40TE Automatic Transmission (Service Information): Disassembly: Disassembly

Fig 1: Solenoid/Pressure Switch Assembly and Gasket

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1 - SOLENOID/PRESSURE SWITCH ASSEMBLY

2 - GASKET

NOTE: If transaxle is being overhauled (clutch and/or seal replacement) or replaced, it is necessary to perform the PCM/TCM Quick Learn Procedure. Refer to Electrical - Electronic Control Modules/Electronic Control Modules/MODULE, Powertrain Control - Standard Procedure .

NOTE: This procedure does not include final drive (differential) disassembly.

1. Remove input and output speed sensors.
2. Remove three solenoid/pressure switch assembly-to-case bolts.
3. Remove solenoid/pressure switch assembly (1) and gasket (2).
   Fig 2: Remove Oil Pan Bolts

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   1 - OIL PAN BOLTS (USE RTV UNDER BOLT HEADS)

4. Remove oil pan-to-case bolts (1) .
   Fig 3: Remove Oil Pan

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   1 - OIL PAN

   2 - 1/8 INCH BEAD OF MOPAR® ATF RTV (MS-GF41)

   3 - OIL FILTER

5. Remove oil pan (1) .
   Fig 4: Remove Filter and O-Ring

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   1 - OIL FILTER

   2 - O-RING

6. Remove oil filter (1) .
   Fig 5: Remove Valve Body-to-Case Bolts

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   1 - VALVE BODY ATTACHING BOLTS (18)

   2 - VALVE BODY

7. Turn manual valve fully clockwise to get park rod into position for removal.
8. Remove valve body-to-case bolts (1) .
   Fig 6: Pushing Park Rod Rollers From Guide Bracket

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   1 - PARK SPRAG ROLLERS

   2 - SCREWDRIVER

   3 - PARK SPRAG GUIDE BRACKET

   CAUTION: Do not handle the valve body assembly from the manual valve. Damage can result.
9. Using a screwdriver (2) , push park rod rollers (1) away from guide bracket (3).
   Fig 7: Valve Body Removal/Installation

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   1 - VALVE BODY

10. Remove valve body assembly (1) .
    Fig 8: Underdrive and Overdrive Accumulators

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    1 - RETURN SPRING

    2 - UNDERDRIVE CLUTCH ACCUMULATOR

    3 - SEAL RING (2)

    4 - OVERDRIVE CLUTCH ACCUMULATOR

    NOTE: Depending on engine application, some accumulators will have two springs and others will have one spring. The springs are color-coded according to application and year. When disassembling, mark accumulator spring location to ease assembly.
11. Remove underdrive (2) and overdrive (4) accumulators.
    Fig 9: Remove Low/Reverse Accumulator Snap Ring

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    1 - SNAP RING

    2 - PLUG

12. Remove low/reverse accumulator snap ring (1) .
    Fig 10: Remove Low/Reverse Accumulator Plug

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    1 - ADJUSTABLE PLIERS

    2 - PLUG

13. Remove low/reverse accumulator plug (2) .
    Fig 11: Low/Reverse Accumulator Piston

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    1 - ACCUMULATOR PISTON

14. Remove low/reverse accumulator piston (1) using suitable pliers.
    Fig 12: Low/Reverse Accumulator Piston & Springs

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    1 - ACCUMULATOR PISTON

    2 - SEAL RINGS

    3 - RETURN SPRINGS

    4 - (NOTE NOTCH)

15. Remove piston (1) along with the seal rings (2) and springs (3) .
    Fig 13: Measure Input Shaft End Play

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    1 - HANDLE

    2 - END PLAY SOCKET SET 8266A

    3 - TOOL C-3339A

16. Measure input shaft end play using End Play Socket Set 8266A (1) and Dial Indicator Set C-3339A (3). Place transaxle so input shaft is vertical. Set up end play set and dial indicator. Input shaft end play should be within 0.13-0.64 mm (0.005-0.025 in.)  If outside of this range, a #4 thrust plate change is required. Record indicator reading for reference upon reassembly.
    Fig 14: Remove Oil Pump-to-Case Bolts

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    1 - PUMP ATTACHING BOLTS

    2 - PUMP HOUSING

17. Remove oil pump-to-case bolts (1) .
    Fig 15: Install Tool C-3752

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    1 - PULLERS TOOL C-3752

    2 - PUMP

    CAUTION: Be sure input speed sensor is removed before removing oil pump.
18. Install Pullers C-3752 (1) .
    Fig 16: Remove Oil Pump

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    1 - "PUSH IN" ON INPUT SHAFT WHILE REMOVING PUMP

19. "Push in" on input shaft while removing pump (1) .
    Fig 17: Oil Pump Removed

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    1 - OIL PUMP

    2 - GASKET

20. Remove oil pump assembly (1) .
    Fig 18: Remove Oil Pump Gasket

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    1 - PUMP GASKET

21. Remove oil pump gasket (1) .
    Fig 19: Remove Bypass Valve

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    1 - COOLER BYPASS VALVE

    CAUTION: If transaxle failure has occurred, the cooler bypass valve must be replaced. Do not reuse or attempt to clean valve.
22. Remove cooler bypass valve (1) .
    Fig 20: Remove No. 1 Caged Needle Bearing

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    1 - #1 CAGED NEEDLE BEARING

    2 - NOTE: TANGED SIDE OUT

23. Remove #1 needle bearing (1) .
    Fig 21: Remove Input Clutch Assembly

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    1 - INPUT CLUTCH ASSEMBLY

    2 - #4 THRUST WASHER

24. Remove input clutch assembly (1) .
    Fig 22: No. 4 Thrust Plate

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    1 - OVERDRIVE SHAFT ASSEMBLY

    2 - #4 THRUST PLATE (SELECT)

    3 - 3 DABS OF PETROLATUM FOR RETENTION

25. Remove #4 thrust plate (2) .
    Fig 23: Remove Front Sun Gear Assembly

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    1 - FRONT SUN GEAR ASSEMBLY

    2 - #4 THRUST WASHER (FOUR TABS)

26. Remove front sun gear assembly (1) and #4 thrust washer (2).
    Fig 24: Remove Front Carrier/Rear Annulus Assembly

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    1 - #6 NEEDLE BEARING

    2 - FRONT CARRIER AND REAR ANNULUS ASSEMBLY (TWIST AND PULL OR PUSH TO REMOVE OR INSTALL).

27. Remove front carrier/rear annulus assembly (2) and #6 needle bearing (1).
    Fig 25: Remove Rear Sun Gear

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    1 - #7 NEEDLE BEARING

    2 - REAR SUN GEAR

28. Remove rear sun gear (2) .
    Fig 26: Number 7 Bearing

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    1 - #7 NEEDLE BEARING

    2 - REAR SUN GEAR

    NOTE: The number 7 needle bearing has three anti-reversal tabs and is common with the number five and number two position. The orientation should allow the bearing to seat flat against the rear sun gear. A small amount of petrolatum can be used to hold the bearing to the rear sun gear.
29. Remove needle bearing (1) .
    Fig 27: Remove 2/4 Clutch Retainer Snap Ring

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    1 - COMPRESSOR 5058A

    2 - SCREWDRIVER

    3 - SNAP RING

    4 - 2/4 CLUTCH RETAINER

30. Setup Compressor 5058A (1) . compress 2/4 clutch return spring (4) (just enough to remove snap ring) and remove snap ring (3).
    NOTE: Verify that Compressor 5058A is centered properly over the 2/4 clutch retainer before compressing. If necessary, fasten Compressor 5058A bar to the bellhousing flange with any combination of locking pliers and bolts to center the tool properly.
    Fig 28: 2/4 Clutch Retainer

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    1 - 2/4 CLUTCH RETAINER

    2 - 2/4 CLUTCH RETURN SPRING

    NOTE: The 2/4 Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.
31. Remove 2/4 clutch retainer (1) .
    Fig 29: Remove 2/4 Clutch Return Spring

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    1 - 2/4 CLUTCH RETURN SPRING

32. Remove 2/4 clutch return spring (1) .
    Fig 30: Remove 2/4 Clutch Pack

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    1 - CLUTCH DISC

    2 - CLUTCH PLATE

33. Remove 2/4 clutch pack . Tag 2/4 clutch pack for reassembly identification. 
    Fig 31: Remove Tapered Snap Ring

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    1 - LOW/REVERSE CLUTCH REACTION PLATE

    2 - SCREWDRIVER

    3 - LOW/REVERSE TAPERED SNAP RING (TAPERED SIDE UP)

    4 - OIL PAN FACE

    5 - LONG TAB

34. Remove tapered snap ring (3) .
    Fig 32: Remove Low/Reverse Reaction Plate

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    1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP)

35. Remove low/reverse reaction plate (1) .
    Fig 33: Remove One Low/Reverse Clutch Disc

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    1 - ONE DISC FROM LOW/REVERSE CLUTCH

36. Remove one low/reverse clutch disc (1) .
    Fig 34: Remove Low/Reverse Reaction Plate Snap Ring

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    1 - SCREWDRIVER

    2 - LOW/REVERSE REACTION PLATE FLAT SNAP RING

    3 - DO NOT SCRATCH CLUTCH PLATE

37. Remove low/reverse reaction plate snap ring (2) .
    Fig 35: Remove/Install Low/Reverse Clutch

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    1 - CLUTCH PLATE

    2 - CLUTCH DISC

38. Remove low/reverse clutch pack .
    Fig 36: Remove Rear Cover Bolts

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    1 - REAR COVER BOLTS

    2 - REAR COVER

    3 - USE SEALANT ON BOLTS

39. Remove transfer gear cover-to-case bolts (1) .
    Fig 37: Remove Rear Cover

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    1 - REAR COVER

    2 - 1/8 INCH BEAD OF MOPAR® ATF RTV (MS-GF41) AS SHOWN

40. Remove transfer gear cover (1) .
    Fig 38: Remove Transfer Shaft Gear Nut

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    1 - TRANSFER SHAFT GEAR

    2 - OUTPUT GEAR

    3 - HOLDER 6259

41. Install Holder 6259 (3) .
    Fig 39: Transfer Shaft Gear Nut and Coned Washer

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    1 - TRANSFER SHAFT

    2 - LOCK WASHER

    3 - NUT

42. Remove transfer shaft gear-to-shaft nut (3) and coned washer (2).
    Fig 40: Remove Transfer Shaft Gear

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    1 - BOLTS

    2 - TRANSFER SHAFT GEAR

    3 - GEAR PULLER L-4407A

43. Using Gear Puller L-4407A (1, 3) , remove transfer shaft gear.
    Fig 41: Remove Transfer Shaft Gear and (Select) Shim

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    1 - TRANSFER SHAFT GEAR

    2 - BEARING CUP RETAINER

    3 - SHIM (SELECT)

44. Remove transfer gear shim (select) (3) .
    Fig 42: Remove Bearing Cup Retainer

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    1 - ALIGN INDEXING TAB TO SLOT

    2 - BEARING CUP RETAINER

45. Remove bearing cup retainer (2) .
    Fig 43: Remove Transfer Gear Bearing Cone

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    1 - WRENCHES

    2 - PULLER SET 5048 WITH JAWS TOOL 5048-4 AND BUTTON TOOL L-4539-2

    3 - TRANSFER SHAFT GEAR

46. Remove transfer gear bearing cone using Puller Set 5048 with Jaws 5048-4 and Button L-4539-2 .
    Fig 44: Remove Transfer Shaft Bearing Cup

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    1 - WRENCHES

    2 - REMOVER 6062A

    3 - TRANSFER SHAFT BEARING CUP RETAINER

47. Remove transfer shaft bearing cup from retainer using Remover 6062A (2) .
    Fig 45: Remove Transfer Shaft Bearing Snap Ring

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    1 - SNAP RING PLIERS 6051A

    2 - TRANSFER SHAFT BEARING SNAP RING

    3 - TRANSFER SHAFT

48. Using Snap Ring Pliers 6051A (1) , remove transfer shaft bearing snap ring (2).
    Fig 46: Remove Transfer Shaft

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    1 - REMOVER/INSTALLER 5049-A

    2 - TRANSFER SHAFT

    3 - OUTPUT GEAR

49. Using Remover/Installer 5049-A (1) , remove transfer shaft (2) from transaxle.
    Fig 47: Bearing Cup Removed

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    1 - BEARING CUP

    2 - BEARING CONE

    3 - TRANSFER SHAFT

    4 - OIL BAFFLE

    5 - O-RING

50. Slip bearing cup (1) and oil baffle (4) off of shaft (3) .
    Fig 48: Remove Transfer Shaft Bearing Cone

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    1 - ARBOR PRESS RAM

    2 - TRANSFER SHAFT

    3 - BEARING SPLITTER P-334

    4 - BEARING CONE

51. Using Bearing Splitter P-334 (3) , press transfer shaft bearing cone (4) off of shaft (2).
    Fig 49: Remove Strap Bolts

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    1 - RETAINING STRAP

    2 - STIRRUP

    3 - RETAINING STRAP BOLTS

52. Bend output gear retaining strap (1) ears flat to allow bolt removal.
53. Remove output shaft stirrup strap bolts (3).
    Fig 50: Remove Stirrup Strap

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    1 - OUTPUT GEAR BOLT

    2 - RETAINING STRAP

    3 - STIRRUP

54. Remove stirrup (3) and strap (2).
    Fig 51: Remove Output Gear Bolt

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    1 - OUTPUT GEAR

    2 - HOLDER 6259

55. Install Holder 6259 (2) .
    Fig 52: Output Gear Bolt and Washer

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    1 - OUTPUT GEAR

    2 - BOLT

    3 - CONED LOCK WASHER

56. Remove output shaft gear-to-shaft bolt (2) and washer (3).
    Fig 53: Remove Output Gear

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    1 - OUTPUT GEAR

    2 - BUTTON TOOL 6055

    3 - WRENCHES

    4 - GEAR PULLER L-4407A

    5 - BOLTS

57. Using Gear Puller L-4407A (4) , and Button 6055 (2), remove output gear (1) from shaft.
    Fig 54: Output Gear and (Select) Shim

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    1 - REAR CARRIER ASSEMBLY

    2 - SHIM (SELECT)

    3 - OUTPUT GEAR

58. Remove output gear bearing shim (select) (2) .
    Fig 55: Remove Bearing Cone

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    1 - PULLER SET 5048 WITH JAWS 5048-5 AND BUTTON L-4539-2

    2 - WRENCHES

    3 - OUTPUT GEAR

59. Using Puller Set 5048 with Jaws 5048-5 and Button L-4539-2 (1) , remove output gear bearing cone.
    Fig 56: Remove Rear Carrier Assembly

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    1 - REAR CARRIER ASSEMBLY

60. Remove rear carrier assembly (1) from transaxle.
    Fig 57: Remove Rear Carrier Bearing Cone

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    1 - PULLER SET 5048 WITH JAWS 5048-3 AND BUTTON 6055

    2 - WRENCHES

    3 - REAR CARRIER ASSEMBLY

61. Remove rear carrier assembly (3) bearing cone using Puller Set 5048 with Jaws 5048-3 and Button 6055 .
    Fig 58: Low/Reverse Spring Compressor Tool

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    1 - DISC 6057

    2 - COMPRESSOR 5059-A

    3 - BAR 5058A-3

62. Assemble Low/reverse spring Disc 6057 (1) , Compressor 5059-A (2) and Bar 5058A-3 (3).
    Fig 59: Compressor Tool in Use

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    1 - LOW/REVERSE CLUTCH RETURN SPRING

    2 - SNAP RING (INSTALL AS SHOWN)

    3 - DISC 6057

    4 - COMPRESSOR 5059

    5 - BAR 5058-3

63. Install low/reverse spring compressor Disc 6057 (1) , Compressor 5059-A (2) and Bar 5058A-3 (3).
    Fig 60: Install Snap Ring

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    1 - SNAP RING OPENING MUST BE BETWEEN SPRING LEVERS

    2 - SNAP RING PLIERS

    3 - COMPRESSOR

64. Compress low/reverse piston return spring and remove snap ring (1) .
    Fig 61: Low/Reverse Piston

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    1 - LOW/REVERSE PISTON RETURN SPRING

    2 - PISTON

65. Remove low/reverse Spring Compressor 5059-A and low reverse piston return spring (1) .
    Fig 62: Remove Anchor Shaft and Plug

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    1 - GUIDE BRACKET ANCHOR SHAFT

    2 - PIVOT SHAFT

    3 - ANCHOR SHAFT PLUG

66. Using a suitable punch, drive out park guide bracket pivot shaft (2) plug .
    Fig 63: Pivot Shaft and Guide Bracket

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    1 - ANTI-RATCHET SPRING

    2 - GUIDE BRACKET

    3 - PIVOT SHAFT

    4 - PAWL

67. Using ordinary pliers, remove pivot shaft (3) and guide bracket assembly (2).
    Fig 64: Guide Bracket Disassembled

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    1 - ANTI-RATCHET SPRING

    2 - GUIDE BRACKET

    3 - SPLIT SLEEVE

    4 - SPACER

    5 - PAWL

    6 - STEPPED SPACER

68. Inspect guide bracket (2) components for excessive wear and replace if necessary .
    Fig 65: Remove Low/Reverse Clutch Piston

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    1 - LOW/REVERSE CLUTCH PISTON

    2 - BONDED SEAL

    3 - BONDED SEAL

    NOTE: The Low/Reverse Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.
69. Remove low/reverse clutch piston (1) .
    Fig 66: Remove Piston Retainer-to-Case Screws

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    1 - LOW/REVERSE CLUTCH PISTON RETAINER

    2 - SCREWDRIVER

    3 - TORX-LOC SCREWS

70. Remove low/reverse piston retainer-to-case screws (3) .
    Fig 67: Remove Piston Retainer

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    1 - LOW/REVERSE CLUTCH PISTON RETAINER

    2 - GASKET

71. Remove low/reverse piston retainer (1) .
    Fig 68: Remove Piston Retainer Gasket

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    1 - GASKET HOLES MUST LINE UP

    2 - LOW/REVERSE CLUTCH PISTON RETAINER GASKET

72. Remove low/reverse piston retainer-to-case gasket (2) .
    Fig 69: Remove Output Bearing Inner Cup

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    1 - OUTPUT BEARING CUPS (REPLACE IN PAIRS)

    2 - HAMMER

    3 - BRASS DRIFT

73. Using a hammer (2) and suitable drift (3), drive out inner output bearing cup (1).
    Fig 70: Remove Output Bearing Outer

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    1 - REMOVER 6062A

74. Using Remover 6062A (1) , remove outer output bearing cup.