Part 1

DISASSEMBLY

Special Tools:














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

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.

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










1. Remove the torque converter (1) (Figure 1) from the transmission input shaft (3).










2. Measure input shaft end play using End Play Set (1, 2). Set up the required items from End Play Set (1, 2) (Figure 2) and a dial indicator (3) as shown.
3. 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 end play exceeds the specified range, the #4 thrust plate needs to be inspected and changed if necessary.










NOTE: The four bolts (3) along the bottom of the adapter or extension housing (2) have a sealing patch applied from the factory. Note the locations of these bolts and separate these bolts for reuse.

4. Remove the bolts (Figure 3) that hold the adapter or extension housing (2) onto the transmission case.










5. Remove the adapter (2)(Figure 4) housing, 4X4 vehicles only, from the transmission case. There are two pry slots located near the bottom corners of the housing for separating the housing from the transmission case.










6. Remove the extension (2)(Figure 5) housing, 4X2 vehicles only, from the transmission case. There are two pry slots located near the bottom corners of the housing for separating the housing from the transmission case.










7. Inspect the lube tube grommet (3)(Figure 6) for damage. If the grommet lip is damaged, it will need to be replaced.

8. On 4X2 transmissions, perform the following, if necessary:
a.








Remove the extension shaft bearing snap ring (3)(Figure 7) from the extension housing.

b.








Remove the extension shaft and bearing assembly (2)(Figure 8) from the extension housing (1).

c.








Remove the extension shaft bearing retaining ring (3)(Figure 9) from the extension shaft (1).

d.








Remove the extension shaft bearing (2)(Figure 10) from the extension shaft (1).





9. Using OTC(R) Slide Hammer 1155 or 7703 (3), or equivalent, and Adapter (2), remove the 4X4 stub shaft (1).









10. Remove the 4X4 stub shaft (1)(Figure 12) from the transmission output shaft. Inspect the cir-clip on the shaft for damage and replace the clip if necessary.










NOTE: The speed sensor bolts have a sealing patch applied from the factory. Separate these bolts for reuse.

11. Remove the input speed sensor bolt. (Figure 13)










NOTE: The speed sensor bolts have a sealing patch applied from the factory. Separate these bolts for reuse.

12. Remove the output speed sensor bolt. (Figure 14)










13. Remove the input and output (2) (Figure 15) speed sensors. Identify the speed sensors for re-installation since they are not interchangeable.










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

14. Remove the transmission oil pan bolts (2)(Figure 16).










15. Remove the transmission oil pan (1)(Figure 17).










16. Remove the transmission oil filter screws (2)(Figure 18).










17. Remove transmission oil filter (1)(Figure 19).










18. Remove the oil filter o-ring (2) (Figure 20) from the valve body.










19. Remove valve body-to-case bolts (1)(Figure 21).










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

20. Remove valve body (1)(Figure 22) from transmission.