Disassembly And Assembly: Transmission: Disassembly

-- Remove the speed sensors (1, 2 and 3).

Fig 1: Identifying Speed Sensor

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-- Remove bolts (1) at the oil filter pan (2).

Fig 2: Identifying Fluid Filter Oil Pan Bolts

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-- Remove the oil filter oil pan (2).

-- Remove the bolts (1) at the oil filter (2).

Fig 3: Identifying Fluid Filter Nuts

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-- Remove the oil filter (2).

-- Remove the oil filter seal (1) at the case.

Fig 4: Identifying Oil Filter Seal

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NOTE: Keep the front sound dampener cover if replacing the unit.

-- If equipped remove the fasteners (1) and the front sound dampener cover (2).

Fig 5: Identifying Front Sound Damper Cover And Fasteners

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NOTE: Keep the top sound dampener cover if replacing the unit.

-- Remove the top sound damper cover (1).

Fig 6: Identifying Top Sound Damper Cover

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-- Remove bolts (2) at the valve body oil pan (1).

Fig 7: Identifying Valve Body Oil Pan Upper Bolts

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-- Remove the pressure tap plug (2) from the valve body oil pan.

Fig 8: Identifying Pressure Tap Plug And Lower Valve Body Oil Pan Bolts

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-- Remove the valve body oil pan.

-- Remove the electrical connector (1) at the range sensor (4).

Fig 9: Identifying Range Sensor, Electrical Connector, Detent Spring And Bolt

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-- Remove the bolt (3) holding the detent spring.

-- Remove the detent spring (2).

-- Remove valve body bolts (1).

Fig 10: Identifying Valve Body Bolts

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-- Remove valve body (1) from oil transfer tubes and manual valve (3) from rooster comb.

Fig 11: Identifying Manual Valve

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-- Remove the oil transfer tubes (2) from the case.

Fig 12: Identifying Oil Transfer Tubes

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-- Remove the six accumulators (1, 2, 3, 5, 6 and 7) from the case along with the accumulator return springs.

Fig 13: Identifying Accumulators

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-- Remove the 2/4 clutch oil supply seal (4) from the case.

-- Remove the manual lever, transmission range sensor and seal. Refer to Removing .

-- Measure the input shaft end play. Place the transmission so the input shaft is vertical. Set up the 8266A (1 and 2) and the dial indicator (3). Check the end play, the reading should be within 0.13 to 0.64 mm (0.005 to 0.025 in). Record indicator reading for reference upon reassembly.

Fig 14: Identifying End Play Socket Set 8266A And Dial Indicator

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-- Remove the front pump bolts (1).

Fig 15: Identifying Oil Pump Bolts

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CAUTION: Be sure input speed sensor is removed before removing oil pump.

-- Install the C-3752 (1) to the oil pump.

Fig 16: Identifying Oil Pump Puller C-3752

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-- Remove the oil pump (1) using the C-3752 (2).

Fig 17: Identifying Oil Pump And Oil Pump Puller C-3752

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-- Remove the oil pump gasket (2).

Fig 18: Identifying Oil Pump Gasket

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CAUTION: If a transaxle failure has occurred, the cooler bypass valve must be replaced. Do not reuse or attempt to clean the valve.

-- Remove the cooler bypass valve (2).

Fig 19: Identifying Cooler Bypass Valve

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NOTE:

The tanged side (2) goes out.

Fig 20: Identifying Tanged Side

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-- Remove the number one caged needle bearing (1).

-- Remove the input clutch assembly (1).

Fig 21: Identifying Input Clutch Assembly

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-- Remove the number four thrust plate (2).

Fig 22: Identifying Number Four Thrust Plate

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-- Remove the front sun gear assembly (1) and number four thrust washer (2).

Fig 23: Identifying Front Sun Gear Assembly And Number Four Thrust Washer

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-- Remove the front carrier/rear annulus assembly (2) and the number six needle bearing (1).

Fig 24: Identifying Front Carrier/Rear Annulus Assembly And Number Six Needle Bearing

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-- Remove the rear sun gear (2) and the number seven needle bearing (1).

Fig 25: Identifying Rear Sun Gear And Number Seven Needle Bearing

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NOTE:

The number seven needle bearing (1) has three anti-reversal tabs and is common with the number five and number two position. The orientation should allow the bearing to seat flat against the rear sun gear (2).

Fig 26: Identifying Number Seven Needle Bearing And Rear Sun Gear

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-- Setup 5058A (1), and compress the 2/4 clutch return spring (4).

Fig 27: Identifying Setup Compressing Tool 5058A And 2/4 Clutch Return Spring

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-- Using a screwdriver (2) remove the snap ring (3).

NOTE: Verify that the 5058A is centered properly over the 2/4 clutch retainer before compressing. If necessary, fasten the 5058A bar to the bellhousing flange with any combination of locking pliers and bolts to center the tool properly.

NOTE:

The 2/4 clutch piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.

Fig 28: Identifying 2/4 Clutch Retainer And 2/4 Clutch Return Spring

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-- Remove the 2/4 clutch retainer (1).

-- Remove the 2/4 clutch return spring (1).

-- Remove the 2/4 clutch pack (1 - clutch plates, four each) and (2 - clutch discs, four each). Tag the 2/4 clutch pack for reassembly identification.

Fig 29: Identifying 2/4 Clutch Pack

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NOTE:

The tapered side goes up.

Fig 30: Identifying Tapered Snap Ring

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-- Remove tapered snap ring (3).

-- Remove low/reverse reaction plate (1).

Fig 31: Identifying Low/Reverse Reaction Plate

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-- Remove one low/reverse clutch disc (1).

NOTE: Do not scratch the clutch plate.

-- Using a screwdriver (1), remove low/reverse reaction plate snap ring (2).

Fig 32: Identifying Low/Reverse Reaction Plate Snap Ring

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-- Remove the low/reverse clutch pack (1 - clutch plates, five each) and (2 - clutch discs, five each).

Fig 33: Identifying Low/Reverse Clutch Pack

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-- Remove the transfer gear cover bolts (2).

Fig 34: Identifying Transfer Gear Cover Bolts

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-- Remove transfer gear cover (1).

-- Remove the oil scavenger (2).

Fig 35: Identifying Transfer Gear Cover And Oil Scavenger

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-- Bend back the locking tabs (2) on the output transfer gear retaining strap (3).

Fig 36: Identifying Locking Tabs

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-- Remove the bolts (1) at the output transfer gear retaining strap (3).

-- Remove the output transfer gear retaining strap (3).

-- Install the 9739 (2) onto the output transfer gear (3).

Fig 37: Identifying Holder 9739

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-- Using a socket (1), remove the output transfer gear bolt.

-- Grind the staked tabs (1) from the transfer gear (underdrive compounder side).

Fig 38: Identifying Staked Tabs

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-- Install the 9739 onto the transfer gear (underdrive compounder side) and remove the nut.

-- Lift the transfer gear from the underdrive compounder shaft.

-- Using L-4407 (1) and 6055 (3), remove the output shaft transfer gear (2) and select shim.

Fig 39: Identifying Puller L-4407, Button 6055 And Output Shaft Transfer Gear

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-- Using 5048 with 5048-5 and L 4539-2 (1) remove the output gear (3) bearing cone.

Fig 40: Identifying Button L 4539-2 And Output Gear

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-- Using C-293-PA (1), 9738 (3) and 9678, remove compounder transfer gear (2) bearing cone.

Fig 41: Identifying Puller Set C-293-PA, Adapter 9738 And Compounder Transfer Gear

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-- Remove the rear carrier assembly (1) from the transmission (2).

Fig 42: Identifying Rear Carrier Assembly

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-- Using 5048 (1) with 5048-3 and 6055, remove the rear carrier assembly (3) bearing cone.

Fig 43: Identifying Puller Set 5048 And Rear Carrier Assembly

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-- Assemble the 6057 (1), 5059A (2) and 5058-3 (3).

Fig 44: Identifying Disc 6057, Compressor 5059A And Compressor Bar 5058-3

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-- Using the assembled 6057 (3), 5059A (4) and 5058-3 (5) compress the low/reverse spring (1).

Fig 45: Identifying Assembled Disc 6057, Compressor 5059A And Compressor Bar 5058-3 And Low/Reverse Spring

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NOTE:

The snap ring (1) opening must be between the spring levers.

Fig 46: Identifying Snap Ring Pliers

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-- Using snap ring pliers (2), remove snap ring (1) at low/reverse piston return spring.

-- Remove the assembled compressor tool and remove the low reverse piston return spring (1).

Fig 47: Identifying Low Reverse Piston Return Spring

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NOTE:

The low/reverse clutch piston (1) has bonded seals (2 and 3) which are not individually serviceable. Seal replacement requires replacement of the piston assembly.

Fig 48: Identifying Low/Reverse Clutch Piston

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-- Remove the low/reverse clutch piston (1).

-- Remove the low/reverse clutch piston retainer screws (3).

Fig 49: Identifying Low/Reverse Clutch Piston Retainer Screws

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-- Remove the low/reverse clutch piston retainer (1).

Fig 50: Identifying Low/Reverse Clutch Piston Retainer

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-- Remove low/reverse piston retainer-to-case gasket (2), gasket holes must line up (1).

Fig 51: Identifying Low/Reverse Piston Retainer-To-Case Gasket

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-- Using a hammer and suitable drift (2), drive out the inner output bearing cup (1).

Fig 52: Using Hammer And Drift To Drive Out Inner Output Bearing Cup

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-- Using 6062A (1), remove the outer output bearing cup (2).

Fig 53: Identifying Remover 6062A And Outer Output Bearing Cup

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-- Remove the underdrive compounder assembly (2) snap ring (1).

Fig 54: Identifying Underdrive Compounder Assembly And Snap Ring

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-- Remove four bolts (1) at the compounder bearing retainer.

Fig 55: Identifying Bolts At Compounder Bearing Retainer

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-- Install puller adapter 9908 (2) to the compounder bearing retainer.

Fig 56: Identifying Puller Adapter 9908

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-- Install C-3752 (1) to 9908 (2) and pull the underdrive compounder assembly from the case.

Fig 57: Identifying Oil Pump Puller C-3752 And Puller Adapter 9908

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NOTE: Insure that the planetary gear set/output hub is removed as part of the underdrive compounder assembly.

-- Using 9908 (2), remove the underdrive compounder assembly (2).

Fig 58: Identifying Puller Adapter 9908 And Underdrive Compounder Assembly

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-- Remove the remote pinion cover bolts (1).

Fig 59: Identifying Remote Pinion Cover Bolts

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-- Remove the remote pinion (1) and the remote pinion cover (2) from the case.

Fig 60: Identifying Remote Pinion And Remote Pinion Cover

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-- Remove the remote pinion cover (1) from the remote pinion (2).

Fig 61: Identifying Remote Pinion Cover And Remote Pinion

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-- Using 8913 (2), 9738 (3) and 8915 (1) remove the remote pinion cover bearing cup (4) and selective shim.

Fig 62: Identifying Remover 8913, Adapter 9738, Kukko Support 8915 And Remote Pinion Cover Bearing Cup

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-- Using 8912 (1) and 8915 (2) remove the remote pinion small bearing cup (3) from the case.

Fig 63: Identifying Remover 8912, Kukko Support 8915 And Remote Pinion Small Bearing Cup

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-- Remove the differential output bearing cover bolts (1).

Fig 64: Identifying Transmission Extension Assembly Bolts

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-- Remove differential output bearing cover (2).

-- Remove the differential cover bolts (1).

Fig 65: Identifying Differential Cover Bolts

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-- Remove the differential cover (1).

Fig 66: Identifying Differential Cover

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-- Remove the outer seal (2), oil slinger (3) and the small bearing cup (4).

-- Remove the large bearing cup.

-- Remove the differential.

Fig 67: Identifying Differential

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-- Remove the manual lever and transmission range sensor. Refer to Removing .

-- Remove the set screw (1) for the park pawl shaft.

Fig 68: Identifying Screwdriver For Set Screw

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-- Remove the snap ring (1) for the park guide assembly (2).

Fig 69: Identifying Snap Ring And Park Guide Assembly

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-- Remove the park guide assembly (1).

Fig 70: Identifying Park Guide Assembly

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-- Remove the plug (1) in order to allow the park pawl shaft to be removed.

Fig 71: Identifying Plug

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-- Slide the shaft (1) out of the park pawl (3).

Fig 72: Identifying Shaft And Park Pawl

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-- Remove the park pawl shaft (1).

Fig 73: Identifying Park Pawl Shaft

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-- Remove the park pawl (1) and the park pawl spring (2).

Fig 74: Identifying Park Pawl And Spring

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