Disassembly

DISASSEMBLY




1. Clean exterior of transmission with suitable solvent or pressure washer.
2. Place transmission in vertical position.
3. Measure the input shaft end play as follows.
a. Attach Adapter 8266-5 (2) to Handle 8266-8 (1).
b. Attach Dial Indicator C-3339 (3) to Handle 8266-8 (1).
c. Install the assembled tool onto the input shaft of the transmission and tighten the retaining screw on Adapter 8266-5 to secure it to the input shaft.
d. Position the dial indicator plunger against a flat spot on the oil pump and zero the dial indicator.
e. Move input shaft in and out and record reading. Record the maximum travel for assembly reference




4. Remove the overdrive unit from the main transmission case. If overdrive unit is not to be serviced, install Alignment Shaft 6227-2 into the overdrive unit to prevent misalignment of the overdrive clutches during service of main transmission components.
5. Remove throttle and shift levers from valve body manual shaft and throttle lever shaft.
6. Remove transmission oil pan and gasket.
7. Remove filter (1) from valve body (2). Keep filter screws separate from other valve body screws. Filter screws are longer and should be kept with filter.




8. Remove the transmission range sensor.
9. Remove hex head bolts (1, 2) attaching valve body to transmission case. A total of 10 bolts are used. Note different bolt lengths for assembly reference.




10. Remove valve body assembly (2). Push valve body harness connector out of case. Then work park rod (3) and valve body out of case.




11. Remove accumulator outer spring (2) (diesel engines only), piston (1), and inner spring (3) (V-10 engine only). Note position of piston and springs for assembly reference. Remove and discard piston seals if worn or cut.




12. Remove pump oil seal with suitable pry tool or slide-hammer mounted screw.
13. Remove front band lever pin access plug (1). Use square end of 1/4 in. drive extension (2) to remove plug as shown.




14. Begin removal of the oil pump and reaction shaft support assembly by tightening the front band adjusting screw (2) until band is tight around front clutch retainer. This will prevent retainer from coming out with pump and possibly damaging clutch or pump components.




15. Remove oil pump bolts.
16. Thread Slide Hammers C-3752 (2) into threaded holes in flange of oil pump housing (1).




17. Remove oil pump and reaction shaft (1) support by bumping slide hammers outward alternately to pull pump from case.




18. Remove oil pump gasket (1). Note gasket position in case for assembly reference.




19. Loosen front band adjusting screw until band is completely loose.
20. Remove front band strut (2) and anchor (3).




21. Squeeze front band (1) together slightly and slide band over front clutch retainer (2) and out of case.




22. Remove front and rear clutch assemblies (1) as a unit.




23. Remove front band reaction pin and lever (1). Start pin through lever and out of case bore with drift or punch. Then use pencil magnet to withdraw pin completely (2).




24. Remove intermediate shaft thrust washer (1). Triangular shaped washer will either be on shaft pilot hub (2) or in rear clutch retainer.




25. Remove thrust plate (1) from intermediate shaft hub (2).




26. Remove intermediate shaft-planetary geartrain assembly (1).




27. Loosen rear band locknut and loosen adjusting screw 3-4 turns.
28. Remove snap-ring (3) that retains low-reverse drum (1) on overdrive piston retainer hub.




29. Slide low-reverse drum (1) and thrust washer (3) off piston retainer hub and out of rear band.




30. Note that overrunning clutch race (1) will remain on splines of low-reverse drum after removal. The race is a permanent press fit on the hub splines. Do not attempt to remove the race.




31. Remove overrunning clutch assembly (2). Assembly can be removed without displacing rollers and springs if care is exercised. Note position of rollers and springs for assembly reference.




32. Remove rear band adjusting lever and reaction pin.
33. Remove rear band.
34. Compress front servo rod guide (2) with large C-clamp (1) and Tool C-4470 (4), or Compressor Tool C-3422-B. Compress guide only enough to permit snap-ring removal (about 1/8 in.).




35. Remove servo piston snap-ring (4). Unseat one end of ring. Then carefully work removal tool around back of ring until free of ring groove. Exercise caution when removing snap-ring. Servo bore can be scratched or nicked if care is not exercised.
36. Remove tools and remove rear servo retainer (3), spring and piston assembly.