Part 1

DISASSEMBLY

NOTE: If the transmission is being reconditioned (clutch/seal replacement) or replaced, it is necessary to perform the Quick Learn Procedure using a Scan Tool Quick Learn Procedure .

Before disassembling transmission, move the shift lever clockwise as far as it will go and then remove the shift lever.

NOTE: Tag all clutch pack assemblies, as they are removed, for reassembly identification.

CAUTION: Do not intermix clutch discs or plates as the unit might then fail.










1. Remove the torque converter from the transmission input shaft.










2. Measure input shaft end play using End Play Set 8266A. Set up the required pieces from End Play Set 8266A and a dial indicator as shown. Move input shaft in and out to obtain end play reading. End play specifications are 0.127 to 0.635 mm (0.005 to 0.025 inch). Record indicator reading for reference when reassembling the transmission. If endplay exceeds the specified range, the #4 thrust plate needs to be inspected and changed if necessary.










NOTE: The four bolts along the bottom of the adapter housing have a sealing patch applied from the factory. Note the locations of these bolts and separate these bolts for reuse.

3. Remove the bolts that hold the adapter housing onto the transmission case.










NOTE: There are two pry slots located near the bottom corners of the housing for separating the housing from the transmission case

4. Remove the adapter housing from the transmission case.










5. Inspect the lube tube grommet for damage. If the grommet lip is damaged, it will need to be replaced.





6. Using OTC(R) Slide Hammer 1155 or 7703 (3), or equivalent, and Adapter 10171 (2), remove the 4X4 stub shaft (1) from the transmission output shaft. Inspect the cir-clip on the shaft for damage and replace the clip if necessary.










7. Remove the input speed sensor bolt and sensor.










8. Remove the output speed sensor bolt and sensor.










NOTE: One of the oil pan bolts has a sealing patch applied from the factory. Separate this bolt for reuse.

9. Remove the transmission oil pan bolts.










10. Remove the transmission oil pan.










11. Remove the transmission oil filter screws.










12. Remove transmission oil filter.










13. Remove the oil filter o-ring from the valve body.










14. Remove valve body-to-case bolts.










CAUTION: Do not handle the valve body by the manual shaft. Damage could result.

15. Remove valve body from transmission.










16. Remove underdrive and overdrive accumulators.










17. Remove the low/reverse accumulator snap ring.










18. Remove the low/reverse accumulator plug.










19. Remove low/reverse accumulator piston and springs.










NOTE: The oil pump bolts are not to be reused.

20. Remove and discard the oil pump-to-case bolts.










21. Remove oil pump using Slide Hammers C-3752.










22. Remove oil pump while pushing in on input shaft.










23. Remove oil pump gasket.










CAUTION: By-pass valve must be replaced if transmission failure occurs.

24. Remove the cooler by-pass valve.










25. Remove the #1 caged needle bearing.










26. Remove the input clutch assembly.










27. Remove the #4 thrust plate.










28. Remove the front sun gear assembly and #4 thrust washer (if still in place).










29. Remove the front carrier/rear annulus and #6 needle bearing.