Disassembly
1. Remove torque converter.2. Remove lower half of filler tube if not previously removed.
3. Remove clamps attaching wire harness and throttle cable to transmission.
4. Remove shift lever from manual valve shaft at left side of transmission.
5. Remove park/neutral position switch.
6. Remove speed sensor.
7. Remove converter housing bolts and remove housing from case.
8. Remove adapter housing.
9. Remove speedometer drive gear snap ring and remove gear and gear spacer if equipped.
10. Remove speed sensor rotor and key. Use wood dowel or hammer handle to loosen and remove rotor.
11. Remove transmission oil pan, oil screen and screen gaskets. Then mount transmission in holding fixture
12. Remove valve body oil feed tubes.
13. Disconnect valve body solenoid wires.
14. Remove harness bracket bolt and remove harness and bracket.
15. Remove valve body bolts.
16. Disconnect throttle cable from throttle cam.
17. Remove valve body from case. Then remove accumulator springs, spacers and check ball and spring.
18. Remove second brake and clutch accumulator pistons with compressed air. Apply air pressure through feed port and ease the pistons out of the bore.
19. Remove overdrive brake accumulator piston with compressed air.
20. Remove overdrive clutch accumulator piston with compressed air.
21. Remove throttle cable.
22. Remove oil pump bolts and remove pump with bridge-type Puller 7536, or equivalent.
23. Remove race from of pump.
24. Remove overdrive planetary gear and clutch assembly.
25. Remove race from overdrive planetary.
26. Remove thrust bearing, race and overdrive planetary ring gear.
27. Measure stroke length of overdrive brake piston as follows:
a. Mount dial indicator on case.
b. Mount Gauge Tool 7546, or equivalent so it contacts piston.
c. Apply 57 - 114 psi air pressure through piston apply port and note piston stroke on dial indicator. Stroke length should be: 1.40 - 1.70 mm (0.055 - 0.0699 inch).
d. If stroke is not within limits, replace clutch piston and retainer.
28. Remove overdrive brake pack snap ring.
29. Remove overdrive brake pack discs and plates. Measure brake pack disc thickness with micrometer. Replace brake pack if any disc thickness is less than 1.84 mm (0.0724 inch).
30. Remove overdrive support lower race and upper bearing and race assembly.
31. Remove overdrive support bolts.
32. Remove overdrive support snap ring with Snap Ring Plier Tool 7540, or equivalent.
33. Remove overdrive support with bridge-type Puller 7536, or equivalent.
34. Remove race from hub of overdrive support.
35. Measure stroke length of second coast brake piston rod as follows:
a. Make reference mark on piston rod as shown.
b. Apply 57 - 114 psi air pressure through piston feed hole and check stroke length with Gauge Tool 7552, or equivalent.
c. Stroke length should be 1.5 - 3.0 mm (0.059 - 0.118 inch).
d. If stroke length is incorrect, install new piston rod and recheck stroke. If stroke is still incorrect, replace second coast brake band.
e. Replacement piston rods are available in two different lengths which are: 71.4 mm (2.811 inch) and 72.9 mm (2.870 inch).
36. Remove second coast brake piston snap ring with Snap Ring Plier Tool 7540, or equivalent. Then remove piston cover and piston assembly with compressed air applied through piston feed hole.
37. Disassemble second coast brake piston.
38. Remove direct and forward clutch assembly.
39. Remove thrust bearing and race from clutch hub.
40. Remove second coast brake band E-ring from band pin and remove brake band.
41. Remove front planetary ring gear front bearing race and remove front planetary ring gear.
42. Remove thrust bearing and rear race from ring gear.
43. Remove planetary thrust race.
44. Relieve load on planetary snap ring as follows: Loosen transmission holding fixture. Turn transmission over and allow output shaft to support transmission weight. Place wood blocks under shaft to protect splines.
45. Remove planetary snap ring and remove planetary gear.
46. Remove sun gear, input drum and one-way clutch as assembly.
47. Measure second brake clutch pack clearance. Clearance should, be 0.62 - 1.98 mm (0.0244 -0.0780 inch). Replace discs if clearance is not within specifications.
48. Remove second brake clutch pack snap ring.
49. Remove second brake clutch pack. Measure disc thickness with micrometer. Minimum thickness should be 1.84 mm (0.0724 inch). Replace discs if not within specifications.
50. Remove bolts attaching park rod bracket to case. Then disconnect park rod from manual shaft lever and remove rod and bracket.
51. Remove park pawl spring, pin and pawl.
52. Measure clearance of first-reverse brake clutch pack. Clearance should be: 0.70 - 1.2 mm (0.028 - 0.047 inch). Replace discs if clearance is not as specified.
53. Remove second brake piston sleeve. Cover remover tool with tape to avoid damaging case.
54. Remove rear planetary gear, second brake drum and output shaft as an assembly.
55. Remove planetary and brake drum thrust bearing and race assembly
56. Remove second brake drum gasket from case with gasket scraper or screwdriver. Retain tube shaped gasket if condition is OK.
57. Measure inside diameter of transmission case rear bushing with bore gauge or inside micrometer. Maximum allowable diameter is 38.18 mm (1.5031 inch). Replace transmission case if bushing I.D. is greater than specified. Bushing is not serviceable.