Required Tools | |||
---|---|---|---|
Tool | Part Number | Part Description | Qty |
A | 1P-2420 | Transmission Repair Stand | 1 |
B | 439-3940 | Link Bracket | 3 |
C | 439-3939 | Link Bracket | 2 |
D | FT-0833 | Clamp | 2 |
E | 1P-1863 | Retaining Ring Pliers | 1 |
F | 5P-5197 | External Pliers | 1 |
G | 1P-0520 | Driver Group | 1 |
H | 126-7183 | Crossblock | 1 |
J | 4C-8356 | Installer | 1 |
K | 1P-0074 | Slide Hammer Puller Gp | 1 |
L | 1P-1861 | Retaining Ring Pliers | 1 |
Start By:
- Separate the transmission and the output transfer gears.
Note: Cleanliness is an important factor. Before the disassembly procedure, the exterior of the component should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism.
- Place the transmission assembly onto Tooling (A).
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Illustration 2 g01915234 - Disconnect tube assembly (1).
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Illustration 3 g01915255 - Install Tooling (B) and a suitable lifting device to modulating valve assembly (2). The weight of modulating valve assembly (2) is approximately
43 kg (95 lb) . - Remove bolts (3). Remove modulating valve assembly (2).
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Illustration 4 g01915279 - Remove tubes (4) and the O-ring seals.
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Illustration 5 g02505637 - Attach Tooling (B) and a suitable lifting device to planetary group (5). The weight of planetary group (5) is approximately
565 kg (1250 lb) . Remove planetary group (5) from transmission case (6). - Place planetary group (5) on suitable blocks.
Note: Put alignment marks across the clutch housings for assembly purposes.
Show/hide tableIllustration 6 g01886812 - Remove bolts (7) and the washers.
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Illustration 7 g02488677 Show/hide tablePersonal injury can result from being struck by parts propelled by a released spring force.
Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all recommended tooling to release the spring force.
- Use Tooling (D) to secure the clutch piston in clutch housing (9).
- Attach Tooling (B) and a suitable lifting device on clutch housing (9). The weight of clutch housing (9) is approximately
32 kg (70 lb) . - Carefully remove clutch housing (9) from manifold assembly. Remove springs (8).
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Illustration 8 g01886814 - Remove clutch piston (11) from clutch housing (9). Remove seals (10) from the piston.
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Illustration 9 g01886815 - Remove friction discs (12), clutch plates (13), and dowels (14) from manifold assembly.
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Illustration 10 g06327035 - Remove gear (15) from the carrier assembly.
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Illustration 11 g06327038 - Use Tooling (E) to remove retaining ring (16) from shaft assembly. Remove the spacer under the retaining ring.
- Remove carrier assembly (17).
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Illustration 12 g01886819 - Use a drift to bend locks (18) from bolts (19). Remove bolts (19), locks (18), and slinger (20) from carrier assembly.
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Illustration 13 g01886826 - Remove spring pin (22) from the carrier and shaft (21). Remove spring pin (22) from shaft (21).
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Illustration 14 g01886833 - Remove thrust discs (23) and (27) and gear (25).
- Remove bearings (24) and (26) from gear (25).
- Repeat Steps 18 through 20 for the removal of the remaining planetary gears.
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Illustration 15 g06327041 - Use Tooling (F) to remove retaining ring (28) from the housing assembly.
- Remove gear (29).
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Illustration 16 g06327045 - Use Tooling (F) to remove retaining ring (30).
- Remove bolts (31) that hold the manifold assembly to the clutch housing.
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Illustration 17 g02488916 Typical Example Show/hide tablePersonal injury can result from being struck by parts propelled by a released spring force.
Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all recommended tooling to release the spring force.
- Attach Tooling (B) and a suitable lifting device to manifold assembly (32). The weight of manifold assembly (32) is approximately
95 kg (210 lb) . - Carefully remove manifold assembly (32) from the clutch housing. Remove O-ring seals (33).
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Illustration 18 g01886839 - Remove retaining ring (34) and bearing (35) from the manifold assembly.
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Illustration 19 g06327052 - Remove O-ring seal (36) and springs (39).
- Remove friction discs (37) and clutch plates (38).
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Illustration 20 g06327058 - Remove rods (40) and dowels (41).
- Remove clutch piston (42).
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Illustration 21 g06327064 - Remove seals (43) and (44) from the clutch piston.
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Illustration 22 g06327069 - Remove retaining ring (45) and clutch housing assembly (46).
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Illustration 23 g06327168 - Remove seal rings (47) from ring carrier (48).
- Check the condition of the ring carrier (48). If ring carrier (48) is worn or damaged, use new parts for replacement. If the ring carrier is not worn or damaged, DO NOT remove ring carrier (48). Use a hammer and a chisel to break the ring carrier. Remove the ring carrier and the pin from housing assembly.
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Illustration 24 g06327170 Typical Example Show/hide tablePersonal injury can result from being struck by parts propelled by a released spring force.
Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all recommended tooling to release the spring force.
- Use Tooling (H), Tooling (J), and a suitable press to apply a force on plate (50) until spiral lockring (49) can be removed. Release the force. Remove the plate and three springs (51) from the housing.
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Illustration 25 g06327172 - Remove piston (52).
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Illustration 26 g06327175 - Remove seals (53) and (54).
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Illustration 27 g06327180 - Use tooling (F) to remove retaining ring (55). Remove clutch hub (56).
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Illustration 28 g06327187 - Remove friction discs (57) and plates (58).
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Illustration 29 g06327190 - Remove gear (59).
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Illustration 30 g06327198 Typical Example Show/hide tablePersonal injury can result from being struck by parts propelled by a released spring force.
Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all recommended tooling to release the spring force.
- Use Tooling (D) to hold clutch piston (61) in clutch housing (60). Attach Tooling (B) and a suitable lifting device to clutch housing (60). The weight of clutch housing (60) is approximately
39 kg (86 lb) . Remove clutch housing (60).Show/hide tableIllustration 31 g06327205 - Remove piston (62) from housing assembly.
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Illustration 32 g06327210 - Remove seals (63) and (64) from the piston.
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Illustration 33 g06327360 - Remove friction discs (66), clutch plates (65), and springs (67).
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Illustration 34 g06327363 Typical Example - Attach Tooling (B) and a suitable lifting device to carrier (68). The weight of carrier (68) is approximately
32 kg (70 lb) .Show/hide tableIllustration 35 g06327421 - Remove gear (69).
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Illustration 36 g06327435 - Use Tooling (E) to remove retaining ring (70) from hub (71). Remove hub (71) from the carrier.
- Remove gear (72) from the carrier.
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Illustration 37 g06327444 - Remove spiral lockring (73). Remove bearing (74) from the carrier.
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Illustration 38 g06327428 - Remove spring pin (75) from the carrier.
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Illustration 39 g06327426 - Remove shaft (80), thrust discs (76) and (79), and gear (77). Remove bearing (78) from the gear (77). Remove pin (75) from shaft (80).
- Repeat Steps 52 through 53 for the removal of the remaining gears.
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Illustration 40 g06327449 - Remove O-ring seal (81) from the shaft assembly.
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Illustration 41 g06327454 Typical Example Show/hide tablePersonal injury can result from being struck by parts propelled by a released spring force.
Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all recommended tooling to release the spring force.
- Remove bolts (82) from clutch housing (83).
- Use Tooling (D) to hold the piston in clutch housing (83). Attach Tooling (B) and a suitable lifting device to clutch housing (83). The weight of clutch housing (83) is approximately
44 kg (97 lb) . - Remove clutch housing (83), springs (84), and dowels (85).
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Illustration 42 g06327457 - Remove piston (86) from the clutch housing.
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Illustration 43 g06327461 - Remove seals (87) and (88) from the clutch piston.
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Illustration 44 g06327475 - Remove friction discs (89) and clutch plates (90).
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Illustration 45 g06327476 - Remove gear assembly (91) and plate assembly (92) from the clutch housing.
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Illustration 46 g06327479 - Remove friction plates (93) and clutch plates (94).
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Illustration 47 g06327481 - Attach Tooling (C) and a suitable lifting device to output shaft assembly (95). The weight of output shaft assembly (95) and the carrier is approximately
68 kg (150 lb) . - Remove the retaining ring that holds output shaft assembly (95) in the bearing on the bottom of the clutch housing.
- Remove output shaft assembly (95) and the carrier from the clutch housing.
- Place output shaft assembly (95) on suitable blocks.
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Illustration 48 g06327483 - Use Tooling (E) to remove retaining ring (96).
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Illustration 49 g06327484 - Use a soft hammer to remove shaft assembly (97) from the bearing in the carrier.
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Illustration 50 g06327487 - Remove carrier assembly (98) from the shaft assembly.
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Illustration 51 g06327493 - Remove seals (101) and (102) from the carrier assembly.
- Remove spiral lockring (99).
- Use Tooling (G) to remove bearing (100).
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Illustration 52 g06327529 - Use a hammer and a punch to push spring pin (103) from the carrier assembly.
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Illustration 53 g06327532 - Remove shaft (108), thrust discs (104) and (107), and gear (105). Remove bearing (106) from gear (105). Remove pin (103) from shaft (108).
- Repeat Steps 74 and 75 for the remaining gears.
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Illustration 54 g06327538 - Remove spacer (110) and gear (109) from the shaft assembly.
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Illustration 55 g06327541 - Put the shaft assembly on suitable blocks, as shown. Use two people to remove carrier assembly (111) from the shaft assembly. The weight of carrier assembly (111) is approximately
32 kg (70 lb) .Show/hide tableIllustration 56 g06327543 - Put the carrier assembly on a suitable block, as shown. Use a screwdriver to compress the retainer ring. Remove gear (112) from the carrier assembly. Remove retaining ring (113).
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Illustration 57 g06327544 - Remove spiral lockring (114). Use Tooling (G) to remove bearing (115) from the carrier. Remove seal rings (116).
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Illustration 58 g06327548 - Use a hammer and a punch to push spring pin (117) from the carrier assembly.
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Illustration 59 g06327556 - Remove shaft (126), thrust discs (118), (121), (122) and (125), and gears (120) and (124). Remove bearings (119) and (123) from the gears. Remove pin (117) from shaft (128).
- Repeat Steps 81 and 82 for the remaining gears.
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Illustration 60 g06327558 - Remove gear (127) from the shaft assembly.
- Remove seals (128) and (129) from the seal carrier.
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Illustration 61 g06327563 - Remove spiral lockring (130) from the shaft assembly.
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Illustration 62 g06327570 - Put shaft assembly on suitable blocks, as shown. Use a soft hammer to strike shaft assembly (132) until the bearing is removed from shaft assembly (131).
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Illustration 63 g06327574 Show/hide tableIllustration 64 g06327575 - Use Tooling (L) to remove retaining ring (133) from the shaft assembly. Remove bearing (134). Remove O-ring seals (135) from the shaft assembly.
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Illustration 65 g06327579 - Use Tooling (H) and a suitable press to remove seal carrier (136) from the shaft assembly.
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Illustration 66 g06327583 - Use Tooling (K) to remove bearing (137) from the shaft assembly.
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Illustration 67 g06327586 - Remove gear (138) from the clutch housing.
- Remove piston (139) from the clutch housing.
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Illustration 68 g06327590 - Remove seals (140) and (141) from the piston.
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Illustration 69 g06327591 - Remove spiral lockring (142). Use Tooling (G) to remove bearing (143) from the housing.
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