Part 1
Part 1 of 5WARNING: Before using an air line ensure all necessary safety precautions are taken to prevent personal injury, i.e., safety glasses, protective clothing etc.
Remove Torque Converter
1. Place transmission into the transmission holding fixture LST118 and tighten.
NOTE: Care must be taken not to over-tighten as casing will distort.
2. Using the torque converter handles 18G1501 remove the converter from the bell housing.
CAUTION: Ensure no damage occurs to the pump bush and seal ring lip when removing the torque converter. The converter is still full of oil even after the transmission has been drained, so care should be taken when removing the unit.
Remove Valve Body
1. Turn the transmission upside down in the fixture.
2. Remove the six bolts and retaining plates which hold the oil pan.
3. Remove the oil pan and rubber seal and discard seal.
4. Using Torx bit TX27, unscrew the three Torx headed bolts which hold the oil screen and remove. Separate the oil screen from the suction tube and discard the two O-rings and oil screen.
5. Using Torx bit TX27, unscrew the thirteen Torx headed bolts which retain the valve block to the transmission.
6. Using circlip pliers remove the eight circlips.
7. Remove the eight springs (four short springs at the front of the transmission and four long springs at the rear of the transmission).
8. Remove the eight sealing rubbers using tool LST113 and discard.
9. Remove the circlip, spring and using the tool LST113 remove the restrictor at the rear of the transmission.
Remove Parking Pawl and Governor
1. Engage PARK position.
2. Using a suitable wrench unscrew the coupling shaft bolt and remove the O-ring.
3. Remove the coupling shaft.
4. Remove the nine bolts and washers from the extension housing.
5. Remove the extension housing and gasket from the transmission and discard the gasket.
6. Disengage PARK position.
7. Withdraw the parking wheel and governor hub.
8. Unscrew the bolt which retains the guide plate using Torx bit TX27.
9. Disengage the spring and remove, also the pin and pawl.
NOTE: Take care when removing the assembly. Do not damage parts which could weaken the spring tension.
10. Using Torx bit TX30 remove the ten Torx bolts from the rear of casing.
Remove Inhibitor Switch
1. Using a suitable wrench remove the bolt and spring washer.
2. Remove the retaining plate.
3. Using a suitable tool remove the inhibitor switch from the casing.
4. Discard switch if damaged.
Remove Bell Housing and Intermediate Plate
1. Using a suitable socket wrench remove the twelve bolts (inside diameter bolt pattern) holding the bell housing.
2. Remove the bell housing and intermediate plate assembly complete, and discard the gasket.
3. Remove the thrust washer, axle bearing and disc washer from the input shaft.
NOTE: Under normal working conditions there is no need to separate the bell housing from the intermediate plate assembly.
Remove A Clutch Assembly
1. Turn transmission with front facing upwards.
2. Remove input shaft and A clutch assembly from transmission.
3. Remove inner carrier A; disc, axial bearing and thrust washer.
Remove B Clutch Assembly
1. Using two suitable screwdrivers remove the small snap ring in cylinder B.
2. Using the B clutch assembly puller hooks LST115 remove the B clutch assembly.
NOTE: To remove assembly, lift up cylinder B until it stops, push assembly back down and lift up again using more weight.
3. Remove support ring and O-ring.
Remove C, C1 and D Clutch Assembly
1. Using a suitable screwdriver remove center plate snap ring via a hole in the casing.
2. Using tool LST117 attached to intermediate shaft remove C, C1 and D clutch assembly.
3. Remove disc, axial bearing and thrust washer.
Remove 4th Gear Assembly
1. Turn transmission to the horizontal position.
2. Push assembly out from the rear, guiding it from the front of the casing.
Transmission Gear Selector Assembly and Kickdown Cable - Remove and Overhaul
1. Remove the kickdown cable from the cam.
2. Using kickdown cable remover LST112, remove the kickdown cable from the casing.
3. Using a punch remove the roll pin from the selector shaft.
4. Using a pair of pliers or grips pull the selector shaft from the casing.
5. Remove the stop washer, connection rod, cam and leg spring.
6. Using a screwdriver pry out the seal ring located in the transmission casing and discard.
NOTE: At this stage the transmission is totally stripped.
7. Inspect and clean casing ensuring no damage has occurred.
Assemble
2. Fit new seal ring into transmission casing using selector shaft oil seal replacer LST114.
3. Fit connection rod into the stop washer.
4. Place stop washer with connection rod into the transmission casing and then feed the selector shaft into the casing.
5. Fit the leg spring onto the cam.
6. Place the assembly into the transmission casing and push the selector shaft through until the hole in the shaft aligns with the hole in the stop washer.
7. Using a suitable punch, fit roll pin with the open side facing the rear of the transmission casing.
8. Fit new kickdown cable assembly into its seat on the transmission casing.
9. Fit the nipple of the kickdown cable into the cam seat ensuring the cam has been turned one revolution to load the spring.
NOTE: After transmission has been refitted check the kickdown cable and gear selector adjustments are correct.