Unit Overhaul Part 1
TRANSMISSION DISASSEMBLYNOTE: During the disassembly and reassembly, perform the following:
- Wash each part thoroughly, and blow air through each oil passage and groove to eliminate blockage.
- Seal rings, roll pins, and gaskets should be replaced.
- When assembling the components, apply DEXRON (R) III Automatic Transmission Fluid (ATF) to each seal, rotating part, and sliding part.
- Do not dip part facings, such as clutch or brake drive plates, in cleaner when washing it. Also, always coat parts with new ATF two or three times after cleaning with solvent.
1. Remove torque converter (1).
- Drain fluid from torque converter.
- Attach J-8763-02 holding fixture to the transmission and set it on J-3289-20 holding fixture base.
NOTE: Do not overtighten the tool, as case damage may result.
2. Remove O-ring (2) from turbine shaft.
3. Remove two 10 mm mode switch screws, selector lever nut, cover, and mode switch (3).
4. Remove twelve 10 mm adapter case oil pan (4) fixing screws, adapter oil pan, and gasket.
5. Disconnect electrical wiring connection (5) from solenoids and 5 pin connector of adapter case. Pull on connectors only, not on wiring harness.
6. Remove seven 13 mm adapter case valve body (6) fixing screws, adapter case valve body assembly, transfer plate, and two gaskets.
- Remove wiring harness and 5 pin connector.
7. Remove sixteen 10 mm main case oil pan (7) fixing screws, main oil pan, magnet, and gasket.
8. Remove three 13 mm oil filter (8) fixing screws and oil filter.
9. Remove two 13 mm manual detent (9) fixing screws, roller and spring, and manual detent.
10. Disconnect wiring harness assembly (10) from band apply solenoid, shift solenoids, and main case 4 pin connector. Pull on connectors only, not on wiring harness.
11. Remove four 13 mm servo cover (11) fixing screws, servo cover, and gasket.
12. Remove seven 13 mm valve body screws and ground wire from main case.
- Remove wiring harness assembly (5) from the adapter case side.
- Remove main valve body assembly (12) with manual valve link and transfer plate. Note the position of the link (long end into valve, short end into range selector lever).
- Remove 4 pin connector.
- Remove gasket transfer plate from main case.
13. Remove two check balls (13) from main case.
14. Turn transmission to vertical position to drain fluid.
Return back to horizontal position when drained.
- Install J-23075 servo piston spring compressor with offset to the rear of case.
- Compress servo piston assembly.
- Remove servo piston retaining ring (14).
- Slowly release servo piston assembly (15).
- Remove tool.
15. Remove servo piston assembly (15), return spring (16), and servo apply rod (17).
16. Rotate transmission to horizontal position, pan side down.
- Remove one 10 mm screw, and speed sensor (18) with "0" ring.
17. Remove seven 8 mm extension housing hexagon socket head screws, extension housing assembly (19), and gasket.
18. Remove retaining ring (20).
NOTE: Use extra long, needle-nose pliers.
19. Remove speed wheel (21).
20. Remove wheel parking lock (with seal ring) (22).
21. Rotate transmission to vertical position, converter housing up.
- Loosen the converter housing and oil pump assembly fixing screws, but do not remove the five 13 mm inner screws if oil pump disassembly is required.
- Remove seven outer screws.
- Remove converter housing and oil pump assembly (23).
22. Remove gasket (24).
23. Remove selective thrust washer (25).
24. Remove fourth clutch retainer (26).
25. rasp turbine shaft and lift out the overrun clutch housing assembly (27) and fourth clutch plates (28).
26. Remove thrust bearing assembly (29).
27. Remove overdrive internal gear (30).
28. Remove thrust washer (31).
29. Remove adapter case and center support assembly (with fourth clutch piston (32).
30. Remove seal ring (33).
31. Remove selective thrust washer (34) and two O-ring seals (35) from main case.
32. Use J-23327 and J-23327-90 compressor to compress the fourth clutch spring retainer and springs (37).
- Release snap ring (36) from groove.
- Remove clutch compressor and snap ring (36).
33. Remove retainer and spring assembly (37).
34. Insert two converter housing/main case screws to hold adapter case while pulling out fourth clutch piston (38).
- Remove fourth clutch piston assembly (38) from the adapter case.
- Remove converter housing/main case screws.
35. rasp intermediate shaft, twist and pull out the second and third clutch drum assemblies with reverse clutch plates while holding onto output shaft (39).
36. Separate second (40) and third clutch (41) assemblies.
37. Remove thrust washer (42).
38. Remove reverse clutch plates (43 and 44) and reverse clutch pressure plate (45).
39. Remove bearing (46) and washer (47).
40. Remove planetary carrier assembly (48).
41. Remove thrust bearing (49).
42. Remove reaction sun gear (50)
43. Remove needle bearing (51).
44. Remove brake drum (52).
45. Remove brake band (53).
46. Remove thrust bearing (54).
47. Rotate case to horizontal position, valve body side facing up.
- Remove spring pin (55), using cuffing pliers, then remove parking lock and selector lever assembly (56).
NOTE: Insert wire in the center of the spring pin to prevent it from collapsing during removal. Be aware of in height. Protect machined face of main case.
48. Remove parking lock and range selector lever 17 Nm nut (57).
49. Remove parking lock and range selector lever (56), and actuator assembly.
50. Remove selector shaft (58).
NOTE: Inspect the shaft for burrs before removing to prevent damaging seal. If necessary, remove burrs by lightly sanding with an oilstone.
TRANSMISSION REASSEMBLY
1. Inspect selector shaft seal, and replace it if necessary.
NOTE: Use a seal installer when replacing the seal.
- Install selector shaft.
NOTE: Spring pin groove must be positioned inside the case.
2. Install spring pin. Be sure the selector shaft can move freely. Do not push the pin flush with the case surface. Leave enough height for removal.
3. Install actuator assembly (1).
4. Install parking lock and range selector lever (2) and new 17 mm nut. Tighten the nut to the specified torque.
Torque: 22 Nm (16 ft. lbs.)
5. Rotate main case to vertical position, extension end facing down.
- Install brake band assembly (3).
NOTE: Be sure to align servo pin area with the servo hole.
6. Install thrust bearing (4).
NOTE: The case bushing acts as a guide for the thrust bearing.
7. Install brake drum (5).
8. Install reaction sun gear (6).
9. Install needle bearing (7).
10. Inspect planetary carrier assembly (8) for wear and damage. If necessary replace it.
- Measure pinion end play clearance with a feeler gauge.
Clearance: 0.13 mm - 0.89 mm (0.005 inch - 0.035 inches)
If clearance is outside specified value, replace the planetary carrier assembly.
11. Install the thrust bearing (9) on the output shaft.
NOTE: Use petroleum jelly to hold the thrust bearing in place.
12. Align planetary pinions. Each pinion is marked with double points to indicate the master tooth space and exactly opposite with a single point to indicate the master tooth. The markings on the planetary carrier consist of double lines which are to be lined up with the double points on two opposite pinions; the single lines are to be lined up with the single points on the other two pinions.
- After all four pinions are lined up, slide on the third clutch assembly. Rotate third clutch and check mark alignment. Considering that the ring gear tooth between the double points of one planetary pinion is tooth number 1, count the teeth to check that the single points on the two adjacent pinions are between teeth 23 and 24 of the ring gear, and that the ring gear tooth between the double points of the opposite pinion is tooth number 46. If the ring gear and pinions are not lined up, remove, and realign them.
13. Install planetary carrier (8) with third clutch (12).
NOTE: Do not force. When properly aligned, the parts will fit together easily.
14. Remove the third clutch (112).
15. Install bearing (11) and washer (110).
NOTE: Use petroleum jelly to hold the washer and bearing in place.
16. Carefully align the second clutch plate inner tangs.
- Install thrust washer tangs pointing downward, and locating tang positioned in slot on second clutch hub.
NOTE: Use petroleum jelly to hold thrust washer in place.
17. Install third clutch and intermediate shaft assembly (13) into the second clutch drum (14).
18. Install second and third clutch assemblies into the main case. Twist output shaft and clutch assemblies to ensure proper fit.
19. Install pressure plate (15) with lip side up, tang facing valve body face.
20. Install reverse clutch plates. Start with a steel plate (17) and alternate with a lined plate (16).
21. Install waved clutch plate (18) with center tang facing valve body side.
22. Second clutch end play measurement
1. Install the J-23085-A Selective washer gauging tool (with spacer ring) on the case flange and against the intermediate shaft.
2. Position the inner shaft of the gauging tool against the thrust surface of the second clutch hub.
3. Tighten thumb screw. Remove the tool.
4. Fit the spacer ring on the inner shaft of the tool.
5. Measure the gap, and select the appropriate washer as shown in the chart.
23. Inspect fourth clutch piston seals and replace if necessary.
- Lubricate J-38554 fourth clutch piston fitter and install it on fourth clutch piston (19).
- Install fourth clutch piston (19) in adapter case (20).
- Remove fitter.
24. Install retainer and spring assembly (22) into fourth clutch piston (21).
25. Install snap ring (23) in adapter case.
- Install J-23327 and J-23327-90 fourth clutch spring compressor.
- Seat snap ring in groove.
- Remove compressor.
26. Install selective washer using petroleum jelly.
27. 1nstall two O-ring seals (24) in main case and adapter case/main case seal ring (25).
28. Install J-38588 guide pins.
- Install adapter case and center support assembly to main case.
29. Install thrust washer (26) into adapter case, with tangs pointing downwards.
30. Preassemble overdrive internal gear (27) and thrust bearing assembly (28) onto the turbine shaft and overrun clutch assembly.
NOTE: Install bearing assembly, black side up. Use petroleum jelly to keep assembly in place.
31. Install overdrive carrier (30) and internal gear assembly into adapter case.
32. Install fourth clutch plates (29) in the following order: Steel, Lined, Steel, Steel, Lined, Steel. Steel plates go in with short tang facing towards valve body surface.
33. Install fourth clutch retainer (31) with the notch facing up and positioned towards valve body surface.
34. Overdrive clutch end play measurement
1. Install the J-23085-A selective washer gauging tool on the adapter case flange and against the input shaft.
2. Position the inner shaft of the tool against the thrust surface of the overrun clutch housing.
3. Tighten thumb screw. Remove the tool.
4. Measure gap. Select appropriate size washer as shown in the chart.
5. Set selective thrust washer aside.
35. Install selective washer (32).
NOTE: Use petroleum jelly to hold selective washer in place.
36. Install gasket (33).
37. Install converter housing and oil pump assembly (34) to adapter case.
- Fit and tighten seven outer 13 mm screws.
Torque: 39 Nm (29 ft. lbs.)
- Ensure free rotation of pump using J-23082-01 oil pump rotation tool.
