Disassembly
Disassembly
WARNING: DO NOT REMOVE THE TORQUE CONVERTER OR TRANSFER CASE FROM THE TRANSMISSION WHILE STILL ON JACK. DOING SO COULD CAUSE THE TRANSMISSION TO FALL OFF THE JACK.
NOTE: For disassembly, relocate the transmission to the top of a flat work bench.
WARNING: THE TORQUE CONVERTER IS HEAVY, ESPECIALLY WHEN FULL OF OIL.
1. Remove torque converter.
2. Remove input shaft.
- The splines on the input shaft are not the same on both ends. The end with the shorter spline goes into the assembly.
Transfer Case Removal:
3. NOTE: For transfer case disassembly and assembly refer to Transfer Case / Service and Repair.
If the vehicle has a transfer case, use a 13mm socket to remove five bolts holding the transfer case to the extension housing. Remove transfer case and set aside for reassembly.
4. NOTE: The case oil pressure plug is a press fit into the extension housing and is not serviced separately.
CAUTION: The parking pawl, parking pawl return spring, and parking pawl shaft could fall out during removal of the extension housing.
Remove the extension housing seal using Seal Remover T74P-77248-A.
5. NOTE: Remove extension housing bushing only if service is required by inspection.
Remove the extension housing bushing using Extension Housing Bushing Remover T77L-7697-E.
6. Use 17mm socket to remove four M10 x 30mm screws and two studs holding the extension housing to the transmission case.
7. Remove the parking pawl, parking pawl return spring, and parking pawl shaft.
8. NOTE: The governor body counterweight need not be removed.
Use a 10mm socket to remove two M6 x 20mm screws holding governor to collector body. Remove the governor assembly, governor primary valve, governor valve spring, and governor weight.
9. CAUTION: The park rod must slip freely into clearance hole in the adapter plate.
NOTE: See the Service Tool section for drawing of this optional adapter plate.
Use four M10 x 30mm screws from the extension housing to attach the adapter plate to the transmission
10. Attach the fixture arm assembly, part of Bench Mounted Holding Fixture T57L-500-B, with two 7/16 x 2-inch bolts and nuts.
11. WARNING: MAKE SURE THE LOCK PIN ON THE BENCH FIXTURE T57-500-B IS SECURE.
Install the transmission assembly to the Bench Mounted Holding Fixture T57-500-B. Rotate to the position shown. Place drain bucket under assembly. Most of the remaining oil will drain in this position.
12. NOTE: A heat shield is on all 4.0L applications.
Remove heat shield retaining nut M6 x 1.0 from studded bolt. Use a screwdriver to carefully pry the heat shield off the oil pan rail near retaining clips.
13. WARNING: MAKE SURE THE LOCK PIN ON BENCH FIXTURE T57-500-B IS SECURE.
Rotate transmission assembly with transmission fluid pan up as shown.
Use a 13mm socket to remove transmission fluid pan screws (M8 x 14mm) holding transmission oil pan to case.
14. CAUTION: Do not reuse the oil pan to case gasket.
Remove transmission oil pan and oil pan to case gasket.
15. Use a 10mm socket to remove one M6 x 45mm screw holding the oil screen assembly to the main control valve body. Remove the oil screen assembly.
16. Use a 10mm socket to remove one M6 x 30mm screw holding manual valve detent spring to main control valve body. Remove the manual valve detent spring.
17. Disconnect the two wires attached to each solenoid at the torque converter clutch solenoid and overdrive 3-4 shift solenoid.
18. WARNING: WHEN REMOVING THE REVERSE BAND SERVO COVER, THE REVERSE BAND SERVO PISTON AND RODS CAN POP OUT UNEXPECTEDLY DUE TO SPRING PRESSURE BEHIND PISTON.
Use a 10mm socket to remove M6 x 20m screws holding reverse band servo cover.
19. Remove the cover, reverse band servo piston and rod, reverse band servo spring, and reverse servo separator plate cover gasket.
20. NOTE: Refer to the Main Control Valve Body - Disassembly and Assembly.
Use a 10mm socket to remove seventeen M6 x 40mm screws, four M6 x 45mm screws and three M6 x 35mm screws holding the main control valve body to the case. Remove the main control valve body and reverse servo separator plate cover gasket.
21. WARNING: AIR PRESSURES SHOULD NOT BE GREATER THAN 137 KPA (20 PSI). WEAR SAFETY GLASSES WHEN USING COMPRESSED AIR. THE PISTON ASSEMBLY CAN POP OUT UNEXPECTEDLY DUE TO SPRING PRESSURE BEHIND THE PISTON. DO NOT STAND DIRECTLY IN FRONT OF THE PISTON.
NOTE: Light tapping on the cover and case, or air pressure applied on release side, may be needed. Use A4LD Transmission Test Plate T86L-7006-A.
NOTE: Tag spring, piston and cover assembly. Label "overdrive" and "intermediate" accordingly for reassembly. Covers have letters cast onto outer surface for identification.
Remove the intermediate servo assembly, snap ring, cover, piston and servo piston spring. Remove the overdrive servo, snap ring, intermediate band servo retainer, intermediate band servo piston and servo piston spring.
22. WARNING: MAKE SURE THE LOCK PIN ON THE BENCH FIXTURE T57L-500-B IS SECURE.
Rotate the transmission assembly with the converter housing facing up.
23. CAUTION: Throw locknuts away. Locknuts are not reusable for assembly.
Remove the overdrive and intermediate band locknuts (19mm hex) and back off the band adjusting screw.
24. CAUTION: Throw screws away. Screws are not reusable for assembly.
Use a 17mm socket to remove eight M10 x 33mm screws holding the converter housing and front pump support and gear to the case.
25. NOTE: Rotate and lift converter housing so that the clutch assemblies will stay in place.
Remove the converter housing and front pump support and gear assembly.
26. NOTE: Refer to Disassembly and Assembly of Subassemblies, Converter Housing and Pump Assembly.
Remove the oil pump gasket, and No. 1 thrust washer. Tag the thrust washer as No. 1 for identification. Discard oil pump gasket.
27. CAUTION: Identify the band. Identify which end of the band is the anchor side or apply side to make sure of correct reassembly.
Remove the overdrive brake band strut and overdrive band.
28. Lift out the overdrive drum assembly.
29. NOTE: No. 12 and No. 2 thrust bearings are in this assembly.
Lift out the planet gear overdrive carrier.
30. NOTE: Tag and identify overdrive lever for reassembly. Lever has a letter stamped into its side.
Remove the servo band lever, overdrive and actuating lever shaft. Remove the overdrive control bracket.
31. Remove the overdrive center shaft. Remove No. 3 center support thrust bearing or washer from the front of the center support and tag to identify.
32. CAUTION: Center overdrive support mating (loose) nut could fall into remaining assembly if not removed. This nut is not serviced separately.
Use a 5mm Allen wrench to remove one capscrew (M6 x 20mm) holding the center overdrive support in place. Remove the mating (loose) nut from the center overdrive support.
33. Remove the center support retaining snap ring.
34. Remove the center overdrive support by pulling evenly around the rear planet support web.
35. NOTE: There are two types of forward geartrain assemblies. Clip together type forward geartrain for 4.0L transmissions, and non-clip together type forward geartrain for all 2.3L, 3.0L transmissions. Read the following procedure to determine which steps apply to the transmission being serviced.
Remove thrust washer below center support (non-clip together type forward geartrain only). Tag and identify thrust washer for reassembly.
36. CAUTION: Identify intermediate band. Identify which end is the anchor or apply side of the low and intermediate band to ensure correct reassembly.
Remove the intermediate brake band strut and intermediate band.
37. NOTE: The select-fit thrust bearing No. 5 is for 4.0L, clip together type forward geartrain only, and sits loosely in this assembly against the forward clutch cylinder face and may fall out.
Remove thrust washer by using a magnet. Tag and identify the thrust washer for reassembly.
38. WARNING: MAKE SURE THE LOCK PIN ON BENCH MOUNTED HOLDING FIXTURE T57L-500-B IS SECURE.
Rotate the transmission so the fluid pan rails are facing upward.
39. Remove intermediate brake drum and direct clutch assembly.
40. Remove forward clutch.
41. Remove forward ring gear.
42. Remove forward planet thrust bearing (No. 7).
43. NOTE: Forward planet carrier is model dependent.
Remove forward planet carrier assembly.
44. Remove input shell with overdrive sun gear.
45. NOTE: The following steps should be used when disassembling the 4.0L, clip together type forward geartrain assembly.
The clip together type forward geartrain assembly is removed as one unit and is fastened together by two locking tabs (positioned 180 degrees apart) from the input shell, to a groove on the intermediate brake drum and direct clutch assembly.
Insert a flat-bladed screwdriver into locking tab groove on the intermediate brake drum and direct clutch assembly at locking tab locations indicated in the illustration.
46. CAUTION: Do not use excessive force while prying. Damage to input shell and reverse brake/high clutch components may occur.
Carefully push down on screwdriver while gently prying against input shell locking tab. Repeat on adjacent locking tab.
47. NOTE: 4.0L applications do not have snap ring.
Remove the snap ring from the reverse planet assembly.
48. Remove No. 8 rear clutch sun gear thrust washer. Use a tag to identify the washer.
49. CAUTION: No. 8 and No. 9 thrust washers are model dependent.
NOTE: Reverse planet is model dependent.
Remove the reverse planet and No. 9 rear clutch sun gear thrust washer. Use a tag to identify the washer.
50. NOTE: The lubricant guide is in 4.0L applications only.
Remove the output shaft lubricant guide.
51. CAUTION: Discard snap ring. A new one must be used for reassembly.
Remove the output shaft snap ring from inside the case on the output shaft.
52. CAUTION: No. 10 output shaft hub thrust washer is model dependent.
Remove output shaft ring gear. Use a tag to identify the washer.
53. NOTE: The inner race of the rear one-way clutch is not removable. It is serviced in the case.
NOTE: Reverse brake drum and one-way clutch are model dependent.
Remove the reverse brake drum and the one-way clutch assembly.
54. Remove the reverse band.
55. NOTE: Tag and identify intermediate lever for reassembly. Lever has letter stamped on its side for identification.
Remove the servo band lever and intermediate band actuating lever shaft.
56. NOTE: 4.0L output shafts do not have a lube hole.
Remove the output shaft.
57. Remove the governor fluid collector body and No. 11 output shaft yoke washer. Identify washer.
58. Use a 10mm socket to remove one (M6 x 12mm) screw and vacuum diaphragm clamp.
59. Remove the vacuum throttle valve diaphragm assembly and throttle control valve rod.
60. Verify that the throttle valve moves freely using flat external snap ring pliers. Then remove the throttle control valve with the external snap ring pliers.
61. CAUTION: Do not use an open-end wrench. The switch assembly could be damaged.
Remove the park/neutral position switch (PNP switch) using Neutral Start Switch Socket T74P-77247-A.
62. CAUTION: Use a crescent wrench or channel lock pliers to hold the inner kickdown lever as shown to prevent case damage using a 13mm socket to loosen the downshift control outer lever.
NOTE: Replace the manual control lever oil seal and downshift control lever oil seals as required.
Remove the nut and throttle valve outer lever. Remove the O-ring seal.
63. CAUTION: Do not bend or damage the manual valve detent lever inner pin.
Back off the 7/8 inch hex inner nut on the manual control lever completely.
64. CAUTION: Do not damage the case oil pan rail.
Use a small hammer and drift to tap lightly on each side of the linkage centering pin (2 or 3 times) to loosen prior to removal.
65. Remove the linkage centering pin with a narrow, sharp edged screwdriver from side as shown.
66. CAUTION: Do not bend the manual valve detent lever inner pin.
Remove the manual control lever downshift detent lever parking lever actuating rod and manual valve detent lever with the manual valve detent lever inner pin.
67. Remove the manual control lever oil seal.
68. NOTE: To remove the case solenoid connector, depress the tab on the outside of the case, backside of the connector, while pulling and twisting with pliers.
Remove case solenoid connector if the case is to be immersed in degreaser, or is being replaced.
69. Remove the case with attached adapter plate and Bench Mounted Holding Fixture (T57L-900-B) from bench fixture pivot. Remove four M10 x 30mm screws holding the adapter plate to extension housing face, leaving adapter plate attached to fixture arm.