Disassembly

NOTE:
^ After transmission is removed for a major overhaul, it is important to completely clean all transmission components, including torque converter , transmission cooler, cooler inlet tube, main control valve body, clutches and all coasting booster valve shuttle balls aver any transmission service that generates contamination. These contaminants are a major cause for recurring transmission concerns and must be removed from the system before the transmission is returned to service.
^ The cleaning of debris from the direct clutch check ball is often omitted. This omission can lead to a repeat servicing of the transmission.
^ Follow cleaning and flushing procedures for transmission components, including the direct clutch check bail.

PRELIMINARY PROCEDURES
Before beginning Disassembly, perform or inspect the following:
^ The transmission service area should be kept clean, well organized and supplied with clean, lint-free shop cloths.
^ Thorough cleaning of the transmission exterior will reduce the possibility that damaging contaminants might enter the subassemblies during disassembly and assembly.
^ If the transmission is being removed for major overhaul, it is important to completely clean all transmission components, including torque converter, cooler, cooler inlet tubes, main control valve body, all clutches and all coasting booster valve shuttle balls after any transmission servicing that generates contamination. These contaminants are a major cause for recurring transmission troubles and must be removed from the system before the transmission is returned to service. The cleaning of debris from the direct clutch check ball is often omitted. This omission can lead to a repeat servicing of the transmission.
^ Debris that collects and builds up in the corners of the stamped clutches must be removed.
^ The pan magnet should be removed from transmission pan and wiped clean along with the transmission pan.
^ Whenever a seal is removed from a piston, shaft or servo, note the type of seal and when applicable, the direction of the sealing lip.





PROCEDURE
1. Mount transmission in Bench Mounted Holding Fixture T57L-500-B.





2. Remove 14 pan retaining bolts, transmission pan and pan-to-case gasket.





3. Remove pan magnet. Clean transmission pan and pan magnet.





4. Using both hands, remove filter by pulling upward.

CAUTION: If installing a new filter, and grommet remains in the main control bore, carefully use a small screwdriver to remove the grommet. Use care not to damage the main control bore.

NOTE: If transmission is being serviced for a contamination-related failure, use a new filter and grommet. The filter may be reused if no excessive contamination is present.





5. Grasp connector at each solenoid or sensor and pull straight out to disconnect.

CAUTION: Do not pull on wires. This may damage wires or connectors and could result in a transmission concern. If required, carefully pry up on locking tab and disconnect the connector.





6. Remove bolt retaining output shaft speed sensor (OSS) to case and remove OSS.

NOTE: Removal of the OSS at this time will prevent sensor damage when removing the output shaft.





7. Remove two bolts retaining transmission range (TR) sensor to case. Remove TR sensor from manual control lever.





8. Remove one bolt retaining manual control valve detent lever spring to the main control valve body.





9. Remove remaining 24 valve body-to-case retaining bolts, the main control valve body and the valve-to-body gasket.





10. Remove manual lever shaft retaining pin.

NOTE: Use a shop cloth to protect pan-to-case surface.





11. Using a 13/16-inch open-end wrench on the inner nut and a 12 mm wrench on the manual control lever shaft flats, loosen the inner nut. Slide manual control lever partially out of the case to complete removal of the inner nut from manual control lever.
12. Using a screwdriver on the manual control lever seal lower edge, carefully pry manual control lever seal out of case bore.

NOTE: Do not damage bore with the prying tool.





13. Lift manual valve detent lever and parking lever actuating rod out of the case.





14. Remove electronic pressure control (EPC) solenoid by sliding it out of the case bore.





15. This illustration shows the position of the overdrive servo, the reverse band servo, 2-3 accumulator piston and the 1-2 accumulator piston.





16. Remove the 2-3 accumulator spring retainer.








17. Remove 2-3 accumulator piston.





18. Use Servo Piston Remover/Replacer T92P-70023-A to compress the overdrive servo piston return spring. Use snap-ring pliers to remove retainer ring.

NOTE: If tool is not available, extreme care must be taken. Spring pressure will force overdrive servo piston assembly out of case. Case bore damage may result from trying to pry on overdrive servo piston retainer.








19. Remove piston assembly. Remove overdrive servo piston return spring.
20. Use Servo Piston Remover/Replacer T92P-70023-A to contact the reverse band servo cover and compress return spring and remove servo cover retaining ring.





21. Remove reverse band servo cover, reverse band servo piston and rod (ID 189) and reverse band servo spring.

NOTE: The length of the rod attached to the piston is graded in three different lengths. Therefore, they should not be installed in any transmission other than the transmission from which they were removed.








22. Apply downward pressure on 1-2 accumulator cover using Servo Piston Remover/Replacer T92P-70023-A. Using snap-ring pliers, remove 1-2 accumulator piston retaining ring.





23. Carefully note the location of the 1-2 accumulator springs and assemble in the same positions. Some models may use two 1-2 accumulator springs. The accumulator piston may also vary with applications. Remove accumulator piston and 1-2 accumulator spring.





24. Remove fluid screen from case.





25. Remove extension housing seal using Seal Remover T74P-77248-A. Make sure seal remover lips are firmly seated under the flange on the extension housing seal.





26. Inspect extension housing bushing. If required, remove the extension housing bushing using Extension Housing Bushing Remover T77L-7697-A.





27. Remove six extension housing bolts. Remove and discard extension housing gasket.

NOTE: The extension housing bolts have been coated with a sealant. More break torque may be required to remove these bolts.





28. The output shaft may have shipping seal still attached. Remove and discard. This seal is not required for assembly.
29. Slide parking pawl shaft out of the case and remove parking pawl and parking pawl return spring.





30. Place transmission in the vertical position with output shaft toward floor.





31. Remove transmission connector from case. Place a screwdriver on the flat portion of the connector and drive the connector out through the bottom of the case.

CAUTION: Extreme care must be taken during transmission connector removal. Do not pull on the wires, or use a hammer on the connector body. This will damage wires or connector and could result in a transmission concern.





32. Remove front pump seal using Seal Remover TOOL-1175-AC or equivalent and Impact Slide Hammer T59L-100-B.





33. Remove seven pump body retaining bolts.

NOTE: All bolts have been coated with a sealant. More break torque might be required to remove bolts.






34. Remove front pump and support assembly using two Impact Slide Hammers T59L-100-B and Pump Puller Adapters T89T-70010-A.
35. Remove and discard pump gasket.





36. Grasp the forward clutch cylinder and shaft firmly and pull the following components out of the case as an assembly:
^ intermediate crutch peck
^ intermediate one-way clutch
^ reverse clutch assembly
^ forward clutch assembly

CAUTION: Remove the assembly carefully to prevent damage to the overdrive band friction material by the reverse clutch drive lugs.





37. Disengage overdrive band (IF 196) from overdrive band anchor pin and remove.

NOTE: Band may be removed with assembly.





38. Remove forward clutch hub and the No. 3 forward clutch hub front bearing.





39. Remove intermediate stub shaft.





40. Rotate reverse clutch gear and shell to align indent with overdrive band anchor pin.





41. Remove forward clutch sun gear, No. 5 needle bearing, reverse clutch gear and shell and the No. 4 needle bearing as an assembly.





42. Remove center planet support retaining ring. Note position of retaining ring tabs for assembly.





43. Using needle-nose pliers, remove case to center support spring out from between the center support and the case. Note location for assembly.





44. Remove planetary gear support and planetary as an assembly.





45. Remove reverse band.





46. Remove retaining ring.





47. Remove output shaft, ring gear and direct clutch assembly as a unit, from the front of the case.





48. Remove No. 9 case rear bearing from rear of the case.





49. Inspect output shaft bushing. If removal is required, use Bearing Cup Puller T77F-1102-A and Impact Slide Hammer T59L-100-B.