Part 1
Do Not Use Air ToolsNotice: Do not use air powered tools in order to disassemble or assemble any vehicle component.
Bolt torques are vital to diagnosis. You can detect bolt torques only when using hand tools.
Improper bolt torques can contribute to vehicle repair problems.
Holding Fixture Installation
Tools Required
J 8763-02 Holding Fixture and Base
1. Install the J 8763-02 onto the transmission.
2. Install the J 8763-02 into the base.
Torque Converter Removal
Remove the torque converter.
Drain Oil
Rotate the transmission so that the converter housing is up. Allow the transmission fluid to drain from the case extension.
2-4 Servo Cover and Assembly Removal
Tools Required
J 29714-A Servo Cover Compressor
1. Install the J 29714-A.
2. Tighten the bolt to compress the servo cover.
3. Remove the servo cover retaining ring.
4. Remove the servo cover and O-ring seal. If the servo cover seems to be hung up on the seal, cut and remove the O-ring seal before removing the cover.
5. Remove the 2-4 servo assembly.
2-4 Servo Disassemble
Disassemble the 2-4 servo assembly.
2-4 Servo Pin Length Check
Tools Required
J 33037 2-4 Band Apply Pin Tool
1. Install the band apply pin and the J 33037.
2. Install the servo cover retaining ring to secure the tool.
3. Apply 11 N.m (98 lb in) torque. If the white line appears in the gage slot (1), the pin length is correct.
4. If a new pin is needed, refer to Band Apply Servo; Application and ID; 2-4 Servo Pin Selection in order to determine correct pin length.
Speed Sensor and Case Extension Removal (2WD Applications Only)
Removal Procedure
Tools Required
J 29837-A Output Shaft Support Fixture
1. Remove the sensor retaining bolt (35).
2. Remove the speed sensor (36) and O-ring seal (37).
3. Remove the case extension bolts (32).
4. Remove the case extension (31) and the case extension to case seal (30).
5. Remove the output shaft sleeve (690) and the output shaft O-ring seal (691). Not all models use an output shaft sleeve (690) and O-ring seal (691).
6. Install the J 29837-A
If the J 29837-A is not used, the output shaft (687) may fall free when the input carrier retaining ring is removed.
Pan and Filter Assembly Removal
1. Spray the ends of the transmission oil pan screws (76) with penetrating oil.
2. Remove the transmission oil pan screws (76).
3. Remove the transmission oil pan (75) and the transmission oil pan gasket (73).
4. Remove the transmission oil filter assembly (72).
1. Pry the metal from the top of the filter and pull the top away.
2. Open the filter.
5. The filter may help in diagnosis. Inspect for the following items which may indicate wear or corrosion:
- Clutch material
- Bronze slivers indicating bushing wear Steel particles
6. Remove the oil filter seal (71).
Valve Body and Wiring Harness Removal
1. Remove all electrical connectors (1 - 6) from the electrical components.
2. Remove the TCC PWM retainer clip (395).
3. Remove the TCC PWM solenoid (396).
4. Remove the TCC solenoid bolts (68).
5. Remove the TCC solenoid and wiring harness (66). Turn the wiring harness over so that it hangs over the side of the transmission.
6. Remove the transmission fluid pressure (TFP) manual valve position switch assembly bolts (62, 70).
7. Remove the TFP manual valve position switch (69).
8. Remove the manual detent spring bolt (64).
9. Remove the manual detent spring assembly (63).
10. Remove all valve Body bolts (62).
11. Remove the fluid level indicator stop bracket (93).
12. Lift the valve Body carefully so that the check balls remain on the spacer plate in the correct location. While lifting the valve Body, disconnect the manual valve link from the manual valve.
13. Remove the seven valve Body check balls (2-6, 8,12).
14. Remove the accumulator cover bolts (58, 59).
15. Remove the 1-2 accumulator cover and pin assembly (57).
16. Disassemble the 1-2 accumulator assembly (54, 56, 57,104).
17. Remove the spacer plate support bolts (77).
18. Remove the spacer plate support (53).
19. Remove the valve Body gasket (52), the valve Body spacer plate (48) and the case gasket (47).
Discard gaskets. Do not reuse.
20. Remove the 3-4 accumulator spring (model dependent) and the 3-4 accumulator piston.
21. Remove the case checkball(#1).
Converter Housing Removal
Removal Procedure
Tools Required
J 41510 50 mm Torx Plus Bit
1. Remove the converter housing bolts (94). Use the J 41510.
2. Remove the converter housing (102).
Turbine Shaft 0-ring Removal
Remove the O-ring (618) (model dependent) from the turbine shaft.
Transmission End Play Check
Tools Required
- J 25022-A End Play Fixture Adapter (245 mm)
- J 34725 End Play Fixture Adapter (298 mm)
- J 43205 End Play Fixture Adapter (300 mm)
- J 24773-A Oil Pump Remover and End Play Checking Fixture
- J 8001 Dial Indicator Set
- J 25025-7A Dial Indicator Mounting Post
1. Install an end play fixture adapter.
- Use J 25022-A for a 245 mm turbine shaft (1).
- Use J 34725 for a 298 mm turbine shaft (2).
- Use J 43205 for a 300 mm turbine shaft (3).
2. Install the J 24773-A.
3. Remove an oil pump bolt.
4. Install J 25025-7A (or a 275 mm or 11 in bolt) and lock nut.
5. Install J 8001.
6. Set the J 8001 to zero.
7. Pull up on J 24773-A.
8. The end play should be 0.13- 0.92 mm (0.005-0.036 in).
Refer to Transmission End Play Check.
9. The selective washer (616), which controls the end play, is located between the input housing (621) and the thrust bearing (615) on the oil pump hub. If the dial indicator shows no end play, the selective washer (616) and thrust bearing (615) may have been misassembled.
Oil Pump Removal
Tools Required
- J 37789-A Oil Pump Remover and Installer
- J 39119 Oil Pump Remover and Installer Adapter
1. Remove all pump bolts (2).
2. Install J 39119 over stator shaft until it locks under splines.
3. Install J 37789-A.
4. Tighten the bolt (1) with a wrench. This will tighten the J 37789-A around the J 39119.
5. Turn the T-handle on top of J 37789-A.
6. Lift the pump out of the case.
7. Remove the pump cover to case gasket (6).
2-4 Band, Input Clutches, Input Gear Set Removal
1. Remove the band anchor pin.
2. Remove the input housing and shaft assembly and the reverse input clutch housing and drum assembly.
3. Remove the 2-4 band assembly (602).
Reaction Gear Set Removal
Important: The retainer must be replaced.
1. Remove the output shaft to input carrier retainer (661).
2. Remove the input carrier assembly (662) and remove the bearing assembly (663).
3. Remove the input internal gear (664) and the reaction carrier shaft assembly (666).
4. Remove the thrust washer (669) and the reaction sun shell (670).
Output Shaft, Reaction Gear, Low/Rev Clutch Removal
Tools Required
J 29837-A Output Shaft Support Fixture
1. Remove the reaction sun gear (673) and the thrust washer (674).
2. Remove the low and reverse support retainer ring (676).
3. Remove the J 29837-A.
4. Push on the output shaft in order to loosen the low and reverse clutch support (679).
5. Remove the low and reverse clutch support (679).
6. Remove the output shaft (687).
7. Remove the low and reverse clutch support retainer spring (680).
8. Remove the reaction carrier assembly (681).
9. Remove the following components:
1. The low and reverse clutch fiber plate assembly (682C)
2. The low and reverse clutch steel plates (682D)
3. The low and reverse clutch selective plate (682B)
4. The low and reverse clutch waved plate (682A)
10. Remove the following components:
1. The thrust bearing assembly (reaction carrier support) (683)
2. The internal reaction gear (684)
3. The internal reaction gear support (685)
4. The reaction gear support bearing (692)
Inner Manual Linkage Removal
1. Remove the following parts: hex head nut (90) and the manual valve link (89); inside detent lever (88) and the parking lock actuator assembly (85): manual shaft retainer (83)and the manual shaft (84).
2. Remove the manual shaft seal (82) with a screwdriver.
3. Remove the following components:
1. The parking lock bracket bolt (87)
2. The parking lock bracket (86)
Low and Reverse Clutch Piston Removal
Tools Required
- J 23327-1 Clutch Spring Compressor
- J 34627 Snap ring Remover and Installer J 42628 Disc
1. Install the J 23327-1 and the J 42628.
2. Tighten the J 23327-1.
3. Remove the low and reverse clutch retainer ring (693) using the J 34627.
4. Remove the low and reverse clutch spring assembly (694).
5. Blow compressed air into the case passage to remove the low and reverse clutch piston (695).
- (1) LO Feed Passage
- (2) REV Feed Passage
Case Assembly Inspection
1. Inspect the spacer plate to case gasket for witness marks. The witness marks should be complete. Incomplete witness marks may come from an uneven case surface or from cross channel leaks.
2. Using compressed air, blow into all of the case fluid passages (3, 7, 8, 11, 16, 18, 26, 29, 37, 45) to ensure that all case fluid passages are clear of any obstruction.
3. Inspect the 24 servo bore, the 3rd accumulator retainer and ball assembly (40), the orifice cup plug (11) in the servo bore, and the 2nd apply piston pin bore for any of the following conditions:
- Porosity
- Burrs
- Debris
- Any other damage
4. Inspect the 3-4 accumulator bore and the orifice cup plug (38) for any of the following conditions:
- Porosity
- Burrs
- Blockage
- Any other damage
5. Inspect all bolt holes for thread damage. Use heli-coil to repair damaged threads.
6. Inspect the cooler connectors for damage and proper torque specification - 38 Newton Meters (28 lb ft).
Retainer and Ball Assembly Leak Check
Installation Procedure
Tools Required
J 29714-A Servo Cover Compressor
1. Install the 2-4 servo into the case.
2. Use the J 29714-A in order to compress the servo cover.
3. Install the servo cover retaining ring.
4. Pour solvent into the accumulator bore until the channel is filled. Watch for leaks in the case channel.
Important: It is normal to see leakage from the small hole next to the larger oval hole.
5. If leakage from the oval shaped hole is observed, replace the third accumulator retainer and ball assembly.