Part 1

DISASSEMBLY

CAUTION: Tag all snap rings, thrust washers, washers, spacers and thrust bearings, etc. during disassembly for quick identification and assembly. Failure to follow these instructions will damage and cause transmission failure.




AS68RC COMPONENTS











DRAIN PLUG

1. Place the transmission manual shift lever into the park lock position.
2. Plug all openings and clean exterior of transmission with water soluble solvent or a pressure washer.
3. Remove oil pan drain plug (1) and drain fluid from transmission.




TORQUE CONVERTER REMOVAL


WARNING: Be certain the transmission is secure when removing the torque converter, the torque converter is very heavy. Failure to follow these instructions may result in personal injury or may be fatal.

4. Remove the torque converter from the transmission.

NOTE: Gear train end play is a very critical pre-disassembly check to help determine the condition of the transmission. End play reading greater than specification (larger gap) indicate that a bearing or thrust plate is either missing, worn or has disintegrated, in which case there will be debris in the oil pan.




INPUT SHAFT END PLAY






5. Using Adapter 8266-19 (1) and the handle from End-Play Tool Set 8266 (2) and Dial Indicator C-3339 (3), measure and record the input shaft end-play.




OUTPUT SHAFT END PLAY

6. Using Dial Indicator C-3339, measure and record the output shaft end-play.




4WD OUTPUT SHAFT END PLAY







The output shaft end-play clearance for both 2WD and 4WD, with the external end-play washer and snap ring removed, is 0.50-0.90 mm (0.019-0.035 in.). On the 4WD extension housing, the output shaft end-play clearance must be performed twice using the dial Indicator set C-3339-A and the 4WD output shaft end-play socket 8266-20, once with the external selectable end-play washer and snap ring removed and a second time with the external selectable end-play washer and snap ring washer in place to achieve a clearance of 0.00 mm - 0.24 mm (0.000-0.009 in.). If the clearance is not within tolerance, choose the correct selectable washer.





TC HOUSING


NOTE: Support the transmission case before removing the torque converter housing.

7. Remove the bolts securing the torque converter housing to the transmission case and remove the housing.




INPUT SPEED SENSOR

8. Remove the input speed sensor.




OUTPUT SPEED SENSOR

9. Remove the output speed sensor




FILL TUBE

1 - FILL TUBE O-RING

10. Remove the bolt (if equipped) securing the transmission fill tube to the transmission case and remove the fill tube.
11. Remove the manual shift lever from the transmission.
12. Remove the transmission range sensor.
13. Using a pry tool remove the manual shift lever seals (one each side of the transmission).




14. Remove the breather hose and fitting, if necessary.




PTO DUST COVER

15. Remove the PTO dust cover bolts and dust cover.




COOLER LINES






16. Remove the temperature sensor (1) from the ATF output cooler line fitting.
17. Remove the Jiffy Tite fittings (2) from both cooler line fittings.
18. Loosen both cooler line fittings (3).
19. Remove both cooler line fittings (3).




OVER HEAD VIEW

20. Remove the valve body.
21. Remove the three accumulator valves (1), (2), (3) and then the accumulator springs.





22. Air check the transmission.




OIL PUMP


NOTE: Using a marker or paint pen, tag the orientation of the oil pump to the transmission case.

23. Remove the bolts securing the oil pump to the transmission case and use tool C-3752 and adapters 9981 to remove the oil pump.




K2 RETAINER

24. Remove the input shaft assembly with the K1 and K2 clutch assemblies attached.




K1 AND K2 CLUTCHES







NOTE: The input shaft end-play clearance is adjusted by means of a selectable thrust bearing race located between the K1 and the K2 clutch pack retainers.

25. Remove the K2 clutch assembly (4) and the selectable input shaft end-play thrust bearing number one (2) and thrust washer (3) from the K1 clutch / input shaft assembly (1).




26. Remove the K1 clutch hub.




K1 THRUST BEARING No 2

27. Remove the K1 thrust bearing number 2.




K2 HUB

28. Remove the K2 clutch hub.




K2 HUB THRUST BEARING No. 3

29. Remove the K2 thrust bearing number three.




FRONT SUN/PTO FRONT THRUST BEARING No. 4