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Automatic Transmission-46RE: Disassembly

WARNING: This page is about a different car, the 2003 Dodge Dakota. However, it is still accessible from the selected car via links, so may be relevant.
  1. Clean exterior of transmission with suitable solvent or pressure washer.
  2. Place transmission in vertical position.
  3. Measure the input shaft end play as follows (Fig 1).
    1. Attach Adapter 8266-5 to Handle 8266-8.
    2. Attach dial indicator C-3339 to Handle 8266-8.
    3. Install the assembled tool onto the input shaft of the transmission and tighten the retaining screw on Adapter 8266-5 to secure it to the input shaft.
    4. Position the dial indicator plunger against a flat spot on the oil pump and zero the dial indicator.
    5. Move input shaft in and out and record reading. Record the maximum travel for assembly reference
      6. Fig 1: Checking Input Shaft End Play
      G02657907Courtesy of DAIMLERCHRYSLER CORP.
  4. Remove throttle and shift levers from valve body manual shaft and throttle lever shaft.
  5. Remove transmission oil pan and gasket.
  6. Remove filter from valve body (Fig 2). Keep filter screws separate from other valve body screws. Filter screws are longer and should be kept with filter.
    Fig 2: Removing Oil Filter
    G02657908Courtesy of DAIMLERCHRYSLER CORP.
  7. Remove the transmission range sensor.
  8. Remove hex head bolts attaching valve body to transmission case (Fig 3). A total of 10 bolts are used. Note different bolt lengths for assembly reference.
    Fig 3: Locating Valve Body Bolts
    G02657909Courtesy of DAIMLERCHRYSLER CORP.
  9. Remove valve body assembly. Push valve body harness connector out of case. Then work park rod and valve body out of case (Fig 4).
    Fig 4: Removing Valve Body
    G02657910Courtesy of DAIMLERCHRYSLER CORP.
  10. Remove accumulator outer spring, piston and inner spring (Fig 5). Note position of piston and springs for assembly reference. Remove and discard piston seals if worn or cut.
    Fig 5: Removing Accumulator Components
    G02657911Courtesy of DAIMLERCHRYSLER CORP.
  11. Remove pump oil seal with suitable pry tool or slide-hammer mounted screw.
  12. Remove front band lever pin access plug (Fig 6). Use square end of 1/4 in. drive extension to remove plug as shown.
    Fig 6: Removing Front Band Lever Pin Access Plug
    G02657912Courtesy of DAIMLERCHRYSLER CORP.
  13. Remove oil pump and reaction shaft support assembly as follows:
    1. Tighten front band adjusting screw until band is tight around front clutch retainer (Fig 7). This will prevent retainer from coming out with pump and possibly damaging clutch or pump components.
      Fig 7: Tightening Front Band Adjusting Screw
      G02657913Courtesy of DAIMLERCHRYSLER CORP.
    2. Remove oil pump bolts.
    3. Thread Slide Hammer Tools C-3752 into threaded holes in flange of oil pump housing (Fig 8).
      Fig 8: Installing Oil Pump Removal Tools
      G02657914Courtesy of DAIMLERCHRYSLER CORP.
    4. Remove oil pump and reaction shaft support by bumping slide hammers outward alternately to pull pump from case (Fig 9).
      Fig 9: Removing Oil Pump
      G02657915Courtesy of DAIMLERCHRYSLER CORP.
  14. Remove oil pump gasket (Fig 10). Note gasket position in case for assembly reference.
    Fig 10: Removing Oil Pump Gasket
    G02657916Courtesy of DAIMLERCHRYSLER CORP.
  15. Loosen front band adjusting screw until band is completely loose.
  16. Remove front band strut and anchor (Fig 11).
    Fig 11: Removing Front Band Strut And Anchor
    G02657917Courtesy of DAIMLERCHRYSLER CORP.
  17. Squeeze front band together slightly and slide band over front clutch retainer and out of case (Fig 12).
    Fig 12: Removing Front Band
    G02657918Courtesy of DAIMLERCHRYSLER CORP.
  18. Remove front and rear clutch assemblies as a unit (Fig 13).
    Fig 13: Removing Front/Rear Clutch Assemblies
    G02657919Courtesy of DAIMLERCHRYSLER CORP.
  19. Remove front band reaction pin and lever. Start pin through lever and out of case bore with drift or punch. Then use pencil magnet to withdraw pin completely (Fig 14).
    Fig 14: Removing Front Band Reaction Pin And Lever
    G02657920Courtesy of DAIMLERCHRYSLER CORP.
  20. Remove intermediate shaft thrust washer. Triangular shaped washer will either be on shaft pilot hub or in rear clutch retainer (Fig 15).
    Fig 15: Removing Intermediate Shaft Thrust Washer
    G02657921Courtesy of DAIMLERCHRYSLER CORP.
  21. Remove thrust plate from intermediate shaft hub (Fig 16).
    Fig 16: Removing Intermediate Shaft Thrust Plate
    G02657922Courtesy of DAIMLERCHRYSLER CORP.
  22. Remove intermediate shaft-planetary geartrain assembly (Fig 17).
    Fig 17: Removing Intermediate Shaft And Planetary Geartrain
    G02657923Courtesy of DAIMLERCHRYSLER CORP.
  23. If overdrive unit is not to be serviced, install Alignment Shaft 6227-2 into the overdrive unit to prevent misalignment of the overdrive clutches during service of main transmission components.
  24. Loosen rear band locknut and loosen adjusting screw 3-4 turns.
  25. Remove snap-ring that retains low-reverse drum on overdrive piston retainer hub (Fig 18).
    Fig 18: Removing Low-Reverse Drum Snap-Ring
    G02657924Courtesy of DAIMLERCHRYSLER CORP.
  26. Slide low-reverse drum and thrust washer off piston retainer hub and out of rear band (Fig 19).
    Fig 19: Removing Low-Reverse Drum And Thrust Washer
    G02657925Courtesy of DAIMLERCHRYSLER CORP.
  27. Note that overrunning clutch race will remain on splines of low-reverse drum after removal (Fig 20). The race is a permanent press fit on the hub splines. Do not attempt to remove the race. 
  28. Remove overrunning clutch assembly (Fig 21). Assembly can be removed without displacing rollers and springs if care is exercised. Note position of rollers and springs for assembly reference.
    Fig 20: Identifying Overrunning Clutch Race Position On Low-Reverse Drum
    G02657926Courtesy of DAIMLERCHRYSLER CORP.
  29. Remove rear band adjusting lever, reaction lever and pin (Fig 22).
  30. Remove strut from rear band. Keep strut with levers and pin for cleaning, inspection and assembly reference.
    Fig 21: Removing Overrunning Clutch
    G02657927Courtesy of DAIMLERCHRYSLER CORP.
    Fig 22: Removing Rear Band Adjusting Lever, Reaction Lever And Pin
    G02657928Courtesy of DAIMLERCHRYSLER CORP.
  31. Remove rear band and link (Fig 23).
    Fig 23: Removing Rear Band And Link
    G02657929Courtesy of DAIMLERCHRYSLER CORP.
  32. Compress front servo rod guide with large C-clamp and Tool C-4470, or Compressor Tool C-3422-B (Fig 24). Compress guide only enough to permit snap-ring removal (about 1/8 in.).
    Fig 24: Removing Front Servo Retaining Snap-Ring
    G02657930Courtesy of DAIMLERCHRYSLER CORP.
  33. Remove servo piston snap-ring (Fig 24). Unseat one end of ring. Then carefully work removal tool around back of ring until free of ring groove. Exercise caution when removing snap-ring. Servo bore can be scratched or nicked if care is not exercised. 
  34. Remove tools and remove servo piston and spring.
  35. Compress rear servo piston with C-clamp and Tool C-4470, or Valve Spring Compressor C-3422-B (Fig 25). Compress servo spring retainer only enough to permit snap-ring removal.
    Fig 25: Removing Rear Servo Retaining Snap-Ring
    G02657931Courtesy of DAIMLERCHRYSLER CORP.
  36. Remove servo piston snap-ring (Fig 25). Start one end of ring out of bore. Then carefully work removal tool around back of snap-ring until free of ring groove. Exercise caution when removing snap-ring. Servo bore can be scratched or nicked if care is not exercised. 
  37. Remove tools and remove rear servo retainer, spring and piston assembly.
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