Disassembly
DISASSEMBLY1. Clean exterior of transmission with suitable solvent or pressure washer.
2. Place transmission in vertical position.
3. Measure the input shaft end play as follows (Fig. 20).
a. Attach Adapter 8266-5 to Handle 8266-8.
b. Attach dial indicator C-3339 to Handle 8266-8.
c. Install the assembled tool onto the input shaft of the transmission and tighten the retaining screw on Adapter 8266-5 to secure it to the input shaft.
d. Position the dial indicator plunger against a flat spot on the oil pump and zero the dial indicator.
e. Move input shaft in and out and record reading. Record the maximum travel for assembly reference
4. Remove throttle and shift levers from valve body manual shaft and throttle lever shaft.
5. Remove transmission oil pan and gasket.
6. Remove filter from valve body (Fig. 21). Keep filter screws separate from other valve body screws. Filter screws are longer and should be kept with filter.
7. Remove the transmission range sensor..
8. Remove hex head bolts attaching valve body to transmission case (Fig. 22). A total of 10 bolts are used. Note different bolt lengths for assembly reference.
9. Remove valve body assembly. Push valve body harness connector out of case. Then work park rod and valve body out of case (Fig. 23).
10. Remove accumulator outer spring, piston and inner spring (Fig. 24). Note position of piston and springs for assembly reference. Remove and discard piston seals if worn or cut.
11. Remove pump oil seal with suitable pry tool or slide-hammer mounted screw.
12. Remove front band lever pin access plug (Fig. 25). Use square end of 1/4 inch drive extension to remove plug as shown.
13. Remove oil pump and reaction shaft support assembly as follows:
a. Tighten front band adjusting screw until band is tight around front clutch retainer (Fig. 26). This will prevent retainer from coming out with pump and possibly damaging clutch or pump components.
b. Remove oil pump bolts.
c. Thread Slide Hammer Tools C-3752 into threaded holes in flange of oil pump housing (Fig. 27).
d. Remove oil pump and reaction shaft support by bumping slide hammers outward alternately to pull pump from case (Fig. 28).
14. Remove oil pump gasket (Fig. 29). Note gasket position in case for assembly reference.
15. Loosen front band adjusting screw until band is completely loose.
16. Remove front band strut and anchor (Fig. 30).
17. Squeeze front band together slightly and slide band over front clutch retainer and out of case (Fig. 31).
18. Remove front and rear clutch assemblies as a unit (Fig. 32).
19. Remove front band reaction pin and lever. Start pin through lever and out of case bore with drift or punch. Then use pencil magnet to withdraw pin completely (Fig. 33).
20. Remove intermediate shaft thrust washer. Triangular shaped washer will either be on shaft pilot hub or in rear clutch retainer (Fig. 34).
21. Remove thrust plate from intermediate shaft hub (Fig. 35).
22. Remove intermediate shaft-planetary geartrain assembly (Fig. 36).
23. If overdrive unit is not to be serviced, install Alignment Shaft 6227-2 into the overdrive unit to prevent misalignment of the overdrive clutches during service of main transmission components.
24. Loosen rear band locknut and loosen adjusting screw 3 - 4 turns.
25. Remove snap-ring that retains low-reverse drum on overdrive piston retainer hub (Fig. 37).
26. Slide low-reverse drum and thrust washer off piston retainer hub and out of rear band (Fig. 38).
27. Note that overrunning clutch race will remain on splines of low-reverse drum after removal (Fig. 39). The race is a permanent press fit on the hub splines. Do not attempt to remove the race.
28. Remove overrunning clutch assembly (Fig. 40). Assembly can be removed without displacing rollers and springs if care is exercised. Note position of rollers and springs for assembly reference.
29. Remove rear band adjusting lever and reaction pin.
30. Remove rear band.
31. Compress front servo rod guide with large C-clamp and Tool C-4470, or Compressor Tool C-3422-B (Fig. 41). Compress guide only enough to permit snap-ring removal (about 1/8 inch).
32. Remove servo piston snap-ring (Fig. 41). Unseat one end of ring. Then carefully work removal tool around back of ring until free of ring groove. Exercise caution when removing snap-ring. Servo bore can be scratched or nicked if care is not exercised.
33. Remove tools and remove servo piston and spring.
34. Compress rear servo piston with C-clamp and Tool C-4470, or Valve Spring Compressor C-3422-B (Fig. 42). Compress servo spring retainer only enough to permit snap-ring removal.
35. Remove servo piston snap-ring (Fig. 42). Start one end of ring out of bore. Then carefully work removal tool around back of snap-ring until free of ring groove. Exercise caution when removing snap-ring. Servo bore can be scratched or nicked if care is not exercised.
36. Remove tools and remove rear servo retainer, spring and piston assembly.
CLEANING
Clean the case in a solvent tank. Flush the case bores and fluid passages thoroughly with solvent. Dry the case and all fluid passages with compressed air. Be sure all solvent is removed from the case and that all fluid passages are clear.
NOTE: Do not use shop towels or rags to dry the case (or any other transmission component) unless they are made from lint-free materials. Lint will stick to case surfaces and transmission components and circulate throughout the transmission after assembly. A sufficient quantity of lint can block fluid passages and interfere with valve body operation. Lubricate transmission parts with Mopar ATF +4, Automatic Transmission fluid during overhaul and assembly Use petroleum jelly to prelubricate seals, O-rings, and thrust washers. Petroleum jelly can also be used to hold parts in place during reassembly.
INSPECTION
Inspect the case for cracks, porous spots, worn bores, or damaged threads. Damaged threads can be repaired with Helicoil thread inserts. However, the case will have to be replaced if it exhibits any type of damage or wear. Lubricate the front band adjusting screw threads with petroleum jelly and thread the screw part-way into the case. Be sure the screw turns freely. Inspect the transmission bushings during overhaul. Bushing condition is important as worn, scored bushings contribute to low pressures, clutch slip and accelerated wear of other components. However, do not replace bushings as a matter of course. Replace bushings only when they are actually worn, or scored. Use recommended tools to replace bushings. The tools are sized and designed to remove, install, and seat bushings correctly. The bushing replacement tools are included in Bushing Tool Set C-3887-B. Pre-sized service bushings are available for replacement purposes. Only the sun gear bushings are not serviced. The use of crocus cloth is permissible where necessary, providing it is used carefully. When used on shafts, or valves, use extreme care to avoid rounding off sharp edges. Sharp edges are vital as they prevent foreign matter from getting between the valve and valve bore. Do not reuse oil seals, gaskets, seal rings, or O-rings during overhaul. Replace these parts as a matter of course. Also do not reuse snap rings or E-clips that are bent or distorted. Replace these parts as well.