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Service Information: Disassembly

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 (Refer to ELECTRICAL/ELECTRONIC CONTROL MODULES/TRANSMISSION CONTROL MODULE - STANDARD PROCEDURE) .
Fig 1: Manual Shaft Lever
G04285172Courtesy of DAIMLERCHRYSLER CORP.
1 - MANUAL SHAFT LEVER
  1. Drain fluid from transmission.
  2. Clean exterior of transmission with suitable solvent or pressure washer.
  3. Remove the torque converter from the transmission.
  4. Remove the manual shift lever (1) from the transmission. See Fig 1.
    Fig 2: Locating Input Speed, Output Speed and Line Pressure Sensors
    GC0005202Courtesy of DAIMLERCHRYSLER CORP.
    1 - OUTPUT SPEED SENSOR
    2 - LINE PRESSURE SENSOR
    3 - INPUT SPEED SENSOR
  5. Remove the input (3), output (1), and line pressure sensors (2) from the transmission case. See Fig 2
  6. Inspect the ends of the sensors for debris, which may indicate the nature of the transmission failure.
    Fig 3: Support Stand Tool 8257
    GC0005203Courtesy of DAIMLERCHRYSLER CORP.
    1 - TOOL 8257
  7. Install Support Stand 8257 (1) onto the transmission case. See Fig 3
    Fig 4: Measuring Input Shaft End Play
    GC0005204Courtesy of DAIMLERCHRYSLER CORP.
    1 - TOOL 8266
    2 - TOOL C-3339
  8. Using Adapter 8266-1 from End-Play Tool Set 8266 (1) and Dial Indicator C-3339 (2), measure and record the input shaft end-play. See Fig 4
    NOTE: When measuring the input shaft end-play, two "stops" will be felt. When the input shaft is pushed inward and the dial indicator zeroed, the first "stop" felt when the input shaft is pulled outward is the movement of the input shaft in the input clutch housing hub. This value should not be included in the end-play measured value and therefore must be recorded and subtracted from the dial indicator reading.
    Fig 5: Measuring Output Shaft End Play
    GC0005205Courtesy of DAIMLERCHRYSLER CORP.
    1 - TOOL 8261
    2 - TOOL 8266
    3 - TOOL C-3339
  9. Remove the bolts holding the transmission extension/adapter housing to the transmission case.
  10. Remove the extension/adapter housing from the transmission case.
  11. Using Alignment Plate 8261 (1), Adapter 8266-17 from End-Play Tool Set 8266 (2) and Dial Indicator C-3339 (3), measure and record the output shaft end-play. See Fig 5
    Fig 6: Locating Primary Oil and Cooler Filters
    GC0005206Courtesy of DAIMLERCHRYSLER CORP.
    1 - PRIMARY OIL FILTER
    2 - COOLER RETURN FILTER
    3 - COOLER RETURN FILTER BYPASS VALVE
    4 - VALVE BODY
  12. Remove the bolts holding the transmission oil pan to the transmission case.
  13. Remove the transmission oil pan from the transmission case.
  14. Remove the primary oil filter (1) and the oil cooler return filter (2). See Fig 6
  15. Remove the cooler return filter bypass valve (3).
    Fig 7: Removing/Installing Valve Body Assembly
    GC0005207Courtesy of DAIMLERCHRYSLER CORP.
    1 - VALVE BODY TO CASE BOLT (6)
  16. Remove the bolts (1) holding the valve body to the transmission case. See Fig 7
  17. Remove the valve body from the transmission case.
    Fig 8: Removing/Installing Transmission Front Cover
    GC0005208Courtesy of DAIMLERCHRYSLER CORP.
    1 - INNER SNAP-RING
    2 - TRANSMISSION FRONT COVER
    3 - OUTER SNAP-RING
  18. Remove the outer snap-ring (3) securing the transmission front cover (2) into the transmission case. See Fig 8
  19. Remove the inner snap-ring (1) securing the transmission front cover to the oil pump. See Fig 8
  20. Reaching through a case opening in the valve body area with a long blunted tool, remove the transmission front cover from the transmission case.
    Fig 9: Removing/Installing Oil Pump
    GC0005209Courtesy of DAIMLERCHRYSLER CORP.
    1 - OIL PUMP TO CASE BOLT (6)
    2 - OIL PUMP
    CAUTION: If the input shaft is not held during oil pump removal, the input clutch assembly will attempt to move forward with the oil pump and the numbers 2, 3, or 4 bearings inside the input clutch assembly may become dislodged.
  21. Remove the bolts (1) holding the oil pump into the transmission case. See Fig 9
  22. Remove the oil pump (2). Hold inward on the input shaft to prevent pulling the input clutch assembly with the oil pump. See Fig 9
    Fig 10: Removing/Installing Input Clutch Assembly
    GC0005210Courtesy of DAIMLERCHRYSLER CORP.
    1 - THRUST BEARING NUMBER 5
    2 - THRUST PLATE (SELECT)
    3 - INPUT CLUTCH ASSEMBLY
    4 - THRUST BEARING NUMBER 1
  23. Remove the number 1 thrust bearing (4) from the input clutch assembly. See Fig 10
  24. Remove the input clutch assembly (3) from the transmission case. See Fig 10
  25. Remove the number 5 thrust bearing (1) and selective thrust plate (2) from the input clutch assembly (3), or the 4C clutch retainer/bulkhead. See Fig 10.
    Fig 11: Removing/Installing 4C Clutch Retainer/Bulkhead
    G04285163Courtesy of DAIMLERCHRYSLER CORP.
    1 - SNAP-RING
    2 - 4C CLUTCH RETAINER/BULKHEAD
  26. Remove the 4C clutch retainer/bulkhead tapered snap-ring (1) from the transmission case. See Fig 11
  27. Remove the 4C clutch retainer/bulkhead (2) from the transmission case. See Fig 11
    Fig 12: Removing/Installing 2C Clutch Pack
    GC0005212Courtesy of DAIMLERCHRYSLER CORP.
    1 - SNAP-RING
    2 - PLATE
    3 - DISC
    4 - REACTION PLATE
  28. Remove the front 2C clutch pack snap-ring (1) from the transmission case. See Fig 12
  29. Remove the 2C clutch pack (2, 3, 4) from the transmission case. See Fig 12
    Fig 13: Removing/Installing Reaction Annulus and Carrier
    GC0005213Courtesy of DAIMLERCHRYSLER CORP.
    1 - THRUST BEARING NUMBER 8 5 - THRUST BEARING NUMBER 7
    2 - THRUST BEARING NUMBER 9 6 - THRUST PLATE (SELECT)
    3 - REACTION PLANETARY CARRIER 7 - THRUST BEARING NUMBER 6
    4 - REACTION SUN GEAR 8 - REACTION ANNULUS
  30. Remove the rear selective plate (6) and number 6 thrust bearing (7) from the reaction annulus (8). See Fig 13
  31. Remove the reaction annulus (8) from the reaction planetary carrier (3). See Fig 13
  32. Remove the number 7 thrust bearing (5). See Fig 13
  33. Remove the reaction sun gear (4). See Fig 13
  34. Remove the number 8 thrust bearing (1) from the reaction planetary carrier (3). See Fig 13
  35. Remove the reaction planetary carrier (3). See Fig 13. Note that this planetary gear set has three pinion gears.
  36. Remove the number 9 thrust bearing (2) from the reverse planetary gear set. See Fig 13
    Fig 14: Removing/Installing Park Sprag Snap Ring
    GC0005214Courtesy of DAIMLERCHRYSLER CORP.
    1 - SNAP-RING
  37. Remove the snap-ring (1) holding the park sprag gear onto the output shaft. See Fig 14
    Fig 15: Removing/Installing Park Sprag Gear
    GC0005215Courtesy of DAIMLERCHRYSLER CORP.
    1 - PARK SPRAG GEAR
  38. Remove the park sprag gear (1) from the output shaft. See Fig 15
    Fig 16: Removing/Installing Input/Reverse Planetary Assembly
    GC0005216Courtesy of DAIMLERCHRYSLER CORP.
    1 - INPUT/REVERSE PLANETARY ASSEMBLY
    2 - BEARING NUMBER 9
    3 - BEARING NUMBER 12
  39. Remove the input/reverse planetary assembly (1). See Fig 16
  40. Remove the number 12 thrust bearing (3) from the input/reverse planetary assembly (1). See Fig 16
    Fig 17: Removing/Installing Low/Reverse Clutch Retainer
    GC0005217Courtesy of DAIMLERCHRYSLER CORP.
    1 - LOW/REVERSE OVERRUNNING CLUTCH ASSEMBLY
    2 - SNAP-RING
  41. Remove the snap-ring (2) holding the low/reverse clutch retainer (1) into the transmission case. See Fig 17
  42. Remove the low/reverse clutch retainer (1) from the transmission case. See Fig 17
    Fig 18: Removing/Installing Manual Shaft/Park Lock Components
    G04285170Courtesy of DAIMLERCHRYSLER CORP.
    1 - GUIDE
    2 - SNAP-RING
    3 - SHAFT
    4 - SPRING
    5 - PARK PAWL
    6 - MANUAL SHAFT/LEVER
    7 - PARK ROD
  43. Remove the park rod (7) and e-clip. See Fig 18
  44. Remove the park rod guide snap-ring (2). See Fig 18
  45. Remove the park rod guide (1). See Fig 18
  46. Remove the park pawl pivot shaft (3), park pawl (5), and spring (4). See Fig 18
  47. Remove the manual selector shaft (6). See Fig 18
  48. Remove the manual selector shaft seal.
  49. Remove the dipstick tube seal.
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