Disassembly

Special Tools:

1. CAUTION: If equipped, the Output Shaft Speed Sensor (OSS) and the Turbine Shaft Speed Sensor (TSS) will need to be removed or damage to the sensors will occur.

If equipped, remove the Turbine Shaft Speed Sensor (TSS) and the Output Shaft Speed Sensor (OSS).

2. Remove the Turbine Shaft Sensor (TSS).
1 Remove the bolt.
2 Remove the Turbine Shaft Sensor (TSS).

3. Remove the Output Shaft Speed Sensor (OSS).
1 Remove the bolt.
2 Remove the Output Shaft Speed Sensor (OSS).

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

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

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

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

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

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

7. Remove the Transmission Range (TR) sensor.
1 Remove the bolts.
2 Remove the Transmission Range (TR) sensor.

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

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

9. 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.

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

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

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

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

12. 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.

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

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

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

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

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

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

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

17. WARNING: Intermediate band servo assembly can come apart and pop out of the case bore.

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.

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

Remove and discard the feed bolts.

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

Remove the pump bolts.

20. 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.

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

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

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.

22. NOTE: The coast clutch assembly is model-dependent.

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

Remove the coast clutch assembly 5.4L, 6.8L without power take-off.

23. On 7.3L engine applications, remove the coast clutch assembly with no power take-off option.

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

25. NOTE: Tag the parts for identification during installation.

Remove the overdrive clutch pressure plate and the clutch pack.

26. On 5.4L, 6.8L and 7.3L without (PTO), remove the (A) overdrive ring gear and overdrive center shaft assembly.

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

28. On 6.8L and 7.3L engine applications, remove the coast clutch assembly, overdrive ring gear and center shaft assembly. With power take-off option using the coast clutch assembly removal/installation tool.

29. Remove the intermediate/overdrive cylinder retaining ring.
1 Install coast clutch retaining removal tool.
2 Tighten center handle.
3 Remove the intermediate/overdrive cylinder retaining ring.

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

Remove the intermediate/overdrive cylinder assembly.

31. Remove the intermediate clutch piston return spring.

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

Carefully remove the center support assembly.

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

34. NOTE: Tag the parts for identification during installation.

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

35. Remove the intermediate band.

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

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

37. Remove the reverse planet retaining ring.

38. Remove the (A) reverse planet assembly with the (B) No. 10B and (C) No. 11 reverse planet carrier thrust washers.

39. WARNING: Use care when removing the output shaft retaining ring. The output shaft can fall out. Do not reuse the output shaft retaining ring.

Remove the output shaft retaining ring.

40. Remove the output shaft ring gear and hub assembly.

41. WARNING: Use care not to drop the output shaft while rotating the transmission.

Remove the following parts as an assembly.
1 Reverse clutch pack (pressure plate, friction plate and seals).
2 Reverse clutch hub.
3 Low/reverse one way clutch assembly.

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

43. Using the extension housing bushing remover, remove the extension housing bushing.

44. Remove the 8 (A) bolts, the (B) stud and the (C) extension housing.
45. Remove and discard the extension housing gasket.

46. NOTE: Be sure not to damage the teeth on the park gear and the tone wheel.

NOTE: The output shaft and the tone wheel are model-dependent.

Remove the output shaft.

47. Remove the No. 13 thrust bearing.

48. Remove the plastic orifice lube plug.

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

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

51. 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.

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

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

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

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

56. CAUTION: The Torx(R)-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.

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

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

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

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

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

Remove the manual control lever shaft assembly.

1 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.

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 (D) manual control valve detent lever spring.

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

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

If required, remove the short fluid inlet tube.
61. Inspect the case assembly for cracks and stripped threads. Inspect the gasket surfaces and mating surfaces for buffs. Check the case vent assembly for obstructions and check all fluid passages for obstructions.
62. Inspect the case assembly bushing for scores. Check all parking linkage parts for wear or damage.
63. If the transmission case assembly thread is damaged, repair kits (helicoil) can be purchased from local jobbers. To repair a damaged thread, follow procedures furnished in the helicoil kit.