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Section 7 (Automatic Transmission - DPS6/DCT250): Disassembly: Transmission

WARNING: This page is about a different variant/trim than selected.
SPECIAL TOOL/GENERAL EQUIPMENT DESCRIPTION

G08064101
 100-001  (T50T-100-A)
Slide Hammer
G08064159
 307-580 
Holding Fixture
TKIT-2006UF-FLM
TKIT-2006UF-ROW
G08064204
 307-670 
Remover/Installer, Shift Lever Seal
TKIT-2010D-FLM
TKIT-2010D-ROW
G08064103
 307-673 
Remover, Outer Input Shaft Seal
TKIT-2010D-FLM
TKIT-2010D-ROW
G08064160
 307-675 
Fixture, Clutch Remover/Installer
TKIT-2010D-FLM
TKIT-2010D-ROW
G08064259
 307-680 
Table, Assembly (DPS6)
TKIT-2010D-FLM
TKIT-2010D-ROW
G08632189
 308-375 
Remover, Input Shaft Seal
TKIT-1999-F/FLM/LT
TKIT-2005U-M
Feeler Gauge
Punch
  1. multimedia:A supplement to the article is available.
    G08409240
  2. Remove the transmission wiring harness.
    G08064261
  3. Remove the following items:
    1. Remove the TCM  .

      Refer to: TRANSMISSION CONTROL MODULE (TCM) .

    2. Remove the TR  sensor.

      Refer to: TRANSMISSION RANGE (TR) SENSOR .

    3. Remove the OSS  sensor.

      Refer to: OUTPUT SHAFT SPEED (OSS) SENSOR .

    4. Remove the ISS  sensor.

      Refer to: INPUT SHAFT SPEED (ISS) SENSOR .

    5. Remove the clutch actuator.

      Refer to: CLUTCH ACTUATOR .

  4. Using the special tools, remove and discard the hollow input shaft seal.

    Install Special Service Tool: 307-673 Remover, Outer Input Shaft Seal  .

    G07979754
  5. Remove the bolts and the guide tube.
    G07979763
  6. Using the special tools, remove and discard the input shaft case seal.

    Use Special Service Tool: 100-001 (T50T-100-A) Slide Hammer  ., 308-375 Remover, Input Shaft Seal  .

    G07979765
  7. Remove and discard the input shaft snap ring.
    G07979766
  8. Using a punch, remove the clutch housing plug.

    Use the General Equipment: Punch

    G09551433
  9. Remove and discard the manual lever bolt and remove the manual lever.
    G09600772
  10. Install the special tool on the shift lever seal. Apply pressure to the top of the special tool while threading it into the seal.

    Use Special Service Tool: 307-670 Remover/Installer, Shift Lever Seal  .

    G09551435
  11. Using the special tool, remove the shift lever seal.

    Use Special Service Tool: 307-670 Remover/Installer, Shift Lever Seal  .

    G08064208
  12. NOTE: Fastener quantity varies by application.

    Remove the transmission case bolts.

    G09551508
  13. NOTE: Fastener quantity varies by application.

    Remove the transmission case bolts.

    G09551509
  14. Install the special tool on the input shaft.

    Use Special Service Tool: 307-675 Fixture, Clutch Remover/Installer  .

    G08064268
  15. Install the special tool and compress the input shaft. Turn the threaded bar 20 turns after it makes contact with the input shaft.

    Use Special Service Tool: 307-675 Fixture, Clutch Remover/Installer  .

    Torque  : 159 lb.in (18 Nm)

    G07979772
  16. Remove the clutch housing from the transmission case.
    G07979773
  17. NOTE: Anytime the transmission case is separated the input shaft bearing must be replaced.

    Remove the bolts, the bearing retainer and the bearing. Discard the bolts and the bearing.

    G09551513
  18. Remove the park plunger plug.
    G08064282
  19. Using a brass punch, gently tap the park plunger from the outside to the inside to remove it from the clutch housing.

    Use the General Equipment: Punch

    G08064283
  20. Remove the park pawl actuator shaft assembly.
    G07979776
  21. Remove the park pawl.
    G07979777
  22. Remove the large clock gears.
    G07979778
  23. Remove the small clock gears.
    G07979779
  24. Remove the differential.
    G09600868
  25. Remove the magnet.
    G07979780
  26. Install the special tool.

    Use Special Service Tool: 307-680 Table, Assembly (DPS6)  .

    G07979781
  27. Install the special tool.

    Remove Special Service Tool: 307-580 Holding Fixture  .

    G07979783
  28. Remove and discard the output shaft bearing retainer bolts.
    G09600872
  29. Remove the transmission case.
    G09600873
  30. Remove the LH  halfshaft seal.
    G08064299
  31. Remove the RH  halfshaft seal.
    G08064322
  32. NOTE: This step only applies to transmissions built before April-2013.

    Remove the oil spout.

    G07979788
  33. Remove the shift fork rods.
    G07979789
  34. Remove the shift drums.
    G07979790
  35. Remove the shift forks.
    G07979791
  36. Install the special tools.

    Use Special Service Tool: 307-680 Table, Assembly (DPS6)  .

    G08064288
  37. Remove the input and output shaft assemblies from the special tool.

    Remove Special Service Tool: 307-680 Table, Assembly (DPS6)  .

    G08064289
  38. Remove the output shaft assembly.

    Use Special Service Tool: 307-680 Table, Assembly (DPS6)  .

    G08064290
  39. Remove the input shaft assembly.

    Use Special Service Tool: 307-680 Table, Assembly (DPS6)  .

    G08064291
  40. Remove the output shaft assembly.

    Use Special Service Tool: 307-680 Table, Assembly (DPS6)  .

    G08064292
  41. Remove the hollow input shaft from the inner input shaft.
    G09600885
  42. Clean and inspect all components for wear or damage.
  43. NOTE: If the clearance is more than the maximum measurement stated in the specifications information or the shift fork or the adjacent synchronizer ring has signs of wear or damage, both the shift fork and the output shaft assembly must be replaced.

    Using a feeler gauge, measure the clearance between the fork and hub in various places around the circumference.

    Use the General Equipment: Feeler Gauge

    G07979800
  44. NOTE: Apply pressure on the synchronizer ring while taking the measurements.
    NOTE: If the clearance is less than the minimum measurement stated in the specifications information, install a new shaft assembly.

    Using a feeler gauge, measure the clearance between the synchronizer ring and gear in various places around the circumference.

    Use the General Equipment: Feeler Gauge

    G07979801
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