Overhaul (Transmission)
TRANSMISSION DISASSEMBLY(1) Drain fluid from transmission.
(2) Clean exterior of transmission with suitable solvent or pressure washer.
(3) Remove the torque converter from the transmission.
(4) Remove the manual shift lever from the transmission.
Fig. 53:
(5) Remove the input, output, and line pressure sensors from the transmission case (Fig. 53).
(6) Inspect the ends of the sensors for debris, which may indicate the nature of the transmission failure.
Fig. 54:
(7) Install Support Stand 8257 onto the transmission case (Fig. 54).
Fig. 55:
(8) Using Adapter 8266-1 from End-Play Tool Set 8266 and Dial Indicator C-3339, measure and record the input shaft end-play (Fig. 55).
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 there- fore must be recorded and subtracted from the dial indicator reading.
(9) Remove the bolts holding the transmission extension/adapter housing to the transmission case.
(10) Remove the extension/adapter housing from the transmission case.
Fig. 56:
(11) Using Alignment Plate 8261, Adapter 8266-17 from End-Play Tool Set 8266 and Dial Indicator C-3339, measure and record the output shaft endplay (Fig. 56).
(12) Remove the bolts holding the transmission oil pan to the transmission case.
(13) Remove the transmission oil pan from the transmission case.
Fig. 57:
(14) Remove the primary oil filter and the oil cooler filter (Fig. 57).
(15) Remove the cooler bypass valve.
Fig. 58:
(16) Remove the bolts holding the valve body to the transmission case (Fig. 58).
(17) Remove the valve body from the transmission case.
Fig. 59:
(18) Remove the outer snap-ring securing the transmission front cover into the transmission case (Fig. 59).
(19) Remove the inner snap-ring securing the transmission front cover to the oil pump (Fig. 59).
(20) Reaching through a case opening in the valve body area with a long blunted tool, remove the transmission front cover from the transmission case.
Fig. 60:
(21) Remove the bolts holding the oil pump into the transmission case (Fig. 60).
(22) Remove the oil pump. Hold inward on the input shaft to prevent pulling the input clutch assembly with the oil pump (Fig. 60).
Fig. 61:
(23) Remove the number 1 bearing from the input clutch assembly (Fig. 61).
(24) Remove the input clutch assembly from the transmission case (Fig. 61).
(25) Remove the number 5 bearing and selective thrust plate from the input clutch assembly (Fig. 61), or the 4C clutch retainer/bulkhead.
Fig. 62:
(26) Remove the 4C clutch retainer/bulkhead tapered snap-ring from the transmission case (Fig. 62).
(27) Remove the 4C clutch retainer/bulkhead from the transmission case (Fig. 62).
Fig. 63:
(28) Remove the front 2C clutch pack snap-ring from the transmission case (Fig. 63).
(29) Remove the 2C clutch pack from the transmission case (Fig. 63).
Fig. 64:
(30) Remove the rear selective plate and number 6 bearing from the reaction annulus (Fig. 64).
(31) Remove the reaction annulus from the reaction planetary carrier (Fig. 64).
(32) Remove the number 7 bearing (Fig. 64).
(33) Remove the reaction sun gear (Fig. 64).
(34) Remove the number 8 bearing from the reaction planetary carrier (Fig. 64).
(35) Remove the reaction planetary carrier (Fig. 64). Note that this planetary gear set has three pinion gears.
(36) Remove the number 9 bearing from the reverse planetary gear set (Fig. 64).
Fig. 65:
(37) Remove the snap-ring holding the park sprag gear onto the output shaft (Fig. 65).
Fig. 66:
(38) Remove the park sprag gear from the output shaft (Fig. 66).
Fig. 67:
(39) Remove the input/reverse planetary assembly (Fig. 67).
(40) Remove the number 12 bearing from the input/reverse planetary assembly (Fig. 67).
Fig. 68:
(41) Remove the snap-ring holding the low/reverse clutch retainer into the transmission case (Fig. 68).
(42) Remove the low/reverse clutch retainer from the transmission case (Fig. 68).
Fig. 69:
(43) Remove the park pawl rod and e-clip (Fig. 69).
(44) Remove the park pawl rod guide snap-ring (Fig. 69).
(45) Remove the park pawl rod guide (Fig. 69).
(46) Remove the park pawl pivot shaft, park pawl, and spring (Fig. 69).
(47) Remove the manual selector shaft (Fig. 69).
(48) Remove the manual selector shaft seal.
(49) Remove the dipstick tube seal.
ASSEMBLY
(1) Clean and inspect all components. Replace any components which show evidence of excessive wear or scoring.
(2) Install the cooler filter bypass valve.
(3) 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 11.3 Nm (100 in. lbs.).
Fig. 70:
(4) Install a new selector shaft seal using Seal Installer 8253 (Fig. 70).
(5) Install the manual selector shaft and retaining screw. Tighten the manual selector shaft retaining screw to 28 Nm (250 in. lbs.).
(6) Install the park pawl, spring, and shaft (Fig. 69).
(7) Install the park rod and e-clip (Fig. 69).
(8) Install the park rod guide and snap-ring (Fig. 69).
Fig. 71:
(9) Install a new dipstick tube seal using Seal Installer 8254 (Fig. 71).
NOTE: Before final assembly of transmission centerline, the 2C/4C clutch components should be installed into position and measured/adjusted as follows:
(10) Install the 2C reaction plate into the transmission case (Fig. 63). The reaction plate is selective and directional. The plate must be installed with the flat side toward the front.
(11) Install the 2C clutch pack into the transmission case (Fig. 63).
(12) Install the flat 2C clutch snap-ring into the transmission case (Fig. 63).
(13) Install the 4C retainer/bulkhead into the transmission case. Make sure that the oil feed holes are pointing toward the valve body area.
(14) Install the 4C retainer/bulkhead tapered snap-ring 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.
(15) 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. Adjust the clearance as necessary. The correct clutch clearance is 0.533 - 1.27 mm (0.021 - 0.050 inch). The reaction plate is selective. Install the chosen reaction plate and re-measure the clutch clearance to verify the selection.
(16) Remove the 4C retainer/bulkhead and all of the 2C clutch components from the transmission case.
Fig. 72:
(17) Install the low/reverse clutch assembly (Fig. 72). 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.
(18) Install the snap-ring to hold the low/reverse clutch retainer into the transmission case (Fig. 72). 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.
(19) Air check the low/reverse clutch and verify correct overrunning clutch operation.
Fig. 73:
(20) Install the reverse/input planetary assembly through the low/reverse clutch assembly (Fig. 73).
(21) Install the number 12 bearing over the output shaft of the rear planetary gear set and onto the low/ reverse clutch assembly. The flat side of the bearing goes toward the clutch assembly.
Fig. 74:
(22) Install the park sprag onto the output shaft (Fig. 74).
Fig. 75:
(23) Install the snap-ring to hold the park sprag onto the output shaft (Fig. 75).
Fig. 76:
(24) Install the 2C reaction plate into the transmission case (Fig. 76). The reaction plate is selective and directional. The plate must be installed with the flat side toward the front.
(25) Install the 2C clutch pack into the transmission case (Fig. 76).
(26) Install the number 8 bearing inside the reaction carrier with the round side against the planetary carrier.
Fig. 77:
(27) Install the reaction planetary gear set and the number 9 bearing into the transmission case (Fig. 77).
(28) Install the flat 2C clutch snap-ring into the transmission case (Fig. 76).
(29) Install the reaction sun gear into the reaction planetary gear set with the small shoulder facing the front of the transmission (Fig. 77).
(30) Install the number 7 bearing onto the reaction sun gear with the flat side against the sun gear (Fig. 77).
Fig. 78:
(31) Install the output shaft selective thrust plate onto the reaction annulus with the oil grooves facing the annulus gear and the tabs and notches aligned as shown in (Fig. 78).
(32) Install the number 6 bearing against the output shaft selective spacer with the flat side against the spacer (Fig. 77).
(33) Install the reaction annulus into the reaction planetary gear set (Fig. 77).
(34) Install the 4C retainer/bulkhead 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.
Fig. 79:
(35) Install the 4C retainer/bulkhead tapered snap-ring into the transmission case (Fig. 79). Make sure that the open ends of the snap-ring are located in the case opening toward the valve body area.
(36) Air check the 2C and 4C clutch operation.
Fig. 80:
(37) Using Alignment Plate 8261, Adapter 8266-17 from End-Play Tool Set 8266, and Dial Indicator C-3339, measure and record the output shaft endplay (Fig. 80). The correct output shaft end-play is 0.53 - 0.78 mm (0.021 - 0.031 inch). Adjust as necessary. Install the chosen output shaft selective spacer and re-measure end-play to verify selection.
(38) Apply a bead of RTV silicone and install the extension/adapter housing onto the transmission case.
(39) Install and torque the bolts to hold the extension/adapter housing onto the transmission case. The correct torque is 54 Nm (40 ft. lbs.).
Fig. 81:
(40) Install the number 5 bearing and spacer onto the 4C retainer/bulkhead (Fig. 81).
(41) Install the input clutch assembly into the transmission case (Fig. 81). 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 on the input clutch assembly is visible, the assembly is fully installed.
(42) Install the number 1 bearing with the flat side down in the pocket of the input clutch assembly (Fig. 81).
Fig. 82:
(43) Install the oil pump into the transmission case (Fig. 82).
(44) Install the bolts to hold the oil pump into the transmission case. Tighten the oil pump bolts to 28 Nm (250 in. lbs.).
Fig. 83:
(45) Using Adapter 8266-1 from End-Play Tool Set 8266 and Dial Indicator C-3339, measure and record the input shaft end-play (Fig. 83). The correct endplay is 0.79 - 1.07 mm (0.031 - 0.042 inch). Adjust as necessary. Install the chosen spacer on the number 5 bearing and re-measure 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. 84:
(46) Install the transmission front cover into the transmission case (Fig. 84).
(47) Install the outer snap-ring to hold the transmission front cover into the transmission case (Fig. 84).
(48) Partially install the inner transmission front cover snap-ring onto the oil pump (Fig. 84).
Fig. 85:
(49) Using Installer 8255, install the inner transmission front cover snap-ring the remainder of the way onto the oil pump (Fig. 85).
Fig. 86:
(50) Install the valve body (Fig. 86). Tighten the valve body to transmission case bolts to 12 Nm (105 in. lbs.).
Fig. 87:
(51) Install the primary oil filter and the oil cooler filter (Fig. 87). Tighten the screws to hold the primary oil filter to the valve body to 4.5 Nm (40 in. lbs.). Using Oil Filter Wrench 8321, tighten the cooler return oil filter to the transmission case to 14 Nm (125 in. lbs.).
(52) Apply RTV silicone to the oil pan and install the transmission oil pan. Tighten the bolts to 12 Nm (105 in. lbs.).
Fig. 88:
(53) Install the input, output, and line pressure sensors (Fig. 88). Tighten the bolts to 12 Nm (105 in. lbs.).
(54) Install the manual shift lever from the transmission. Torque the retaining cross-bolt to 16 Nm (140 in. lbs.).