Part 1

DISASSEMBLY

Special Tools:










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.




Figure 1 - AS68RC COMPONENTS








Figure 2 - 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.




Figure 3 - 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.




Figure 4 - INPUT SHAFT END PLAY





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




Figure 5 - OUTPUT SHAFT NUT





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




Figure 6 - 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 (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




Figure 8 - 4WD OUTPUT SHAFT END PLAY





1. With the 4WD extension housing installed onto the transmission case, install Adapter (1) and the handle from End-Play Tool Set and Dial Indicator (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 (1) and the handle from End-Play Tool Set and Dial Indicator (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.)




Figure 11 - 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.




Figure 12 - INPUT SPEED SENSOR
8. Remove the input speed sensor.




Figure 13 - OUTPUT SPEED SENSOR
9. Remove the output speed sensor




Figure 14 - 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.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.




Figure 16 - PTO DUST COVER
15. Remove the PTO dust cover bolts and dust cover.




Figure 17 - 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).




Figure 18 - OVER HEAD VIEW
20. Remove the valve body.Valve Body - Removal
21. Remove the three accumulator valves (1), (2), (3) and then the accumulator springs.





22. Air check the transmission. Air Testing Transmission Clutch And Band Operation




Figure 19 - 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 and adapters to remove the oil pump.




Figure 20 - K2 RETAINER
24. Remove the input shaft assembly with the K1 and K2 clutch assemblies attached.