Transmission

Tools Required:

• Bench Mounted Holding Fixture T57L-500-B
• Impact Slide Hammer T59L-100-B
• Gauge Bar T80L-77003-A
• Servo Piston Selection Tool T80L-77030-A
• Servo Piston Remover T80L-77030-B
• Front Pump Remover Adapters T80L-77103-A
• Pump Puller Adapters T89L-70010-A
• Depth Micrometer D80P-4201-A
• Dial Indicator with Bracketry TOOL-4201-C

Disassembly

NOTE: The torque converter is relatively heavy. Be prepared to handle the weight.

1. Remove torque converter prior to mounting in bench fixture.

2. Mount the transmission in Bench Mounted Holding Fixture T57L-500-B.
   
   
   
   

3. Remove the 14 oil pan retaining bolts, the oil pan and the pan gasket. Discard the gasket.
   
   
   
   

4. Remove the three oil filter retaining bolts.
   
   
   
   

   Remove the filter, grommet and gasket and discard.

   NOTE: Always use a new filter. Never attempt to clean or reuse a dirty filter.

   
   
   
   
   

5. Remove the manual lever detent spring and roller assembly.
   
   
   
   

   NOTE: The four front, one center and three rear retaining bolts are shorter than the others.

6. Remove the remaining 24 valve body-to-case retaining bolts, the valve body assembly and the valve body gasket.
   
   
   
   

7. This illustration shows the position of the overdrive servo, the low reverse servo, and the 2-3 accumulator.

   Remove these components from the transmission using the following procedures.
   
   
   
   

2-3 Accumulator

Removal

8. Lift piston retainer from bore.

9. Remove the accumulator piston spring.
   
   
   
   

10. Remove the accumulator piston.

Low/Reverse Servo

Removal

11. Using a hammer handle or wooden dowel, push down on the servo cover and remove the retaining ring.
    
    
    
    

12. Remove the servo piston, and the piston return spring.
    
    
    
    

    NOTE: If necessary, a magnet can be used to lift the piston from the bore.

    
    
    
    
    

Overdrive Servo

Removal

13. Using a hammer handle or wooden dowel, push down on the servo cover and remove the retaining ring.
    
    
    
    

14. Remove spring.
    
    
    
    

15. Remove the cover and piston as a unit.
    
    
    
    

     CAUTION: Make certain a portion of the Servo Piston Remover T80L-77030-B extends over the bore to prevent the cover from flying out of the bore.

    If the cover sticks in the bore, use Servo Piston Remover T80L-77030-B and air pressure to aid removal.

16. Remove the direct driveshaft.
    
    
    
    

17. Using a 10mm socket, remove the seven pump body retaining bolts. All bolts have been coated with a sealant. More break torque might be required to remove the bolts. Before reinstallation, clean bolts and bolt holes in case and pump. Coat bolts with Threadlock and Sealer E0AZ-19554-AA (ESE-M4G204-A) or Pipe Sealant with Teflon® D8AZ-19554-A (ESG-M4G194-A and ESR-M18P7-A) or equivalent.
    
    
    
    

18. Remove the pump assembly using Impact Slide Hammer T59L-100-B and Pump Puller Adapters T89L-70010-A.
    
    
    
    

19. Remove the pump-to-case gasket and discard.
    
    
    
    

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

20. Grasp the turbine shaft firmly and pull the following components out of the case as an assembly:
    1. Intermediate clutch pack
    2. Intermediate one-way clutch
    3. Reverse clutch
    4. Forward clutch
       
       
       
       

21. Disengage the overdrive band from the anchor pins and remove from the case.
    
    
    
    

22. Remove the forward clutch hub and the No. 3 needle bearing as an assembly.
    
    
    
    

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

24. Remove the center support retaining ring. Note position of tabs for assembly.
    
    
    
    

25. Using a screwdriver, pry the anti-clunk spring out from between the center support and the case.

    NOTE: Note the location for assembly.

    
    
    
    
    

26. Remove the center support and planetary carrier as an assembly.
    
    
    
    

27. Remove the reverse band.
    
    
    
    

28. If the direct clutch hub and No. 7 needle bearing did not come out with the planetary carrier, reach in and lift them out of the direct clutch.
    
    
    
    

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

29. Remove the six extension housing retaining bolts and the extension housing. Note location of one stud bolt for installation.
    
    
    
    
    
    
    
    

     CAUTION: If the transmission is positioned with the output shaft pointing up, do not allow the shaft assembly to fall through the case when the governor is removed.

30. Remove the retaining ring and governor assembly.
    
    
    
    

31. Remove the governor drive ball from the output shaft. A magnet may be used to aid removal.
    
    
    
    

32. Remove the output shaft, the ring gear and the direct clutch as an assembly, through the front of the case.
    
    
    
    

33. Remove the output shaft No. 9 needle bearing from the rear of the case.
    
    
    
    

34. Remove the intermediate clutch pack from the intermediate one-way clutch.
    
    
    
    

35. Remove the reverse clutch assembly from the forward clutch assembly.