Part 1
AUTOMATIC TRANSMISSION DISASSEMBLY1. Place the transmission on a workbench.
2. Remove the Torque Converter Hold Down Tool SST 307-346 (T97T-7902-A) or equivalent if necessary.
3. If equipped, remove the transfer case from the transmission.
Warning: The torque converter is heavy, especially when full of fluid.
4. Using Torque Converter Handles SST 307-091 (T81P-7902C) or equivalent, remove the torque converter.
1) Install the SSTs.
2) Remove the torque converter.
5. Remove the input shaft.
Note: The splines on the input shaft are not the same on both ends. The end with the shorter spline goes into the assembly.
6. Remove the screw (1) and output shaft speed (OSS) sensor (2) (4.0L only).
7. Remove the heat shield (4.0L only).
8. Remove manual control outer lever nut and manual control outer lever.
9. Remove the digital transmission range (TR) sensor.
1) Remove the bolts.
2) Remove digital TR sensor.
10. Use Impact Slide Hammer SST 49 0223 630B and Seal Puller SST 49 UN01 080 to remove extension housing seal.
11. Use the Extension Housing Bushing Remover SST 307064 (T77L-7697-E) or equivalent to remove the extension housing bushing.
1) Inspect the extension housing bushing and driveshaft slip-yoke for nicks, gauges, scoring, and wear.
Note: Remove the extension housing bushing only if service is required.
Caution: The parking pawl, parking pawl return spring and parking pawl shaft could fall out during removal of the extension housing.
12. Remove the extension housing screws, stud, and the extension housing.
1) Discard the extension housing gasket.
13. Remove the parking pawl assembly.
1) Remove the parking pawl shaft.
2) Remove the parking pawl.
3) Remove the parking pawl return spring.
Caution: The parking pawl actuating rod must slip freely into the clearance hole in the adapter plate.
14. Install Holding Fixture Adapter.
1) Position the Holding Fixture Adapter SST 307-262 (T93T-77002-AH) or equivalent on the rear of the transmission case.
2) Install the screws.
15. Attach the fixture arm of Bench Mounted Holding Fixture SST 307-003 (T57L-500-B) or equivalent to Holding Fixture Adapter SST 307-262 (T93T-77002-AH) or equivalent.
Warning: Make sure the lock pin on bench-mounted holding fixture is secure.
16. Install the transmission into Bench Mounted Holding Fixture SST 307-003 (T57L-500-B). Rotate transmission so oil pan is facing up.
Note: If these tools are unavailable, use Carrier Hanger SST 49 M005 561.
Caution: Do not reuse the oil pan gasket.
17. Remove the oil pan and oil pan gasket and then discard gasket.
18. Remove the oil strainer and discard.
1) Remove the oil strainer screw.
2) Remove the oil strainer.
19. Carefully lift up on the wire loom guide and protector. Disengage the retaining pins from the solenoid clamps.
20. Disconnect the solenoid electrical connectors.
1) Disconnect the SS1, SS2, SS3, and the CCS (4R44E) or SS4 (5R55E) electrical connectors.
2) Disconnect the torque converter clutch (TCC) solenoid electrical connector.
3) Disconnect the electronic pressure control (EPC) solenoid electrical connector.
21. Remove the detent spring.
1) Remove the detent screw.
2) Remove the detent lever spring.
Warning: The piston assembly can pop out due to spring pressure when removing the cover.
22. Remove the reverse band servo cover.
1) Remove the reverse servo cover bolts.
2) Remove the reverse band servo cover and the reverse servo separator plate cover gasket. Discard the gasket.
23. Remove the reverse band servo piston and rod assembly.
Caution: To prevent solenoid valves from failing out, do not remove the two screws shown in the illustration.
24. Do not remove the two (gold colored) screws specified.
25. Remove the 23 main control valve body bolts.
Note: Use a 10 mm socket to remove the sixteen M6 X 40 MM, four M6 X 45 MM and three M6 X 35 MM main control valve body bolts.
26. Remove the main control valve body, valve body separator plate and main control to case gaskets. Discard gaskets.
Caution: Throw the locknuts away. The locknuts are not reusable for assembly.
27. Remove the locknuts. Back off screws.
Caution: Servo cover is under spring tension.
28. Remove the intermediate servo cover retaining ring.
1) Install Servo Compressor SST 49 UN01 144. Using 1/2 inch wrench, tighten nut on J-hook until there is a gap between cover and snap ring.
2) Remove the snap ring.
3) Remove Servo Compressor SST 49 UN01 144.
29. Remove servo cover, piston and spring by gently pushing on hook-type tool. Use a small piece of cardboard or similar material to prevent tool from damaging passage.
Note: Tag the servo cover, piston and spring. Label accordingly for assembly. The covers have letters cast on the outer surface for identification.
30. Remove the intermediate band servo cover, piston, and spring.
Caution: Servo cover is under spring tension.
31. Remove the overdrive servo cover.
1) Install Servo Compressor SST 49 UN01 144 and compress the overdrive servo cover. Using 1/2 inch wrench, tighten nut on J-hook until there is a gap between cover and snap ring.
2) Remove the snap ring.
3) Remove Servo Compressor SST 49 UN01 144.
32. Remove servo cover, piston and spring by gently pushing on hook-type tool. Use a small piece of cardboard or similar material to prevent tool from damaging passage.
Note: Tag the servo cover, piston and servo piston spring. Label accordingly for assembly. The covers have letters cast on the outer surface for identification.
33. Remove the overdrive band servo cover, piston and spring.
Warning: Make sure the lock pin on bench mounted holding fixture is secure. Failure to follow these instructions may result in personal injury.
34. Rotate the transmission so the converter housing faces up.
35. Remove the converter housing-to-case screws. Discard the screws.
Caution: Discard the screws. The screws are not reusable for assembly.
36. Remove the converter housing and oil pump support.
1) Turn and lift the converter housing and oil pump support from the case.
37. Remove the oil pump input thrust washer (No. 1).
1) Tag and identify the thrust washer.
38. Remove the overdrive band adjusting screw.
39. Compress the overdrive band around the overdrive brake and coast clutch drum and remove the overdrive band anchor strut.
Caution: Identify the anchor and apply ends of the overdrive band.
40. Remove the overdrive band.
41. Remove the overdrive brake and coast clutch drum.
42. Remove the overdrive band apply strut.
Note: The overdrive band lever shaft is longer than the intermediate band lever shaft.
43. Remove the overdrive band actuating lever shaft.
Caution: Do not bend trigger wheel.
Note: The No. 2 thrust bearing is in this assembly.
44. Remove the planetary gear front carrier.
Note: Tag and identify the overdrive band servo lever. The overdrive servo band lever has a letter stamped on the side.
45. Remove the overdrive servo band lever and overdrive band lever to case bracket.
46. Remove the overdrive planet thrust bearing (No. 2).
47. Remove the overdrive ring gear, overdrive one-way clutch assembly, and center shaft as an assembly.
48. Remove the No. 3 center shaft thrust bearing.
Note: Tag and identify the center shaft thrust bearing (No. 3) for assembly.
Caution: The center support locknut could fall into the remaining assembly if not removed. This is not serviced separately.
49. Remove the M6 X 20 center support cap screw using a 5 mm alien wrench.
