Disassembly

DISASSEMBLY




1. Remove the torque converter (1).




2. Place transmission in a vertical position.
3. Measure input shaft end play as follows:
a. Attach Adapter 8266-18 (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 8266-18 (2) 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 the input shaft in and out. Record the maximum travel for assembly reference.




4. Loosen adapter plug bolt (11) and remove the adapter plug (12) from the transmission housing.
5. Detach oil pan (5).
6. Remove oil filter (4).
7. Unscrew Torx socket bolts (3) and remove electrohydraulic unit (2).
8. Air check the transmission.




9. Place the transmission in PARK to prepare for the removal of the output shaft nut.
10. Remove the nut, with a 30 mm 12 point socket, holding the propeller shaft flange to the output shaft and remove the flange.
11. Remove the transmission rear oil seal with a suitable slide hammer and screw.
12. Remove the transmission output shaft washer. Be sure to tag the washer since it is very similar to the geartrain end-play shim and they must not be interchanged.
13. Remove the transmission rear output shaft bearing retaining ring (1).




14. Position Bearing Remover 9082 (1) over the inner race of the output shaft bearing (3).




15. Slide the collar (3) on the Bearing Remover 9082 (1) downward over the fingers (4) of the tool.




16. Remove the output shaft bearing (3).
17. Remove the geartrain end-play shim from the output shaft. Be sure to tag the shim since it is very similar to the output shaft washer and they must not be interchanged.




Remove K1, K2, and K3 Clutches






18. Remove the bolts holding the transmission housing to the converter housing from inside the converter housing.
19. Stand the transmission upright on the converter housing.
20. Remove the remaining bolts holding the transmission housing to the converter housing.
21. Remove the transmission housing from the converter housing.
22. Remove output shaft with center and rear gear set and clutch K3 (3).
23. Remove thrust needle bearing (4) and thrust washer (5).
24. Remove input shaft with clutch K2 and front gear set (6).
25. Remove clutch K1 (1).




Remove Holding Clutch B1 and Oil Pump






26. Unscrew Torx socket bolts (4) and remove oil pump (6). Screw two opposed bolts into the oil pump housing and press the oil pump out of the converter housing by applying light blows with a plastic hammer.
27. Remove and discard the torque converter hub seal and the oil pump outer O-ring seal from the oil pump.
28. Unscrew Torx socket bolts (1) and remove multiple-disc holding clutch B1 (5) from converter housing. Screw two opposed bolts into the multiple-disc holding clutch B1 (5) and separate from the converter housing by applying light blows with a plastic hammer.
29. Detach intermediate plate (3) from converter housing (2).




Remove B2, B3, and Parking Gear






30. Remove multiple-disc pack B3 (2) and spring washer (3) by removing snap-ring (1) in transmission housing. To facilitate removal of the snap-ring (1), compress the multiple-disc pack B3 (2). Note which clutch disc is removed just prior to the spring washer (3) for re-assembly. If the clutch discs are re-used, this disc must be returned to its original position on top of the spring washer.
31. Unscrew Torx socket bolts (7).
32. Remove multiple-disc holding clutch B2 (4) from transmission housing. The externally toothed disc carrier for multiple-disc holding clutch B2 is also the piston for multiple-disc holding clutch B3.
33. Remove parking lock gear (5).