Disassembly

Transmission

Special Tool(s)

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

NOTE: 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.

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

NOTE: Make an identifying mark on the nut, stud and adapter plate to allow for correct installation.

If the vehicle is equipped, and installation of a new or remanufactured torque converter is necessary, remove the torque converter adapter plate.

3. If the adapter has been removed use the special tool to remove the torque converter.

Item 2: Transmission Case Disassembly Note

1. WARNING: Make sure the lock pin on the bench-mounted holding fixture is secure. Failure to follow these instructions can result in personal injury.

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

Item 10: Output Shaft Seal (4x2) Disassembly Note

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

Item 12: Extension Housing (4x2) Disassembly Note

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

Remove the extension housing.

Item 13: Output Shaft Seal (4x4) Disassembly Note

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

Item 15: Extension Housing (4x4) 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.

Remove the reverse servo assembly

Item 31: 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 36: Front Pump Fluid Seal Disassembly Note

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

Item 37 and 38: 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.

CAUTION: Throw the locknuts away. The locknuts are not reusable for assembly.

Remove the locknuts, and loosen the OD band adjusting screw

Item: 39: Band and Anchor Strut Disassembly Note

1. Remove and tag part for assembly.

Item 40: 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 41: Front Pump Disassembly Note

1. Install the special tool.

2. Using the special tools, remove the pump.

Item 43: 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 47: 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 52: Band Apply Strut Disassembly Note

1. NOTE: Tag and identify part for assembly.

Compress the overdrive band and remove the apply strut.

Item 53: Overdrive Intermediate 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 55: 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 58: 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 assembly.

Remove the No. 3 center shaft thrust bearing.

Item 59: Center Support Bolt Disassembly Note

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

Remove the screw.

Item 62: Center Support Assembly Disassembly Note

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

1. NOTE: When removing the center support, pull evenly around the center support web.

Remove the center support.

Item 62: 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 the center support bearing to locate the direct clutch feed hole.
2 Inspect the direct clutch feed hole for blockage or damage.

Item 63: Intermediate Clutch Drum Bearing (Select Fit) No. 4 Disassembly Note

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

Remove the No. 4 intermediate brake drum thrust bearing.

Item 64: Band Anchor Strut Disassembly Note

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

Item 65: Overdrive 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 66: Band Apply Strut Disassembly Note

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

Item 68: 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.

1mItem 69: 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 70: Forward Clutch Cylinder Assembly Disassembly Note

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

Remove the forward clutch cylinder.

Item 71: 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.

Item 72 and 73: 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 74: 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 78: 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 81: 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 82: 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 83: 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 86: 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 can 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 88: 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 88: 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 91: Output Shaft Thrust Washer Disassembly Note

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

Remove the output shaft thrust washer.

Item 92: 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 97: Manual Control Lever Shaft Seal Disassembly Note

1. CAUTION: Do not damage the bore.

Remove the manual control lever seal.