Overhaul (Disassembly)

Transmission











Special Tool(s)

CAUTION: The screws are not reusable for assembly. Discard the screws. If the screws are reused, the housing may become separated from the transmission.

NOTE: The transmission fluid pan gasket is reusable. Clean and inspect the gasket for damage. If not damaged, the gasket should be reused. Tag and identify all parts for reassembly.








1. Illustration 1 of 2. Remove the components in the order indicated in the illustration and table.











2. Illustration 2 of 2. Remove the components in the order indicated in the illustration and table.

Item 1: Torque Converter Disassembly Note





1. WARNING: The torque converter is heavy, especially when full of fluid.

NOTE: If not installing a new torque converter, leave the adapter plate screwed to the torque converter.

Using the special tools, remove the torque converter and adapter plate as an assembly.

Item 2: Transmission Disassembly Note





1. Using the special tool. install the transmission into the bench with the torque converter housing facing up.

Item 9: Output Shaft Flange Disassembly Note





1. Using the special tool, remove the output shaft flange.

Item 10: Output Shaft Seal Disassembly Note





1. Using the special tools, remove the extension housing seal.

Item 12: Extension Housing Disassembly Note





1. CAUTION: The parking pawl, parking pawl return spring and parking pawl shaft could fail out during removal of the extension housing.

Remove the extension housing.

Item 25: Reverse Servo Piston Disassembly Note





1. WARNING: The upper and lower servo covers are under spring tension. Use care when removing the piston and cover assembly. Failure to follow these instructions may result in personal injury.

Item 28: Solenoid Body Disassembly Note





1. CAUTION: Do not damage solenoid body connector pins.

Remove the solenoid body assembly by lifting on the body and pushing the connector from the other side of the case.

Item 33: Front Pump Fluid Seal Disassembly Note





1. Using the special tools, remove the converter hub seal.

Items 34 and 35: Band Adjusting Locknut and Screw Disassembly Note





1. CAUTION: Failure to loosen the OD band adjusting screw prior to pump removal may cause damage to the pump and OD band. Throw the locknuts away. The locknuts are not reusable for assembly.

Remove the locknuts, and loosen the OD band adjusting screw.

Item 36: Band Anchor Strut Disassembly Note





1. Remove and tag part for assembly

Item 37: Front Pump Screws Disassembly Note





1. CAUTION: The screws are not reusable for assembly. Discard the screws. If the screws are reused, the housing may become separated from the transmission.

Remove and discard the screws.

Item 38: Front Pump Disassembly Note





1. Install the special tool.





2. Using the special tools, remove the pump.

Item 40: Intermediate Servo Retaining Ring Disassembly Note





1. CAUTION: Servo cover is under spring tension.

Using the special tool, remove the intermediate servo cover retaining ring.

Item 44: Overdrive Servo Cover Retaining Ring Disassembly Note





1. CAUTION: Servo cover is under spring tension.

Using the special tool, remove the overdrive servo cover retaining ring and cover.

Item 49: Band Strut Disassembly Note





1. NOTE: Tag and identify parts for reassembly.

Compress the overdrive band and remove the apply strut.

Item 50: Intermediate Overdrive Band Disassembly Note





1. CAUTION: Identify the anchor and apply ends of the overdrive band.

NOTE: The overdrive band is new, and dark in color. This is a normal condition of the band. Hairline cracks in the band are also considered normal. Do not install a new band based solely on the color.

Remove and inspect the overdrive band. Check the following conditions for installing a new band:
^ Inspect for glazing.
^ Inspect for missing friction material.
^ Inspect for material flaking.
^ Inspect for damage to the anchor pins.

Item 52: Overdrive Planetary Gear Carrier Disassembly Note





1. CAUTION: Do not bend the trigger wheel.

NOTE: The No. 12 thrust bearing is in this assembly.

Remove the planetary gear overdrive carrier

Item 55: Center Shaft and Forward Clutch Cylinder Bearing Assembly No. 3 Disassembly Note





1. NOTE: Tag and identify the center shaft thrust bearing No. 3 for reassembly.

Remove the No. 3 center shaft thrust bearing.

Item 56: Center Support Bolt Disassembly Note





1. CAUTION: The center support locknut could fall into the remaining assembly if not removed.

Remove the bolt.

Item 59: Center Support Assembly Disassembly Note





1. CAUTION: The center support locknut could fall into the remaining assembly if not removed.

Remove the screw.

Item 59: Center Support Assembly Inspection Note

NOTE: The center support is repaired as an assembly. Any damage requires installing a new component.





1. Inspect the center support assembly for wear or damage.
1 Inspect the thrust surfaces for wear, scoring or damage.
2 Inspect the center support sealing surface.
3 Inspect the fluid passage for blockage or damage.





2. Inspect the seal rings for damage.





3. Inspect the bearing for missing rollers or damage.





4. Inspect the direct clutch feed hole for blockage or damage.
1 Rotate center support bearing to locate the direct clutch feed hole.
2 Inspect the direct clutch feed hole for blockage or damage.

Item 60: Intermediate Clutch Drum Bearing (Select Fit) No. 4 Disassembly Note





1. NOTE: Tag and identify the No. 4 intermediate clutch drum thrust bearing.

Remove the No. 4 intermediate brake drum thrust bearing.

Item 61: Band Anchor Strut Disassembly Note





1. Remove, tag, and identify the band anchor strut.

Item 62: Intermediate Band Disassembly Note





1. CAUTION: Identify the anchor and apply ends of the intermediate band.

NOTE: The intermediate band is new, and dark in color. This is a normal condition of the band. Hairline cracks in the band are also considered normal. Do not install a new band based solely on the color.

Remove and inspect the intermediate band. Check the following conditions when installing a new band:
^ Inspect for glazing.
^ Inspect for missing friction material.
^ Inspect for material flaking.
^ Inspect for damage to the anchor pins.

Item 63: Band Apply Strut Disassembly Note





1. Remove, tag, and identify the band apply strut.

Item 65: Intermediate Brake Drum Assembly Disassembly Note





1. NOTE: The No. 5 forward clutch cylinder thrust bearing may come out with the intermediate brake and direct clutch drum.

Remove the direct clutch drum.

Item 66: Center Shaft and Forward Clutch Cylinder Bearing Assembly No. 5 Disassembly Note





1. Remove the No. 5 forward clutch cylinder thrust bearing, tag and identify.

Item 67: Forward Clutch Cylinder Assembly Disassembly Note





1. NOTE: The No. 6A thrust bearing may come out with the cylinder. Tag and identify for reassembly.

Remove the forward clutch cylinder.

Item 68: Forward Ring Gear Hub Thrust Bearing No. 6A Disassembly Note





1. NOTE: The No. 6A forward ring gear hub thrust bearing may have come out with the forward clutch cylinder.

Remove the No. 6A forward ring gear hub thrust bearing.

Items 69 and 70: Forward Ring Gear and Hub Assembly and Forward Clutch Hub Thrust Washer No. 6B Disassembly Note





1. NOTE: The No. 7 forward planet thrust bearing may come out with the forward ring gear and hub assembly.

Remove the forward ring gear and hub as an assembly.





2. Remove the No. 6B forward clutch thrust washer from the forward ring gear hub.

Item 71: Forward Planetary Thrust Bearing Assembly No. 7 Disassembly Note





1. NOTE: The No. 7 forward planet thrust bearing may come out with the forward ring gear and hub assembly.

Remove the No. 7 forward planet thrust bearing.

Item 72: Forward Planet Assembly Disassembly Note





1. Remove the forward planetary assembly.

Item 75: Center Shaft and Forward Clutch Cylinder Bearing Assembly No. 8 Disassembly Note





1. NOTE: Tag and identify the No. 8 low/reverse planetary carrier thrust bearing.

Remove the thrust bearing.

Item 78: Center Shaft and Forward Clutch Cylinder Bearing Assembly No. 9 Disassembly Note





1. NOTE: Tag and identify the No. 9 low/reverse planetary carrier thrust bearing.

Remove the thrust bearing.

Item 79: Output Shaft Sleeve Disassembly Note





1. NOTE: Use slots located around the outside of the sleeve.

Using a small pick, remove the output shaft sleeve.

Item 80: Output Shaft Retaining Ring Disassembly Note





1. WARNING: The output shaft may fall out after removing the snap ring. Failure to follow these instructions may result in personal injury.

CAUTION: Discard the output shaft retaining ring. A new retaining ring must be used for assembly.

While holding the output shaft, remove and discard the output shaft retaining ring.

Item 83: Reverse Band Actuating Lever Shaft Disassembly Note





1. CAUTION: Do not pry on the outer edge of the case. Damage to the gasket sealing surface could occur.

NOTE: It may be necessary to grind flat spots on the edges of the reverse band actuating lever shaft in order to remove it.

Using a pair of vice grips, hold the flat spots on the reverse band actuating lever shaft, wiggle it back and forth and remove the reverse band actuating lever shaft.

Item 85: Reverse Brake Drum and Clutch Assembly Disassembly Note





1. NOTE: The inner race of the rear one-way clutch is not removable. It is repaired in the case.

Remove the low/reverse brake drum and one-way clutch assembly by rotating it clockwise.

Item 85: Reverse Brake Drum and Clutch Assembly Inspection Note





1. NOTE: The reverse one-way clutch is part of the reverse brake drum assembly. Install a new reverse brake drum as an assembly only.

Inspect the reverse brake drum assembly and install a new reverse brake drum assembly if damaged.
1 Inspect the reverse brake drum sprays.
2 Inspect the reverse brake drum rollers.
3 Inspect the reverse brake drum.

Item 88: Output Shaft Thrust Washer Disassembly Note





1. NOTE: Tag and identify the No 11 output shaft thrust washer.

Remove the output shaft thrust washer

Item 89: Manual Control Lever Inner Nut Disassembly Note





1. CAUTION: To avoid damage, make sure the wrench does not strike the manual valve inner lever pin.

Remove the nut.

Item 93: Manual Control Lever Shaft Seal Disassembly Note





1. CAUTION: Do not damage the bore.

Remove the manual control lever seal.