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8HP45/845RE Automatic Transmission (Service Information): Disassembly: Disassembly

CAUTION:

The Transmission Control Module (TCM), or Transmission Control Module Assembly (TCMA) is extremely sensitive to Electrostatic Discharge (ESD). Always use a ground strap and follow the ESD guidelines in ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES. Failure to follow these instructions may result in damage to the TCM/TCMA.

NOTE:

If the transmission is being reconditioned (clutch/seal replacement) or replaced, it is necessary to perform the TCM Adaptation Procedure. Refer to MODULE, TRANSMISSION CONTROL, MODULE PROGRAMMING .

NOTE:

Tag all clutch pack assemblies, as they are removed, for reassembly identification.

Fig 1: Torque Converter
GC0152102Courtesy of CHRYSLER GROUP, LLC
NOTE:

RWD Shown, 4WD similar.

  1. Remove the torque converter (1).
    Fig 2: Transmission Housing Extension Bolts, Housing & Rear Oil Seal (AWD)
    GC0152264Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    4WD only.

  2. Remove the seven transmission housing extension bolts (2) and remove the housing (1).
  3. Remove the transmission rear oil seal (3) with a suitable slide hammer and screw.
    Fig 3: Output Shaft Snap Ring (AWD)
    GC0152265Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    4WD only.

  4. Remove the output shaft snap ring (1) and washer.
    Fig 4: Flange, Flange Holder & Socket
    GC0152101Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    RWD only.

  5. Using a suitable punch, remove the staking from the propeller shaft flange nut, and loosen the nut about 1 thread using a 34 mm 12 point socket (3) and (special tool #C-3281, Holder, Flange) (2) to hold the flange (1).
    Fig 5: Measuring End Play
    GC0152257Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    RWD shown, 4WD similar.

    NOTE:

    End play specification is between 0.11 - 0.42 mm (0.0043 - 0.0165 in.). If end play is outside this range, a different selectable end play shim must be used during assembly.

  6. Measure the output shaft (1) end play as follows:
    1. Attach a dial indicator (2) and position the plunger against the end of the output shaft (1).
    2. Zero the dial indicator (2).
    3. Move the output shaft (1) in and out, and record the maximum travel for assembly reference.
    Fig 6: Propeller Shaft Flange, Rear Dust Seal & Rear Oil Seal
    GC0152116Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    RWD only.

  7. Finish removing the propeller shaft flange nut.
  8. Remove the propeller shaft flange (1).
  9. Remove the transmission rear dust seal (2).
  10. Remove the transmission rear oil seal (3) with a suitable slide hammer and screw.
  11. Remove the transmission output shaft washer.
    Fig 7: Thirteen Oil Pan Retaining Bolts
    GC0152099Courtesy of CHRYSLER GROUP, LLC
  12. Remove the thirteen oil pan retaining bolts (2).
    NOTE:

    Inspect the gasket for reuse. If the seal is cut or torn, replace the gasket.

  13. Carefully detach the oil pan (1) and gasket.
    Fig 8: Hydraulic Impulse Storage Unit & Bolts
    GC0154626Courtesy of CHRYSLER GROUP, LLC
  14. If equipped, disconnect Hydraulic Impulse Oil Storage (H.I.S.) accumulator (1) electrical connector.
  15. If equipped, remove three bolts (2 and 3) and the H.I.S. accumulator (1).
    Fig 9: Valve Body Assembly End Retainer Bolts
    GC0152103Courtesy of CHRYSLER GROUP, LLC
  16. Remove the valve body assembly end retainer bolts (3).
  17. Lift the electrical connector lock (2) to release the internal harness end from inside the transmission for valve body assembly removal.
  18. Remove the sensor retaining bolt (1) and pull the sensor (4) loose from the case.
    Fig 10: Remover/Installer, Guide Sleeve, Electrical Harness Insulator & Transmission Case
    GC0152117Courtesy of CHRYSLER GROUP, LLC
  19. Using (special tool #10377, Remover/Installer, Guide Sleeve) (1) carefully pull the electrical harness insulator (2) straight out from the transmission case (3).
    Fig 11: Valve Body Bolts Loosening And Tightening Sequence
    GC0169780Courtesy of CHRYSLER GROUP, LLC
  20. Remove valve body assembly retaining bolts 1-14 (15-18 are already removed).
  21. Carefully lift the valve body assembly from the transmission.
    Fig 12: Fluid Port, Two O-Rings, Compression Seal
    GC0152241Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The fluid port (1) may be in the transmission or the valve body assembly.

  22. Pull the fluid port (1) from the transmission or valve body assembly.
  23. Remove the two O-rings (2).
  24. Remove the compression seal (3) from the transmission.
    Fig 13: Thirteen Oil Pump Housing Retaining Bolts
    GC0152104Courtesy of CHRYSLER GROUP, LLC
  25. Remove the thirteen oil pump housing retaining bolts (2).
    Fig 14: Input Shaft O-Ring & Small Pick
    GC0152105Courtesy of CHRYSLER GROUP, LLC
  26. Remove the input shaft O-ring (1) using a small pick (2) or equivalent.
    Fig 15: Prying Oil Pump Housing Away From Case
    GC0154661Courtesy of CHRYSLER GROUP, LLC
  27. Carefully pry the oil pump housing (1) away from the case (2) with a small flat blade screwdriver or equivalent through the case opening.
  28. From the front of the transmission, remove the oil pump housing (2).
    Fig 16: B-Piston, Hole & B-Piston Alignment Tab
    GC0152249Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Apply air pressure slowly because oil may spray when B-piston releases from the assembly.

  29. With one hand above B-piston (1), carefully apply air pressure into the hole (2) directly above the B-piston alignment tab (3) to remove B-piston (1) from the assembly.
    Fig 17: Outer Ring, Snap Ring, Hub & Spacers
    GC0152250Courtesy of CHRYSLER GROUP, LLC
  30. Remove the outer ring (1) (under B-piston).
  31. Remove the snap ring (2).
  32. Remove the clutches and spacers (4).
  33. Remove the hub (3).
    Fig 18: Oil Pump Housing Assembly
    GC0152251Courtesy of CHRYSLER GROUP, LLC
  34. Position the oil pump housing assembly (4) in a suitable arbor press.
  35. Using (special tool #8285, Compressor, Spring) (1), press on the fingers of the piston retaining ring to remove tension, and remove the two halves of the split retainer ring (2, 3).
    Fig 19: Piston Retaining Ring And Piston
    GC0152254Courtesy of CHRYSLER GROUP, LLC
  36. Remove the piston retaining ring and piston below it.
    Fig 20: Six Bolts, Oil Pump Housing & Oil Pump Cover
    GC0152253Courtesy of CHRYSLER GROUP, LLC
  37. Remove the six bolts (1) and separate the oil pump housing (2) from the oil pump cover (3).
    Fig 21: Seal Remover & Slide Hammer
    GC0152247Courtesy of CHRYSLER GROUP, LLC
  38. Using (special tool #9667, Remover, Seal) (2) and (special tool #C-3752, Slide Hammers) (1), remove the oil seal from the front pump cover.
    Fig 22: Remover, Bearing Cup & Slide Hammers
    GC0152248Courtesy of CHRYSLER GROUP, LLC
  39. Remove the outer lip seal (3) from the front pump cover.
  40. Remove the outer snap ring securing center needle bearing.
  41. Using (special tool #6787A, Remover, Bearing Cup) (1) and (special tool #C-3752, Slide Hammers) (2) remove the needle bearing from the front cover (3).
    Fig 23: Inner Snap Ring & Needle Bearing
    GC0154603Courtesy of CHRYSLER GROUP, LLC
  42. Remove the inner snap ring (1).
  43. Using (special tool #9585, Remover, Bearing Cup) and (special tool #C-637, Slide Hammer, Universal) remove the needle bearing (2).
    Fig 24: Manual Park Release Lever Retaining Nut & Lever
    GC0152243Courtesy of CHRYSLER GROUP, LLC
  44. Remove the manual park release lever retaining nut (2) and remove the lever (1).
    Fig 25: Three Park Pawl Lock Rod Guide Plate Retaining Screws & Plate
    GC0152140Courtesy of CHRYSLER GROUP, LLC
  45. Remove the three park pawl lock rod guide plate retaining screws (1) and remove the plate (2).
    Fig 26: Park Pawl Lock Rod & Fork
    GC0152141Courtesy of CHRYSLER GROUP, LLC
  46. Remove the park pawl lock rod (1) from the fork (2).
    Fig 27: Selector Shaft, Suitable Pin Punch, Spring & Fork
    GC0152142Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Pay attention to the spring position for installation.

  47. Remove the roll pin from the selector shaft (4) using a suitable pin punch (3).
  48. Remove the shaft (4), spring (2) and fork (1) from the case.
  49. Remove the selector shaft seal using a small screwdriver or equivalent.
    Fig 28: Park Pawl Shaft Plug
    GC0152143Courtesy of CHRYSLER GROUP, LLC
  50. Remove the park pawl shaft plug (1) from the rear of the case.
    Fig 29: Removing/Installing Park Pawl Shaft Using A Suitable Pin Punch, Park Pawl And Spring
    GC0152144Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Pay attention to the spring position for installation.

  51. Remove the park pawl shaft using a suitable pin punch (3), remove the park pawl (1) and spring (2).
    Fig 30: Park Pawl
    GC0154476Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The transmission must be in a upright position when removing the input/output shaft P4 annulus drum assembly (1) from the case.

  52. Remove the input/output shaft and P4 annulus drum assembly (1) from the case.
    Fig 31: Outer Bearing Snap Ring & Outer Needle Bearing
    GC0152266Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    4WD shown, RWD similar. The 4WD bearing is a needle bearing and the RWD is a ball bearing.

  53. Remove the outer bearing snap ring (1), and the outer needle bearing (2) (4WD) or outer ball bearing (RWD).
    Fig 32: Bearing Cup, Slide Hammer, Universal & Oil Dam
    GC0152267Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    4WD shown, RWD similar.

  54. Remove the oil dam snap ring.
  55. Using (special tool #9664, Remover, Bearing Cup) (1) and (special tool #C-637, Slide Hammer, Universal) (2), remove the oil dam (3).
    Fig 33: Bearing Cup, Slide Hammer & Inner Needle Bearing
    GC0152269Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    4WD shown, RWD similar.

  56. Remove the output shaft inner needle bearing snap ring.
  57. Using (special tool #9664, Remover, Bearing Cup) (1) and (special tool #C-637, Slide Hammer, Universal) (2), remove the inner needle bearing (3).
    Fig 34: P4 Annulus Drum Assembly, Press Fixture Assembly & Bearing/Gear Splitter
    GC0152139Courtesy of CHRYSLER GROUP, LLC
  58. Position the input/output shaft and P4 annulus drum assembly (1) on (special tool #8925-3, Assembly, Press Fixture) (3) and (special tool #1130, Splitter, Bearing/Gear) (4).
  59. Remove the B clutch pack (2).
    Fig 35: P1 Annulus/B-Clutch Hub Assembly, Needle Bearing And Holding Plate
    GC0152146Courtesy of CHRYSLER GROUP, LLC
  60. Remove the O-ring and 5 squared O-rings.
  61. Remove the P1 annulus/B clutch hub assembly (1) from the P4 annulus drum.
    NOTE:

    The washer may stick to the bottom of the P1 annulus/B clutch hub assembly (1).

  62. Remove the selectable shim from the P1 annulus/B clutch hub.
  63. Remove the needle bearing and holding plate (2) from the P1 planetary carrier.
    Fig 36: Tool & Snap Ring
    GC0152147Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The (special tool #10378, Rings, Support) are three pieces intended to be used in multiple locations around the drum.

  64. Position the (special tool #10378, Rings, Support) (1) on the P4 annulus drum assembly to protect the drum.
    NOTE:

    Pry the snap ring from the opposite side of the snap ring openings to release.

    NOTE:

    When the snap ring is removed the internal clutch drum may drop slightly.

  65. Using a suitable tool (3), release the snap ring (2) by prying in and up from the opposite side of the snap ring openings.
    Fig 37: Snap Ring & P1 Planetary Carrier
    GC0152148Courtesy of CHRYSLER GROUP, LLC
  66. Remove the P1 planetary carrier (3).
  67. Remove P1/P2 sun gear from the bottom of the P1 planetary carrier (3).
  68. Remove the input shaft with P2 planetary carrier (3) from the drum assembly.
    Fig 38: P2 Planetary Carrier & Needle Bearing
    GC0152150Courtesy of CHRYSLER GROUP, LLC
  69. Remove the needle bearing (2) and washer.
    Fig 39: P2 Annulus/P3 Sun Gear & Drum Assembly
    GC0152151Courtesy of CHRYSLER GROUP, LLC
  70. Remove the P2 annulus/P3 sun gear (1) from the drum assembly (2).
    Fig 40: D-Clutch Drum & P4 Annulus Drum
    GC0152172Courtesy of CHRYSLER GROUP, LLC
  71. Remove the D clutch drum (1) from the P4 annulus drum (2).
    Fig 41: Support Rings, Tool & P3 Planetary Carrier
    GC0152152Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The (special tool #10378, Rings, Support) are three pieces intended to be used in multiple locations around the drum.

  72. Position the (special tool #10378, Rings, Support) (4) on the P4 annulus drum assembly to protect the drum.
  73. Using a suitable tool (1), release and remove the snap ring (2).
  74. Remove the P3 planetary carrier (3).
  75. Remove the needle bearing from the planetary carrier.
    Fig 42: P4 Sun Gear/C/E Clutch Retainer & D-Clutch Drum
    GC0152170Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The C/E clutch retainer will drop slightly when the snap ring is removed.

  76. Remove the P4 sun gear/C/E clutch retainer (1) from the D clutch drum (2).
    Fig 43: Snap Ring & P4 Sun Gear/C/E Clutch Retainer
    GC0152173Courtesy of CHRYSLER GROUP, LLC
  77. Remove the snap ring (1) from the P4 sun gear/C/E clutch retainer (2).
    Fig 44: P3 Annulus & P4 Sun Gear/C/E Clutch Retainer
    GC0152174Courtesy of CHRYSLER GROUP, LLC
  78. Remove the P3 annulus (1) from the P4 sun gear/C/E clutch retainer (2).
    Fig 45: Snap Ring & P4 Sun Gear/C/E Clutch Retainer
    GC0152175Courtesy of CHRYSLER GROUP, LLC
  79. Remove the snap ring (1) from the P4 sun gear/C/E clutch retainer (2).
    Fig 46: E-Clutch & P4 Sun Gear/C/E Clutch Retainer
    GC0152176Courtesy of CHRYSLER GROUP, LLC
  80. Remove the E clutch (1) from the P4 sun gear/C/E clutch retainer (3).
  81. Remove the needle bearing (2) from the E clutch (1).
    Fig 47: C-Clutch & P4 Sun Gear/C/E Clutch Retainer
    GC0152177Courtesy of CHRYSLER GROUP, LLC
  82. Remove the C clutch (1) from the P4 sun gear/C/E clutch retainer (2).
  83. Remove the bearing from top and bottom of C clutch (1).
    Fig 48: P4 Planetary Carrier/Output Shaft & P4 Annulus Drum
    GC0152270Courtesy of CHRYSLER GROUP, LLC
  84. Remove the P4 planetary carrier/output shaft (2) from the P4 annulus drum (1).
    Fig 49: Snap Ring & P4 Annulus Drum & P4 Annulus
    GC0152178Courtesy of CHRYSLER GROUP, LLC
  85. Remove the snap ring (1) from the P4 annulus drum (2).
  86. Remove the P4 annulus (3) from the P4 annulus drum (2).
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