545RFE Automatic Transmission (Service Information): Disassembly: Disassembly

1 - THRUST BEARING NO. 1	8 - THRUST BEARING NO. 8
2 - THRUST BEARING NO. 2	9 - THRUST BEARING NO. 9
3 - THRUST BEARING NO. 3	10 - THRUST BEARING NO. 10
4 - THRUST BEARING NO. 4	11 - THRUST BEARING NO. 11
5 - THRUST BEARING NO. 5	12 - THRUST BEARING NO. 12
6 - THRUST BEARING NO. 6	13 - OUTPUT SHAFT BEARING
7 - THRUST BEARING NO. 7	-

Fig 1: Removing/Installing Manual Shaft Lever

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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.
   Fig 2: Removing/Installing Input, Output & Line Pressure Sensors

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   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.
6. Inspect the ends of the sensors for debris, which may indicate the nature of the transmission failure.
   Fig 3: Removing/Installing Support Stand - Tool 8257

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   1 - TOOL 8257

7. Install Support Stand 8257 (1) onto the transmission case.
   Fig 4: Measure Input Shaft End Play

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   1 - TOOL 8266

   2 - TOOL C-3339A

8. Using Adapter 8266-1 from End-Play Tool Set 8266 (1) and Dial Indicator C-3339A (2), measure and record the input shaft end-play.
   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: Measure Output Shaft End Play

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   1 - TOOL 10065

   2 - TOOL 8266-20

   3 - TOOL C-3339A

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-3339A (3), measure and record the output shaft end-play.
    Fig 6: Remove/Install Valve Body Assembly

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    1 - PRIMARY OIL FILTER

    2 - COOLER RETURN FILTER

    3 - 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).
    Fig 7: Removing/Installing Valve Body Assembly

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    1 - VALVE BODY TO CASE BOLT (6)

15. Remove the bolts (1) holding the valve body to the transmission case.
16. Remove the valve body from the transmission case.
    Fig 8: Removing/Installing Transmission Front Cover

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    1 - Front Cover

    2 - Front Cover O-Ring

    3 - Snap Ring

    4 - Front Cover Seal

17. Remove the outer snap-ring (3) securing the transmission front cover (1) into the transmission case.
18. Reaching through a case opening in the valve body area with a long blunted tool, remove the transmission front cover (1) from the transmission case.
    Fig 9: Removing/Installing Oil Pump

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    1 - OIL PUMP TO CASE BOLT (6)

    2 - OIL PUMP

19. Remove the bolts (1) holding the oil pump into the transmission case.
20. Remove the oil pump (2). Hold inward on the input shaft to prevent pulling the input clutch assembly with the 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.
    Fig 10: Removing/Installing Input Clutch Assembly

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    1 - THRUST BEARING NUMBER 5

    2 - THRUST PLATE (SELECT)

    3 - INPUT CLUTCH ASSEMBLY

    4 - THRUST BEARING NUMBER 1

21. Remove the number 1 thrust bearing (4) from the input clutch assembly.
22. Remove the input clutch assembly (3) from the transmission case.
23. Remove the number 5 thrust bearing (1) and selective thrust plate (2) from the input clutch assembly (3) , or the 4C clutch retainer/bulkhead.
    Fig 11: Removing/Installing 4C Clutch Retainer/Bulkhead

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    1 - SNAP-RING

    2 - 4C CLUTCH RETAINER/BULKHEAD

24. Remove the 4C clutch retainer/bulkhead tapered snap-ring (1) from the transmission case.
25. Remove the 4C clutch retainer/bulkhead (2) from the transmission case.
    Fig 12: Removing/Installing 2C Clutch Pack

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    1 - SNAP-RING

    2 - PLATE

    3 - DISC

    4 - REACTION PLATE

26. Remove the front 2C clutch pack snap-ring (1) from the transmission case.
27. Remove the 2C clutch pack (2, 3, 4) from the transmission case.
    Fig 13: Removing/Installing Reaction Annulus & Carrier

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    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

28. Remove the rear selective thrust plate (6) and number 6 thrust bearing (7) from the reaction annulus (8).
29. Remove the reaction annulus (8) from the reaction planetary carrier (3).
30. Remove the number 7 thrust bearing (5).
31. Remove the reaction sun gear (4).
32. Remove the number 8 thrust bearing (1) from the reaction planetary carrier (3).
33. Remove the reaction planetary carrier (3) . Note that this planetary gear set has three pinion gears.
34. Remove the number 9 thrust bearing (2) from the reverse planetary gear set.
    Fig 14: Removing/Installing Park Sprag Snap-Ring

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    1 - SNAP-RING

35. Remove the snap-ring (1) holding the park sprag gear onto the output shaft.
    Fig 15: Removing/Installing Park Sprag Gear

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    1 - PARK SPRAG GEAR

36. Remove the park sprag gear (1) from the output shaft.
    Fig 16: Removing/Installing Input/Reverse Planetary Assembly

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    1 - INPUT/REVERSE PLANETARY ASSEMBLY

    2 - BEARING NUMBER 9

    3 - BEARING NUMBER 12

37. Remove the input/reverse planetary assembly (1).
38. Remove the number 12 thrust bearing (3) from the input/reverse planetary assembly (1).
    Fig 17: Removing/Installing Low/Reverse Clutch Retainer

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    1 - LOW/REVERSE OVERRUNNING CLUTCH ASSEMBLY

    2 - SNAP-RING

39. Remove the snap-ring (2) holding the low/reverse clutch retainer (1) into the transmission case.
40. Remove the low/reverse clutch retainer (1) from the transmission case.
    Fig 18: Manual Shaft/Park Lock Components

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    1 - GUIDE

    2 - SNAP-RING

    3 - SHAFT

    4 - SPRING

    5 - PARK PAWL

    6 - MANUAL SHAFT/LEVER

    7 - PARK ROD

41. Remove the park rod (7) and e-clip.
42. Remove the park rod guide snap-ring (2).
43. Remove the park rod guide (1).
44. Remove the park pawl pivot shaft (3), park pawl (5), and spring (4).
45. Remove the manual selector shaft (6).
46. Remove the manual selector shaft seal.
47. Remove the dipstick tube seal.