Part 1

AUTOMATIC TRANSMISSION DISASSEMBLY





1. Place the transmission on a workbench.





2. Remove the Torque Converter Hold Down Tool T97T-7902A or equivalent if necessary.
3. If equipped, remove the transfer case from the transmission.

WARNING: The torque converter is heavy, especially when full of fluid.





4. Using Torque Converter Handles T18P-7902-C or equivalent, remove the torque converter.
(1). Install the Torque Converter Handles.
(2). Remove the torque converter.

5. Remove the input shaft.





NOTE: The splines on the input shaft are not the same on both ends. The end with the shorter spline goes into the assembly.





6. Remove the screw (1) and output shaft speed (OSS) sensor (2).





7. Remove the heat shield (4.0L only).





8. Remove manual control outer lever nut and manual control outer lever.





9. Remove the digital transmission range (TR) sensor.
(1). Remove the screws.
(2). Remove digital TR sensor.





10. Use SSTs to remove extension housing seal.





11. Use the Extension Housing Bushing Remover T77L-7697-F or equivalent to remove the extension housing bushing.
(1). Inspect the extension housing bushing and driveshaft slip-yoke for nicks, gauges, scoring, and wear.

NOTE: Remove the extension housing bushing only if service is required.

CAUTION: The parking pawl, parking pawl return spring and parking pawl shaft could fall out during removal of the extension housing.





12. Remove the extension housing screws, stud, and the extension housing.
(1). Discard the extension housing gasket.





13. Remove the parking pawl assembly.
(1). Remove the parking paw shaft.
(2). Remove the parking pawl.
(3). Remove the parking pawl return spring.

CAUTION: The parking pawl actuating rod must slip freely into the clearance hole in the adapter plate.





14. Install Holding Fixture Adapter.
(1). Position the Holding Fixture Adapter T93T-77002-AH or equivalent on the rear of the transmission case.
(2). Install the bolts.





15. Attach the fixture arm of Bench Mounted Holding Fixture T57L-500-B or equivalent to the Holding Fixture Adapter.

WARNING: Make sure the lock pin on bench-mounted holding fixture is secure.





16. Install the transmission into the Bench Mounted Holding Fixture. Rotate transmission so oil pan is facing up.

NOTE: If these tools are unavailable, use SST 49 M005 561.

CAUTION: Do not reuse the oil pan gasket.





17. Remove the oil pan and oil pan gasket and then discard gasket.





18. Remove the oil strainer and discard.
(1). Remove the oil strainer screw.
(2). Remove the oil strainer.





19. Carefully lift up on the wire loom guide and protector. Disengage the retaining pins from the solenoid clamps.





20. Disconnect the solenoid electrical connectors.
(1). Disconnect the SS1 SS2, SS3, and the COS (4R44E) or SS4 (5R55E) electrical connectors.
(2). Disconnect the torque converter clutch (TCC) solenoid electrical connector.
(3). Disconnect the electronic pressure control (EPC) solenoid electrical connector.





21. Remove the detent spring.
(1). Remove the detent bolt.
(2). Remove the detent lever spring.

WARNING: The piston assembly can pop out due to spring pressure when removing the cover.





22. Remove the reverse band servo cover.
(1). Remove the reverse servo cover bolts.
(2). Remove the reverse band servo cover and the reverse servo separator plate cover gasket.
(3). Discard the reverse servo separator plate cover gasket.





23. Remove the reverse band servo piston and rod assembly.

CAUTION: To prevent solenoid valves from failing out, do not remove the two screws shown In the illustration.





24. Do not remove the two (gold colored) screws specified.
25. Remove the twenty-three main control valve body bolts.





NOTE: Use a 10 mm socket to remove the sixteen M6 X 40 mm, four M6 X 45 MM and three M6 X 35 mm main control valve body bolts.