Transmission

NOTE: Before beginning Disassembly, perform/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 (7902), cooler, transmission oil cooler inlet tubes (7A030), main control valve body (7A100), all clutches and all coasting booster valve shuttle balls (7E195) 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 oil pan magnet (7L027) should be removed from transmission oil pan (7A194) and wiped clean along with the transmission oil 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.

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

2. Using a 10mm socket, remove 14 oil pan retaining bolts, transmission oil pan and oil pan to case gasket (7A191). Discard oil pan to case gasket.
   
   
   
   

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

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

    CAUTION: If grommet remains in main control bore, use a small screwdriver to pry it out. Take care not to damage main control bore.

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

    CAUTION: Do not pull on wires. If required, carefully pry up on locking tab and disconnect the connector.

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

   NOTE: Removal of the OSS at this time will prevent sensor damage when removing the output shaft (7060) .

6. Using an 8mm socket, remove bolt attaching output shaft speed sensor (OSS) to case (7005) and remove OSS.
   
   
   
   

7. Using an 8mm socket, remove two bolts retaining manual lever position sensor to case. Remove manual lever position sensor from manual control lever (7A256).
   
   
   
   

8. Using an 8mm socket, remove one bolt retaining manual control valve detent lever spring (7A261) to the main control valve body.
   
   
   
   

9. Using an 8mm socket, remove remaining 24 valve body-to-case retaining bolts, the main control valve body and the valve-to-body gasket.
   
   
   
   

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

10. Remove manual lever shaft retaining pin (7B210).
    
    
    
    

11. Using a 13/16-inch open- end wrench on the inner nut and a 12mm 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.

    NOTE: Do not damage bore with the prying tool.

12. Using a screwdriver on the manual control lever oil seal (7B498) lower edge, carefully pry manual control lever oil seal out of case bore.

13. Lift manual valve detent lever (7A115) and parking lever actuating rod (7A232) 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 piston and rod (7D189) , 2-3 accumulator piston (7F251) and the 1-2 accumulator piston.
    
    
    
    

16. Remove the 2-3 accumulator spring retainer.
    
    
    
    

17. Remove 2-3 accumulator piston.
    
    
    
    

NOTE: If tool is not available, extreme care must be taken. Spring pressure will force overdrive servo piston (7F200) assembly out of case. Case bore damage may result from trying to pry on overdrive servo piston retainer (7G280).

18. Use snap-ring pliers to remove retainer ring. Use Servo Piston Remover/Replacer T92P-70023-A to compress the overdrive servo piston return spring (7F201).
    
    
    
    

19. Remove piston assembly. Remove overdrive servo piston return spring.
    
    
    
    

20. Use Servo Piston Remover/Replacer T92P-70023-A to compress the reverse band servo cover (7D036) and remove retaining ring.

    NOTE: The length of the rod attached to the piston may vary in length from transmission to transmission. Therefore, they should not be installed in any transmission other than the transmission from which they were removed.

21. Remove reverse band servo cover, reverse band servo piston and rod and reverse band servo spring (7D031).
    
    
    
    

1-2 Accumulator

1. 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 (7384) .

2. Remove cover and 1-2 accumulator outer spring (7G267). Use reverse snap-ring pliers to remove accumulator piston and 1-2 shift spring (7F284).

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

3. Remove oil screen from case.
   
   
   
   

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

5. Inspect extension housing bushing (7A034). If required, remove the extension housing bushing using Extension Housing Bushing Remover T77L-7697-A.
   
   
   
   

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

6. Using a 13mm socket, remove six extension housing bolts. Remove and discard extension housing gasket (7086) .
   
   
   
   

7. The output shaft may have shipping seal still attached. Remove and discard. This seal is not required for assembly.
   
   
   
   

8. Slide parking pawl shaft (7D071) out of the case and remove parking pawl (7A441) and parking pawl return spring (7D070).

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

    CAUTION: Extreme care must be taken during transmission connector removal.

    CAUTION: Do not pull on the wires, or use a hammer on the connector body.

10. 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.
    
    
    
    

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

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

12. Using a 10mm socket, remove seven pump body retaining bolts.
    
    
    
    

13. Remove front pump and support assembly using two Impact Slide Hammers T59L-100-B and Front Pump Remover Adapters T89T-70010-A.

14. Remove and discard oil pump gasket (7A136).
    
    
    
    

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

15. Grasp the forward clutch cylinder and shaft (7F207) firmly and pull the following components out of the case as an assembly:
    • Intermediate clutch pack
    • Intermediate one-way clutch
    • Reverse clutch assembly
    • Forward clutch assembly
    
    
    
    
    

    NOTE: Band may be removed with assembly.

16. Disengage overdrive band (7F196) from overdrive band anchor pin (7F295) and remove.
    
    
    
    

17. Remove forward clutch hub and the No. 3 forward clutch hub front bearing (7F231).
    
    
    
    

18. Remove intermediate stub shaft.
    
    
    
    

19. Rotate reverse clutch gear and shell (7A019) to align indent with overdrive band anchor pin.
    
    
    
    

20. Remove primary sun gear (7A399), No. 5 needle bearing, reverse clutch gear and shell and the No. 4 needle bearing as an assembly.
    
    
    
    

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

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

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

24. Remove reverse band.
    
    
    
    

25. Remove retaining ring.
    
    
    
    

26. Remove output shaft, ring gear (7A153) and direct clutch as a unit, from the front of the case .
    
    
    
    

27. Remove No. 9 case rear bearing (7F242) from rear of the case.
    
    
    
    

28. Inspect output shaft bearing (7025). If removal is required, use Bearing Cup Puller T77F-1102-A and Impact Slide Hammer T59L-100-B.