Automatic Transmission

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

NOTE: If the transmission is being reconditioned (clutch/seal replacement) or replaced, it is necessary to perform the Quick Learn Procedure using the DRBIII® Scan Tool. Refer to STANDARD PROCEDURE .

Before disassembling transmission, move the shift lever clockwise as far as it will go and then remove the shift lever.

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

CAUTION: Do not intermix clutch discs or plates as the unit might then fail.

Fig 1: Removing/Installing Torque Converter

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1 - TORQUE CONVERTER

2 - TRANSMISSION

3 - INPUT SHAFT

Remove the torque converter from the transmission input shaft.

Fig 2: Measuring Input Shaft End Play Using End Play Set 8266

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1 - TOOL 8266-8

2 - TOOL 8266-2

3 - TOOL C-3339

Measure input shaft end play using End Play Set 8266. Set up the required pieces from End Play Set 8266 and a dial indicator as. Move input shaft in and out to obtain end play reading. End play specifications are 0.127 to 0.635 mm (0.005 to 0.025 inch). Record indicator reading for reference when reassembling the transmission. If endplay exceeds the specified range, the #4 thrust plate needs to be inspected and changed if necessary.

Fig 3: Removing/Installing Adapter Housing Bolts

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1 - TRANSMISSION CASE

2 - ADAPTER HOUSING

3 - BOLTS

NOTE: The four bolts along the bottom of the adapter housing have a sealing patch applied from the factory. Note the locations of these bolts and separate these bolts for reuse.

Remove the bolts that hold the adapter housing onto the transmission case.

Fig 4: Removing/Installing Adapter Housing
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1 - TRANSMISSION CASE

2 - ADAPTER HOUSING

NOTE: There are two pry slots located near the bottom corners of the housing for separating the housing from the transmission case

Remove the adapter housing from the transmission case.

Fig 5: Lube Tube Grommet

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1 - HOUSING

2 - LUBE TUBE

3 - GROMMET

4 - PRY SLOTS

Inspect the lube tube grommet for damage. If the grommet lip is damaged, it will need to be replaced.

Fig 6: Removing 4X4 Stub Shaft Using C-3752
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1 - 4X4 STUB SHAFT

2 - SLIDE HAMMER C-3752
Using a Slide Hammer C-3752, remove the 4X4 stub shaft from the transmission output shaft. Inspect the circlip on the shaft for damage and replace the clip if necessary.

Fig 7: Removing/Installing Input Speed Sensor Bolt
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1 - INPUT SPEED SENSOR

2 - TRANSMISSION CASE
Remove the input speed sensor bolt and sensor.

Fig 8: Removing/Installing Output Speed Sensor Bolt
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1 - OUTPUT SPEED SENSOR

2 - TRANSMISSION CASE
Remove the output speed sensor bolt and sensor.

Fig 9: Removing/Installing Transmission Oil Pan Bolts
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1 - TRANSMISSION OIL PAN

2 - BOLTS

NOTE: One of the oil pan bolts has a sealing patch applied from the factory. Separate this bolt for reuse.
Remove the transmission oil pan bolts.

Fig 10: Removing/Installing Transmission Oil Pan
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1 - TRANSMISSION OIL PAN
Remove the transmission oil pan.

Fig 11: Removing/Installing Oil Filter Screws
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1 - OIL FILTER

2 - SCREWS
Remove the transmission oil filter screws.

Fig 12: Removing/Installing Transmission Filter
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1 - TRANSMISSION FILTER
Remove transmission oil filter.

Fig 13: Locating Oil Filter O-Ring
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1 - VALVE BODY

2 - O-RING
Remove the oil filter o-ring from the valve body.

Fig 14: Removing/Installing Valve Body Bolts
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1 - BOLTS
Remove valve body-to-case bolts.

Fig 15: Removing/Installing Valve Body
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1 - VALVE BODY

CAUTION: Do not handle the valve body by the manual shaft. Damage could result.
Remove valve body from transmission.

Fig 16: Identifying Underdrive And Overdrive Accumulators
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1 - OVERDRIVE PISTON AND SPRING

2 - UNDERDRIVE PISTON AND SPRING
Remove underdrive and overdrive accumulators.

Fig 17: Removing/Installing Low/Reverse Accumulator Snap Ring
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1 - SNAP RING

2 - LOW/REVERSE ACCUMULATOR
Remove the low/reverse accumulator snap ring.

Fig 18: Removing/Installing Low/Reverse Accumulator Plug
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1 - ADJUSTABLE PLIERS

2 - PLUG
Remove the low/reverse accumulator plug.

Fig 19: Low/Reverse Accumulator Piston And Springs
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1 - PISTON

2 - RETURN SPRINGS
Remove low/reverse accumulator piston and springs.

Fig 20: Removing/Installing Oil Pump Attaching Bolts
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1 - BOLTS

2 - OIL PUMP

NOTE: The oil pump bolts are not to be reused.
Remove and discard the oil pump-to-case bolts.

Fig 21: Removing Oil Pump
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1 - OIL PUMP

2 - PULLERS
Remove oil pump using Slide Hammers C-3752.

Fig 22: Removing Oil Pump While Pushing In On Input Shaft
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1 - "PUSH IN" ON INPUT SHAFT WHILE REMOVING PUMP
Remove oil pump while pushing in on input shaft.

Fig 23: Removing/Installing Oil Pump Gasket
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1 - BELLHOUSING

2 - OIL PUMP GASKET
Remove oil pump gasket.

Fig 24: Removing/Installing By-Pass Valve
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1 - BYPASS VALVE

CAUTION: By-pass valve must be replaced if transmission failure occurs.
Remove the cooler by-pass valve.

Fig 25: Removing/Installing No. 1 Caged Needle Bearing
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1 - #1 CAGED NEEDLE BEARING

2 - NOTE: TANGED SIDE OUT
Remove the #1 caged needle bearing.

Fig 26: Removing/Installing Input Clutch Assembly
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1 - INPUT CLUTCH ASSEMBLY

Remove the input clutch assembly.

Fig 27: Remove #4 Thrust Plate

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1 - OVERDRIVE SHAFT ASSEMBLY

2 - #4 THRUST PLATE (SELECT)

3 - PETROLATUM FOR RETENTION

Remove the #4 thrust plate.

Fig 28: View Of Front Sun Gear Assembly And #4 Thrust Washer
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1 - FRONT SUN GEAR ASSEMBLY

2 - #4 THRUST WASHER (FOUR TABS)

Remove the front sun gear assembly and #4 thrust washer (if still in place).

Fig 29: Identifying Front Carrier/Rear Annulus And Needle Bearing

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1 - #6 NEEDLE BEARING

2 - FRONT CARRIER AND REAR ANNULUS ASSEMBLY (TWIST AND PULL OR PUSH TO REMOVE OR INSTALL).

Remove the front carrier/rear annulus and #6 needle bearing.

Fig 30: Removing/Installing Rear Sun Gear
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1 - #7 NEEDLE BEARING

2 - REAR SUN GEAR

NOTE: The number seven needle bearing has three anti-reversal tabs and is common with the number five and number two position. The orientation should allow the bearing to seat flat against the rear sun gear.

Remove the rear sun gear and #7 needle bearing and.

Fig 31: Removing 2/4 Clutch Retainer Snap Ring

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1 - TOOL 5058

2 - SCREWDRIVER

3 - SNAP RING

4 - 2/4 CLUTCH RETAINER

NOTE: Verify that Compressor 5058A is centered properly over the 2/4 clutch retainer before compressing. If necessary, fasten the Compressor 5058A bar to the bellhousing flange with any combination of locking pliers and bolts to center the tool properly.

Install and load Compressor 5058A to remove the 2/4 clutch retainer snap ring.
NOTE: The 2/4 Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.

Fig 32: View Of 2/4 Clutch Retainer & Return Spring
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1 - 2/4 CLUTCH RETAINER

2 - 2/4 CLUTCH RETURN SPRING
Remove the 2/4 clutch retainer.

Fig 33: Removing/Installing 2/4 Clutch Return Spring
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1 - 2/4 CLUTCH RETURN SPRING
Remove the 2/4 clutch return spring.

Fig 34: Removing/Installing 2/4 Clutch Pack
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1 - CLUTCH PLATE (4)

2 - CLUTCH DISC (4)

Remove the 2/4 clutch pack.

Fig 35: Removing Tapered Snap Ring

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1 - LOW/REVERSE CLUTCH REACTION PLATE

2 - LONG TAB

3 - SCREWDRIVER

4 - LOW/REVERSE TAPERED SNAP RING (TAPERED SIDE UP)

5 - OIL PAN FACE

Remove the tapered snap ring.

Fig 36: Removing/Installing Low/Reverse Reaction Plate
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1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP)
Remove the low/reverse reaction plate.

Fig 37: Low/Reverse Clutch Disc
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1 - ONE DISC FROM LOW/REVERSE CLUTCH

Remove one (1) low/reverse clutch disc to facilitate snap ring removal.

Fig 38: Removing/Installing Low/Reverse Reaction Plate Snap Ring

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1 - SCREWDRIVER

2 - LOW/REVERSE REACTION PLATE FLAT SNAP RING

3 - DO NOT SCRATCH CLUTCH PLATE

Remove the low/reverse reaction plate snap ring.

Fig 39: Removing/Installing Low/Reverse Clutch Pack
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1 - CLUTCH PLATES (5)

2 - CLUTCH DISCS (5)

Remove the low/reverse clutch pack.

Fig 40: Locating Stakes Of Output Shaft Nut

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1 - OUTPUT SHAFT

2 - GRIND HERE

3 - GRIND HERE

4 - NUT STAKE

CAUTION: Failure to grind and open stakes of the output shaft nut will result in thread damage to the shaft during nut removal.

WARNING: Wear safety goggles while grinding stake nuts.

Using a die grinder or equivalent, grind the stakes in the shoulder of the shaft nuts. Do not grind all the way through the nut and into the shaft. There are two stakes on each nut.

Fig 41: Opening Nut Stakes
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1 - CHISEL

2 - NUT STAKE

Using a small chisel, carefully open the stakes on nut.

Fig 42: Removing/Installing Output Shaft Nut

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1 - WRENCH 6497

2 - WRENCH 6498A

3 - BREAKER BAR

Use Wrench 6497 and Wrench 6498A to remove the transfer shaft nut or the output shaft nut.

Fig 43: Removing Output Shaft From Case Using Shop Press

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1 - OUTPUT SHAFT

2 - PRESS

3 - TRANSMISSION CASE

Remove the output shaft from case using a press.

Fig 44: Removing Front Bearing Cup
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1 - PRESS

2 - REMOVER 6596

Use Remover 6596 with a press to remove the front output shaft bearing cup .

Fig 45: Removing Rear Output Shaft Bearing Cup
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1 - UNIVERSAL HANDLE 4171 AND HANDLE EXTENSION 4171-2

2 - REMOVER 6597

Use Remover 6597 and Universal Handle C-4171 and Handle Extension C-4171-2 to press the rear output shaft bearing cup rearward.

Fig 46: Removing Rear Carrier Front Bearing Cone

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1 - INSTALLER 5048-1

2 - PULLER JAWS 6545

3 - REAR CARRIER

4 - INSTALLER 5048

Remove the rear carrier front bearing cone.

Fig 47: Low/Reverse Spring Compressor Tool

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1 - DISC 6057

2 - COMPRESSOR 5059

3 - COMPRESSOR 5058-3

Fig 48: Compressor Tool In Use

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1 - LOW/REVERSE CLUTCH RETURN SPRING

2 - SNAP RING (INSTALL AS SHOWN)

3 - COMPRESSOR 5058A-3

4 - COMPRESSOR 5059A

5 - DISC 6057

Install and load compressor

Fig 49: Removing Belleville Spring Snap Ring

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1 - SNAP RING OPENING MUST BE BETWEEN SPRING LEVERS (AS SHOWN)

2 - SNAP RING PLIERS

3 - COMPRESSOR 5059A

Remove the low/reverse Belleville spring snap ring.

Fig 50: Removing/Installing Low/Reverse Piston Belleville Spring
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1 - LOW/REVERSE PISTON RETURN SPRING

2 - PISTON
Remove the low/reverse piston Belleville spring.
Remove the park sprag pivot retaining screw.

Fig 51: Anchor Shaft Removal
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1 - PIN PUNCH

2 - GUIDE BRACKET ASSEMBLY

Drive out the anchor shaft using suitable punch.

Fig 52: Removing/Installing Guide Bracket Pivot Pin

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1 - PIVOT PIN

2 - GUIDE BRACKET ASSEMBLY

Fig 53: Guide Bracket Assembly

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1 - GUIDE BRACKET

2 - PAWL

3 - SPLIT SLEEVE

4 - SPACER

5 - STEPPED SPACER

6 - ANTIRATCHET SPRING

Remove the guide bracket pivot shaft. Inspect all components for wear and replace if necessary.

Fig 54: Removing/Installing Low/Reverse Clutch Piston

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1 - LOW/REVERSE CLUTCH PISTON

2 - BONDED SEAL

3 - BONDED SEAL

NOTE: The Low/Reverse Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.

Remove the low/reverse clutch piston.
Remove the low/reverse piston retainer screws.

Fig 55: Removing/Installing Piston Retainer
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1 - LOW/REVERSE CLUTCH PISTON RETAINER

2 - GASKET
Remove low/reverse piston retainer.

Fig 56: Removing/Installing Piston Retainer Gasket
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1 - GASKET HOLES MUST LINE UP

2 - LOW/REVERSE CLUTCH PISTON RETAINER GASKET
Remove the low/reverse piston retainer gasket.