Section 172 (As68RC Automatic Transmission (Service Information)): Disassembly: Disassembly

WARNING: This page is about a different car, the 2012 RAM Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION:

Tag all snap rings, thrust washers, washers, spacers and thrust bearings, etc. during disassembly for quick identification and assembly. Failure to follow these instructions will damage and cause transmission failure.

Fig 1: AS68RC Transmission Components

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1 - CONVERTER HOUSING	11 - F1 ONE WAY CLUTCH
2 - TRANSMISSION CASE	12 - OUTPUT SHAFT
3 - K2 CLUTCH	13 - PARKING LOCK GEAR
4 - K1 CLUTCH	14 - EXTENSION HOUSING
5 - P1 PLANETARY GEAR	15 - SUN GEAR SHAFT
6 - K3 CLUTCH	16 - VALVE BODY
7 - P2 PLANETARY GEAR	17 - OIL PAN
8 - B1 BRAKE	18 - OIL PUMP
9 - B2 BRAKE	19 - TORQUE CONVERTER
10 - P3 PLANETARY GEAR	20 - INPUT SHAFT

Fig 2: Drain Plug

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1 - DRAIN PLUG

Place the transmission manual shift lever into the park lock position.
Plug all openings and clean exterior of transmission with water soluble solvent or a pressure washer.
Remove oil pan drain plug (1) and drain fluid from transmission.

Fig 3: Removing/Installing Torque Converter From Transmission
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WARNING:
Be certain the transmission is secure when removing the torque converter, the torque converter is very heavy. Failure to follow these instructions may result in personal injury or may be fatal.

Remove the torque converter from the transmission.

NOTE:

Gear train end play is a critical pre-disassembly check to help determine the condition of the transmission. End play reading greater than specification (larger gap) indicate that a bearing or thrust plate is either missing, worn or has disintegrated, in which case there will be debris in the oil pan.

Fig 4: Measuring Input Shaft End Play

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1 - Socket 8266-19

2 - Dial Indicator C-3339A

3 - Handle 8266-A

Using Adapter (special tool #8266-19, Spline Tool, AS68RC Input) (1) and the handle from End-Play Tool Set (special tool #8266B, End Play Socket Set) (2) and Dial Indicator (special tool #C-3339A, Set, Dial Indicator) (3), measure and record the input shaft end-play.

Fig 5: Removing/Installing Output Shaft Nut
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1 - FLANGE HOLDER TOOL C-3281
Using a small chisel pry open the stakes on the output shaft flange nut and install Flange Holder tool (special tool #C-3281, Holder, Flange) (1) to assist in removing the output flange nut. Remove the output shaft flange nut.

Fig 6: Output Shaft Flange & O-Ring Seal
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1 - OUTPUT SHAFT FLANGE

2 - O-RING SEAL
Remove the output flange (1) and o-ring seal (2).
Using a pry tool, remove the output shaft seal.

Fig 7: Measuring 2WD Output Shaft End-Play
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1 - PRY TOOL

2 - C-3339A DIAL INDICATOR
Install a NEW nut on the output shaft and install the Dial Indicator (special tool #C-3339A, Set, Dial Indicator) (2).

With the transmission in a vertical position, and using a pry tool (1) on the output shaft nut measure and record the output shaft end-play. The output shaft end-play clearance is 0.50-0.90 mm (0.019-0.035 in.)

NOTE:

The 4WD extension housing has two output shaft end-play shims fore and aft of the output shaft bearing, therefor the output shaft end-play checking procedure must be performed twice. The external shim and snap ring is in place to prevent excess forward pressure on the NO. 9 thrust bearing while the 4WD transfer case is bolted to the extension housing.

4WD OUTPUT SHAFT END PLAY CHECK

Fig 8: Measuring 4WD Output Shaft End Play

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1 - OUTPUT SHAFT END PLAY TOOL 8266-20

2 - DIAL INDICATOR SET C-3339A

With the 4WD extension housing installed onto the transmission case, install Adapter (special tool #8266-20, Spline Tool, AS68RC Output) (1) and the handle from End-Play Tool Set (special tool #8266B, End Play Socket Set) and Dial Indicator (special tool #C-3339A, Set, Dial Indicator) (2).
With the transmission in a vertical position, measure and record the output shaft end-play. The output shaft end-play clearance is 0.00 - 0.24 mm (0.000-0.009 in.)

Fig 9: 4WD Output Shaft Seal Retainer
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1 - 4WD OUTPUT SHAFT SEAL RETAINER
Using a pry tool, remove the output shaft seal.

Remove seal retainer (1).

Fig 10: 4WD Output Shaft & Snap Ring

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1 - 4WD OUTPUT SHAFT SNAP RING

2 - 4WD OUTPUT SHAFT

Remove the external snap ring (1) and selectable output shaft end-play washer.
Using Adapter (special tool #8266-20, Spline Tool, AS68RC Output) (1) and the handle from End-Play Tool Set (special tool #8266B, End Play Socket Set) and Dial Indicator (special tool #C-3339A, Set, Dial Indicator) (2), measure and record the output shaft end-play. The output shaft end-play clearance is 0.50-0.90 mm (0.019-0.035 in.)

Fig 11: Torque Converter Housing

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NOTE:

Support the bottom of the transmission case before removing the torque converter housing.

Remove the bolts securing the torque converter housing to the transmission case and remove the housing.

Fig 12: Input Speed Sensor
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Remove the input speed sensor.

Fig 13: Output Speed Sensor
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Remove the output speed sensor

Fig 14: Fill Tube & O-Ring
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1 - FILL TUBE O-RING
Remove the bolt (if equipped) securing the transmission fill tube to the transmission case and remove the fill tube.
Remove the manual shift lever from the transmission.
Remove the transmission range sensor. Refer to SENSOR, TRANSMISSION RANGE, REMOVAL .
Using a pry tool remove the manual shift lever seals (one each side of the transmission).

Fig 15: Breather Fitting
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Remove the breather hose and fitting, if necessary.

Fig 16: PTO Dust Cover
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Remove the PTO dust cover bolts and dust cover.

Fig 17: Temperature Sensor & Line Fittings

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1 - TEMPERATURE SENSOR

2 - JIFFY TITE FITTINGS

3 - COOLER LINE FITTINGS

Remove the temperature sensor (1) from the ATF output cooler line fitting.
Remove the Jiffy Tite fittings (2) from both cooler line fittings.
Loosen both cooler line fittings (3).
Remove both cooler line fittings (3).

Fig 18: Accumulator Valves
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Remove the valve body. Refer to VALVE BODY, REMOVAL .

Remove the three accumulator valves (1), (2), (3) and then the accumulator springs.

	ACCUMULATORS		SPRING COLOR
	DIAMETER	HEIGHT	SPRING COLOR
ACCUMULATOR NO. ONE (1)	16 mm (0.63 in.)	40.18 mm (1.58 in.)	PURPLE
ACCUMULATOR NO. TWO (2)	20 mm (0.79 in.)	38.18 mm (1.50 in.)	PINK
ACCUMULATOR NO. THREE (3)	20 mm (0.79 in.)	39.18 mm (1.54 in.)	BLUE

Air check the transmission. Refer to AIR CHECKING TRANSMISSION CLUTCH OPERATION .

Fig 19: Removing Oil Pump
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NOTE:
Using a marker or paint pen, tag the orientation of the oil pump to the transmission case.
Remove the bolts securing the oil pump to the transmission case and use tool (special tool #C-3752, Slide Hammers) and adapters (special tool #9981, Adapters, Puller) to remove the oil pump.

Fig 20: Input Shaft With K1 & K2 Clutch Assemblies
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Remove the input shaft assembly with the K1 and K2 clutch assemblies attached.

Fig 21: K1 & K2 Clutches

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1 - K1 CLUTCH ASSEMBLIES

2 - NO. 1 BEARING RACE (SELECT)

3 - THRUST WASHER

4 - K2 CLUTCH ASSEMBLIES

NOTE:

The input shaft end-play clearance is adjusted by means of a selectable thrust bearing race located between the K1 and the K2 clutch pack retainers.

Remove the K2 clutch assembly (4) and the selectable input shaft end-play thrust bearing number one (2) and thrust washer (3) from the K1 clutch / input shaft assembly (1).

Fig 22: K1 Clutch Hub
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Remove the K1 clutch hub.

Fig 23: K1 Thrust Bearing No 2
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1 - K1 THRUST BEARING No. 2
Remove the K1 thrust bearing number 2.

Fig 24: K2 Clutch Hub
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Remove the K2 clutch hub.

Fig 25: K2 Hub Thrust Bearing No. 3
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1 - K2 THRUST BEARING No. 3
Remove the K2 thrust bearing number three.

Fig 26: Removing Front Sun/PTO Front Thrust Bearing No. 4
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Remove the front sun / PTO front thrust bearing number four.

Fig 27: Front Sun / PTO Drive Gear
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Remove the front sun / PTO drive gear.

Fig 28: Front Sun / PTO Rear Thrust Bearing No. 5
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Remove the front sun/PTO rear thrust bearing number five.

Fig 29: Carrier Snap Ring
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NOTE:
The beveled edge of the snap ring is facing outward.
Remove the snap ring from the transmission case.

Fig 30: P1 Carrier Bolts
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1 - BOLTS
Remove the two bolts (1) securing the P1 carrier to the transmission case.

Fig 31: Removing P1 Carrier
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Remove the P1 carrier using tool (special tool #C-3752, Slide Hammers) and adapters (special tool #9980, Adapters, Puller).

Fig 32: P1 Thrust Bearing No. 6
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1 - THRUST BEARING NO. 6
Remove the P1 thrust bearing number six.

Fig 33: P1 Annulus Gear
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Remove the P1 annulus gear and thrust bearing.

Fig 34: P1 Annulus Thrust Washer No. 7
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1 - P1 ANNULUS THRUST BEARING NO. 7
Remove the P1 annulus thrust bearing number seven.

Fig 35: K3 Clutch
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Remove the K3 clutch assembly.

Fig 36: K3 Hub Rear Thrust Bearing No. 8
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Remove the K3 hub rear thrust bearing number eight.

Fig 37: K3 Support Seal Rings
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1 - K3 SUPPORT SEAL RINGS
Remove the K3 support seal rings if necessary.

Fig 38: Extension Housing
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Remove the bolts securing the 2WD or the 4WD extension housing to the transmission case and remove the housing.

Fig 39: Compressing B2 Piston With Special Tools

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1 - BOLT 8622

2 - COMPRESSOR PLATE MB991790

3 - WASHER 9982-2

Install tools (special tool #8622, Screw, Clutch Spring Compressor) (1), (special tool #9982-2, Plate, Back Up) (3), (special tool #MB991790, Compressor, Spring) (2) onto the B2 clutch piston assembly in the extension housing and compress the piston.

Fig 40: B2 Piston Snap Ring
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1 - SNAP RING
Remove the B2 piston snap ring (1).

Fig 41: B2 Piston Return Spring
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Remove the B2 piston return spring assembly.

Fig 42: B2 Brake Piston
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Remove the B2 piston.

Fig 43: Output Shaft End Play Selectable Washer & Spacer
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1 - OUTPUT SHAFT END PLAY SELECTABLE WASHER

2 - SPACER
Remove the output shaft end play selectable washer (1) and the spacer (2)

Fig 44: Output Shaft Lock Gear
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NOTE:
On 4WD models remove the snap ring from the output shaft in order to remove the output shaft park lock gear from the 4WD extension housing.
Remove the output shaft and the park lock gear.

Fig 45: F1 Clutch Thrust Bearing No. 14
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1 - F1 CLUTCH THRUST BEARING NO. 14
Remove the F1 clutch thrust bearing number fourteen.

Fig 46: One Way Clutch Snap Ring
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Remove the F1 one way clutch rear snap ring.

Fig 47: F1 One Way Clutch
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Scribe the orientation of the F1 one way clutch to the transmission case.

Remove the F1 one way clutch and front snap ring.

Fig 48: Park Pawl Assembly

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1 - PARK PAWL

2 - PARK PAWL WASHER

3 - PARK PAWL SPRING

Remove the park pawl assembly from the transmission case.

Fig 49: P3 Annulus Gear
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Remove the P3 annulus gear.

Fig 50: Thrust Bearing & Washer No. 13
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Remove the thrust bearing and washer number thirteen.

Fig 51: P3 Planetary Gear Carrier
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NOTE:
Be certain that the P3 carrier thrust bearing race is in position while removing the P3 carrier.
Remove the P3 planetary gear carrier.

Fig 52: P3 Planetary Front Thrust Bearing No. 12
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Remove the P3 planetary gear carrier front thrust bearing number twelve.

Fig 53: Sun Gear Shaft, Thrust Bearing No. 11 & Thrust Bearing Race/Washer

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1 - SUN GEAR SHAFT

2 - THRUST BEARING NO. 11

3 - THRUST BEARING RACE / WASHER

Remove the sun gear shaft (1) thrust bearing number eleven (2) and thrust bearing race / washer (3).
NOTE:
The selectable clutch pack reaction plates are identified by an alpha numeric numeral stamped into the face of the plate.

Fig 54: B2 Brake Clutches
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Remove the snap ring and B2 brake clutch assembly.

Fig 55: P2 Planetary Gear Carrier
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Remove the P2 planetary gear carrier.

Fig 56: P2 Planetary Gear Thrust Bearing No. 10
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Remove the P2 planetary gear thrust bearing number ten.

Fig 57: P2 Planetary Annulus Gear
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Remove the P2 planetary annulus gear.

Fig 58: P2 Planetary Annulus Gear Thrust Bearing No. 9
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Remove the P2 planetary annulus gear thrust bearing number nine.

Fig 59: Two Snap Rings
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1 - SNAP RINGS
Remove the two snap rings (1).

Fig 60: B1 Brake Clutch Assembly
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NOTE:
The selectable clutch pack reaction plates are identified by an alpha numeric numeral stamped onto the face of the plate.
Remove the B1 brake clutch assembly.

Fig 61: Compressing B1 Brake Piston
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Install tools (special tool #8622, Screw, Clutch Spring Compressor), (special tool #9982, Compressor, Spring) and MB 991790, onto the B1 brake piston assembly and compress the piston.

Fig 62: B1 Brake Piston Snap Ring & Return Spring Assembly
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Remove the B1 brake piston snap ring and the B1 piston return spring assembly.

Fig 63: B1 Piston Groove
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NOTE:
The orientation of the groove on the B1 piston is at the 12:00 o'clock position to the transmission case.
Remove the B1 brake piston.