Part 1
DISASSEMBLY
NOTE: If the transmission is being reconditioned (clutch/seal replacement) or replaced, it is necessary to perform the Quick Learn Procedure using the scan tool Quick Learn Procedure.
NOTE: Tag all clutch pack assemblies, as they are removed, for reassembly identification.
CAUTION: Do not intermix clutch discs or plates as the unit might then fail.
Before disassembling transmission, move the shift lever clockwise as far as it will go and then remove the shift lever.
1. Remove the torque converter (1) from the transmission input shaft (3).
2. Measure input shaft end play using pieces from End Play Set 8266A (1, 2). Set up tool 8266 and Dial Indicator C-3339A as shown.
3. Move input shaft in and out to obtain end play reading. End play specifications are 0.127 to 0.635 mm (0.005 to 0.025 inch). Record indicator reading for reference when reassembling the transmission. If endplay exceeds the specified range, the #4 thrust plate needs to be inspected and changed if necessary.
NOTE: The four bolts (3) along the bottom of the extension housing (2) have a sealing patch applied from the factory. Note the locations of these bolts and separate these bolts for reuse.
4. Remove the bolts that hold the extension housing (2) onto the transmission case.
5. Remove the extension (2) housing, from the transmission case. There are two pry slots located near the bottom corners of the housing for separating the housing from the transmission case.
6. Inspect the lube tube grommet (3) for damage. If the grommet lip is damaged, it will need to be replaced.
7. Perform the following, if necessary:
a.
Remove the extension shaft bearing snap ring (3) from the extension housing.
b.
Remove the extension shaft and bearing assembly (2) from the extension housing (1).
c.
Remove the extension shaft bearing retaining ring (3) from the extension shaft (1).
d.
Remove the extension shaft bearing (2) from the extension shaft (1).
8. Using OTC(R) Slide Hammer 1155 or 7703 (3), or equivalent, and Adapter 10171 (2), remove the 4X4 stub shaft (1).
9. Inspect the cir-clip on the shaft for damage and replace the clip if necessary.
NOTE: The speed sensor bolts have a sealing patch applied from the factory. Separate these bolts for reuse.
10. Remove the input speed sensor bolt.
NOTE: The speed sensor bolts have a sealing patch applied from the factory. Separate these bolts for reuse.
11. Remove the output speed sensor bolt.
12. Remove the input and output (2) speed sensors. Identify the speed sensors for re-installation since they are not interchangeable.
NOTE: One of the oil pan bolts has a sealing patch applied from the factory. Separate this bolt for reuse.
13. Remove the transmission oil pan bolts (2).
14. Remove the transmission oil pan (1).
15. Remove the transmission oil filter screws (2).
16. Remove transmission oil filter (1).
17. Remove the oil filter o-ring (2) from the valve body.
18. Remove valve body-to-case bolts (1).
CAUTION: Do not handle the valve body by the manual shaft. Damage could result.
19. Remove valve body (1) from transmission.
20. Remove underdrive and overdrive accumulators (1, 2).
21. Remove the low/reverse accumulator snap ring (1).
22. Remove the low/reverse accumulator plug (2).
23. Remove low/reverse accumulator piston (1) using suitable pliers.
24. Remove piston (1) and springs (2).
25. Remove and discard the oil pump-to-case bolts (1). The oil pump bolts are not to be reused.
26. Remove oil pump using Slide Hammers C-3752 (2).
27. Remove oil pump while pushing in on input shaft (1).
28. Remove oil pump gasket (2).
CAUTION: By-pass valve must be replaced if a transmission failure has occurred.
29. Remove the cooler by-pass valve (1).
30. Remove the #1 caged needle bearing (1).