Disassembly And Assembly

WARNING: This page is about a different variant/trim than selected.

8HP75

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 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 (TCM), MODULE PROGRAMMING .

NOTE:

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

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Remove the torque converter (1).

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4X4 ONLY, Remove the transmission housing extension bolts (1) and remove the extension housing (2).

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Remove the transmission rear oil seal (1) with a suitable slide hammer and screw.

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NOTE:
4X4 only
Remove the output shaft snap ring (1).

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NOTE:
RWD only.
Remove the output shaft flange locknut (1) staking.

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NOTE:
RWD shown, 4X4 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.
Measure the output shaft end play as follows:
1. Attach a dial indicator (2) and position the plunger (3) against the end of the output shaft.
2. Zero the dial indicator (2).
3. Move the output shaft flange (4) in and out, and record the maximum travel on the dial (2) for assembly reference.
Using a flange holder (special tool #C-3281, Holder, Flange), remove the output shaft flange nut.
Remove the output shaft flange and inspect the output shaft flange sealing surface for damage, replace as needed.

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Remove the thirteen oil pan retaining bolts (1).
NOTE:
Inspect the gasket for reuse. If the seal is cut or torn, replace the gasket.
Carefully remove the oil pan (2) and gasket.

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If equipped, disconnect the Hydraulic Impulse Oil Storage (H.I.S) connector (1).
If equipped, remove three bolts (2) and the H.I.S. accumulator.

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Verify the seal (1) on the input end of the H.I.S. accumulator is not torn or cut. Replace the seal if it looks worn or damaged,

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Remove the valve body assembly end retainer bolts (1, 2).
Lift the electrical connector lock (3) to release the internal harness end from inside the transmission for valve body assembly removal.

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Remove the Output Speed Sensor bolt (1) and gently lift the Output Speed Sensor out from the case.

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Using (special tool #10377, Remover/Installer, Guide Sleeve) (1), carefully pull the electrical harness insulator (2) straight out from the transmission case.

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Remove the valve body assembly bolts (1-14) in the order shown and remove the valve body.

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Remove the fluid port (1) from the transmission or valve body assembly (the fluid port may stick in the valve body upon removal).
Inspect the fluid port O-rings for damage or wear and replace as necessary.

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Remove and DISCARD the 14 oil pump housing retaining bolts (1).

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NOTE:
Remove the input shaft O-ring before the oil pump is removed.
Remove the input shaft O-ring (1) using a small pick or equivalent.

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Carefully pry the oil pump housing away from the case with a small flat blade screwdriver or equivalent through the case opening (1).
From the front of the transmission, remove the oil pump housing.

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Remove the B clutch spring damper (1).

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Remove the B-piston (1) from the assembly.

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Check the B-piston seal (1) for damage or wear and replace if necessary.

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Remove the snap ring (1).
Remove the clutches and spacers (2).

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Remove the hub (1).

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Position the oil pump housing assembly (3) in a suitable arbor press (2).
Using (special tool #8285, Compressor, Spring) (1), press on the fingers of the piston retaining ring to remove tension.

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Remove the two retainer halves (1) from the clutch housing.

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Remove the wave spring (1).

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Remove the clutch piston (1) by rotating and gently lifting.

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Inspect the inner (2) and outer (1) piston seals for wear or damage and replace as necessary.

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Remove the bolts (1) and separate the oil pump housing (2) from the oil pump cover (3).

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Using (special tool #9667, Remover, Seal) (1) and (special tool #C-3752, Slide Hammers) (2), remove the oil seal (3) from the front pump cover.
Remove the snap ring.

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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).
Remove the front pump needle bearing snap ring.
Using (special tool #9585, Remover, Bearing Cup) and (special tool #C-637, Slide Hammer, Universal)remove the front pump needle bearing.

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Remove the manual park release lever retaining nut (2) and remove the lever (1).

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Remove the three park pawl lock rod guide plate retaining bolts (1) and remove the plate (2).

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Remove the park pawl lock rod (1) from the fork (2).
NOTE:
Pay attention to the spring position for installation.
Remove the roll pin from (3) the selector shaft using a suitable pin punch.
Remove the shaft, spring and manual lever assembly (2) from the case.
Remove the selector shaft seal using a small screwdriver or equivalent.

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Remove the park pawl shaft plug (1) from the rear of the case.

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NOTE:
Pay attention to the spring position for installation.
Remove the park pawl shaft using a suitable pin punch (Notation arrow for location and drive-out direction), remove the park pawl (2) and spring (1).

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NOTE:
The transmission must be in a vertical position before the main stack is removed, so damage to the drums do not occur.
Remove the input/output shaft and P4 annulus drum assembly (1) from the case.

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Remove the outer bearing cup snap ring (1).

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NOTE:
4X4 shown, RWD similar.
Using (special tool #9664, Remover, Bearing Cup) (1) and (special tool #C-637, Slide Hammer, Universal) (2), remove the bearing cup (3).

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Remove the output shaft oil dam snap ring (1).

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Using (special tool #9664, Remover, Bearing Cup) (1) and (special tool #C-637, Slide Hammer, Universal) (2), remove the oil dam (3).

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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).
Remove the B clutch pack (2).

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Remove the O-ring and five squared O-rings from the input shaft.
Remove the P1 annulus/B clutch hub assembly (1) from the P4 annulus drum.

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Remove the selectable shim (3) from the P1 annulus/B clutch hub.
Remove the thrust bearing (1) and holding plate (2) from the P1 planetary carrier.

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NOTE:
The (special tool #10378, Rings, Support) are three pieces intended to be used in multiple locations around the drum to prevent damage from prying.
Position the (special tool #10378, Rings, Support) on the P4 annulus drum assembly to protect the drum.
NOTE:
Pry the snap ring (1) from the opposite side of the snap ring openings to release.

NOTE:
When the snap ring (1) is removed the internal clutch drum may drop slightly.

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Using a suitable tool release the snap ring (1) by prying in and up from the opposite side of the snap ring openings (2).
Remove the P1 planetary carrier.

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Remove the input shaft with P2 planetary carrier (1) from the drum assembly.
Remove the thrust bearing and washer (2).

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Remove the P2 annulus/P3 sun gear (1) from the drum assembly.
Remove the D clutch drum (2) from the P4 annulus drum (3).

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NOTE:
The (special tool #10378, Rings, Support) are three pieces intended to be used in multiple locations around the drum to prevent damage from prying.
Position the (special tool #10378, Rings, Support) on the P4 annulus drum assembly to protect the drum.
Using a suitable tool, release and remove the snap ring (1) holding down the P3 Planetary Carrier (2).

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Remove the P3 planetary carrier (1).
Remove the thrust bearing from the planetary carrier.

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Remove the P4 sun gear/C/E clutch retainer (1) from the D clutch drum (2).

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Remove the snap ring (1) from the P4 sun gear/C/E clutch retainer and remove the annulus ring.

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Remove the snap ring (1) from the P4 sun gear/C/E clutch retainer.
Remove the E clutch (2) from the P4 sun gear/C/E clutch retainer.
Remove the thrust bearing from the E clutch (2).
NOTE:
Thrust bearing may stick to sun gear upon removal.

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NOTE:
The E clutch and C clutch are similar. The C clutch hub is removable and has six fricton plates.
Remove the C clutch (1) from the P4 sun gear/C/E clutch retainer.
Remove the bearings from the top and bottom of the C clutch.

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Remove the P4 planetary carrier/output shaft lock ring from the P4 annulus drum by gently prying the locking tabs (1) open and turning the lock ring to center the locating tabs in the output shaft tab openings. Discard the lock ring and install a NEW lock ring during assembly.

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Remove the snap ring (1) from the P4 annulus drum.
Remove the P4 annulus (2) from the P4 annulus drum.

CAUTION:

A unique transmission fluid has been developed for this transmission. This fluid is NOT compatible with ATF+4 or any other current FCA US LLC transmission fluid. For specifics about this unique fluid see FLUIDS, LUBRICANTS AND GENUINE PARTS.

CAUTION:

NOTE:

ASSEMBLY

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Insert the P4 annulus (2) into the P4 annulus drum.
Install the snap ring (1) into the P4 annulus drum.

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Install the NEW P4 planetary carrier/output shaft lock ring from the P4 annulus drum by turning the lock ring to center the lock ring tabs (1) in the output shaft tab openings and gently staking the locking tabs closed.

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Position the bearings on the top and the bottom of C clutch (1).
Install the C clutch (1) into the P4 sun gear/C/E clutch retainer.

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Install the needle bearing onto the hub of the E clutch (2).
Install the E clutch (2) into the P4 sun gear/C/E clutch retainer.
Install the snap ring (1) into the P4 sun gear/C/E clutch retainer.

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Install the P3 annulus ring into the P4 sun gear/C/E clutch retainer and install the snap ring (1).

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Install the P4 sun gear/C/E clutch retainer (1) into the D clutch drum (2).

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Install the needle bearing onto the planetary carrier.
Install the P3 planetary carrier (2) in the D clutch drum.
Install the snap ring (1) and verify the relief on the snap ring (1) is set in the locating pin (2).

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Install the D clutch drum (2) into the P4 annulus drum (3).

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Install the P2 annulus\P3 sun gear (1) in the drum assembly.
Install the thrust bearing (2) and washer.

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Install the input shaft with P2 planetary carrier (1) into the drum assembly (2).

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Install the snap ring (1) in the orientation shown (snap ring will only install one way) with the locating tabs (2).

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Install the thrust bearing and holding plate (1) onto the P1 planetary carrier (2).
Install the selectable shim (3) to the P1 annulus/B clutch hub.

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Install the P1 annulus\B clutch hub assembly (1) onto the P4 annulus drum.
Install the O-ring and five squared O-rings.

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The B-Clutch, dependent on transmission Julian Date, may contain wave springs that sit around each fiber. there will be five fibers (3), five wave springs (4), five steels (5), one cover plate (2), one snap ring (1), and one wave plate (last plate far left in figure).

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Install the clutch pack (2).

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Install the output shaft oil dam and the snap ring (1).

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Install the needle bearing (AWD) or ball bearing (RWD).
Install the snap ring (1).

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NOTE:
The transmission must be in a vertical position when installing the main stack, so damage to the drums does not occur.
Install the input/output shaft and P4 annulus drum assembly (1) into the case.

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From outside the transmission case, install the park pawl shaft and install the park pawl (2) and spring (1).

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Install the park pawl shaft plug (1) into the rear of the case and tighten to the proper torque specifications. Refer to TORQUE SPECIFICATIONS .

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Using (special tool #6936, Spacer) (1), install the selector shaft seal (2).

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Install the shaft, spring, and manual lever assembly (2) into the case.
Install the roll pin (3) flush with the manual lever assembly hub using a suitable pin punch.
Install the park pawl lock rod (1) onto the fork (2).

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Position the park pawl lock rod guide plate (2), install the three park pawl lock rod guide plate retaining bolts (1) and tighten to the proper torque specifications. Refer to TORQUE SPECIFICATIONS .

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Install the oil pump cover lip seal (3) on the oil pump cover (2).
Using (special tool #10375, Installer, Oil Pump Cover Oil Seal) (1), install the input shaft seal in the oil pump cover (2).

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Position the oil pump housing (2) and oil pump cover (3) together.
Install the five bolts (1) and tighten to the proper torque specifications. Refer to TORQUE SPECIFICATIONS .

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Lube the seals (1, 2) using transmission assembly lube.

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Install the piston (1) in the housing.

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Install the wave spring (1) in the housing.

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Position the oil pump housing (3) in a suitable arbor press (2).
Using (special tool #8285, Compressor, Spring) (1), press on the fingers of the piston retaining ring to remove tension, and install the two halves of the split retainer ring (2).

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Verify the split retainer ring halves (1) are seated in the groove.

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Install the hub (1).

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Install the clutches and spacers (2).
Install the snap ring (1).

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Verify the B-Piston seal (1) is not worn or damaged, replace if the seal is questionable.

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Install the B-piston (1).

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Install the apply cushion spring (1) on the assembly.

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Carefully position the oil pump housing assembly into the case.
Install the NEW input shaft O-ring (1).

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NOTE:
Firmly press the oil pump in place before drawing it in with bolts.
Install the oil pump cover retaining bolts (1) and tighten the oil pump cover to the proper torque specifications. Refer to TORQUE SPECIFICATIONS .

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NOTE:
The manual park release lever (2) can be reversed to release tension and ease the installation of the valve body assembly.
Temporarily install the manual park release lever (2) to release tension on the shift fork as follows:
1. Install the manual shift shaft lever (2) 180 degrees offset from its original position.
2. Install the nut (1) and hand tighten.
3. Turn the manual park release lever (2) and using a tie strap (3), secure the lever (2) into position so the park release fork is in the same position as it was before valve body assembly removal.
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Install the fluid port (1) with NEW O-rings to the transmission case.

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Install the (special tool #10379, Pins, Valve Body Alignment) (1) in the transmission case as guides for the valve body assembly.
NOTE:
Verify the shift fork lines up properly.
Using the valve body alignment pins (1) to guide, position the valve body assembly to the transmission.
NOTE:
After several bolts have been hand tightened, remove the guide pins (1).

Fig 1: ***Valve Body Assembly Bolts Tightening Sequence
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Install the 14 valve body assembly retaining bolts and tighten in order to the proper torque specifications. Refer to TORQUE SPECIFICATIONS .

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Using (special tool #10377, Remover/Installer, Guide Sleeve) (1), carefully install the electrical harness insulator (2) into the transmission case.

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Latch the electrical connector insulator lock (3) by pushing down.
Install the rear valve body retaining bolts (1, 2) and tighten to the proper torque specifications. Refer to TORQUE SPECIFICATIONS .

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When installing the OSS into the case, take care to position the OSS guide pin as shown below or DAMAGE to the sensor may result. This is the INCORRECT alignment of the pin.

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This is the CORRECT installation and pin alignment.

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Install the OSS and the OSS bolt (1) in the case and tighten to the proper torque specifications. Refer to TORQUE SPECIFICATIONS .

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Verify the H.I.S. accumulator O-ring (1) is not torn or damaged. Replace if necessary.

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If equipped, install the H.I.S. accumulator.
Tighten the H.I.S. accumulator bolts (2) to the proper torque specifications. Refer to TORQUE SPECIFICATIONS .
Connect the H.I.S. electrical connector (1).

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Remove the tie strap and return the manual release lever (1) to the original position.
Install the manual release lever nut (2) and tighten to the proper torque specifications. Refer to TORQUE SPECIFICATIONS .

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Position the oil pan and gasket (2).
Install the 13 oil pan retaining bolts (1) and tighten to the proper torque specifications. Refer to TORQUE SPECIFICATIONS .

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NOTE:
4X4 only.

CAUTION:
The seal must be installed flush with the case. Driving the seal deeper could damage the seal causing a leak.
Position the new output shaft seal (1) over the output shaft and against the transmission case.

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Using (special tool #9677, Installer, Seal) (1), install the output shaft seal.

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4X4 ONLY, position the extension housing (2).
Install the transmission housing extension bolts (1) and tighten to the proper torque specifications. Refer to TORQUE SPECIFICATIONS .

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Using (special tool #5065, Installer, Bearing) (2) install the NEW output flange oil dam (1) on to the tool.
Drive the NEW output flange oil dam (1) in to the output flange using (special tool #5065, Installer, Bearing) (2) and a driver handle.

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Install the output shaft flange (2).
Install a NEW output shaft flange nut (1) and washer using a 34 mm 12 point socket and (special tool #C-3281, Holder, Flange)to hold the flange (2). Tighten to the proper torque specifications. Refer to TORQUE SPECIFICATIONS .
Stake the nut (1).

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Install the torque converter (1).
Before installing the transmission in the vehicle, pre-fill the transmission as outlined in FILL TRANSMISSION AFTER SERVICE. Refer to appropriate service information .