Disassembly- Part 1

Disassembly- Part 1


CAUTION: Tag all snap rings, thrust washers, washers, spacers and thrust bearings, etc. during disassembly for quick identification and assembly. Failure to follow these instructions will damage and cause transmission failure.




AS68RC COMPONENTS










DRAIN PLUG


1. Place the transmission manual shift lever into the park lock position.
2. Plug all openings and clean exterior of transmission with water soluble solvent or a pressure washer.
3. Remove oil pan drain plug (1) and drain fluid from transmission.



TORQUE CONVERTER REMOVAL


WARNING: Be certain the transmission is secure when removing the torque converter, the torque converter is very heavy. Failure to follow these instructions may result in personal injury or may be fatal.

4. Remove the torque converter from the transmission.

NOTE: Gear train end play is a critical pre-disassembly check to help determine the condition of the transmission. End play reading greater than specification (larger gap) indicate that a bearing or thrust plate is either missing, worn or has disintegrated, in which case there will be debris in the oil pan.




INPUT SHAFT END PLAY







5. Using Adapter 8266-19 (1) and the handle from End-Play Tool Set 8266 (2) and Dial Indicator C-3339-A (3), measure and record the input shaft end-play.



OUTPUT SHAFT NUT







6. Using a small chisel pry open the stakes on the output shaft flange nut and install Flange Holder tool C-3281 (1) to assist in removing the output flange nut. Remove the output shaft flange nut.



OUTPUT SHAFT FLANGE







7. Remove the output flange (1) and o-ring seal (2).
8. Using a pry tool, remove the output shaft seal.




9. Install a NEW nut on the output shaft and install the Dial Indicator C-3339-A (2).
10. With the transmission in a vertical position, and using a pry tool (1) on the output shaft nut measure and record the output shaft end-play. The output shaft end-play clearance is 0.50-0.90 mm (0.019-0.035 in.)

NOTE: The 4WD extension housing has two output shaft end-play shims fore and aft of the output shaft bearing, therefor the output shaft end-play checking procedure must be preformed twice. The external shim and snap ring is in place to prevent excess forward pressure on the NO.9 thrust bearing while the 4WD transfer case is bolted to the extension housing.

4WD OUTPUT SHAFT END PLAY CHECK





4WD OUTPUT SHAFT END PLAY







1. With the 4WD extension housing installed onto the transmission case, install Adapter 8266-20 (1) and the handle from End-Play Tool Set 8266 and Dial Indicator C-3339-A (2).
2. With the transmission in a vertical position, measure and record the output shaft end-play. The output shaft end-play clearance is 0.00 - 0.24 mm (0.000-0.009 in.)




3. Using a pry tool, remove the output shaft seal.
4. Remove seal retainer (1).




5. Remove the external snap ring (1) and selectable output shaft end-play washer.
6. Using Adapter 8266-20 (1) and the handle from End-Play Tool Set 8266 and Dial Indicator C-3339-A (2), measure and record the output shaft end-play. The output shaft end-play clearance is 0.50-0.90 mm (0.019-0.035 in.)





TC HOUSING


NOTE: Support the bottom of the transmission case before removing the torque converter housing.

7. Remove the bolts securing the torque converter housing to the transmission case and remove the housing.



INPUT SPEED SENSOR


8. Remove the input speed sensor.



OUTPUT SPEED SENSOR


9. Remove the output speed sensor



FILL TUBE







10. Remove the bolt (if equipped) securing the transmission fill tube to the transmission case and remove the fill tube.
11. Remove the manual shift lever from the transmission.
12. Remove the transmission range sensor. Removal
13. Using a pry tool remove the manual shift lever seals (one each side of the transmission).




14. Remove the breather hose and fitting, if necessary.



PTO DUST COVER


15. Remove the PTO dust cover bolts and dust cover.



COOLER LINES







16. Remove the temperature sensor (1) from the ATF output cooler line fitting.
17. Remove the Jiffy Tite fittings (2) from both cooler line fittings.
18. Loosen both cooler line fittings (3).
19. Remove both cooler line fittings (3).



OVER HEAD VIEW


20. Remove the valve body. Removal
21. Remove the three accumulator valves (1), (2), (3) and then the accumulator springs.





22. Air check the transmission.Refer to appropriate AS68RC Transmission testing



OIL PUMP


NOTE: Using a marker or paint pen, tag the orientation of the oil pump to the transmission case.

23. Remove the bolts securing the oil pump to the transmission case and use tool C-3752 and adapters 9981 to remove the oil pump.



K2 RETAINER


24. Remove the input shaft assembly with the K1 and K2 clutch assemblies attached.



K1 AND K2 CLUTCHES







NOTE: The input shaft end-play clearance is adjusted by means of a selectable thrust bearing race located between the K1 and the K2 clutch pack retainers.

25. Remove the K2 clutch assembly (4) and the selectable input shaft end-play thrust bearing number one (2) and thrust washer (3) from the K1 clutch / input shaft assembly (1).




26. Remove the K1 clutch hub.



K1 THRUST BEARING No 2


27. Remove the K1 thrust bearing number 2.



K2 HUB


28. Remove the K2 clutch hub.



K2 HUB THRUST BEARING No. 3


29. Remove the K2 thrust bearing number three.



FRONT SUN/PTO FRONT THRUST BEARING No. 4


30. Remove the front sun / PTO front thrust bearing number four.



FRONT SUN / PTO DRIVE GEAR