Part 1 of 2

Disassembly





1. WARNING: DO NOT REMOVE THE TORQUE CONVERTER OR TRANSFER CASE FROM THE TRANSMISSION WHILE STILL ON THE JACK. DOING SO COULD CAUSE THE TRANSMISSION TO FALL OFF THE JACK.

Relocate the transmission to the top of a flat workbench.






2. NOTE: Refer to Section 07-07A, Section 07-07B, Section 07-07C, Section 07-07D or Section 07-07E for transfer case service.


If the vehicle has a transfer case, use a 13mm socket to remove the five transfer case-to-extension housing screws. Remove the transfer case and set aside for assembly.






3. WARNING: THE TORQUE CONVERTER IS HEAVY, ESPECIALLY WHEN FULL OF FLUID.

Remove the torque converter using Torque Converter Handles T81P-7902-C.






4. NOTE: The splines on the input shaft are not the same on both ends. The end with the shorter spline goes into the assembly.

Remove the input shaft.

5. Remove the extension housing seal using Seal Remover TOOL-1175-AC and Impact Slide Hammer T50T-100-A.






6. NOTE: Remove the extension housing bushing only if service is required.


Inspect the extension housing bushing and driveshaft slip-yoke for nicks, gouges, scoring and wear.

Remove the extension housing bushing using Extension Housing Bushing Remover T77L-7697-E.






7. CAUTION: The parking pawl, parking pawl return spring and parking pawl shaft could fall out during removal of the extension housing.

Use a 17mm socket to remove the five M10 x 30mm extension housing-to-transmission case screws and stud.






8. Remove the parking pawl, parking pawl return spring and parking pawl shaft.






9. CAUTION: The parking pawl actuating rod must slip freely into the clearance hole in the adapter plate.

NOTE: See the Special Service Tool section for a drawing of this optional adapter plate.

Use the four M10 x 30mm extension housing to transmission case screws to attach the adapter plate to the transmission.






10. Attach the fixture arm assembly (part of T57L-500-B) with two 7/16 x 2-inch bolts and nuts.






11. WARNING: MAKE SURE THE LOCK PIN ON BENCH-MOUNTED HOLDING FIXTURE T57L-500-B IS SECURE.

Install the transmission assembly to Bench-Mounted Holding Fixture T57L-500-B. Rotate to the position shown. Place a drain pan under the assembly.






12. NOTE: A transmission heat shield is on all 4.0L vehicle.

Remove the M6 x 1.0 transmission heat shield nut from the studded screw.






13. Carefully pry the transmission heat shield off of the fluid pan rail near the retaining clips.

14. WARNING: MAKE SURE THE LOCK PIN ON BENCH-MOUNTED HOLDING FIXTURE T57L-500-B IS SECURE.

Rotate the transmission assembly so the converter housing is facing up.






15. Remove the manual control outer lever nut and manual control outer lever.






16. Remove the two M6 x 25 transmission range (TR) sensor screws and remove the TR sensor.



17. WARNING: MAKE SURE THE LOCK PIN ON BENCH-MOUNTED HOLDING FIXTURE T57L-500-B IS SECURE.

Rotate transmission assembly so that the fluid pan is facing up.

Fluid Pan Removal:

Fluid Pan Filter Removal:

18. CAUTION: Do not reuse the fluid pan gasket.

Use a 13mm socket to remove the eighteen M8 x 1.4mm fluid pan screws. Remove the fluid pan and fluid pan gasket. Discard the fluid pan gasket.

19. Use a 10mm socket to remove the M6 x 55mm fluid pan filter assembly screw. Remove and discard the fluid pan filter assembly.






20. Carefully lift up on the wire loom guide and protector. Disengage the retaining pins from the solenoid clamps.






21. Disconnect the six solenoid connectors from the solenoids by carefully pulling upward and wiggling side to side.






22. Use a 10mm socket to remove the M6 x 30mm manual valve detent spring screw. Remove the manual valve detent spring.










23. Use a 10mm socket to remove the four M6 x 20mm reverse servo cover screws. Remove the reverse servo cover, reverse servo piston and rod and reverse servo.






24. CAUTION: To prevent solenoid valves from falling out, do not remove the two screws shown below.

NOTE: Refer to the Main Control disassembly and assembly in this section.


Use a 10mm socket to remove the seventeen M6 x 40mm, four M6 x 45mm, two M6 x 35mm and one M6 x 30mm main control valve body screws.





25. Remove the main control assembly.


26. NOTE: The J-hook must be in the appropriate hole for the servo being removed.


Install Servo Cover Compressor T95L-77028-A over the intermediate servo cover at the fluid pan rail with tool stamping facing up. Tighten the screws.






27. Using a 1/2-inch wrench, tighten the nut on the J-hook until there is a gap between the servo cover and the snap ring.






28. Carefully remove the servo cover retaining ring.


29. CAUTION: The servo cover is under spring tension.

Carefully back off the nut on the J-hook until the servo spring is unloaded.






30. WARNING: AIR PRESSURE SHOULD NOT BE GREATER THAN 138 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 the release side may be needed. Use 4R44E/4R55E Transmission Test Plate T95L-77000-AH and Transmission Test Plate Gasket T95L-7006A.

NOTE: Tag the spring, piston and cover assembly. Label accordingly for assembly. The covers have letters cast on the outer surface for identification.

Remove the intermediate servo cover, piston and spring.

31. Remove Servo Cover Compressor T95L-77028-A.

32. NOTE: The J-hook must be in the appropriate hole for the servo being removed.

Install Servo Cover Compressor T95L-77028-A over the overdrive servo cover at the fluid pan rail. Tighten the screws.






33. Using a 1/2-inch wrench, tighten the nut on the J-hook until there is a gap between the servo cover and the retaining ring.






34. Carefully remove the servo cover retaining ring.

35. CAUTION: The servo cover is under spring tension.

Carefully back off the nut on the J-hook until the servo spring is unloaded.






36. WARNING: AIR PRESSURE SHOULD NOT BE GREATER THAN 138 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 the release side may be needed. Use 4R44E/4R55E Transmission Test Plate T95L-77000-AH.

NOTE: Tag the spring, piston and cover assembly. Label accordingly for assembly. The covers have letters cast on the outer surface for identification.

Remove the overdrive servo cover, piston and spring.

37. Remove Servo Cover Compressor T95L-77028-A.

38. WARNING: MAKE SURE THE LOCK PIN ON BENCH-MOUNTED HOLDING FIXTURE T57L-500-B IS SECURE.

Rotate the transmission assembly with the converter housing facing up.






39. CAUTION: Throw the locknuts away. The locknuts are not reusable for assembly.

Remove the overdrive and intermediate band locknuts and discard. Back off the band adjusting screws.






40. CAUTION: Throw the screws away. The screws are not reusable for assembly.

Use a 17mm socket to remove the eight M10 x 33mm converter housing-to-case screws. Discard the screws.






41. NOTE: Rotate and lift the converter housing so that the clutch assemblies will stay in place.

Remove the converter housing and fluid pump support and gear assembly.






42. NOTE: Refer to Converter Housing And Pump Assembly under subassemblies for service information.

Remove the fluid pump gasket and No. 1 fluid pump thrust washer and discard the gasket. Tag the No. 1 fluid pump thrust washer for identification.






43. Remove overdrive band adjusting screw. Compress the overdrive band around the overdrive brake and coast clutch drum. Remove the overdrive band anchor strut.






44. CAUTION: Identify which end of the overdrive band is the anchor side or the apply side.

Remove the overdrive band.






45. Remove the overdrive brake and coast clutch drum.