Disassembly

Transmission













1. Remove the Torque Converter Retainer.





2. WARNING: Secure the torque converter in the transmission during removal or installation. The torque converter is heavy and may result in injury if it falls out of the transmission. Failure to follow this instruction may result in serious personal injury.

NOTE: Transmission fluid loss will occur when removing the torque converter.

Using the Torque Converter Handles, remove the torque converter.





3. Remove the Turbine Shaft Speed (TSS) and intermediate shaft speed sensor.

1. Remove the bolt.

2. Remove the sensor.





4. Remove the Output Shaft Speed (OSS) sensor.

1. Remove the bolt.

2. Remove the sensor.





5. Mount the transmission onto a suitable stand.

6. Remove the input shaft.





7. Install a new transmission fluid drain plug and seal assembly if there is evidence of leaking.





8. NOTE: Do not discard the transmission fluid pan gasket unless damaged. This is a reusable transmission fluid pan gasket.

Remove the transmission fluid pan and the gasket. Check and clean the magnet if foreign material is evident.





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

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





10. NOTICE: There is no retainer on the manual valve. Hold the manual valve in place while removing the solenoid assembly from the transmission to avoid dropping the valve.

Remove the solenoid body.

1. Disconnect the Transmission Range (TR) sensor.

2. Remove the solenoid body bolts.

3. Remove the solenoid body.





11. Remove and discard the solenoid body gasket.





12. Remove the feedbolts.





13. Remove and discard the front pump bolts.





14. Using the Transmission Fluid Pump Remover and Slide Hammer, remove the front pump.





15. NOTE: The No. 1 pump thrust washer and the No. 2A Overdrive (O/D) sun gear thrust bearing may stay with the pump.

Remove the No. 1 pump thrust washer.

1. Remove the No. 1 pump thrust washer.

2. Remove the No. 2A O/D sun gear thrust bearing.

3. Remove the pump gasket and discard.





16. Remove the O/D separator plates, clutch plates and O/D pressure plate.





17. Remove the O/D clutch retaining ring.





18. Install the Clutch Loading Fixture.





19. NOTE: The No. 3 O/D carrier thrust bearing and race assembly may come out with the coast clutch cylinder assembly or it may stay in the transmission.

Using the Clutch Loading Fixture, remove the coast clutch cylinder assembly.





20. Remove the No. 4 thrust bearing.





21. Remove the O/D ring gear and center shaft.





22. Remove the No. 5 sun gear thrust bearing.





23. Using the Retaining Ring Pliers, remove the center support retaining ring.





24. Install the Coast Clutch Fixture Body and Coast Clutch Fixture Handle into the center support assembly.





25. Using the Coast Clutch Fixture Body and Coast Clutch Fixture Handle, remove the center support, direct clutch and forward clutch cylinder assembly.





26. Remove the forward clutch hub and the No. 9 thrust washer.





27. Remove the forward ring gear and hub assembly.





28. Remove the forward carrier race and the No. 11 bearing assembly.





29. Remove the forward carrier.





30. Remove the sun gear and the No. 12 thrust bearing.





31. Remove the low reverse sun gear and shell assembly.





32. Remove and discard the low/reverse clutch retaining ring.





33. Remove and discard the low/reverse clutch retaining ring.





34. NOTE: The output hub and ring gear assembly may stick to the low/reverse rocker clutch, clutch pack and carrier and hub assembly.

Remove the rocker clutch, low/reverse clutch pack and carrier and hub assembly.





35. Remove the No. 15 thrust bearing.





36. Place the transmission manual control lever in PARK to lock the output shaft from rotating.

37. Remove the output hub and ring gear.





38. Remove the low reverse No. 16 thrust bearing.





39. If equipped, remove the output shaft flange.

1. Remove and discard the bolt.

2. Remove the output shaft flange.





40. If equipped, use the Output Shaft Locknut Socket to remove and discard the output shaft retaining nut.





41. If equipped with a fixed flange, use the Torque Converter Fluid Seal Remover along with the Transmission Extension Housing Seal Remover and Slide Hammer to remove the output shaft seal.





42. If equipped with a slip yoke, use the Torque Converter Fluid Seal Remover along with the Transmission Extension Housing Seal Remover and Slide Hammer to remove the output shaft seal.





43. Remove the 9 bolts and the extension housing.





44. Inspect the extension housing ball bearing. If any damage is evident, install a new extension housing. Check the output shaft journal.





45. Remove and discard the extension housing gasket.





46. Remove the output shaft.





47. For vehicles equipped with a fixed yoke, remove the No. 17 park gear thrust washer.





48. For vehicles equipped with a slip yoke, remove the No. 17 park gear thrust bearing.





49. NOTICE: Do not fully compress the return spring or damage to the spring may occur.

Using the Clutch Spring Compressor Aligner and Clutch Spring Compressor, remove and discard the reverse clutch return spring retaining ring.





50. Remove the return spring.





51. While applying air to the bottom of the case, remove and discard the reverse piston.





52. Remove the parking rod guide plate bolts and plate.





53. Remove the plastic orifice lube plug from the rear of the case and discard.





54. Remove the parking pawl.

1. Remove the parking pawl return spring.

2. Remove the parking pawl.

3. Remove the parking pawl shaft.





55. NOTICE: The Torx head screw has a threadlocking compound and should be removed only if a new case is being installed. If the bolt is removed, it must be discarded and a new bolt installed.

Remove the parking pawl abutment.





56. NOTE: The pin should be driven down into the case.

Using a suitable tool, remove and discard the manual control lever shaft retaining pin.





57. Using the Roll Pin Set, remove the manual control lever shaft retaining pin.





58. Remove the manual control lever shaft.





59. Remove the TR sensor, manual control lever and park rod as an assembly.





60. Using the Pilot Bearing Remover, remove and discard the manual control lever seal.





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

If required, remove the short transmission fluid inlet tube.





62. NOTE: The top portion seal groove will work the best when removing the seal pack.

Inspect the rear case Teflon(R) seal retainer for damage. If damage is evident, use the Output Shaft Seal/Housing Remover and Handle to remove the seal retainer.





63. If equipped, remove the Power Take-Off (PTO) plate. Inspect the case assembly for cracks and stripped threads. Inspect the gasket surfaces and mating surfaces for burrs. Check the case vent assembly and all transmission fluid passages for obstructions.

64. Inspect the rear case snubber bushing. If damage is found, install a new transmission case.

65. Inspect the case assembly bushing for scores. Check all parking linkage parts for wear or damage.

66. Inspect the reverse clutch case vent for blockage. The vent is located in the case at the 12 o'clock position. If evidence of blockage is found, use low air pressure to clear out the blockage. Apply air pressure to the extension housing side of the vent.

67. If the low/reverse clutch-to-case snap ring has rotated in the case snap ring groove, or is partially dislodged, the case snap ring groove has been damaged. To avoid repeat repairs, use a new case for the overhaul.

68. If equipped with a Power Take-Off (PTO) cover, remove the PTO cover and discard the PTO gasket. Inspect the gasket surface and cover surface for damage.

69. If installing a new case, remove the transmission fluid cooler tube fittings and replace the O-rings.