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Transmission Disassembly

NOTE: See Figure , Figure and Figure for exploded view of internal parts, thrust washer and needle bearing locations.
  1. On 4WD models, remove Vehicle Speed Sensor (VSS). Remove transfer case. On all models, remove torque converter and input shaft. Splined input shaft ends are different. End with shorter splines is inserted first into transmission. On 2WD models, remove VSS. On all models, remove transmission modulator heat shield (if equipped). Remove manual control outer lever. Remove TR sensor.
  2. Remove extension housing oil seal. Remove extension housing bushing (if necessary). Remove extension housing. Remove parking pawl, return spring and shaft. Remove oil pan and filter screen. Lift up wire loom guide and protector to disengage retaining pins from solenoid brackets. Disconnect 6 solenoid electrical connectors. Remove manual valve detent lever spring. Remove low-reverse servo bolts. Remove servo cover, gasket, piston and rod.
    NOTE: DO NOT remove center bolt from SS1 and SS3 solenoid bracket or forward bolt from TCC, SS2, CCS and EPC solenoid bracket. See Figure .
  3. Remove valve body bolts. Remove valve body and gasket from case. Remove and discard overdrive and intermediate band adjusting screw lock nuts. Back off adjusting screws completely. Using Servo Cover Compressor (49 UN01 144 ), remove overdrive and intermediate servo cover snap rings. Install Transmission Test Plate (49 UN01 021 ). Apply 20 psi (1.4 kg/cm2 ) of air pressure (maximum) to appropriate passage to remove overdrive and intermediate servo covers, pistons and springs. See Figure .
  4. Remove and discard converter housing-to-case bolts. Remove converter housing and pump as an assembly. Use a twisting motion to keep clutches in place. Remove gasket and No. 1 thrust washer. Compress overdrive band and remove anchor strut and adjusting screw.
  5. Remove and mark overdrive band. Mark anchor and apply end of band for reassembly reference. Lift out overdrive brake and coast clutch drum. Remove overdrive band apply strut and actuating lever shaft. Lift out front planetary gear carrier assembly with No. 2 thrust bearing. Remove servo band lever and overdrive control bracket.
    NOTE: Mark actuating lever and shaft for reassembly to overdrive band assembly. Overdrive actuating lever shaft is longer than the intermediate actuating lever shaft.
  6. Lift out overdrive ring gear, one-way clutch and center shaft assembly. Remove No. 3 thrust bearing. Remove 5 mm Allen head bolt retaining center support. Remove lock nut from center support. Disconnect Turbine Shaft Speed (TSS) sensor connector from 16-pin case connector. Remove TSS sensor.
  7. Remove case wiring connector retaining ring. Depress tab on back side of case wiring connector while pushing down on connector. Remove connector and harness through bottom of case. Remove center support snap ring from case. Remove center support by pulling upward, carefully and evenly. Remove No. 4 thrust bearing behind center support.
  8. Remove intermediate band anchor strut through bottom of case. Remove intermediate band adjusting screw. Remove and mark intermediate band. Mark anchor and apply end of band for reassembly reference. Remove intermediate band actuating lever and shaft. Remove and mark intermediate band servo lever.
    NOTE: Mark actuating lever and shaft for reassembly to intermediate assembly. Intermediate actuating lever shaft is shorter than the overdrive actuating lever shaft.
  9. Remove intermediate brake and direct clutch drum, No. 5 thrust washer and forward clutch cylinder. Remove No. 6A thrust bearing. Remove forward ring gear and hub. Remove No. 6B thrust bearing from forward ring gear hub. Remove No. 7 thrust bearing from the forward planetary gear set.
  10. Remove forward planetary gear set. Remove input shell with forward sun gear. Remove and mark reverse planet carrier No. 8 thrust bearing. Remove low-reverse planetary gear retaining ring.
  11. Remove low-reverse planetary gear assembly. Remove and mark No. 9 thrust bearing. Remove output shaft sleeve. Remove and discard output shaft snap ring. Remove output shaft ring gear and hub. Remove and mark No. 10 thrust washer.
  12. Remove low-reverse drum and rear one-way clutch assembly. Inner race of rear one-way clutch is not removable. Remove low-reverse band. Remove output shaft and park gear. Remove and mark No. 11 thrust washer.
  13. Remove manual valve inner lever nut. Remove manual valve inner lever and parking pawl actuating rod. To loosen manual control lever shaft retaining pin, tap lightly on each side pin, using small hammer and drift. Remove retaining pin, manual control lever shaft and seal.
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