Disassembly
DISASSEMBLY1. Remove torque converter.
2. Remove clamps attaching wire harness and throttle cable (Fig. 13) to transmission.
3. Remove shift lever from manual valve shaft at left side of transmission.
4. Remove transmission range sensor.
5. Remove speed sensor.
6. Remove converter housing bolts and remove housing (Fig. 14) from case.
7. Remove adapter housing, speedometer drive gear, and speed sensor rotor.
8. Remove transmission oil pan, oil screen and screen gaskets (Fig. 15).
9. Remove valve body oil feed tubes (Fig. 16).
10. Disconnect valve body solenoid wires (Fig. 17).
11. Remove harness bracket bolt and remove harness and bracket (Fig. 18).
12. Remove valve body bolts (Fig. 19).
13. Disconnect throttle cable from throttle cam (Fig. 20).
14. Remove valve body from case. Then remove accumulator springs, check ball, and spring (Fig. 21).
15. Remove second brake and clutch accumulator pistons with compressed air (Fig. 22). Apply air pressure through feed port and ease the pistons and springs out of the bore. Note and identify the original location of all springs.
16. Remove overdrive brake accumulator piston with compressed air (Fig. 22). Note and identify the original location of all springs.
17. Remove overdrive clutch accumulator piston with compressed air (Fig. 22).
18. Remove throttle cable.
19. Remove oil pump bolts and remove pump with bridge-type Puller 7536 (Fig. 23).
20. Remove race from oil pump (Fig. 24).
21. Remove overdrive planetary gear and clutch assembly (Fig. 25).
22. Remove race from overdrive planetary (Fig. 26).
23. Remove thrust bearing, race and overdrive planetary ring gear (Fig. 27).
24. Measure stroke length of overdrive brake piston as follows:
a. Mount dial indicator on case using Miller Tool C-3339 and a suitable bolt threaded into the transmission case.
b. Verify that the dial indicator is mounted solidly and square to the direction of the piston travel.
c. Apply 57-114 psi air pressure through piston apply port and note piston stroke on dial indicator. Stroke length should be: 1.40 - 1.70 mm (0.055 - 0.0699 inch).
d. Record the reading for use during re-assembly.
e. Remove the dial indicator set-up from the transmission.
25. Measure stroke length of second coast brake piston rod as follows:
a. Install a small wire tie strap around the second coast brake piston rod tight against the transmission case.
b. Apply 57-114 psi air pressure through piston feed hole and check stroke length with Gauge Tool 7552.
c. Stroke length should be 1.5 - 3.0 mm (0.059 - 0.118 inch).
d. Record the reading for use during re-assembly.
26. Remove the bolt holding the input speed sensor to the transmission case.
27. Remove the input speed sensor from the transmission case.
28. Remove overdrive brake pack snap-ring (Fig. 28).
29. Remove overdrive brake pack discs and plates. Inspect and replace as necessary.
30. Remove overdrive support lower race and upper bearing and race assembly (Fig. 29).
31. Remove overdrive support snap-ring with Snap-Ring Plier Tool 7540 (Fig. 30).
32. Remove overdrive support bolts (Fig. 31).
33. Remove overdrive support (Fig. 32) with bridge-type Puller 7536.
34. Remove race from hub of overdrive support (Fig. 33).
35. Remove second coast brake piston snap ring with Snap-Ring Plier Tool 7540. Then remove piston cover and piston assembly.
36. Disassemble second coast brake piston (Fig. 34), if necessary.
37. Remove direct and forward clutch assembly (Fig. 35).
38. Remove thrust bearing and race from clutch
39. Remove second coast brake band E-ring from band pin and remove pin and brake band (Fig. 37).
40. Remove front planetary bearing race and remove front planetary ring gear (Fig. 38).
41. Remove thrust bearing and rear race from ring gear (Fig. 39).
42. Remove planetary thrust race.
43. Push forward on output shaft to relieve the load on the planetary snap-ring.
44. Remove planetary snap-ring and remove planetary gear (Fig. 40).
45. Remove sun gear, input drum, one-way clutch, and thrust washer as assembly (Fig. 41).
46. Measure second brake clutch pack clearance (Fig. 42). Clearance should be 0.62 - 1.98 mm (0.0244 - 0.0780 inch). Record measurement for use during re-assembly.
47. Remove second brake clutch pack snap-ring (Fig. 43).
48. Remove second brake clutch pack (Fig. 44). Inspect and replace as necessary.
49. Remove bolts attaching park rod bracket to case. Then disconnect park rod from manual shaft lever and remove rod and bracket (Fig. 45).
50. Remove park pawl spring, pin and pawl (Fig. 46).
51. Measure clearance of first-reverse brake clutch pack (Fig. 47). Clearance should be: 0.70 - 1.2 mm (0.028 - 0.047 inch). Record measurement for use during re-assembly.
52. Remove second brake piston sleeve (Fig. 48).
53. Remove second brake snap-ring.
54. Remove rear planetary gear, second brake drum and output shaft as an assembly (Fig 49).
55. Remove planetary and brake drum thrust bearing and race assembly (Fig. 50).
56. Remove second brake drum gasket from case with screwdriver.
57. Measure inside diameter of transmission case rear bushing with bore gauge or inside micrometer (Fig. 51). Maximum allowable diameter is 38.18 mm (1.5031 inch). Replace transmission case if bushing I.D. is greater than specified. Bushing is not serviceable.
58. Check first/reverse brake piston operation with compressed a (Fig. 52). Piston should move smoothly and not bind or stick. If piston operation is incorrect, case or piston may require replacement.
59. Compress piston return springs with Tool 7539 and remove piston snap-ring (Fig. 53).
60. Remove Tool 7539 and remove piston return springs.
61. Remove No. 2 first-reverse brake piston with compressed air. Apply air through same transmission feed hole used for checking piston operation.
62. Remove reaction sleeve with Sleeve Remover Tool 7542 (Fig. 54). Insert tool flanges under sleeve and lift tool and sleeve out of case.
63. Remove No. 1 first/reverse brake piston with Piston Puller 7543 (Fig. 55). Slip tool under piston and lift tool and piston out of case.