545RFE - Service Information: Assembly

NOTE: Clean and inspect all components. Replace any components which show evidence of excessive wear or scoring.

Fig 1: Identifying Seal And Tool (8253)

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1. Install the cooler filter bypass valve. Torque the bypass valve to specification. The valve uses a tapered pipe thread and excessive torque can damage the transmission case. Tighten the cooler filter bypass valve to 4.5 N.m (40 in. lbs.). 
2. Install a new selector shaft seal (1) using Seal Installer 8253 (2). 
   Fig 2: Identifying Manual Shaft Lever

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3. Install the manual selector shaft and retaining screw. Tighten the manual selector shaft retaining screw to 28 N.m (250 in. lbs.). 
4. Install the manual shift lever (1) onto the manual selector shaft. Torque the retaining cross-bolt to 16 N.m (140 in. lbs.). 
   Fig 3: Identifying Guide, Snap Ring, Shaft, Spring, Park Pawl, Manual Shaft Lever & Park Rod

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5. Install the park pawl (5), spring (4), and shaft (3). 
6. Install the park rod (7) and e-clip. 
7. Install the park rod guide (1) and snap-ring (2). 
   Fig 4: Identifying Tool (8254) And Seal

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8. Install a new dipstick tube seal (2) using Seal Installer 8254 (1). 
   Fig 5: Identifying Snap Ring, Plate, Disc And Reaction Plate

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   NOTE: Before final assembly of transmission centerline, the 2C/4C clutch components should be installed into position and measured as follows:
9. Install the 2C reaction plate (4) into the transmission case. 
10. Install the 2C clutch pack (2, 3) into the transmission case. 
11. Install the flat 2C clutch snap-ring (1) into the transmission case. 
    Fig 6: Identifying Snap Ring And 4C Clutch Retainer/Bulkhead

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12. Install the 4C retainer/bulkhead (2) into the transmission case. Make sure that the oil feed holes are pointing toward the valve body area. 
13. Install the 4C retainer/bulkhead tapered snap ring (1) into the transmission case. Make sure that the open ends of the snap-ring are located in the case opening toward the valve body area. 
14. Using a feeler gauge through the opening in the rear of the transmission case, measure the 2C clutch pack clearance between the 2C reaction plate and the transmission case at four different points. The average of these measurements is the 2C clutch pack clearance. The correct clutch clearance is 0.455-1.335 mm (0.018-0.053 in.). The reaction plate is not selective. If the clutch pack clearance is not within specification, the reaction plate, all the friction discs, and steels must be replaced. 
15. Remove the 4C retainer/bulkhead and all of the 2C clutch components from the transmission case. 
    Fig 7: Identifying Low/Reverse Overrunning Clutch Assembly And Snap Ring

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16. Install the low/reverse clutch assembly (1). Make sure that the oil feed hole points toward the valve body area and that the bleed orifice is aligned with the notch in the rear of the transmission case. 
17. Install the snap-ring (2) to hold the low/reverse clutch retainer into the transmission case. The snap-ring is tapered and must be installed with the tapered side forward. Once installed, verify that the snap-ring is fully seated in the snap-ring groove. 
18. Air check the low/reverse clutch and verify correct overrunning clutch operation. 
    Fig 8: Identifying Input/Reverse Planetary Assembly And Bearing Number 9 And 12

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19. Install the number 12 thrust bearing (3) over the output shaft and against the rear planetary gear set. The flat side of the bearing goes toward the planetary gearset and the raised tabs on the inner race should face the rear of the transmission. 
20. Install the reverse/input planetary assembly (1) through the low/reverse clutch assembly. 
    Fig 9: Identifying Park Sprag Gear

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21. Install the park sprag gear (1) onto the output shaft. 
    Fig 10: Identifying Snap Ring

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22. Install the snap-ring (1) to hold the park sprag onto the output shaft. 
    Fig 11: Identifying Snap Ring, Plate, Disc And Reaction Plate

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23. Install the 2C reaction plate (4) into the transmission case. 
24. Install the 2C clutch pack (2, 3, 4) into the transmission case. 
    Fig 12: Exploded View Of Thrust Plate, Thrust Bearings, Reaction Planetary Carrier, Reaction Sun Gear & Reaction Annulus

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25. Install the number 8 thrust bearing (1) inside the reaction carrier with the outer race against the reaction planetary carrier (3). 
26. Install the reaction planetary gear set and the number 9 thrust bearing (2), with the inner race against the reaction planetary carrier (3), into the transmission case. 
27. Install the flat 2C clutch snap-ring into the transmission case. 
28. Install the reaction sun gear (4) into the reaction planetary gear set. Make sure the small shoulder is facing the front of the transmission. 
29. Install the number 7 thrust bearing (5) onto the reaction sun gear (4) with the inner race against the sun gear. 
    Fig 13: Identifying Locating Lug And Thrust Plate

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30. Install the output shaft selective thrust plate (2) onto the reaction annulus with the oil grooves facing the annulus gear and the lugs (1) and notches aligned as shown. 
    Fig 14: Exploded View Of Thrust Plate, Thrust Bearings, Reaction Planetary Carrier, Reaction Sun Gear & Reaction Annulus

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31. Install the number 6 thrust bearing (7) against the output shaft selective thrust plate (6) with the flat side against the thrust plate and the raised tabs on the inner race facing the front of the transmission. 
32. Install the reaction annulus (8) into the reaction planetary gear set. 
    Fig 15: Identifying 4C Clutch Retainer/Bulkhead And Snap Ring

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33. Install the 4C retainer/bulkhead (2) into the transmission case. Make sure that the oil feed holes are pointing toward the valve body area. Rotate the reaction annulus during the installation of the 4C retainer/bulkhead to ease installation. 
34. Install the 4C retainer/bulkhead tapered snap-ring (1) into the transmission case with the taper toward the front of the case. Make sure that the open ends of the snap-ring are located in the case opening toward the valve body area. 
35. Air check the 2C and 4C clutch operation. 
    Fig 16: Measuring Output Shaft End Play Using Special Tools

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36. Using Alignment Plate 8261 (1), Adapter 8266-17 from End-Play Tool Set 8266 (2) and Dial Indicator C-3339 (3), measure and record the output shaft end play. The correct output shaft end play is 0.22-0.55 mm (0.009-0.021 in.). Adjust as necessary. Install the chosen output shaft selective thrust plate and remeasure end play to verify selection. 
37. Apply a bead of RTV silicone and install the extension/adapter housing onto the transmission case. 
38. Install and torque the bolts to hold the extension/adapter housing onto the transmission case. The correct torque is 54 N.m (40 ft. lbs.). 
    Fig 17: Identifying Input Clutch Assembly, Thrust Plate (Select) And Thrust Bearing Numbers 1 And 5

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39. Install the number 5 thrust bearing (1) and selective thrust plate (2) onto the 4C retainer/bulkhead. Be sure that the outer race of the bearing is against the thrust plate. 
40. Install the input clutch assembly (3) into the transmission case. Make sure that the input clutch assembly is fully installed by performing a visual inspection through the input speed sensor hole. If the tone wheel teeth on the input clutch assembly are centered in the hole, the assembly is fully installed. 
41. Install the number 1 thrust bearing (4) with the outer race up in the pocket of the input clutch assembly. 
    Fig 18: Identifying Oil Pump Case Bolt And Oil Sump

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42. Install the oil pump (2) into the transmission case. 
43. Install the bolts (1) to hold the oil pump into the transmission case. Tighten the oil pump bolts to 28 N.m (250 in. lbs.). 
    Fig 19: Measuring Input Shaft End Play Using Special Tools

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44. Using Adapter 8266-1 from End-Play Tool Set 8266 (1) and Dial Indicator C-3339 (2), measure and record the input shaft end play. The correct end play is 0.46-0.89 mm (0.018-0.035 in.). Adjust as necessary. Install the chosen thrust plate on the number 5 thrust bearing and remeasure end play to verify selection. 
    NOTE: When measuring the input shaft end play, two "stops" will be felt. When the input shaft is pushed inward and the dial indicator zeroed, the first "stop" felt when the input shaft is pulled outward is the movement of the input shaft in the input clutch housing hub. This value should not be included in the end play measured value and therefore must be recorded and subtracted from the dial indicator reading.
    Fig 20: Identifying Inner Snap Ring, Transmission Front Cover And Outer Snap Ring

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45. Install the transmission front cover (2) into the transmission case. 
46. Install the outer snap-ring (3) to hold the transmission front cover (2) into the transmission case. 
47. Partially install the inner transmission front cover snap-ring (1) onto the oil pump. 
    Fig 21: Identifying Snap Ring And Tool (8255)

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48. Using Installer 8255 (1), install the inner transmission front cover snap-ring (2) the remainder of the way onto the oil pump. 
    Fig 22: Identifying Valve Body Case Bolt

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49. Install the valve body. Verify that the pin on the manual lever has properly engaged the TRS selector plate. Tighten the valve body to transmission case bolts (1) to 12 N.m (105 in. lbs.). 
    Fig 23: Identifying Primary Oil Filter, Cooler Return Filter, Cooler Return Filter Bypass Valve And Valve Body

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    CAUTION: The primary oil filter seal MUST be fully installed flush against the oil pump body. DO NOT install the seal onto the filter neck and attempt to install the filter and seal as an assembly. Damage to the transmission will result.
50. Install a new primary oil filter seal in the oil pump inlet bore. Seat the seal in the bore with the butt end of a hammer, or other suitable tool. 
51. Install the primary oil filter (1) and the oil cooler return filter (2). Tighten the screw to hold the primary oil filter to the valve body to 4.5 N.m (40 in. lbs.). Using Oil Filter Wrench 8321, tighten the cooler return oil filter to the transmission case to 9.5 N.m (7 ft. lbs.). 
52. Apply RTV silicone to the oil pan and install the transmission oil pan. Tighten the bolts to 12 N.m (105 in. lbs.). 
    Fig 24: Identifying Output And Input Speed Sensors And Line Pressure Sensor

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53. Install the input (3), output (1), and line pressure sensors (2). Tighten the bolts to 12 N.m (105 in. lbs.).