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Transmission Disassembly

NOTE: See Figure , Figure , Figure and Figure for exploded view of internal parts, thrust washer and needle bearing locations.
  1. Remove transfer case, if equipped. Remove torque converter and input shaft. Splined input shaft ends are different. Note direction of installation for reassembly reference. Remove extension housing oil seal. Using Bushing Remover (T77L-7697-E), remove extension housing bushing (if necessary).
  2. Remove extension housing. Remove parking pawl, return spring and shaft. Remove heat shield (if equipped). Remove manual control outer lever. Remove TR sensor. Remove oil pan and filter screen. Lift up wire loom guide and protector to disengage retaining pins from solenoid brackets. Disconnect 6 solenoid electrical connectors. Remove manual valve detent spring. Remove low-reverse servo bolts. Remove servo cover, gasket, piston and rod.
    NOTE: DO NOT  remove center bolt from SS1 and SS3 solenoid bracket or forward bolt from TCC, CCS, SS2 and EPC solenoid bracket. See Figure and Figure .
  3. Remove valve body bolts. Remove valve body and gasket from case. Using Servo Cover Compressor (T95L-77028-A), remove intermediate servo cover snap ring. Remove and mark intermediate servo cover, piston and spring. Using servo cover compressor, remove overdrive servo cover snap ring. Remove and mark overdrive cover, piston and spring.
    NOTE: Servo covers are under spring pressure. Use care during snap ring removal. If covers stick, lightly tap cover or side of case. Air pressure may be used, but DO NOT  exceed 20 psi (1.4 kg/cm2 ). See Figure .
  4. Remove and discard overdrive and intermediate band lock nuts and back off adjusting screws. Remove and discard converter housing-to-case bolts. Remove converter housing and pump as an assembly. Use a twisting motion to keep clutches in place. Remove gasket and No. 1 thrust washer. Compress overdrive band and remove anchor strut and adjusting screw.
  5. Remove overdrive band. Tag band as overdrive. Tag anchor or apply end of band for reassembly reference. Lift out overdrive brake and coast clutch drum. Remove overdrive band apply strut and actuating lever shaft. Lift out overdrive planetary gear carrier assembly with No. 2 and No. 12 thrust bearings. Remove servo band lever and overdrive control bracket.
    NOTE: Mark actuating lever and shaft for reassembly to overdrive assembly. Overdrive actuating lever shaft is longer than the intermediate actuating lever shaft.
  6. Lift out overdrive ring gear, one-way clutch and center shaft assembly. Remove No. 3 thrust bearing. Remove 5 mm Allen head bolt retaining center support. Remove lock nut from center support. Disconnect Turbine Shaft Speed Sensor (TSS) connector from 16-pin case connector. Remove TSS.
  7. Remove case connector retaining ring. Depress tab on back side of case connector while pushing down on connector. Remove connector and harness through bottom of case. Remove center support snap ring from case. Remove center support by pulling upward, carefully and evenly. Remove No. 4 thrust bearing behind center support.
  8. Remove intermediate band anchor strut through bottom of case. Remove intermediate band adjusting screw. Remove intermediate band. Tag band as intermediate. Tag anchor or apply end of band for reassembly reference. Remove intermediate band actuating lever and shaft. Remove intermediate band servo lever. Tag for reassembly reference.
    NOTE: Mark actuating lever and shaft for reassembly to intermediate assembly. Intermediate actuating lever shaft is shorter than the overdrive actuating lever shaft.
  9. Remove intermediate brake and direct clutch drum, No. 5 thrust washer, forward clutch cylinder and forward ring gear and hub. Remove No. 7 thrust bearing. Remove forward planetary gear set. Remove input shell with forward sun gear. Remove large snap ring from reverse planet gear carrier (except 4.0L models). On all models, remove reverse planet carrier and No. 8 and No. 9 thrust washers.
  10. On models with 4.0L engine, remove output shaft sleeve. On all models, remove and discard small output shaft snap ring. Remove output shaft ring gear and hub. Remove No. 10 thrust washer. Remove low-reverse drum and one-way clutch assembly. Inner race of rear one-way clutch is not removable. Remove low-reverse band. Remove output shaft. Remove park gear. Remove No. 11 thrust washer.
  11. Remove manual valve inner lever nut. Remove manual valve inner lever and parking pawl actuating rod. To loosen manual control lever shaft retaining pin, tap lightly on each side pin, using small hammer and drift. Remove retaining pin, manual control lever shaft and seal.
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