Part 2
TransmissionDisassembly (Steps 36-71)
Late build vehicles
36. Remove and discard the low/reverse clutch retaining ring.
37. NOTE: The output hub and ring gear assembly may stick to the low/reverse rocker clutch, clutch pack and carrier and hub assembly.
Remove the rocker clutch, low/reverse clutch pack and carrier and hub assembly.
All vehicles
38. Remove the No. 15 thrust bearing.
39. Place the transmission manual lever in PARK to lock the output shaft from rotating.
40. Remove the output hub and ring gear.
41. Remove the low reverse No. 16 thrust bearing.
42. If equipped, remove the output shaft flange.
1. Remove and discard the bolt.
2. Remove the output shaft flange.
43. If equipped, use the special tool to remove and discard the output shaft retaining nut.
44. If equipped with a fixed flange, use the special tools to remove the output shaft seal.
45. If equipped with a slip yoke, use the special tools to remove the output shaft seal.
46. Remove the 9 bolts and the extension housing.
47. Inspect the extension housing ball bearing. If any damage is evident, install a new extension housing. Check the output shaft journal.
48. Remove and discard the extension housing gasket.
49. Remove the output shaft.
50. For vehicles equipped with a fixed yoke, remove the No. 17 park gear thrust washer.
51. For vehicles equipped with a slip yoke, remove the No. 17 park gear thrust bearing.
52. CAUTION: Do not fully compress the return spring or damage to the spring may occur.
Using the special tools, remove and discard the reverse clutch return spring retaining ring.
53. Remove the return spring.
54. While applying air to the extension housing side of the case, remove and discard the reverse piston.
55. Remove the parking rod guide plate bolts and plate.
56. Remove the plastic orifice lube plug from the rear of the case and discard.
57. Remove the parking pawl.
1. Remove the parking pawl return spring.
2. Remove the parking pawl.
3. Remove the parking pawl shaft.
58. CAUTION: The Torx(R) head screw has a threadlocking compound and should be removed only if a new case is being installed. If the bolt is removed, it must be discarded and a new bolt installed.
Remove the parking pawl abutment.
59. NOTE: The pin should be driven down into the case.
Using a suitable tool, remove and discard the manual lever shaft retaining pin.
60. Using the special tool, remove the manual lever shaft retaining pin.
61. Remove the manual control lever shaft.
62. Remove the TR position sensor, manual control lever and park rod as an assembly.
63. Using the special tool, remove and discard the manual control lever seal.
64. NOTE: The short fluid inlet tube should be removed only if it is loose or damaged.
If required, remove the short fluid inlet tube.
65. NOTE: The top portion seal groove will work the best when removing the seal pack.
Inspect the rear case Teflon(R) seal retainer for damage. If damage is evident, use the special tool to remove the seal retainer.
66. Inspect the case assembly for cracks and stripped threads. Inspect the gasket surfaces and mating surfaces for burrs. Check the case vent assembly and all fluid passages for obstructions.
67. Inspect the rear case snubber bushing. If damage is found, install a new transmission case.
68. Inspect the case assembly bushing for scores. Check all parking linkage parts for wear or damage.
69. Inspect the reverse clutch case vent for blockage. The vent is located in the case at the 12 o'clock position. If evidence of blockage is found, use low air pressure to clear out the blockage. Apply air pressure to the extension housing side of the vent.
70. If the low/reverse clutch-to-case snap ring has rotated in the case snap ring groove, or is partially dislodged, the case snap ring groove has been damaged. To avoid repeat repairs, use a new case for the overhaul.
71. If installing a new case, remove the transmission fluid cooler tube nut case fittings and the vent assembly.