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, fluid cooler inlet tubes, 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 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.

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

   

2. Using a 10mm socket, remove 14 transmission pan retaining bolts, transmission pan and pan to case gasket. Clean and inspect pan to case gasket. If OK, reuse during assembly.

   

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

   

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

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

   Using both hands, remove filter by pulling upward.

   

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

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

   

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

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

   

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

   

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

   

9. Remove the EPC solenoid bracket retaining bolt. Remove the EPC solenoid bracket.

   

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

    Remove manual lever shaft retaining pin (7B210).

    

11. Remove manual valve detent lever inner nut using an open-end wrench while holding the manual control lever with a crescent wrench.

    Slide manual control lever shaft partially out of the case to complete removal of the inner nut from manual control lever shaft.

12. Remove manual control lever shaft nut using an open-end wrench while holding the manual control lever with a crescent wrench.

13. Remove manual control lever.

14. Using an 8mm socket, remove two bolts retaining transmission range (TR) sensor to case. Remove TR sensor from manual control lever shaft.

    

15. Slide manual control lever shaft out of case.

16. NOTE: Do not damage bore with the prying tool.

    Using a screwdriver on the manual control lever seal lower edge, carefully pry manual control lever seal out of case bore.

17. Lift manual valve detent lever (7A115) and parking lever actuating rod (7A232) out of the case.

    

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

    

19. The following illustration shows the position of the overdrive servo, 1-2 shift accumulator, reverse servo and 2-3 shift accumulator.

    

20. Remove the 2-3 shift accumulator spring retainer and spring.

    

21. Remove 2-3 shift accumulator piston.

    

    Overdrive Servo

    

22. 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 internal retaining ring.

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

    

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

    

    Reverse Servo

    

24. Use Servo Piston Remover/Replacer T92P-70023-A to depress the reverse band servo cover (7D036) and compress the return spring. Remove internal retaining ring.

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

    Remove reverse band servo cover, reverse band servo piston and rod (7D189) and reverse band servo spring (7D031).

    

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

    

27. NOTE: Carefully note the location of the 1-2 shift springs (7F284) and assemble in the same positions. Some models may use two 1-2 shift springs. The 1-2 shift accumulator piston may also vary with applications.

    Remove cover and 1-2 shift spring. Use reverse snap-ring pliers to remove 1-2 shift accumulator piston and 1-2 shift spring.

28. Remove fluid screen from case.

    

29. 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.

    

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

    

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

    Using a 13mm socket, remove six extension housing bolts. Slide extension housing off output shaft. Remove and discard extension housing gasket (7086).

    

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

    

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

    

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

35.  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.

    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.

    

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

    

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

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

    

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

    

39. Remove and discard pump gasket.

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

    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

    

41. NOTE: Band may be removed with assembly.

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

    

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

    

43. Remove intermediate stub shaft.

    

44. Rotate reverse clutch sun gear to align indent with overdrive band anchor pin.

    

45. Remove forward clutch sun gear, No. 5 forward clutch sun gear bearing, reverse clutch sun gear and the No. 4 forward clutch hub bearing.

    

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

    

47. Using needle-nose pliers, remove case to planet support spring out from between the planetary gear support and the case. Note location for assembly.

    

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

    

49. Remove reverse band.

    

50. Remove retaining ring.

    

51. Remove output shaft, output shaft ring gear and direct clutch as an assembly.

    

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

    

53. Inspect rear case bushing. If removal is required, use Bearing Cup Puller T77F-1102-A and Impact Slide Hammer T59L-100-B.