Part 3

Transmission - Overhaul

Special Tool(s)










Material(s)






Exploded View











































Overhaul

72. Remove the 3 bolts and the fluid pump and filter assembly.





73. NOTE: Note the orientation of the fluid filter to the fluid pump.

Remove and discard the fluid filter.

1. Pull the filter out of the bore of the fluid pump. Discard the fluid filter.

2. If the filter seal did not come off with the filter, remove the seal from the pump and discard the seal.





74. Clean and inspect the components of the pump assembly for wear or damage. Inspect the fluid drained from the pump for excessive metal or foreign material. If excessive wear, damage or excessive metal is found, replace the fluid pump as an assembly.

75. Remove the fluid pump sprocket and chain assembly.





76. Inspect the pump chain and sprocket assembly for damage or wear and install new components as necessary.

1. Check the drive chain for wear, damage, stretching or tightness of the chain links.

2. Check the chain sprockets for excessive wear in the chain contact areas and thrust washer areas.





77. Remove the fluid pump drive sprocket and driven sprocket thrust washers.





78. NOTICE: If the transfer shaft bearing cup is damaged, a new bearing and bearing cup must be installed on both sides of the transfer shaft or excessive noise or transmission failure can occur.

Inspect the torque converter housing side transfer shaft bearing cup for damage. If the torque converter housing side transfer shaft bearing cup is damaged, install a new bearing cup. REFER to Torque Converter Housing Torque Converter Housing. If a new bearing cup is installed in the torque converter housing, install a new transfer shaft bearing cup in the transmission case. REFER to Transmission Case Transmission Case. Install new bearings on the transfer shaft. REFER to Transfer Shaft and Gear Transfer Shaft and Gear.





79. NOTE: Front Wheel Drive (FWD) Only.

Using a suitable tool, remove the halfshaft seal from the torque converter housing.





80. NOTICE: If the differential bearing cup is damaged, a new bearing and bearing cup must be installed on both sides of the differential or excessive noise or transmission failure can occur.

Inspect the torque converter housing side differential bearing cup for damage. If the torque converter housing side differential bearing cup is damaged, install a new bearing cup. REFER to Torque Converter Housing Torque Converter Housing. If a new bearing cup is installed in the torque converter housing, install a new differential bearing cup in the transmission case. REFER to Transmission Case Transmission Case. If a new bearing cup was installed, the differential bearings must also be replaced. REFER to Differential - Front Wheel Drive (FWD) Differential for FWD (Front Wheel Drive) vehicles or REFER to Differential - All Wheel Drive (AWD) Differential for AWD (All-Wheel Drive) vehicles.





81. Using a suitable dent puller, remove the torque converter hub seal from the torque converter housing.





82. Clean and inspect the transmission case and torque converter housing for damage and install a new transmission case or torque converter housing if necessary. If a new transmission case or torque converter housing is installed, REFER to Transmission Case Transmission Case for bearing cup installation and REFER to Differential Shim Selection Differential Shim Selection for differential/transfer gear bearing shim measurement.

83. Clean and inspect the thrust bearings and washers for damage and install new bearings or washers as necessary.

84. Remove the overdrive clutch snap ring.





85. Remove the overdrive clutch hub and clutch assembly.





86. Remove the bottom overdrive clutch steel plate.





87. Remove the No. 2 rear sun gear thrust bearing.





88. Install 307-589/1 and 307-584/2 on the balance piston. Using a press, compress the overdrive piston return spring.





89. With the overdrive piston return spring compressed, remove the balance piston snap ring.





90. Remove 307-589/1 and 307-584/2.





91. Remove and discard the balance piston.





92. Remove the overdrive piston return spring.





93. Using petroleum jelly, install the No. 1 thrust bearing on the overdrive/direct clutch assembly .





94. Position the overdrive/direct clutch assembly in the rear cover.





95. Apply air pressure to the overdrive piston port on the rear cover and remove the overdrive piston.





96. Remove the overdrive/direct clutch assembly from the rear cover.





97. Remove and discard the overdrive clutch piston inner seal.





98. Remove and discard the overdrive clutch piston outer seals from the piston.





99. NOTICE: Only compress the direct clutch piston return spring far enough to take the tension from the direct clutch cylinder off the snap ring. If the piston is compressed too far, the piston alignment tab may be broken off.

Install 307-589/2 and 307-584/2 on the direct clutch cylinder. Using a press, compress the direct clutch piston return spring, and remove the snap ring. Do not contact the overdrive/direct clutch hub and shaft assembly with the direct clutch cylinder. Remove the snap ring.





100. Remove 307-589/2 and 307-584/2.





101. Using petroleum jelly, install the No. 1 thrust bearing on the overdrive/direct clutch assembly .





102. Remove the direct clutch cylinder. Position the overdrive/direct clutch assembly in the cover assembly. Apply 483 kPa (70.05 psi) of air pressure to the direct clutch piston port to remove the direct clutch cylinder from the overdrive/direct clutch assembly. Remove the overdrive/direct clutch assembly from the rear cover and remove the direct clutch cylinder.





103. Remove the rear direct clutch cylinder seal.





104. Remove and discard the direct clutch piston.





105. Remove the direct clutch piston return spring.





106. Remove and discard the direct clutch piston seals.





107. Remove the direct clutch snap ring.





108. Remove the direct clutch pressure plate, clutch assembly and wave spring.