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DISASSEMBLY1. Remove torque converter.
Typical Harness And Cable Clamp Attachment:
2. Remove clamps attaching wire harness and throttle cable to transmission.
3. Remove shift lever from manual valve shaft at left side of transmission.
4. Remove park/neutral position switch.
5. Remove speed sensor.
Converter Housing Removal:
6. Remove converter housing bolts and remove housing from case.
7. Remove adapter housing, speedometer drive gear, and speed sensor rotor.
Removing Oil Screen:
8. Remove transmission oil pan, oil screen and screen gaskets.
Valve Body Oil Tubes Removal:
9. Remove valve body oil feed tubes.
Solenoid Wire Location:
10. Disconnect valve body solenoid wires.
Removing Bracket And Harness:
11. Remove harness bracket bolt and remove harness and bracket.
Valve Body Bolt Locations:
12. Remove valve body bolts.
Disconnecting Throttle Cable:
13. Disconnect throttle cable from throttle cam.
Removing Accumulator Springs, Spacers And Check Ball:
14. Remove valve body from case. Then remove accumulator springs, check ball, and spring.
Accumulator Piston Removal:
15. Remove second brake and clutch accumulator pistons with compressed air. Apply air pressure through feed port and ease the pistons and springs out of the bore. Note and identify the original location of all springs.
16. Remove overdrive brake accumulator piston with compressed air. Note and identify the original location of all springs.
17. Remove overdrive clutch accumulator piston with compressed air.
18. Remove throttle cable.
Oil Pump Removal:
19. Remove oil pump bolts and remove pump with bridge-type Puller 7536.
Oil Pump Race Removal:
20. Remove race from oil pump.
Removing Overdrive Planetary And Clutch Assembly:
21. Remove overdrive planetary gear and clutch assembly.
Fourth Gear Planetary Race Removal:
22. Remove race from overdrive planetary.
Removing Bearing, Race And Planetary Ring Gear:
23. Remove thrust bearing, race and overdrive planetary ring gear.
24. Measure stroke length of overdrive brake piston as follows:
a. Mount dial indicator on case using Miller Tool C-3339 and a suitable bolt threaded into the transmission case.
b. Verify that the dial indicator is mounted solidly and square to the direction of the piston travel.
c. Apply 57-114 psi air pressure through piston apply port and note piston stroke on dial indicator. Stroke length should be: 1.40 - 1.70 mm (0.055 -0.0699 inch).
d. Record the reading for use during reassembly.
e. Remove the dial indicator set-up from the transmission.
25. Measure stroke length of second coast brake piston rod as follows:
a. Install a small wire tie strap around the second coast brake piston rod tight against the transmission case.
b. Apply 57 - 114 psi air pressure through piston feed hole and check stroke length with Gauge Tool 7552.
c. Stroke length should be 1.5 - 3.0 mm (0.059 - 0. 118 inch).
d. Record the reading for use during reassembly.
26. Remove the bolt holding the input speed sensor to the transmission case.
27. Remove the input speed sensor from the transmission case.
Removing Overdrive Brake Pack Snap Ring:
28. Remove overdrive brake pack snap ring.
29. Remove overdrive brake pack discs and plates. Inspect and replace as necessary.
Overdrive Support Bearing/Race Removal:
30. Remove overdrive support lower race and upper bearing and race assembly.
Overdrive Support Snap Ring Removal/Installation:
31. Remove overdrive support snap ring with Snap Ring Plier Tool 7540.
Overdrive Support Bolt Removal:
32. Remove overdrive support bolts.
Removing Overdrive Support:
33. Remove overdrive support with bridge-type Puller 7536.
Remove Overdrive Support Race:
34. Remove race from hub of overdrive support.
35. Remove second coast brake piston snap ring with Snap Ring Plier Tool 7540. Then remove piston cover and piston assembly.
Second Coast Brake Piston Components:
36. Disassemble second coast brake piston, if necessary.
Removing Direct And Forward Clutch Assembly:
37. Remove direct and forward clutch assembly.
Bearing And Race Removal From Clutch Hub:
38. Remove thrust bearing and race from clutch hub.
Second Coast Brake Band Removal:
39. Remove second coast brake band E-ring from band pin and remove pin and brake band.
Front Planetary Ring Gear Removal:
40. Remove front planetary bear7ing race and remove front planetary ring gear.
Removing Ring Gear Bearing And Rear Race:
41. Remove thrust bearing and rear race from ring gear.
42. Remove planetary thrust race.
43. Push forward on output shaft to relieve the load on the planetary snap ring.
Removing Planetary Snap Ring And Gear:
44. Remove planetary snap ring and remove planetary gear.
Removing Sun Gear, Input Drum And One-Way Clutch:
45. Remove sun gear, input drum, one-way clutch, and thrust washer as assembly.
Checking Second Brake Clutch Pack Clearance:
46. Measure second brake clutch pack clearance. Clearance should be 0.62 - 1.98 mm (0.0244 - 0.0780 inch). Record measurement for use during re-assembly.
Removing Second Brake Clutch Pack Snap Ring:
47. Remove second brake clutch pack snap ring.
Removing/Measuring Second Brake Clutch Disc Thickness:
48. Remove second brake clutch pack. Inspect and replace as necessary.
Removing Park Rod And Bracket:
49. Remove bolts attaching park rod bracket to case. Then disconnect park rod from manual shaft lever and remove rod and bracket.
Removing Park Pawl, Pin And Spring:
50. Remove park pawl spring, pin and pawl.
Checking First-Reverse Brake Clutch Pack Clearance:
51. Measure clearance of first-reverse brake clutch pack. Clearance should be: 0.70 - 1.2 mm (0.028 - 0.047 inch). record measurement for use during re-assembly.
Removing Second Brake Piston Sleeve:
52. Remove second brake piston sleeve.
53. Remove second brake snap-ring.
Removing Rear Planetary, Second Brake Drum And Output Shaft:
54. Remove rear planetary gear, second brake drum and output shaft as an assembly.
Removing/Installing Bearing And Race Assembly:
55. Remove planetary and brake drum thrust bearing and race assembly.
56. Remove second brake drum gasket from case with screwdriver.
Checking Rear Bushing Inside Diameter:
57. Measure inside diameter of transmission case rear bushing with bore gauge or inside micrometer. Maximum allowable diameter is 38.18 mm (1.5031 inch). Replace transmission case if bushing I.D. is greater than specified. Bushing is not serviceable.
Checking First-Reverse Brake Piston Operation:
58. Check first/reverse brake piston operation with compressed air. Piston should move smoothly and not bind or stick. If piston operation is incorrect, case or piston may require replacement.
Removing/Installing Piston Snap Ring:
59. Compress piston return springs with Tool 7539 and remove piston snap ring.
60. Remove Tool 7539 and remove piston return springs.
61. Remove No. 2 first-reverse brake piston with compressed air. Apply air through same transmission feed hole used for checking piston operation.
Removing/Installing Reaction Sleeve:
62. Remove reaction sleeve with Sleeve Remover Tool 7542. Insert tool flanges under sleeve and lift tool and sleeve out of case.
Removing/Installing First-Reverse Brake No.1 Piston:
63. Remove No. 1 first/reverse brake piston with Piston Puller 7543. Slip tool under piston and lift tool and piston out of case.
ASSEMBLY
Thrust Bearing Chart:
1. During assembly, lubricate components with transmission fluid or petroleum jelly as indicated.
2. Verify thrust bearing and race installation during assembly. Refer to the Thrust Bearing Chart for bearing and race location and correct positioning.
3. Install new seals onto the No.1 first-reverse brake piston. Lubricate seals with transmission fluid.
4. Install the No.1 first-reverse brake piston into the transmission case.
5. Install new seal onto the first-reverse brake piston reaction sleeve. Lubricate seals with transmission fluid.
6. Install the first-reverse brake piston reaction sleeve into the transmission case.
7. Install new seal onto the No.2 first-reverse brake piston. Lubricate seals with transmission fluid.
8. Install the No.2 first-reverse brake piston into the transmission case.
9. Install the spring plate into the No.2 first-reverse brake piston.
10. Install Spring Compressor 7539 onto the first-reverse brake piston.
11. Compress the first-reverse brake piston spring and install the first-reverse brake piston snap-ring.
12. Remove Spring Compressor 7539.
13. Install rear planetary gear, second brake drum and output shaft as outlined in following steps:
14. Verify No. 10 thrust bearing and race. Bearing and race outer diameter is 57.7 mm (2.272 inch) and inside diameter is 39.2 mm (1.543 inch).
Installing Thrust Bearing And No. 10 Race:
15. Coat thrust bearing and race assembly with petroleum jelly and install in case. Race faces down. Bearing rollers face up.
Aligning Second Brake Drum And Clutch Pack Teeth:
16. Align teeth of second brake drum and clutch pack.
Output Shaft/Rear Planetary Assembly Installation:
17. Align rear planetary-output shaft assembly teeth with case slots and install assembly in case.
Planetary Snap Ring Installation:
18. Install rear planetary snap ring with snap ring pliers. Chamfered side of snap ring faces up and toward case front.
Checking First-Reverse Brake Pack Clearance:
19. Check first-reverse brake pack clearance with feeler gauge. Clearance should be 0.70 - 1.20 mm (0.028 - 0.047 inch). If clearance is incorrect, planetary assembly, thrust bearing or snap ring is not properly seated in case. Remove and reinstall components if necessary.
Second Brake Piston Sleeve Installation:
20. Install second brake piston sleeve. Sleeve lip faces up and toward case front as shown.
21. Install second brake drum gasket.
Park Lock Pin, Spring And Pawl Installation:
22. Install park lock pawl, spring and pin.
23. Install the manual valve shift assembly.
Park Lock Rod Installation:
24. Connect park lock rod to manual valve shift sector.
Park Rod Bracket Installation:
25. Position park lock rod bracket on case and tighten bracket attaching bolts to 10 Nm (7 ft. lbs.) torque.
Checking Park Pawl Engagement:
26. Verify park lock operation. Move shift sector to Park position. Park pawl should be firmly engaged (locked) in planetary ring gear.
Installing No.1 One-Way Clutch:
27. Install No. 1 one-way clutch. Short Ranged side of clutch faces up and toward case front.
Second Brake Pack Installation:
28. Install second brake pack. Install disc then plate. Continue installation sequence until five discs and five plates are installed.
29. Install second brake pack retainer with rounded edge of retainer facing disc.
30. Install second brake pack snap ring.
Checking Second Brake Pack Clearance:
31. Check brake pack clearance with feeler gauge. Clearance should be 0.062 - 1.98 mm (0.024 - 0.078 inch). If brake pack clearance is not correct, brake pack components are not seated. Reassemble brake pack if necessary.
Installing Sun Gear And Input Drum:
32. Install planetary sun gear and input drum. Be sure drum thrust washer tabs are seated in drum. Use petroleum jelly to hold thrust washer in position if necessary.
Installing Front Planetary Gear:
33. Install front planetary gear on sun gear.
Supporting Output Shaft:
34. Support output shaft with wood blocks.
Installing Front Planetary Snap Ring:
35. Install planetary snap ring on sun gear with snap ring plier tool 7541.
36. Install tabbed thrust race on front planetary gear. Washer tabs face down and toward gear. Race outer diameter is 47.8 mm (1.882 inch). Inside diameter is 34.3 mm (1.350 inch).