Disassembly

Special Tools:

1. Mount the (A) transmission to the (B) Car/Truck Engine Repair Stand.

NOTE: Remove the torque converter prior to mounting the transmission to the repair stand.

2. Remove the input shaft.

CAUTION: The input shaft and overdrive planet assembly are replaced as mating components.

3. Remove the cooler bypass valve.
1. Remove the cooler line case fittings.
2. Remove the cooler bypass valve.

CAUTION: Sealing washers may fall off the cooler line case fittings.

NOTE: The bolts are part of the Cooler Bypass Valve (CBV) assembly.

4. Remove the 20 (A) bolts, the (B) transmission fluid pan, and the (C) gasket.

CAUTION: Do not discard the gasket unless damaged. This is a reusable gasket.

5. Remove the filter and seal assembly by carefully pulling and rotating the filter as necessary.

CAUTION: If the seal remains in the pump bore, remove it carefully with a small screwdriver so as not to scratch or damage the aluminum bore.

NOTE: After removal, discard the filter and seal assembly.

6. Remove the (A) bolts, the (B) nuts, and the (C) accumulator body.

7. Remove the (B) bolts, the (C) nuts, and the (D) main control valve body.

NOTE: Do not remove the (A) lower-to-upper main control valve body assembly retaining bolts. Keep the main control valve bodies attached as an assembly.

8. Remove the (A) bolts, the (B) nut, and the (C) solenoid body assembly, by pushing the solenoid body connector upward to help separate the assembly from the case bore.

9. Remove the solenoid screen assembly by rotating and pulling.

10. Remove the (A) bolts, the (B) separator plate reinforcing plate, and the (C) valve body separator plate with the 2 gaskets. Discard both gaskets.

CAUTION: The steel Electronic Pressure Control (EPC) check ball is spring-loaded under the valve body separator plate.

11. Remove the (A) steel EPC check ball and the (B) spring.

NOTE: The steel EPC check ball has a 0.25 inch diameter and is smaller than the other check balls.

12. Using a small screwdriver, carefully remove the 8 rubber check balls.

CAUTION: Use care not to damage the rubber check balls. Transmission shift problems may occur.

13. Using a plastic- or rubber-headed hammer, tap gently on the intermediate band servo assembly piston. The downward force will compress the spring. The upward momentum of the spring will force the assembly to be released from the case bore.

WARNING: INTERMEDIATE BAND SERVO ASSEMBLY CAN COME APART AND POP OUT OF THE CASE BORE.

14. Remove and discard the feed bolts.

CAUTION: After removal, discard the feed bolts. The bolts will not retain torque specification if reused.

15. Remove the pump bolts.

CAUTION: After removal, discard the pump bolt washers. The washers will not retain the torque specification if reused.

16. Using the (A) Pump Puller Adapter and the (B) Impact Slide Hammer, remove the (C) pump.

CAUTION: Use a slide hammer-type puller only.

NOTE: The Pump Puller Adapters should be installed into the pump threaded holes at approximately the 2 o'clock and 8 o'clock positions, as shown.

17. Remove the (A) No. 1 pump thrust washer, the (B) No.2A overdrive sun gear thrust bearing and the (C) pump gasket. Discard the pump gasket.

NOTE: The No. 1 pump thrust washer and the No. 2A overdrive sun gear thrust bearing may stay with the pump.

18. Remove the coast clutch assembly.

NOTE: The overdrive sun gear may stay with the coast clutch or the overdrive planet assembly.

19. Remove the overdrive clutch pressure plate retainer snap ring.

20. Remove the overdrive clutch pressure plate and the clutch pack.

NOTE: Tag the parts for identification during installation.

21. Remove the (A) overdrive ring gear and overdrive center shaft assembly.

22. The overdrive ring gear and overdrive center shaft assembly consists of the following:
1. Overdrive sun gear assembly.
2. Overdrive one-way clutch assembly.
3. No. 3 overdrive overrunning clutch thrust washer.
4. Overdrive planet assembly.
5. No. 4 overdrive planet thrust bearing assembly.
6. Overdrive ring gear.
7. Overdrive center shaft.
8. No. 5 overdrive center shaft thrust bearing assembly.

23. Remove the No. 5 overdrive center shaft thrust bearing assembly.

24. Position the (A) Clutch Spring Fixture Plate, the (B) Clutch Spring Fixture Adapter and the (C) Clutch Spring Compressor Bar onto the (D) intermediate/overdrive cylinder assembly. Install the (E) screws into the threaded holes in the pump face.

NOTE: Refer to the Special Tool(s) chart preceding Step 1 of Disassembly for proper tool number identification.

25. Tighten the center bolt.

26. Remove the (A) intermediate/overdrive cylinder retaining ring. Loosen the (B) center bolt and remove the (C) Clutch Spring Fixture assembly.

27. Remove the intermediate/overdrive cylinder assembly.

CAUTION: During removal, do not misalign the intermediate/overdrive cylinder assembly in the case bore. This can damage the case bore.

28. Remove the intermediate clutch piston return spring.

29. Carefully remove the center support assembly.

CAUTION: During removal, do not misalign the center support in the case bore. This can damage the case bore.

30. Remove the No. 6 center support thrust washer.

31. Remove the (A) intermediate clutch pressure apply plate, the (B) intermediate clutch pack and the (C) intermediate clutch rear pressure plate.

NOTE: Tag the parts for identification during installation.

32. Remove the intermediate band.

33. Using the (A) Clutch Remover/Replacer, remove the (C) direct clutch, forward clutch and input shell as an assembly.

NOTE: When installing the (A) Clutch Remover/Replacer, the hooks on the crossbar must be rotated to engage notches on the (B) input shell.

34. Remove the reverse planet retaining ring.

35. Remove the (A) reverse planet assembly with the (B) No. 1OB and (C) No. 11 reverse planet carrier thrust washers.

36. Remove the output shaft retaining ring.

WARNING: USE CARE WHEN REMOVING THE OUTPUT SHAFT RETAINING RING. THE OUTPUT SHAFT CAN FALL OUT. DO NOT REUSE THE OUTPUT SHAFT RETAINING RING.

37. Remove the (A) output shaft ring gear, the (B) reverse clutch hub, the (C) low one-way clutch assembly and the (D) No. 12 thrust bearing behind the output shaft ring gear.

38. Remove the (A) reverse clutch pressure plate retainer snap ring.

WARNING: USE CARE NOT TO DROP THE OUTPUT SHAFT WHILE ROTATING THE TRANSMISSION.

39. Remove the (A) reverse clutch pressure plate, the (B) clutch pack and the (C) cushion spring.

NOTE: Tag the parts for identification during installation.

40. Using the (A) Seal Remover and the (B) Impact Slide Hammer, remove the (C) extension housing seal.

41. Remove the 8 (A) bolts, the (B) stud and the (C) extension housing.

42. Remove and discard the extension housing gasket.

43. Remove the (A) output shaft, the (B) park gear and the (C) No. 13 parking gear thrust washer.

44. Remove the 5 bolts retaining the low/reverse one-way clutch inner race to the case.

45. Remove the (A) reverse clutch return spring assembly and the (B) low/reverse one-way clutch inner race.

46. To remove the reverse clutch piston, reinstall the (A) reverse clutch pressure plate and the (B) reverse clutch pressure plate retainer snap ring to restrain the (C) reverse clutch piston.

47. Using compressed air, blow into the reverse clutch feed port to blow out the reverse clutch piston against the reverse clutch pressure plate.

48. Remove the (A) reverse clutch pressure plate retainer snap ring, the (B) reverse clutch pressure plate and the (C) reverse clutch piston.

49. If required, remove the (A) bolts and the (B) parking rod guide plate.

50. If required, remove the (A) parking pawl return spring, the (B) parking pawl and the (C) parking pawl shaft.

51. If required, remove the (A) Torx-head screw and the (B) parking pawl abutment.

CAUTION: The Torx-head screw has a thread-locking compound and should be removed only if the case is being replaced. If the bolt is removed, it must be discarded and a new one installed.

52. Remove the (A) bolts and the (B) digital transmission range (TR) sensor.

53. Using the (A) Lock Nut Pin Remover, remove the (B) manual lever shaft retaining pin.

NOTE: A No. 53 drill bit (1/16 inch) can be used instead to capture and remove the manual lever shaft retaining pin.

54. Remove the manual control lever shaft assembly.

NOTE: Use a crescent wrench on the manual control lever or outer flats of the manual control lever shaft assembly when removing the inner manual valve detent lever nut.

1. Remove the (A) nut, the (B) inner manual valve detent lever and the (C) parking pawl actuating rod.
2. Remove the manual control lever shaft assembly.
3. Remove the (D) bolt and the (E) manual control valve detent lever spring.

CAUTION: Use care not to damage the manual control lever bore.

NOTE: The manual control lever and manual control lever shaft are one piece.

55. Using the (A) Puller, remove the (B) manual control lever seal.

56. If required, remove the short fluid inlet tube.

NOTE: The short fluid inlet tube should be removed only if it is loose or damaged.

57. Inspect the case assembly for cracks and stripped threads. Inspect the gasket surfaces and mating surfaces for burrs. Check the case vent assembly for obstructions and check all fluid passages for obstructions.
58. Inspect the case assembly bushing for scores. Check all parking linkage parts for wear or damage.
59. If the transmission case assembly thread is damaged, repair kits (heli coil) can be purchased from local jobbers. To repair a damaged thread, follow procedures furnished in the heli coil kit.