AUTOMATIC TRANSMISSION DISASSEMBLY

id051300260100


Exploded View

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1
Torque converter installation nut
2
Torque converter
3
Input shaft
4
Fluid pump seal
5
Fluid pump seal ring
6
Bolt and washer
7
Fluid pump cover
8
Fluid pump adapter plate
9
Fluid pump gasket
10
Seal ring
11
Stator support seal
12
Fluid pump support
13
O-ring
14
Fluid pump control valve
15
Fluid pump component
16
Bolt
17
Seal ring
18
Thrust washer (No.1)
19
Intermediate and overdrive brake band anchor strut
20
Intermediate and overdrive brake band
21
Intermediate and overdrive brake band apply strut
22
Intermediate and overdrive brake band adjusting screw
23
Locknut
24
Overdrive brake drum
25
Direct clutch and coast clutch piston outer seals
26
Direct clutch and coast clutch piston inner seals
27
Direct clutch and coast clutch pistons
28
Direct clutch and coast clutch piston spring
29
Direct clutch and coast clutch piston spring retainer
30
Retaining ring
31
Coast clutch external spline plate (steel)
32
Coast clutch internal spline friction plate (friction)
33
Direct clutch and coast clutch pressure plate
34
Retaining ring (select fit)
35
Carrier adapter
36
Overdrive sun gear
37
Overdrive planetary gear carrier component
38
Thrust bearing (No.2)
39
Overdrive ring gear
40
Overdrive one-way clutch
41
Overdrive center shaft
42
Retaining ring
43
Overdrive center shaft and ring gear component
44
Thrust bearing (No.3, No.5, No.8 and No.9)
45
Retaining ring
46
Center support
47
Nut and cage component
48
Bolt
49
Thrust bearing (No.4)
50
Intermediate brake drum
51
Direct clutch external spline plate (steel)
52
Direct clutch internal spline plate (friction)
53
Forward clutch cylinder
54
Forward clutch piston
55
Forward clutch piston spring component
56
Retaining ring
57
Forward clutch external spline plate (steel)
58
Forward clutch internal spline plate (friction)
59
Forward clutch pressure plate
60
Retaining ring (select fit)
61
Thrust bearing (No.6A)
62
Thrust washer (No.6B)
63
Retaining ring
64
Forward ring gear hub
65
Forward ring gear
66
Thrust bearing (No.7)
67
Forward planetary component
68
Input shell and sun gear component
69
Spacer
70
Retaining ring
71
Lower/reverse planetary component
72
Output shaft sleeve
73
Retaining ring
74
Output shaft ring gear
75
Output shaft hub
76
Retaining ring
77
Output shaft hub seal
78
Thrust bearing (No.10)
79
Low/reverse brake drum and one-way clutch component
80
Low/reverse brake band
81
Output shaft needle bearing
82
Thrust washer (No.11)
83
Parking gear
84
Output shaft (4×2)
85
Parking pawl
86
Parking pawl return spring
87
Parking pawl shaft
88
Extension housing gasket
89
Extension housing (4×2)
90
Bolt (4×2)
91
Extension housing seal (4×2)
92
Output shaft (4×4)
93
Extension housing (4×4)
94
Extension housing seal (4×4)
95
Bolt (4×4)
96
Fluid pipe connector component
97
Retaining ring
98
Overdrive brake servo cover seal
99
Overdrive brake servo cover
100
Overdrive brake servo piston
101
Spring
102
Retaining ring
103
Intermediate brake servo cover seal
104
Intermediate brake servo cover
105
Intermediate brake servo piston
106
Transmission case
107
TSS sensor, ISS sensor and OSS sensor
108
O-ring
109
Bolt
110
Vent tube (4×2)
111
Low/reverse brake actuating lever
112
Low/reverse brake band actuating lever shaft
113
Pressure tap plug (pressure control solenoid C circuit)
114
Fluid fill plug
115
Manual shaft retaining pin
116
Parking pawl actuating rod
117
Manual shaft outer and inner nut
118
Manual valve inner lever
119
Manual shaft seal
120
Manual shaft
121
Digital TR sensor
122
Bolt and washer
123
Manual shaft lever
124
Reverse brake servo component
125
Reverse brake servo plate
126
Spring
127
Reverse brake servo piston and seal
128
O-ring
129
Reverse brake servo cover
130
Bolt
131
Control valve spring retainer
132
Spring
133
Reverse brake servo check valve
134
Bolt
135
Separating plate (bonded)
136
Lower control valve body
137
Bolt
138
Bolt
139
Detent spring
140
Bolt
141
Bolt
142
Control valve body component
143
O-ring
144
Solenoid body
145
Bolt
146
Bolt
147
Transmission fluid filter
148
Transmission fluid pan gasket
149
Magnet
150
Bolt
151
Transmission fluid pan
152
Drain plug
153
Bolt
154
Fluid level indicating plug (short hex)
155
Overdrive brake and coast clutch drum component
156
Intermediate brake and direct clutch drum component
157
Forward clutch component
158
Overdrive brake servo
159
Intermediate brake servo

Note
•  Tag and identify all parts during disassembly.

1.  Place the transmission on a workbench.

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Warning
•  The torque converter is heavy, especially when full of fluid.

2.  Remove the torque converter.

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3.  Remove the input shaft.

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4.  Install the SST (49 G019 0A0) to the transmission.

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5.  Install the transmission with the torque converter housing facing up to the SST (49 0107 680A).

6.  Remove the sensors.

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7.  Remove the manual shaft lever.

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8.  Remove the digital TR sensor.

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9.  Using a flathead screwdriver, lift up the extension housing seal plate area.

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10.  Using the SST, remove the extension housing seal. (4×2)

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Caution
•  The parking pawl, parking pawl return spring and parking pawl shaft could fall out during removal of the extension housing.

11.  Remove the extension housing. (4×2)

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12.  Using a flathead screwdriver, remove the extension housing seal. (4×4)

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Caution
•  The parking pawl, parking pawl return spring and parking pawl shaft could fall out during removal of the extension housing.

13.  Remove the extension housing. (4×4)

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Note
•  4×2 shown, 4×4 similar.

14.  Remove the parking pawl component and discard the gasket.

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(1)  Remove the parking pawl shaft.
(2)  Remove the parking pawl.
(3)  Remove the parking pawl return spring.
(4)  Remove and discard the gasket.

Note
•  The transmission fluid pan gasket is reusable. Clean and inspect the gasket for damage. If not damaged, the gasket should be reused.

15.  Remove the transmission fluid pan screws, transmission fluid pan and gasket.

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16.  Remove the transmission fluid filter and seal component and discard.

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17.  Remove the detent spring.

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Warning
•  The upper and lower servo covers are under spring tension. Use care when removing the piston and cover component. Failure to follow these instructions can result in personal injury.

18.  Remove the low/reverse brake servo component.

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Caution
•  Do not damage solenoid body connector pins.

19.  Remove the solenoid body component by lifting on the body and pushing the connector from the other side of the case.

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20.  Remove the main control valve body, separator plate and gasket.

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21.  Using a flathead screwdriver, remove the fluid pump seal.

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Caution
•  Failure to loosen the overdrive brake band adjusting screw prior to pump removal may cause damage to the pump and overdrive brake band.
•  Throw the locknut away. The locknut are not reusable for assembly.

22.  Remove and discard the locknut, and loosen the overdrive brake band adjusting screw.

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23.  Remove and tag the overdrive brake band anchor strut for assembly.

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Caution
•  The screws are not reusable for assembly. Discard the screws. If the screws are reused, the housing may become separated from the transmission.

24.  Remove and discard the screws.

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25.  Install the SST.

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26.  Using the SST, remove the fluid pump.

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Caution
•  Servo cover is under spring tension.

27.  Using the SST, remove the retaining ring and overdrive brake servo cover.

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28.  Remove the overdrive brake servo piston and spring.

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29.  Remove the screw.

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30.  Compress the overdrive brake band and remove the apply strut.

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Note
•  Tag and identify parts for reassembly.

Caution
•  Identify the anchor and apply ends of the overdrive brake band.

31.  Remove and inspect the overdrive brake band. Check the following conditions for installing a new band:

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•  Inspect for glazing.
•  Inspect for missing friction material.
•  Inspect for material flaking.
•  Inspect for damage to the anchor pins.
Note
•  The new overdrive brake band is dark in color. This is a normal condition of the band. Hairline cracks in the band are also considered normal. Do not install a new band based solely on the color.

32.  Remove the overdrive brake and coast clutch drum component.

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Caution
•  Do not bend the trigger wheel.

33.  Remove the overdrive planetary gear carrier.

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Note
•  The thrust bearing (No.12) is in this component.

34.  Remove the thrust bearing (No.2).

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35.  Remove the overdrive ring gear, overdrive one-way clutch component and center shaft as an assembly.

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36.  Remove the thrust bearing (No.3).

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Note
•  Tag and identify the thrust bearing (No.3) for assembly.

Caution
•  The center support nut could fall into the remaining assembly if not removed.

37.  Remove the screw.

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38.  Remove the nut and cage.

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39.  Remove the retaining ring.

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40.  Remove the center support.

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Note
•  The center support is repaired as an assembly. Any damage requires installing a new component.
•  When removing the center support, pull evenly around the center support web.

41.  Inspect the center support component for wear or damage.

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(1)  Inspect the thrust surfaces for wear or damage.
(2)  Inspect the center support sealing surface.
(3)  Inspect the fluid passage for blockage or damage.

42.  Inspect the seal rings for damage.

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43.  Inspect the bearing for missing rollers or damage.

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44.  Inspect the direct clutch feed hole for blockage or damage.

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(1)  Rotate the center support bearing to locate the direct clutch feed hole.
(2)  Inspect the direct clutch feed hole for blockage or damage.

45.  Remove the thrust bearing (No.4).

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Note
•  Tag and identify the thrust bearing (No.4).

Caution
•  Failure to loosen the intermediate brake band adjusting screw prior to pump removal may cause damage to the pump and intermediate brake band.
•  Throw the locknut away. The locknut are not reusable for assembly.

46.  Remove and discard the locknut, and loosen the intermediate brake band adjusting screw.

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Caution
•  Servo cover is under spring tension.

47.  Using the SST, remove the retaining ring and intermediate brake servo cover.

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48.  Remove the intermediate brake servo piston and spring.

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49.  Remove and tag the intermediate brake band anchor strut for assembly.

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Caution
•  Identify the anchor and apply ends of the intermediate brake band.

Note
•  The new intermediate brake band is dark in color. This is a normal condition of the band. Hairline cracks in the band are also considered normal. Do not install a new band based solely on the color.

50.  Remove and inspect the intermediate brake band. Check the following conditions for installing a new band:

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•  Inspect for glazing.
•  Inspect for missing friction material.
•  Inspect for material flaking.
•  Inspect for damage to the anchor pins.

51.  Remove and tag the intermediate brake band apply strut for assembly.

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52.  Remove the screw.

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53.  Remove the intermediate brake and direct clutch drum component.

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Note
•  The thrust bearing (No.5) may come out with the intermediate brake and direct clutch drum.

54.  Remove the thrust bearing (No.5), tag and identify.

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55.  Remove the forward clutch cylinder.

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Note
•  The thrust bearing (No.6A) may come out with the cylinder. Tag for reassembly.

56.  Remove the thrust bearing (No.6A).

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Note
•  The thrust bearing (No.6A) may have come out with the forward clutch cylinder.

57.  Remove the forward ring gear and hub as an assembly.

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Note
•  The thrust bearing (No.7) may come out with the forward ring gear and hub component.

58.  Remove the thrust washer (No. 6B) from the forward ring gear hub.

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59.  Remove the thrust bearing (No.7).

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Note
•  The thrust bearing (No.7) may come out with the forward ring gear and hub component.

60.  Remove the forward planetary component.

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61.  Remove the input shell and sun gear component.

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62.  Remove the spacer.

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63.  Remove the thrust bearing (No.8).

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Note
•  Tag and identify the thrust bearing (No.8).

64.  Remove the retaining ring.

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65.  Remove low/reverse planetary component.

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66.  Remove the thrust bearing (No.9).

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Note
•  Tag and identify the thrust bearing (No.9).

67.  Using a small pick, remove the output shaft sleeve.

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Note
•  Use slots located around the outside of the sleeve.

Warning
•  The output shaft may fall out after removing the retaining ring. Failure to follow these instructions may result in personal injury.
Caution
•  Discard the retaining ring. A new retaining ring must be used for assembly.

68.  While holding the output shaft, remove and discard the retaining ring.

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69.  Remove the output shaft and park gear.

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70.  Remove the output shaft thrust washer.

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Note
•  Tag and identify the thrust washer (No.11).

71.  Remove the output shaft ring gear and hub.

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72.  Remove the thrust bearing (No.10).

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Caution
•  Do not pry on the outer edge of the case or damage to the gasket sealing surface could occur.

73.  Using a pair of vice grips, hold the flat spots on the low/reverse brake band actuating lever shaft, wiggle it back and forth and remove the low/reverse brake band actuating lever shaft.

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Note
•  It may be necessary to grind flat spots on the edges of the low/reverse brake band actuating lever shaft in order to remove it.

74.  Remove the low/reverse brake band actuating lever component.

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75.  Remove the low/reverse brake drum and one-way clutch component by rotating it clockwise.

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Note
•  The inner race of the rear one-way clutch is not removable. It is repaired in the case.

76.  Inspect the low/reverse brake drum component and install a new low/reverse brake drum component if damaged.

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(1)  Inspect the low/reverse brake drum sprags.
(2)  Inspect the low/reverse brake drum rollers.
(3)  Inspect the low/reverse brake drum.
Note
•  The reverse one-way clutch is part of the low/reverse brake drum component. Install a new low/reverse brake drum as an assembly only.

77.  Remove the low/reverse brake band.

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Caution
•  To avoid damage, make sure the wrench does not strike the manual valve inner lever pin.

78.  Remove the nut.

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79.  Remove the manual shaft retaining pin.

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80.  Remove the manual shaft.

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81.  Disconnect the manual valve inner lever from the parking lever actuating rod.

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82.  Remove the manual valve inner lever.

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83.  Remove the parking lever actuating rod.

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Caution
•  Do not damage the bore.

84.  Remove the manual shaft seal.

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