Section 2 (Automatic Transmission): Disassembly: Transmission

SPECIAL TOOL(S)

	Remover, Input Shaft Oil Seal 308-375
	Remover, Transmission Fluid Pump 307-397
	Holding Fixture, Transmission 307-003 (T57L-500-B)
	Slide Hammer 100-001 (T50T-100-A)
	Remover, Torque Converter Fluid Seal 307-309 (T94P-77001-BH)
	Compressor, Servo Cover 307-402
	Handle, Torque Converter 307-091 (T81P-7902-C)
	Remover, Output Shaft Flange 307-523

NOTE: Tag and identify all parts for reassembly.

1. Place the transmission on a bench.
   Fig 1: Identifying Transmission View

   
   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.
   Fig 2: Identifying Special Tool To Torque Converter

   
3. If the vehicle is equipped, and installation of a new or remanufactured torque converter is necessary, remove the torque converter adapter plate.
   Fig 3: Locating Torque Converter Adapter Plate

   
4. If the adapter plate has been removed, use the special tools to remove the torque converter.
   Fig 4: Identifying Special Tool To Torque Converter

   
5. Remove the input shaft.
   Fig 5: Locating Input Shaft

   
6. Using the special tool, install the transmission into the bench with the torque converter housing facing up.
   Fig 6: Installing Transmission Into Bench

   
7. Remove the transmission sensors.
   Fig 7: Locating Transmission Sensors

   
8. Remove the transmission range (TR) senor.
   Fig 8: Locating Transmission Range (TR) Sensor

   
9. Remove and discard the nut.
   Fig 9: Locating Nut

   
10. Using the special tool, remove the output shaft flange.
    Fig 10: Identifying Special Tool

    
11. Using the special tools, remove the extension housing seal.
    Fig 11: Identifying Special Tool Into Extension Housing Seal

    
    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.
    Fig 12: Identifying Extension Housing And Mounting Screws

    
13. Remove the parking pawl assembly and discard the gasket.
    1. Remove the parking pawl shaft.
    2. Remove the parking pawl.
    3. Remove the parking pawl return spring.
    4. Remove and discard the gasket.
       Fig 13: Identifying Parking Pawl Assembly

       
14. Remove the drain plug and discard the gasket
    Fig 14: Locating Drain Plug

    
    NOTE: The transmission fluid pan gasket is reusable. Clean and inspect the gasket for damage. If the gasket is not damaged, the gasket should be reused.
15. Remove the 16 transmission fluid pan screws, transmission fluid pan and gasket.
    Fig 15: Locating Transmission Fluid Pan Gasket

    
16. Remove the transmission fluid filter and discard.
    Fig 16: Identifying Transmission Fluid Filter Mounting Screws

    
17. Remove the manual control valve detent spring.
    Fig 17: Identifying Manual Control Valve Detent Spring

    
    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.
18. Remove the reverse servo assembly.
    Fig 18: Locating Reverse Servo Assembly

    
    CAUTION: Do not damage solenoid body connector pins.
19. Remove the solenoid body assembly by lifting on the body and pushing the connector from the other side of the case.
    Fig 19: Locating Solenoid Body Mounting Screws

    
20. Remove the main control valve body, separator plate and gasket.
    Fig 20: Locating Main Control Valve Body Bolts & Main Control Valve Body

    
21. Using the special tools, remove the converter hub seal.
    Fig 21: Locating Converter Hub Seal

    
    CAUTION: Failure to loosen the overdrive band adjusting screw prior to pump removal may cause damage to the pump and overdrive band.
    CAUTION: Throw the locknuts away. The locknuts are not reusable for assembly.
22. Remove and discard the locknuts, and loosen the overdrive/intermediate band adjusting screw.
    Fig 22: Locating Locknuts

    
23. Remove and tag part for assembly.
    Fig 23: Identifying And Tag Components

    
    CAUTION: The screws are not reusable for assembly. Discard the screws. If the screws are reused, the housing may become separated from the transmission.
24. Remove and discard the screws.
    Fig 24: Locating Screws

    
25. Install the special tool.
    Fig 25: Identifying Special Tool

    
26. Using the special tools, remove the pump.
    Fig 26: Identifying Special Tool To Pump

    
    CAUTION: Servo cover is under spring tension.
27. Using the special tool, remove the intermediate servo cover retaining ring.
    Fig 27: Locating Retaining Ring

    
28. Remove the intermediate band servo piston and spring.
    Fig 28: Locating Intermediate Band Servo Piston And Spring

    
    CAUTION: Servo cover is under spring tension.
29. Using the special tool, remove the overdrive servo cover retaining ring and cover.
    Fig 29: Locating Overdrive Servo Cover Retaining Ring

    
30. Remove the front band servo piston and spring.
    Fig 30: Locating Front Band Servo Piston And Spring

    
31. Remove the screw.
    Fig 31: Locating Screw

    
    NOTE: Tag and identify parts for reassembly.
32. Compress the overdrive band and remove the apply strut.
    Fig 32: Identifying Apply Strut

    
    CAUTION: Identify the anchor and apply ends of the overdrive band.
    NOTE: The new overdrive band is 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.
33. 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.
      Fig 33: Identifying Overdrive Band

      
34. Remove the overdrive brake and coast clutch drum.
    Fig 34: Identifying Overdrive Brake And Coast Clutch Drum

    
    CAUTION: Do not bend the trigger wheel.
    NOTE: The No. 12 thrust bearing is in this assembly.
35. Remove the planetary gear overdrive carrier.
    Fig 35: Identifying Planetary Gear Overdrive Carrier

    
36. Remove the No. 2 overdrive planet thrust bearing.
    Fig 36: Identifying Overdrive Planet Thrust Bearing

    
37. Remove the overdrive ring gear, overdrive one-way clutch assembly and center shaft as an assembly.
    Fig 37: Identifying Overdrive Ring Gear

    
    NOTE: Tag and identify the center shaft thrust bearing No. 3 for reassembly.
38. Remove the No. 3 center shaft thrust bearing.
    Fig 38: Identifying Center Shaft Thrust Bearing

    
    CAUTION: The center support locknut could fall into the remaining assembly if not removed.
39. Remove the bolt.
    Fig 39: Locating Bolt

    
40. Remove the locknut and cage.
    Fig 40: Locating Center Support Locknut And Cage

    
41. Remove the center support retaining ring.
    Fig 41: Identifying Center Support Retaining Ring

    
    NOTE: The center support is repaired as an assembly. Any damage requires installing a new component.
    NOTE: When removing the center support, pull evenly around the center support web.
42. Remove the center support.
    Fig 42: Identifying Center Support

    
43. Inspect the center support assembly for wear or damage.
    1. Inspect the thrust surfaces for wear or damage.
    2. Inspect the center support sealing surface.
    3. Inspect the fluid passage for blockage or damage.
       Fig 43: Identifying Fluid Passage For Blockage

       
44. Inspect the seal rings for damage.
    Fig 44: Identifying Seal Rings

    
45. Inspect the bearing for missing rollers or damage.
    Fig 45: Locating Rollers Bearing

    
46. 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.
       Fig 46: Rotating Center Support Bearing

       
    NOTE: Tag and identify the No. 4 intermediate clutch drum thrust bearing.
47. Remove the intermediate brake drum thrust bearing (No. 4).
    Fig 47: Identifying Intermediate Brake Drum Thrust Washer

    
48. Remove, tag and identify the band anchor strut for assembly.
    Fig 48: Identifying Intermediate Band Anchor Strut

    
    CAUTION: Identify the anchor and apply ends of the intermediate band.
    NOTE: The new intermediate band is 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.
49. 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.
      Fig 49: Identifying Intermediate Band

      
50. Remove, tag and identify the band apply strut.
    Fig 50: Locating Intermediate Band Apply Strut

    
51. Remove the screw.
    Fig 51: Locating Screw

    
    NOTE: The No. 5 forward clutch cylinder thrust bearing may come out with the intermediate brake and direct clutch drum.
52. Remove the direct clutch drum.
    Fig 52: Identifying Direct Clutch Drum

    
53. Remove the No. 5 forward clutch cylinder thrust bearing, tag and identify.
    Fig 53: Identifying Thrust Bearing

    
    NOTE: The No. 6A thrust bearing may come out with the cylinder. Tag and identify for reassembly.
54. Remove the forward clutch cylinder.
    Fig 54: Identifying Forward Clutch Cylinder

    
    NOTE: The No. 6A forward ring gear hub thrust bearing may have come out with the forward clutch cylinder.
55. Remove the No. 6A forward ring gear hub thrust bearing.
    Fig 55: Identifying Forward Ring Gear Hub Thrust Bearing

    
    NOTE: The No. 7 forward planet thrust bearing may come out with the forward ring gear and hub assembly.
56. Remove the forward ring gear and hub as an assembly.
    Fig 56: Identifying Forward Ring Gear And Hub

    
57. Remove the No. 6B forward clutch thrust washer from the forward ring gear hub.
    Fig 57: Identifying Forward Clutch Thrust Washer

    
    NOTE: The No. 7 forward planet thrust bearing may come out with the forward ring gear and hub assembly.
58. Remove the No. 7 forward planet thrust bearing.
    Fig 58: Identifying Forward Planet Thrust Bearing

    
59. Remove the forward planetary assembly.
    Fig 59: Identifying Forward Planetary Assembly

    
60. Remove the input shell and sun gear assembly.
    Fig 60: Identifying Input Shell And Sun Gear Assembly

    
61. Remove the spacer.
    Fig 61: Locating Spacer

    
    NOTE: Tag and identify the No. 8 low/reverse planetary carrier thrust bearing.
62. Remove the thrust bearing.
    Fig 62: Locating Thrust Bearing

    
63. Remove the retaining ring.
    Fig 63: Locating Retaining Ring

    
64. Remove the low/reverse planetary assembly.
    Fig 64: Locating Low/Reverse Planetary Assembly

    
    NOTE: Tag and identify the No. 9 low/reverse planetary carrier thrust bearing.
65. Remove the thrust bearing.
    Fig 65: Locating Thrust Bearing

    
    NOTE: Use slots located around the outside of the sleeve.
66. Using a small pick, remove the output shaft sleeve.
    Fig 66: Locating Output Shaft Sleeve

    
    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.
67. While holding the output shaft, remove and discard the output shaft retaining ring.
    Fig 67: Identifying Output Shaft Retaining Ring

    
68. Remove the output shaft ring gear and hub.
    Fig 68: Identifying Output Shaft Ring Gear

    
69. Remove the No. 10 low/intermediate sun gear bearing.
    Fig 69: Identifying Low Intermediate Sun Gear Bearing

    
    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.
70. Using a pair of vise 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.
    Fig 70: Identifying Reverse Band Actuating Lever Shaft

    
71. Remove the reverse band actuating lever assembly.
    Fig 71: Identifying Reverse Band Actuating Lever

    
    NOTE: The inner race of the rear one-way clutch is not removable. It is repaired in the case.
72. Remove the low/reverse brake drum and one-way clutch assembly by rotating it clockwise.
    Fig 72: Identifying Low/Reverse Brake Drum

    
    NOTE: The reverse one-way clutch is part of the reverse brake drum assembly. Install a new reverse brake drum as an assembly only.
73. Inspect the reverse brake drum assembly and install a new reverse brake drum assembly if damaged.
    1. Inspect the reverse brake drum sprags.
    2. Inspect the reverse brake drum rollers.
    3. Inspect the reverse brake drum.
       Fig 73: Identifying Reverse Brake Drum Assembly

       
74. Remove the reverse band.
    Fig 74: Identifying Low/Reverse Band

    
75. Remove the output shaft and park gear.
    Fig 75: Identifying Output Shaft And Park Gear

    
    NOTE: Tag and identify the No. 11 output shaft thrust washer.
76. Remove the output shaft thrust washer.
    Fig 76: Identifying Output Shaft Thrust Washer

    
    CAUTION: To avoid damage, make sure the wrench does not strike the manual valve inner lever pin.
77. Remove the nut.
    Fig 77: Locating Nut

    
78. Remove the manual shaft retaining pin.
    Fig 78: Locating Manual Shaft Retaining Pin

    
79. Remove the manual control lever shaft.
    Fig 79: Removing Manual Control Lever Shaft

    
80. Disconnect the manual valve inner lever from the parking lever actuating rod.
    Fig 80: Locating Parking Lever Actuating Rod

    
81. Remove the manual valve inner lever.
    Fig 81: Identifying Manual Control Valve Inner Lever

    
82. Remove the parking lever actuating rod.
    Fig 82: Identifying Parking Lever Actuating Rod

    
    CAUTION: Do not damage the bore.
83. Remove the manual control lever seal.
    Fig 83: Locating Manual Control Lever Seal