Center Support and Gear Unit Assembly Disassemble

1. Separate the center support assembly (640) from the reaction drum and carrier assembly (651).
2. Remove the reaction drum thrust washer (642). The washer may be stuck to the center support.
3. Remove the sun gear shaft (649).





4. Inspect the sun gear shaft for the following:
- Nicked, scored or worn bushings
- Damaged splines and teeth
- Cracks





5. Remove the reaction drum and carrier assembly (51) from the output carrier assembly (661).
6. Remove the roller clutch assembly (644) from the reaction drum and carrier assembly (651).
7. Inspect the reaction drum and carrier assembly for the following:
- The pinion gear and pocket thrust surfaces for damage
- Cracks or damage to band apply surface
- Pinion gear damage
- Planet pinion pin for proper location (walking)
- The bushings for damage

8. Inspect the roller clutch assembly for damage to the rollers, springs and cage surfaces.





9. Remove the center support to reaction carrier thrust bearing (647).
10. Remove the thrust bearing races (646, 647). One race may be stuck to the center support.
11. Remove the sun gear (650).
12. Remove the front internal reaction carrier washer (659) from the carrier.
13. Inspect the thrust washers, the bearings and the races for damage.
14. Inspect the sun gear teeth for damage.





15. Turn the output carrier assembly (661) over so that the output shaft (671) faces up.
16. Remove the output shaft thrust washer (673).
17. Remove the output shaft retainer ring (672).
18. Remove the output shaft (671).
19. Inspect the output shaft for the following:
- Stripped splines
- Damaged teeth
- Cracks
- Damage to the bushing

20. Remove the thrust bearing (647, 648, 669) and the thrust bearing races from the rear internal ring gear (666). The thrust bearing may be stuck to the output shaft (671).
21. Inspect the thrust bearings and races for damage.





22. Remove the rear internal gear (666) and the main shaft (662) from the output carrier assembly (661).
23. Remove the rear internal gear thrust bearing (664) and races (663 and 665).
24. Inspect the thrust washers, the bearings, and races for damage.





25. Remove the main shaft retainer ring (670). Hold the main shaft so it will not fall and become damaged.
26. Remove the main shaft (662) from the rear internal gear (666).
27. Inspect the main shaft for damaged splines.
28. Inspect the main shaft for wear.
29. Inspect the rear internal gear for the following:
- Stripped splines
- Damaged teeth
- Wear





30. Clean all components thoroughly.
31. Inspect the output carrier assembly (661) for the following:
- Excessive wear
- Damage to the park pawl lugs
- Damage to the pinion gears
- Excessive wear to the pinion gear steel and brass washers for excessive wear
- Damage to the pinion gear and pocket thrust surfaces.

32. Inspect the front internal gear for damage and cracks.
33. Inspect the output speed sensor ring (660) for tightness and damage.