Torque Converter Housing Disassemble

Torque Converter Housing Disassemble

^ Tools Required
- J 26941 Bushing and Bearing Remover
- J 29369-2 Bushing and Bearing Remover - 2-3 in
- J 29369-1 Bushing and Bearing Remover
- DT 46424 Bearing Puller
- SA9133T Axle Seal Puller
- SA9133T-1 Axle Seal Puller Adapter





1. Using the J 26941 (3), SA9133T (1) and SA9133T-1 (2), remove the torque converter seal (116) from the torque converter housing (150).

Important: Ensure the jaws of the J 26941 do not catch on the other side of the bearing bore.

2. Using the J 26941 (3), SA9133T (1) and SA9133T-1 (2), remove the torque converter bearing (115) from the torque converter housing (150).





3. Inspect the output shaft front bearing (136) for wear or damage. Do not reuse the bearing after the bearing is removed. Replace the bearing if necessary.
4. Using the J 26941 (2), SA9133T (1) and SA9133T-1, remove the output shaft front bearing (136) from the torque converter housing (150).
5. By hand, remove the output shaft lube feed plate (135) from the torque converter housing (150).





6. Remove the 1st/2nd clutch shaft intermediate bearing retainer bolt (133) from the torque converter housing (150).
7. Remove the intermediate bearing retainer (132) and the front bearing retainer washer (131).





8. Using the J 29369-2 (2), SA9133T and SA9133T-1 (1), remove the 1st/2nd clutch shaft intermediate bearing (130) from the torque converter housing (150).





9. Using the J 29369-1 by hand, remove the 1st/2nd clutch shaft lube feed collar (129) from the torque converter housing (150).
10. Remove the 1st/2nd clutch shaft lube feed collar seals (128).





11. Using the J 29369-1 (1), SA9133T (2) and SA9133T-1 (3), remove the 1st/2nd clutch shaft front bearing (127) from the torque converter housing (150).
12. Inspect the bearing for wear or damage. Replace the bearing if necessary.





13. Using the J 29369-1 (2), SA9133T (3) and SA9133T-1 (1), remove the 3rd clutch shaft front bearing (138).
14. Remove the 3rd clutch shaft lube feed plate (139).
15. Inspect the bearing for wear or damage. Replace the bearing if necessary.





16. Using the DT 46424 (1) and SA9133T-1 (2), remove the park pawl actuator shaft front bearing (134) from the transmission torque converter housing (150).
17. Inspect the bearing for wear or damage. Replace the bearing if necessary.





18. Remove the magnetic chip collector (137) from the torque converter housing (150).
19. Clean and inspect the magnet. If there is heavy build up on the magnet, determine the cause of this build-up and correct as needed.
20. If the chip collector is damaged, replace the complete assembly.





21. Remove the fluid baffle bolts (125).
22. Remove the fluid baffle (124).





23. Inspect the front differential bearing race (901) for damage or excessive wear.
24. Using a hammer and punch, remove the front differential tapered front roller bearing race (901) and (900) from the torque converter housing (150)Tap lightly and evenly around the race, the race will slide out if kept even to the bore.





25. Using a hammer and punch, remove the transfer case input shaft seal (118) from the torque converter housing (150).





26. Using a hammer and punch, remove the front wheel drive shaft fluid seal (117) from the torque converter housing (150).





27. Remove the case plug (147) with the sealing washer (148).
28. Remove the 8 fluid pressure test hole plugs (67) with sealing washer (78).





29. Clean the torque converter housing in solvent and air dry. Ensure that all cleaning solvent is removed from the fluid passages.
30. Inspect the torque converter housing for being broken or cracked.
31. Inspect the control valve body mounting surface for damage.
32. Inspect the following bearing bores for cracks or a spun bearing:
^ 1st/2nd clutch shaft front bearing (1)
^ 1st/2nd clutch shaft intermediate bearing (2)
^ Output shaft front bearing (3)
^ Front differential bearing race (4)
^ 3rd clutch shaft front bearing (5)
^ Torque converter bearing (6)
33. Replace the torque converter housing if any of the above conditions are found.
34. Inspect the sealing surfaces for damage.
35. Repair small scratches or nicks with a soft stone.
36. Inspect the transmission to torque converter housing mounting surface for damage.
37. Inspect the case threaded bolt holes for damage.
38. Repair any damaged threads.

Repair Instructions



Torque Converter Housing Assemble

^ Tools Required
- DT 46412 Driver
- DT 46413 Driver
- DT 46414 Driver
- DT 46415 Driver
- DT 46516 Driver
- DT 46417 Driver
- DT 46428 Driver
- DT 46429 Oil Seal Driver
- EN 46342 Driver Handle





Notice: Refer to Fastener Notice in Service Precautions.

1. Install the eight 8 mm fluid pressure test hole plugs (67) with new sealing washers (78).
^ Tighten the test hole plugs to 18 Nm (13 ft. lbs.).
2. Install the 10 mm case plug (147) with the sealing washer (148).
^ Tighten the plug to 26 Nm (20 ft. lbs.).





3. Using the 25 mm side of the DT 46516 (1) and EN 46342 (2), install the 12 x 24 x 6 mm park pawl actuator shaft front bearing (134) until flush in the transmission torque converter housing (150).





4. Install the 3rd clutch shaft lube feed plate (139) into the torque converter housing (150).
5. Install the 28 x 52 x 12.8 mm 3rd clutch shaft front bearing (138) into the torque converter housing (150).





6. Using the 52 mm side of DT 46412 (2) and EN 46342 (1), install the 3rd clutch shaft front bearing (138) until it bottoms in the torque converter housing (150).





7. Install the output shaft lube feed plate (135) into the torque converter housing (150).
8. Install the 40.5 x 74 x 21 mm output shaft front bearing (136) in the direction as shown in the insert.





9. Using the 72 mm side of DT 46415 (2) and EN 46342 (1), install the output shaft front bearing (136) until it bottoms out in the torque converter housing. When the bearing is fully seated the bearing will be slightly above the housing surface due to the design of the bearing.





10. Using the 37 mm side of the DT 46413 (2) and EN 46342 (1), install the 29 x 39 x 9.5 mm 1st/2nd clutch shaft front bearing (127) until it bottoms out into the torque converter housing (150).





11. Install both 1st/2nd clutch shaft lube feed collar O-ring seals (128) on the 1st/2nd clutch shaft lube feed collar (129). Lubricate the O-ring seals with transmission fluid.





Important: Ensure the lube feed collar is fully seated into the torque converter housing. Ensure there is no damage to the O-ring seals during installation.

12. Install the lube feed collar (129) into the torque converter housing bore with the aid of the 40 mm side of DT 46413 (2) and EN 46342 (1) as shown.





13. Using the 62 mm side of DT 46414 (2) and EN 46342 (1), install the 32 x 63 x 19 mm 1st/2nd clutch shaft intermediate bearing (130) with the groove for the lock tab facing up. The 1st/2nd clutch shaft intermediate bearing is properly installed into the torque converter housing when the following conditions are met:
^ Install the bearing until the lock tab groove is aligned to the lock tab surface.
^ When the lock tab is flush to the mounting surface, the lock tab will slide into the bearing groove.





14. Install the 1st/2nd clutch shaft intermediate bearing retainer lock tab retainer (132).
15. Install the 1st/2nd clutch shaft intermediate bearing retainer M6 x 1.0 x 20 mm bolt (133).
^ Tighten the bolt to 12 Nm (106 inch lbs.)
16. Secure the bolt by bending the lock tab against the bolt head.





Important:
^ Lubricate all parts with automatic transmission fluid during installation.

17. ^ Replace the tapered roller bearing with a NEW one whenever the race is replaced.
^ Do not use the selective shim or shims on the torque converter housing side.
^ Adjust the preload after replacing the tapered roller bearing and race.

Install the front differential front bearing race spacer (900) into the torque converter housing (150).
18. Install the front differential tapered front roller bearing 80 mm race (901) into the torque converter housing (150).





19. Using the 78 mm side of DT 46428 (2) and EN 46342 (1), install the 80 mm front differential tapered front roller bearing race (901) until fully seated.





20. Using the DT 46414 (2) and EN 46342 (1), install the torque converter bearing (115) until it bottoms out flush in the torque converter housing (150) using the 68 mm side of the driver.





Notice: Do not install the torque converter fluid seal (116) below the flanged section of the torque converter housing or premature failure of the mainshaft front bearing could occur.

21. Using the DT 46417 and EN 46342, install the torque converter fluid seal (116) until it is flush with the flanged section of the torque converter housing (150) using the 45 mm side of the driver.





22. Using EN 46342 (1) and DT 46429 (2), install the 35 x 54 x 8 mm front wheel drive shaft fluid seal (117) into the torque converter housing (150) until the seal is flush with the housing surface.





23. Using the 65 mm side of DT 46417 (2) and EN 46342 (1) install a NEW 48 x 65 x 7.5 mm transfer case input shaft seal (118) into the torque converter housing (150) until the seal is flush with the housing surface.





24. Install the fluid baffle (124).
25. Install the fluid baffle bolts (125).
^ Tighten the bolts to 12 Nm (106 inch lbs.)





26. Install the magnetic chip collector (137) back into the torque converter housing assembly (150).