Disassembly
GENERAL NOTESThe oil pan could contain small chips, shavings, and other particles helpful in checking the condition of the transmission and diagnosing certain problems. To ensure that all foreign particles stay in the oil pan, make sure that the transmission is never tipped completely over while the oil pan is still installed.
1. Disassemble the transmission in a clean area (dust-proof work space) to prevent entry of dust into the mechanisms.
2. Inspect the individual transmission components in accordance with the QUICK DIAGNOSIS CHART during disassembly.
3. Use only plastic hammers when applying force to separate the light alloy case joints.
4. Never use rags during disassembly; they may leave particles that can clog fluid passages.
5. Several parts resemble one another; arrange them so that they do not get mixed up.
6. Disassemble the control valve component and thoroughly clean it when the clutch or brake band has burned or when the ATF has degenerated.
Part 1 Of 4:
Part 2 Of 4:
Part 3 Of 4:
Part 4 Of 4:
PROCEDURE
1. Support the transmission by placing wooden blocks under the converter housing and the extension housing.
2. Remove the oil pan and gasket. Examine any material found in the pan or on the magnet to determine the condition of the transmission.
a. Clutch facing material: Drive plate and brake band wear
b. Steel (magnet): Bearing, gear, and driven-plate wear
c. Aluminum (nonmagnetic): Bushings or cast aluminum parts wear
3. If large amounts of material are found, replace the torque converter and carefully check the transmission for the cause.
4. Install the oil pan with a few bolts to protect the valve body.
5. Remove the vacuum diaphragm, torque converter clutch control solenoid valve, input/turbine speed sensor, and O-rings.
6. Remove the transmission range switch.
7. Remove the speedometer driven gear from the extension housing.
8. Remove the O-ring from the speedometer driven gear.
9. Remove the torque converter, and immediately turn it so that the hole faces upward. This will help to keep any remaining fluid from spilling.
10. Assemble the Special Service Tool (SST) as shown.
11. Mount the transmission onto the SST.
12. Remove the oil pan and gasket.
13. Remove the magnets.
14. Disconnect the solenoid valve connectors.
15. Remove the harnesses from the bracket.
16. Remove the control valve body as shown in the illustration.
17. Remove the solenoid valve connector from the
18. Mark the converter housing, fourth gear case, and transmission case for proper reassembly.
19. Remove the converter housing from the fourth gear case.
CAUTION: The converter housing is made of aluminum, and is therefore easily dented and scratched by metal tools. When removing old sealant, do not gouge or strike the sealing surface of the converter housing.
20. Clean the sealing compound from the converter housing.
21. Remove the fourth gear band servo cover and gasket.
22. Loosen the fourth gear band servo locknut and tighten the piston stem.
23. Mark the fourth gear case and oil pump for proper reassembly.
24. Install the SST to the oil pump component.
25. Slowly remove the oil pump from the transmission case by evenly sliding the weights of the SST.
26. Remove the SST from the oil Pump.
27. Loosen the piston stem of the fourth gear band servo. Remove the fourth gear connecting shell and fourth gear planetary gear unit (fourth gear sun gear, fourth gear planetary pinion carrier, fourth gear clutch hub), and direct clutch.
28. Remove the fourth gear brake band, and hold it together with a piece of wire as shown in the illustration.
29. Remove the band strut.
30. Remove the bearing races and bearing.
31. Remove the intermediate shaft.
32. Loosen the second gear band servo locknut and tighten the piston stem.
33. Separate the drum support, accumulator, and fourth gear case from the transmission case by tapping it lightly with a plastic hammer. Remove the gasket.
34. Remove the bearing races and bearing from the drum support, accumulator and fourth gear case. Remove the bearing from the front clutch hole.
35. Loosen the second gear band servo piston stem and remove the second gear band strut. Hold the brake band together with a piece of wire as shown in the illustration.
36. Remove the band strut.
37. Remove the bearing race, front clutch, rear clutch, connecting shell, and front planetary gear unit (rear clutch hub, front planetary pinion carrier, rear sun gear) as a unit.
38. Remove the extension housing and gasket.
39. Remove the snap ring from the output shaft by using snap-ring pliers.
40. Remove the rear planetary gear unit (connecting drum, rear planetary pinion carrier, one-way clutch).
41. Pull out the output shaft.
42. Remove the oil distributor.
43. Remove the bearing.