Disassembly

DISASSEMBLY




1. Remove transmission speed sensor (2) and O-ring seal (3) from overdrive case.




2. Remove overdrive piston thrust bearing (1).

OVERDRIVE PISTON





1. Remove overdrive piston thrust plate (2). Retain thrust plate. It is a select fit part and may possibly be reused.




2. Remove intermediate shaft spacer (2). Retain spacer. It is a select fit part and may possibly be reused.




3. Remove overdrive piston (2) from retainer (1).

OVERDRIVE CLUTCH PACK





1. Remove overdrive clutch pack wire retaining ring (1).




2. Remove overdrive clutch pack (1).




3. Note position of clutch pack components for assembly reference (1-4).

OVERDRIVE GEARTRAIN





1. Remove overdrive clutch wave spring (1), 5 disc clutch only.




2. Remove overdrive clutch reaction snap-ring (1). Note that snap-ring is located in same groove as wave spring.




3. Remove Torx head screws (1) attach access cover and gasket to overdrive case.




4. Remove access cover and gasket (1).




5. Expand output shaft bearing snap-ring with expanding-type snap-ring pliers (1). Then push output shaft forward to release shaft bearing from locating ring.




6. Lift gear case (2) up and off geartrain assembly (1).




7. Remove snap-ring (3) that retains rear bearing (2) on output shaft (1).
8. Remove rear bearing from output shaft.

DIRECT CLUTCH, HUB AND SPRING


WARNING: The next step in disassembly involves compressing the direct clutch spring. It is extremely important that proper equipment be used to compress the spring as spring force is approximately 830 pounds. Use spring compressor tool 6227-1 and a hydraulic shop press with a minimum ram travel of 5-6 inches. The press must also have a bed that can be adjusted up or down as required. Release clutch spring tension slowly and completely to avoid personal injury.




1. Mount geartrain assembly in shop press (1, 5).
2. Position Spring Compressor Tool 6227-1 (6) on clutch hub (3). Support output shaft flange with steel press plates (4) as shown and center assembly under press ram (1).




3. Apply press pressure slowly. Compress hub and spring far enough to expose clutch hub retaining ring (3) and relieve spring pressure on clutch pack snap-ring.
4. Remove direct clutch pack retaining ring (3).




5. Remove direct clutch hub retaining ring (2).




6. Release press load slowly and completely.
7. Remove Spring Compressor Tool 6227-1. Then remove clutch pack (3) from hub (2). Note the orientation of the clutch discs. The clutch pack consists of 10 double-sided friction discs and they must be installed in the same orientation as they were removed.

GEARTRAIN





1. Remove direct clutch hub (2) and spring (1).




2. Remove sun gear (5) and spring plate (3). Then remove planetary thrust bearing (2) and planetary gear (1).




3. Remove overrunning clutch assembly (1) with expanding type snap-ring pliers. Insert pliers into clutch hub. Expand pliers to grip hub splines and remove clutch with counterclockwise, twisting motion.




4. Remove thrust bearing from overrunning clutch hub.
5. Remove overrunning clutch from hub.
6. Mark position of annulus gear and direct clutch drum (1) for assembly alignment reference. Use small center punch (3) or scriber to make alignment marks.




7. Remove direct clutch drum (2) rear retaining ring (1).




8. Remove direct clutch drum outer retaining ring (1).




9. Mark annulus gear and output shaft (1) for assembly alignment reference. Use punch (3) or scriber to mark gear and shaft.




10. Remove snap-ring (3) that secures annulus gear (2) on output shaft (1). Use two screwdrivers to unseat and work snap-ring out of groove as shown.




11. Remove annulus gear (2) from output shaft (1). Use rawhide or plastic mallet to tap gear off shaft.

GEAR CASE AND PARK LOCK

1. Remove locating ring from gear case.
2. Remove park pawl shaft retaining bolt and remove shaft, pawl and spring.
3. Remove reaction plug snap-ring and remove reaction plug.
4. Remove output shaft seal.