS .

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NOTE:
A light coating of assembly lube can be applied to the O-ring seals (2) of the valve body wire harness connector to ease installation.
Install NEW O-ring seals (2) on the valve body wire harness connector (1).

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Place the valve body cover pan (1) in position on the transmission.
NOTE:
Be certain that the flat side (2) on the valve body wire harness connector (3) is aligned with the flat spot on the valve body cover pan (1).
Insert the valve body wire harness connector (3) into the opening on the inside of valve body cover pan (1).

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Press the transmission solenoid connector inward until the retainer clip groove (1) is exposed on the outside of the valve body cover pan.
Install the clip (2) to hold the transmission solenoid connector in the valve body cover pan.

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NOTE:
The gasket seal (1) and valve body cover pan (2) are replaced together. If either are damaged you must replace the valve body cover pan/gasket as an assembly.
Make sure the gasket seal (1) is in the groove around the sealing surface of the valve body cover pan (2).

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Install the valve body cover pan and valve body cover pan bolts (1) to hold the valve body cover pan to the transmission housing and tighten to the proper torque specifications. Refer to TORQUE SPECIFICATIONS .