8HP75 - Disassembly

DISASSEMBLY 

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1. Remove the torque converter (1).

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

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

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   NOTE:

   4X4 only

4. Remove the output shaft snap ring (1).

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   NOTE:

   RWD only.

5. 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.

6. 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.
7. Using a flange holder (special tool #C-3281, Holder, Flange), remove the output shaft flange nut.
8. Remove the output shaft flange and inspect the output shaft flange sealing surface for damage, replace as needed.

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9. Remove the thirteen oil pan retaining bolts (1).
   NOTE:

   Inspect the gasket for reuse. If the seal is cut or torn, replace the gasket.

10. Carefully remove the oil pan (2) and gasket.

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

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13. 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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14. Remove the valve body assembly end retainer bolts (1, 2).
15. 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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16. Remove the Output Speed Sensor bolt (1) and gently lift the Output Speed Sensor out from the case.

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

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

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21. 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. 

22. Remove the input shaft O-ring (1) using a small pick or equivalent.

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

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25. Remove the B clutch spring damper (1).

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

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

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

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30. Remove the hub (1).

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

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

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34. Remove the wave spring (1).

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

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

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

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38. 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.
39. Remove the snap ring.

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40. 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).
41. Remove the front pump needle bearing snap ring.
42. 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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43. Remove the manual park release lever retaining nut (2) and remove the lever (1).

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

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45. Remove the park pawl lock rod (1) from the fork (2).
    NOTE:

    Pay attention to the spring position for installation.

46. Remove the roll pin from (3) the selector shaft using a suitable pin punch.
47. Remove the shaft, spring and manual lever assembly (2) from the case.
48. Remove the selector shaft seal using a small screwdriver or equivalent.

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49. 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.

50. 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. 

51. Remove the input/output shaft and P4 annulus drum assembly (1) from the case.

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52. Remove the outer bearing cup snap ring (1).

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    NOTE:

    4X4 shown, RWD similar.

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

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55. 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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56. 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).
57. Remove the B clutch pack (2).

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

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60. Remove the selectable shim (3) from the P1 annulus/B clutch hub.
61. 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.

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

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

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67. Remove the P2 annulus/P3 sun gear (1) from the drum assembly.
68. 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.

69. Position the (special tool #10378, Rings, Support) on the P4 annulus drum assembly to protect the drum.
70. Using a suitable tool, release and remove the snap ring (1) holding down the P3 Planetary Carrier (2).

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

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

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

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75. Remove the snap ring (1) from the P4 sun gear/C/E clutch retainer.
76. Remove the E clutch (2) from the P4 sun gear/C/E clutch retainer.
77. 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 friction plates. 

78. Remove the C clutch (1) from the P4 sun gear/C/E clutch retainer.
79. Remove the bearings from the top and bottom of the C clutch.

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