Disassembly 1 - 43

Special Tools:

1. WARNING: Do not remove the torque converter or the transfer case from the transmission while still on the jack, doing so could cause the transmission to fall. Failure to follow these instructions may result in personal injury.

Place the transmission on a workbench.





2. Remove the Torque Converter Holding Tool.





3. WARNING: The torque converter is heavy, especially when full of fluid. Failure to follow these instructions may result in personal injury.

Using the Converter Handles, remove the torque converter.
1 Install the Converter Handles.
2 Remove the torque converter.





4. Note: The splines on the input shaft are not the same on both ends. The end with the shorter spline goes into the transmission assembly.

Remove the input shaft.





5. Remove manual control outer lever nut and manual control outer lever.





6. Remove the digital Transmission Range (TR) sensor.
1 Remove the screws.
2 Remove the digital TR sensor.





7. Using the Converter Oil Seal Remover and Impact Slide Hammer, remove extension housing seal.





8. Note: Remove the extension housing bushing only if service is required.

Use the Bushing Remover to remove the extension housing bushing.
- Inspect the extension housing bushing and driveshaft slip-yoke for nicks, gouges, scoring, and wear.





9. CAUTION: The parking pawl, parking pawl return spring and parking pawl shaft could fall out during removal of the extension housing.

Remove the screws, studs, and the extension housing.
- Discard the extension housing gasket.





10. Remove the parking pawl assembly.
1 Remove the parking pawl shaft.
2 Remove the parking pawl.
3 Remove the parking pawl return spring.





11. CAUTION: The parking pawl actuating rod must slip freely into the clearance hole in the adapter plate.

Note: See the special service tool chart for a drawing of this optional adapter plate.

Install the A4LD Holding Fixture.
1 Position the A4LD Holding Fixture on the rear of the transmission case.
2 Install the screws.





12. Attach the fixture arm of Holding Fixture to the A4LD Holding Fixture.





13. WARNING: Make sure the lock pin on Holding Fixture is secure. Failure to follow these instructions may result in personal injury.

Install the transmission into the Holding Fixture. Rotate transmission so fluid pan is facing up.

14. CAUTION: Do not reuse the fluid pan gasket.

Remove the transmission fluid pan and transmission pan gasket and then discard gasket.





15. Remove the transmission fluid filter and discard.
1 Remove the screw.
2 Remove the transmission fluid filter.





16. Carefully lift up on the wire loom guide and protector. Disengage the retaining pins from the solenoid clamps.





17. Disconnect the solenoid electrical connectors.
1 Disconnect the SSA, SSB, SSC, and the CCS electrical connectors.
2 Disconnect the Torque Converter Clutch (TCC) solenoid electrical connector.
3 Disconnect the Electronic Pressure Control (EPC) solenoid electrical connector.





18. Remove the manual control valve detent lever spring.
1 Remove the screw.
2 Remove the manual control valve detent lever spring.





19. Remove the low/reverse band servo cover.
1 Remove the screws.
2 Remove the low/reverse band servo cover and the low/reverse servo separator plate cover gasket.
- Discard the low/reverse servo separator plate cover gasket.





20. Remove the low/reverse band servo piston and rod assembly.





21. CAUTION: To prevent solenoid valves from falling out, do not remove the two screws shown below.

Note: Do not remove the two (gold colored) screws specified.





22. Remove the 23 screws.





23. Remove the main control valve body, valve body separator plate and main control to case gaskets.
- Discard gaskets.





24. CAUTION: Throw the locknuts away. The locknuts are not reusable for assembly.

Remove the locknuts. Back off the screws.





25. CAUTION: Servo cover is under spring tension.

Remove the intermediate servo cover retaining ring.
1 Install Servo Cover Compressor and compress the intermediate servo cover.
2 Remove the intermediate servo cover retaining ring.
- Remove Servo Cover Compressor.





26. Note: Use Servo Removal Tool to prevent damage to the servo, cover and bore.

Note: Tag the servo cover, piston and spring. Label accordingly for assembly. The covers have letters cast on the outer surface for identification.

Use Servo Removal Tool to release the intermediate band servo piston.





27. Remove the intermediate band servo cover, piston and spring.





28. CAUTION: Servo cover is under spring tension.

Remove the overdrive servo cover.
1 Install Servo Cover Compressor and compress the overdrive servo cover.
2 Remove the overdrive servo cover retaining ring.
- Remove Servo Cover Compressor.





29. Note: Use Servo Removal Tool to prevent damage to the servo, cover and bore.

Note: Tag the servo cover, piston and servo piston spring. Label accordingly for assembly. The covers have letters cast on the outer surface for identification.

Use Servo Removal Tool to release the overdrive band servo piston.





30. Remove the overdrive band servo cover, piston and spring.





31. WARNING: Make sure the lock pin on bench mounted holding fixture is secure. Failure to follow these instructions may result in personal injury.

Rotate the transmission so the converter housing faces up.





32. CAUTION: Discard the screws. The screws are not reusable for assembly.

Remove and discard the screws.
33. Remove the converter housing and fluid pump support.
- Turn and lift the converter housing and fluid pump support from the case.





34. Remove the fluid pump input thrust washer (No. 1).
- Tag and identify the thrust washer.





35. Remove the overdrive band adjusting screw.





36. Compress the overdrive band around the overdrive brake and coast clutch drum and remove the overdrive band anchor strut.





37. CAUTION: Identify the anchor and apply ends of the overdrive band.

Remove the overdrive band.





38. Remove the overdrive brake and coast clutch drum.





39. Remove the overdrive band apply strut.





40. Note: The overdrive band lever shaft is longer than the intermediate band lever shaft.

Remove the overdrive band actuating lever shaft.





41. CAUTION: Do not bend trigger wheel.

Note: The No. 2 thrust bearing is in this assembly.

Remove the planetary gear front carrier.





42. Note: Tag and identify the overdrive band servo lever. The overdrive servo band lever has a letter stamped on the side.

Remove the overdrive servo band lever and overdrive band lever to case bracket.





43. Remove the overdrive planet thrust bearing (No. 2).