948TE - 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 clutch Ees 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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1 - Split Roller Bearing
Install the split roller bearing in position on the input shaft support.

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1 - Outer Seal-Rings
Install the outer seal-rings in the lands in the input shaft support.

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1 - Inner Seal-Ring
Install the inner seal-rings in the lands in the input shaft support.

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1 - Clutch C Piston

2 - Inner Seal

NOTE:
The seal lip will be facing upward when the piston is oriented as shown in the photo.
Install the inner seal on the clutch C piston.

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1 - Clutch C Piston

2 - Outer Seal

NOTE:
The seal lip will be facing upward when the piston is oriented as shown in the photo.
Install the outer seal on the clutch C piston.

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1 - Clutch C Piston

2 - Pliers
Lubricate the clutch C piston seals with clean transmission fluid and install the clutch C piston in the transmission housing.

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1 - Clutch C Belleville Spring

2 - Clutch C Piston

Place the fingers of the clutch C belleville spring within the notches of the clutch C piston.

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1 - Compressor, Spring 10504

2 - Clutch C Belleville Spring

3 - Transmission Housing

Place the tool over the clutch C belleville spring at the bottom of the transmission housing.
(Special tool #10504, Compressor, Spring)

Position the transmission housing on a suitable arbor press using wooden blocks for support.

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1 - Stepped Snap-Ring Groove

2 - Compressor, Spring 10504

3 - Installer, Bearing 8228

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

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

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1 - Snap-Ring Ends in Correct Location
The clutch C piston snap-ring ends must be in the machined pocket of the housing as shown.

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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1 - Clutch C Select Snap-Ring

2 - Clutch C Reaction Plate

3 - Friction Disc

4 - Steel Plate

NOTE:

Diesel and V-6 gas engine clutch pack shown, 4 cylinder gas engines will have one less friction disc and steel plate.

Install the clutch C steel plates and friction discs.

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1 - Clutch C Reaction Plate
Install the clutch C reaction plate with raised bosses upward on top of the clutch C disc and plate pack.

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1 - Snap-Ring Ends

2 - Anti-Rotation Protrusion

Install the selective snap-ring in the groove in the transmission housing, abut the snap-ring ends to the anti- rotation protrusion of the reaction plate.

NOTE:

Perform clutch C measurements to verify that the correct selective snap-ring is installed.

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1 - Friction Disc

2 - Clutch D Select Reaction Plate

3 - Steel Plate

4 - Belleville Spring

5 - Clutch D Snap-Ring

NOTE:

Perform clutch D measurements to verify that the correct selective reaction plate is installed.

Install the correct thickness clutch D selective reaction plate.
Starting with a friction plate, alternately install the friction and steel plates in to the case.

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1 - Input Shaft Rear Support Selective Thrust Washer

2 - Thrust Surface
Install the input shaft rear support selective thrust washer.

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1 - Thrust Bearing
Install the thrust bearing onto the input shaft rear support.

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1 - Clutch D

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

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1 - Thrust Bearing

2 - Clutch C Hub
Place the thrust bearing in position on the clutch C hub.

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1 - Annulus Gear 2, Clutch D Hub

2 - Clutch C Hub

Place the Annulus gear 2, clutch D hub in position on the clutch C hub.

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1 - Sun Gear 1

2 - Annulus Gear 2, Clutch D Hub

3 - Clutch C Hub

Insert the sun gear 1 into annulus gear 2, clutch D and clutch C hub.

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1 - Annulus Gear 2, Clutch D and Clutch C Hub

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

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1 - Snap-Ring Pliers

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

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1 - Thrust Washer

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

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1 - Seal-Rings

2 - Seal-Ring Lands

3 - Input Shaft

Install NEW seal-rings in the lands on the input shaft.

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1 - Clutch B Hub

2 - Snap-Ring

3 - Snap-Ring Pliers

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

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

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1 - Belleville Spring

2 - Input Shaft Assembly
Place the belleville spring in position on the transmission housing.

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1 - Clutch D Piston Retainer

2 - O-Ring Seal
Install NEW O-ring seal in the clutch D piston retainer.

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1 - Inner Lip Seal

2 - Outer Lip Seal
Install NEW inner and outer lip seal in the clutch D piston.

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1 - Clutch D Piston Retainer

2 - Clutch D Piston
Install the clutch D piston in the retainer.

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1 - Clutch D Piston Retainer

2 - Clutch D Piston

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

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1 - Pressing Tool 8901A With Adapter, Pressing Tool 10428

2 - Clutch D Piston Retainer

Position the transmission housing on a suitable arbor pressure using wooden blocks for support.
Using the pressing tool (with the pressure scale removed) and legs adapter, compress the belleville spring to gain access to the snap-ring groove in the transmission housing.
(Special tool #8901A, Pressing Tool) and (special tool #10428, Adapter, Pressing Tool)
Install the snap-ring to hold the clutch D piston retainer 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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1 - O-Ring
Install the NEW O-ring seal into the carrier gear 1 and 2.

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1 - Annulus Gear 3
Install the annulus gear 3 into the carrier gear 1 and 2.

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1 - Snap-Ring

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

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1 - Thrust Bearing

2 - Annulus Gear 1 Hub
Place the thrust bearing in position under the annulus gear 1 hub.

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1 - Annulus Gear 1 Hub

2 - Pinion Gear 1 and Carrier 2
Install the annulus gear 1 hub into the pinion gear 1 and 2.

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1 - Thrust Bearing

2 - Annulus Gear 1 Hub

Place the trust bearing onto the annulus gear 1 hub.

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1 - Transfer Gear Bearing Cone

2 - Installer, Seal 6888

3 - Driver Handle, Universal C-4171

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

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1 - Annulus Gear 4 and Pinion Gear Carrier 3

2 - Annulus Gear 3
Install the annulus gear 4 and pinion gear carrier 3 in the annulus gear 3.

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1 - Thrust spacer

2 - Pinion Gear Carrier 4
Install a NEW thrust spacer on the underside of the pinion gear carrier 4.

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1 - Thrust Spacer

2 - Pinion Gear Carrier 4
Install a NEW thrust spacer on the topside of the pinion gear carrier 4.

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1 - Pinion Gear Carrier 4
Install the pinion gear carrier 4 into the annulus gear 4.

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1 - Sun Gear 3 and 4 and Dog Clutch-F
Install the sun gear 3 and 4 and Dog Clutch-F in the pinion gear carrier 4.

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1 - Thrust Bearing

2 - Sun Gear 3 and 4 and Dog Clutch-F
Install the roller type thrust bearing onto the sun gear 3 and 4 and Dog Clutch-F.
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 INPUT SHAFT END PLAY MEASUREMENT . 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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1 - Output Gear Support

2 - Pinion Gear Carrier 4
Install the output gear support into the pinion gear carrier 4.

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1 - Clutch E Hub

2 - Output Gear Support
Install the clutch E hub and shaft in the output gear support.

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1 - Thrust Bearing

2 - Clutch E Assembly
Install the thrust bearing on the clutch E hub.

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1 - Clutch E Retainer

2 - Gap

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

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

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

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1 - Differential Assembly

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

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1 - Seal
Install a NEW seal in the port in the transmission housing.

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1 - Gasket

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

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1 - Bellhousing

2 - Transmission Housing
Guide the bellhousing downward over the input and output shafts and onto the transmission housing.

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1 - Guide Pin
Rotate the output gear clockwise to assure guide pin alignment.

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1 - Output Gear Support

2 - Output Gear Support Window
Rotate the output gear support through the window 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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1 - Bellhousing to Output Gear Support Bolts
Install the bolts with NEW seal washers to hold the bellhousing to the output gear support and tighten to the proper specifications. Refer to TORQUE SPECIFICATIONS .

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1 - Bellhousing Bolts
Install the bellhousing bolts and tighten to the proper specifications. Refer to TORQUE SPECIFICATIONS .

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

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1 - Speed Sensor
Insert the speed sensors into the transmission with the wire harness connected.

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1 - Speed Sensor Screw
Install the speed sensor screw and tighten to the proper specifications. Refer to TORQUE SPECIFICATIONS .

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

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1 - Transmission Range Sensor (TRS) Screw
Install the TRS screw and tighten to the proper specifications. Refer to TORQUE SPECIFICATIONS .
Align the valve body with the fluid transfer tubes.

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1 - Manual Lever Cam

2 - Manual Valve
Guide the manual lever cam into the slot 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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1 - Valve Body Bolts

Install the valve body bolts and tighten to the proper specifications. Refer to TORQUE SPECIFICATIONS .

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1 - Valve Body Wire Harness Connector

2 - Valve Body Wire Harness Connector O-Rings

NOTE:

A light coating of assembly lube can be applied to the O-rings of the valve body wire harness connector to ease installation.

Install NEW O-rings on the valve body wire harness connector.

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1 - Transmission Oil Pan

2 - Flat Side of Valve Body Wire Harness Connector and Flat Side of Valve Body Oil Pan

3 - Valve Body Wire Harness Connector

Align the flat side of the valve body wire harness connector with the flat side of the valve body oil pan and insert the valve body wire harness connector into the transmission oil pan.

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1 - Transmission Solenoid Connector

2 - Clip
Press the transmission solenoid connector inward until the retainer clip groove is exposed on the outside of the transmission oil pan.
Install the clip to hold the transmission solenoid connector in the transmission oil pan.

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1 - Transmission Oil Pan Gasket

2 - Transmission Oil Pan

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

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1 - Transmission Oil Pan Bolts
Install the transmission oil pan and transmission oil pan bolts to hold the transmission oil pan to the transmission housing and tighten to the proper specifications. Refer to TORQUE SPECIFICATIONS .