1.Mount transmission in Bench Mounted Holding Fixture T57L-500-B.
2.Using a 10 mm socket, remove 14 pan retaining bolts, transmission pan and pan-to-case gasket.
3.Remove pan magnet. Clean transmission pan and pan magnet.
4. CAUTION: If installing a new filter, and grommet remains in the main control bore, carefully use a small screwdriver to remove the grommet. Use care not to damage the main control bore.
NOTE: If transmission is being serviced for a contamination-related failure, use a new filter and grommet. The filter may be reused if no excessive contamination is present.
Using both hands, remove filter by pulling upward.
5. CAUTION: Do not pull on wires. This may damage wires or connectors and could result in a transmission concern. If required, carefully pry up on locking tab and disconnect the connector.
Grasp connector at each solenoid or sensor and pull straight out to disconnect.
6.NOTE: Removal of the OSS at this time will prevent sensor damage when removing the output shaft (7060).
Using an 8 mm socket, remove bolt retaining output shaft speed sensor (OSS) to case (7005) and remove OSS.
7.Using an 8 mm socket, remove two bolts retaining transmission range (TR) sensor to case. Remove transmission range (TR) sensor from manual control lever (7A256).
8.Using an 8 mm socket, remove one bolt retaining manual control valve detent lever spring (7A261) to the main control valve body.
9.Using an 8 mm socket, remove remaining 24 valve body-to-case retaining bolts, the main control valve body and the valve-to-body gasket.
10.NOTE: Use a shop cloth to protect pan-to-case surface.
Remove manual lever shaft retaining pin (7B210).
11.Using a 13/16-inch open-end wrench on the inner nut and a 12 mm wrench on the manual control lever shaft flats, loosen the inner nut. Slide manual control lever partially out of the case to complete removal of the inner nut from manual control lever.
12.NOTE: Do not damage bore with the prying tool.
Using a screwdriver on the manual control lever seal lower edge, carefully pry manual control lever seal out of case bore.
13.Lift manual valve detent lever (7A115) and parking lever actuating rod (7A232) out of the case.
14.Remove electronic pressure control (EPC) solenoid by sliding it out of the case bore.
15.This illustration shows the position of the overdrive servo, the reverse band servo, 2-3 accumulator piston (7F251) and the 1-2 accumulator piston.
16.Remove the 2-3 accumulator spring retainer.
17.Remove 2-3 accumulator piston.
18.NOTE: If tool is not available, extreme care must be taken. Spring pressure will force overdrive servo piston (7F200) assembly out of case. Case bore damage may result from trying to pry on overdrive servo piston retainer (7G280).
Use Servo Piston Remover/Replacer T92P-70023-A to compress the overdrive servo piston return spring (7F201). Use snap-ring pliers to remove retainer ring.
19.Remove piston assembly. Remove overdrive servo piston return spring.
20.Use Servo Piston Remover/Replacer T92P-70023-A to contact the reverse band servo cover (7D036) and compress return spring and remove servo cover retaining ring.
21.NOTE: The length of the rod attached to the piston is graded in three different lengths. Therefore, they should not be installed in any transmission other than the transmission from which they were removed.
Remove reverse band servo cover, reverse band servo piston and rod (7D189) and reverse band servo spring (7D031).
22.Apply downward pressure on 1-2 accumulator cover using Servo Piston Remover/Replacer T92P-70023-A. Using snap-ring pliers, remove 1-2 accumulator piston retaining ring (7384).
23.Carefully note the location of the 1-2 accumulator outer springs (7G267) and assemble in the same positions. Some models may use two 1-2 accumulator outer springs. The accumulator piston may also vary with applications. Remove cover and 1-2 accumulator outer spring. Use reverse snap-ring pliers to remove accumulator piston and 1-2 shift spring (7F284).
24.Remove fluid screen from case.
25.Remove extension housing seal using Seal Remover T74P-77248-A. Make sure seal remover lips are firmly seated under the flange on the extension housing seal.
26.Inspect extension housing bushing (7A034). If required, remove the extension housing bushing using Extension Housing Bushing Remover T77L-7697-A.
27.NOTE: The extension housing bolts have been coated with a sealant. More break torque may be required to remove these bolts.
Using a 13 mm socket, remove six extension housing bolts. Remove and discard extension housing gasket (7086).
28.The output shaft may have shipping seal still attached. Remove and discard. This seal is not required for assembly.
29.Slide parking pawl shaft (7D071) out of the case and remove parking pawl (7A441) and parking pawl return spring (7D070).
30.Place transmission in the vertical position with output shaft toward floor.
31. CAUTION: Extreme care must be taken during transmission connector removal. Do not pull on the wires, or use a hammer on the connector body. This will damage wires or connector and could result in a transmission concern.
Remove transmission connector from case. Place a screwdriver on the flat portion of the connector and drive the connector out through the bottom of the case.
32.Remove front pump seal using Seal Remover TOOL-1175-AC or equivalent and Impact Slide Hammer T59L-100-B.
33.NOTE: All bolts have been coated with a sealant. More break torque might be required to remove bolts.
Using a 10 mm socket, remove seven pump body retaining bolts.
34.Remove front pump and support assembly using two Impact Slide Hammers T59L-100-B and Pump Puller Adapters T89T-70010-A.
35.Remove and discard pump gasket.
36. CAUTION: Remove the assembly carefully to prevent damage to the overdrive band friction material by the reverse clutch drive lugs.
Grasp the forward clutch cylinder and shaft (7F207) firmly and pull the following components out of the case as an assembly:
•intermediate clutch pack
•intermediate one-way clutch
•reverse clutch assembly
•forward clutch assembly
37.NOTE: Band may be removed with assembly.
Disengage overdrive band (7F196) from overdrive band anchor pin (7F295) and remove.
38.Remove forward clutch hub and the No. 3 forward clutch hub front bearing (7F231).
39.Remove intermediate stub shaft.
40.Rotate reverse clutch gear and shell (7A019) to align indent with overdrive band anchor pin.
41.Remove forward clutch sun gear, No. 5 needle bearing, reverse clutch gear and shell and the No. 4 needle bearing as an assembly.
42.Remove center planet support retaining ring. Note position of retaining ring tabs for assembly.
43.Using needle-nose pliers, remove case to center support spring out from between the center support and the case. Note location for assembly.
44.Remove planetary gear support and planetary as an assembly.
45.Remove reverse band.
46.Remove retaining ring.
47.Remove output shaft, ring gear (7A153) and direct clutch assembly as a unit, from the front of the case.
48.Remove No. 9 case rear bearing (7F242) from rear of the case.
49.Inspect output shaft bushing. If removal is required, use Bearing Cup Puller T77F-1102-A and Impact Slide Hammer T59L-100-B.