Part 1
GENERAL NOTESThe instructions here are organized so that you work on only one component group at a time.
This will help avoid confusion from similar-looking parts of different subassemblies being on your workbench at the same time.
The component groups are inspected and repaired from the converter housing side.
As much as possible, complete the inspection, repair and assembly before proceeding to the next component group. If a component group cannot be assembled because parts are being ordered, be sure to keep all parts of that group in a separate container while proceeding with disassembly, inspection, repair and assembly for other component groups.
General Cleaning Notes:
1. All disassembled parts should be washed clean and any fluid passages and holes blown through with compressed air.
2. When using compressed air to dry parts, always aim away from yourself to prevent accidentally spraying automatic transmission fluid or kerosene in your face.
3. The recommended automatic transmission fluid or kerosene should be used for cleaning.
Parts Arrangement:
1. After cleaning, the parts should be arranged in the correct order to allow efficient inspection, repairs and reassembly.
2. When disassembling a valve body, be sure to keep each valve together with the corresponding spring.
3. New brakes and clutches that are to be used for replacement must be soaked in transmission fluid for at least 15 minutes before assembly.
General Assembly:
1. All oil seal rings, clutch discs, clutch plates, rotating parts, and sliding surfaces should be coated with transmission fluid prior to reassembly.
2. All gaskets and rubber O-rings should be replaced.
3. Make sure that the ends of a snap ring are not aligned with one of the cutouts and are installed in the groove correctly.
4. If a worn bushing is to be replaced, the subassembly containing that bushing must be replaced.
5. Check thrust bearings and races for wear or damage. Replace if necessary.
6. Use petroleum jelly to keep parts in place.
COMPONENTS
DISASSEMBLY
1. REMOVE TRANSMISSION CONTROL SHAFT LEVER
2. REMOVE PARK/NEUTRAL POSITION SWITCH
a. Unstake the lock washer.
b. Remove the nut and bolt.
c. Remove the park/neutral position switch.
d. Remove the lock washer and grommet.
3. REMOVE UNIONS
a. Remove the 2 unions.
b. Remove the O-rings from both unions.
4. REMOVE NO.1 VEHICLE SPEED SENSOR
a. Remove the No.1 vehicle speed sensor.
b. Remove the O-ring from it.
5. REMOVE NO.2 VEHICLE SPEED SENSOR
a. Remove the No.2 vehicle speed sensor.
b. Remove the O-ring from it.
6. REMOVE TRANSMISSION HOUSING
a. Remove the throttle cable clamp.
b. Remove the 6 bolts.
c. Remove the transmission housing.
7. INSTALL TRANSMISSION CASE
Install the transmission case on the overhaul attachment.
8. REMOVE EXTENSION HOUSING
a. Remove 6 bolts.
b. Using a brass bar and hammer, remove the extension housing.
c. Remove the oil apply tube and gasket from the extension housing.
9. REMOVE SPEEDOMETER DRIVE GEAR AND BALL
a. Using snap ring pliers, remove the snap ring.
b. Remove the speedometer drive gear and ball.
10. REMOVE SENSOR ROTOR AND KEY
a. Remove the sensor rotor and key.
b. Using snap ring pliers, remove the snap ring.
11. REMOVE OIL PAN
NOTICE: Do not turn the transmission over as this will contaminate the valve body with any foreign matter at the bottom of the pan.
a. Remove 19 bolts.
b. Install the blade of SST between the transmission case and oil pan, cut off applied sealer.
SST 09032-00100
NOTICE: Be careful not to damage the oil pan flange.
c. Remove the pan by lifting the transmission case.
12. EXAMINE PARTICLES IN PAN
Remove the magnets and use them to collect steel particles.
Carefully look at the foreign matter and particles in the pan and on the magnets to anticipate the type of wear you will find in the transmission.
Steel (magnetic) ... bearing, gear and clutch plate wear
Brass (nonmagnetic) ... bushing wear
13. REMOVE OIL STRAINER AND GASKETS
a. Remove the 3 bolts holding the oil strainer to the valve body.
b. Remove the oil strainer and 2 gaskets.
14. REMOVE OIL TUBES
Pry up both tube ends with a large screwdriver and remove the 2 oil tubes.
15. REMOVE SOLENOID WIRING
a. Disconnect 3 connectors from No.1, No.2 and lockup solenoids.
b. Remove the stopper plate from the case.
c. Pull out the solenoid wiring from the transmission case.
d. Remove the O-ring from the grommet.
16. REMOVE VALVE BODY
a. Remove 17 bolts.
b. Disconnect the throttle cable from the cam and remove the valve body.
17. REMOVE CHECK BALL BODY, ACCUMULATOR SPRINGS AND PISTONS
a. Remove the check ball body and spring.
b. Remove the 2 springs from Co accumulator piston.
c. Applying compressed air to the oil hole, remove B2 and C2 accumulator pistons and 2 (or 3) springs.
d. Applying compressed air to the oil hole, remove the Bo accumulator piston and spring.
e. Applying compressed air to the oil hole, remove the Co accumulator piston.
f. Remove the O-ring from each piston.
18. REMOVE THROTTLE CABLE
a. Remove the retaining bolt and pull out the throttle cable.
b. Remove the O-ring from the cable.
19. REMOVE PARKING LOCK ROD AND PAWL
a. Remove the parking lock pawl bracket.
b. Disconnect the parking lock rod from the manual valve lever.
c. Remove the E-ring from the shaft.
d. Pull the parking lock pawl shaft out from the front side, then remove the lock pawl and spring.