Usage:
Start By:
a. remove torque converter
NOTE: Put a mark on the outside of the clutch housings for correct assembly.
1. Remove bolt (1) that holds the pump drive gear assembly to the transmission.
2. Use two pry bars as shown and remove pump drive gear assembly (2).
3. Remove shaft (3), bearing cone (4), spacer (5), bearing cone (7) and spacer (8) from pump drive gear (6).
4. Remove bearing cups (9) and ring (10) from pump drive gear (6).
5. Remove shaft (11) from the torque converter end of the transmission.
6. Remove retaining ring (13) with tool (B). Remove bolts (12) and rear manifold (14).
7. Remove retaining ring (15) and bearing (16) from the rear manifold (14).
8. Use tooling (C) to hold the piston and top plate in the No. 4 clutch housing. Remove No. 4 clutch housing (17).
| NOTICE |
|---|
Keep the pistons, clutch disc and plates for the individual clutch in their original sequence and with their respective clutch housings. |
9. Remove top plate (18) and piston (19) from No. 4 clutch housing (17).
10. Remove teflon rings (20) from piston (19).
11. Remove discs (21) and remainder of plates (18) for the No. 4 clutch housing (17).
12. Use tool (D) and push the ends of retaining ring (23) together. Remove housing assembly (22) from the ring gear.
13. Remove seal rings (24) from the seal carrier.
| NOTICE |
|---|
Retaining ring (28) holds spring (27) under compression. |
14. Put housing assembly (22) in position in a press. Put spring (27) under compression with tool (E) and the press until retaining ring (28) can be removed with tool (B).
15. Remove one spacer (29), spring (27), other spacer (29) and shaft (25) from the housing assembly.
16. Remove piston (26) from the housing assembly. Remove teflon rings (30) and O-ring seal from piston (26).
| NOTICE |
|---|
It will be necessary to break the seal carrier if it is to be removed from the housing. Remove the pin shown from the housing. |
17. Remove retaining ring (31) with tool (F). Remove ring gear (32).
18. Remove disc (33) and plates (34) for the No. 5 clutch from the ring gear.
19. Remove ring (35) and plate (36) from the ring gear.
20. Remove output shaft (37), hub (38) and planetary carrier (39) as a unit.
21. Remove retaining ring (40) with tool (F) that holds hub (38) on the output shaft. Remove hub (38) from the output shaft.
22. Remove output shaft (37) from the planetary carrier (39).
23. Remove bearings (41) from each end of output shaft (37).
24. Push pins (42) and (45) even with the inside surface of gear (44). Remove plate (43).
25. Turn the planetary carrier over. Remove sun gear (46) from the planetary carrier.
26. Use tooling (D) to push ring (47) toward the inside of the groove in the planetary carrier. Remove planetary carrier (39) from ring gear (44).
27. Remove ring (47) from the planetary carrier.
28. Remove bearing (48) from the planetary carrier.
29. Use a hammer and punch and push pins (54) into shafts (53).
30. Remove shafts (53) from planetary carrier (39). Remove gears (51), thrust washers (49 and 52) and bearings (50) in the gears. After the shafts are removed, remove the pins from the shafts.
31. Remove springs (55) and plate (56).
32. Remove four disc (57) and the four plates for the No. 3 clutch.
33. Use tooling (C) to hold the piston and top plate. Remove No. 2 and 3 clutch housing (58).
34. Remove top plate (59) and piston (60) for the No. 2 clutch.
35. Turn No. 2 and 3 clutch housing (58) around and remove piston (61) for the No.3 clutch.
36. Remove teflon rings (62) from the pistons for the No. 2 and 3 clutches.
37. Remove discs (65) and remainder of plates (59) for the No. 2 clutch.
38. Remove springs (64), guide rods (63) and ring gear (66).
39. Remove planetary carrier (67) and ring gear (68) as a unit.
40. Use tooling (D) to push ring (69) toward the inside of the groove in the planetary carrier. Remove ring gear (68) from planetary carrier (67).
41. Remove plate (70) from ring gear (68).
42. Remove ring (69) from planetary carrier (67).
43. Remove retaining ring (71) that holds the sun gears together with tool (F).
44. Use tooling (G) and remove sun gear (72) from the planetary carrier.
45. Use tooling (G) and remove bearing (73) and sun gear (74) from the planetary carrier.
46. Use a hammer and a punch to push pins (78) into shafts (75).
47. Remove shafts (75) from planetary carrier (67). Remove gears (76), thrust washers (79 and 80) and bearings (77) in the gears. After the shafts are removed, remove the pins from the shafts.
48. Remove plate (81) from the No. 1 clutch housing.
49. Remove disc (82), plates (83) and ring gear (84).
50. Remove piston (85) from the No. 1 clutch housing.
51. Remove teflon rings (86) from piston (85).
52. Turn the No. 1 clutch housing and planetary carrier over. Remove retaining ring (87) with tool (F). Remove No. 1 clutch housing (88) from the planetary carrier.
53. Remove seal ring (90) from planetary carrier (89).
54. If a replacement is needed, remove bearing (91) from planetary carrier (89).
55. Use a hammer and punch to push pins (95) into shafts (92).
56. Remove shafts (92) from planetary carrier (89). Remove gears (96), thrust washers (93 and 97) and bearings (94) in the gears. After the shafts are removed, remove the pins from the shafts.
57. Remove bearing (98) from the No. 1 clutch housing.
58. Remove ring (99) from bearing (98).
Assemble Transmission (3F/3R Power Shift)
NOTE: Torque for two bolts (X) (one each side) 270 ± 40 N·m (200 ± 30 lb ft)
NOTE: Tighten planetary retaining bolt (X) on side of case containing oil cooler line connections first to insure positive seal between case and manifold.
1. Inspect all parts for damage and make replacements if needed.
2. Install bearings (94) in gear (96) for planetary carrier (89). Install gears (96) in the planetary carrier with thrust washers (93) and (97) on both sides of the gears. Install shaft (92). Make an alignment of the hole in the shaft with the hole in the planetary carrier.
3. Install pins (95) that hold shafts (92) in planetary carrier (89).
4. Use tooling (G) and a press to install the bearing in planetary carrier (89) if it was removed.
5. Install seal ring (90) on planetary carrier (89).
| NOTICE |
|---|
Make sure the notch in bearing (98) is in alignment with dowel (100) in the planetary carrier. |
6. Heat bearing (98) to a maximum temperature of 135° C (275° F). Install bearing (98) on planetary carrier (89).
7. Install retaining (87) with tool (F).
8. Install No. 1 clutch housing (88) on planetary carrier (89).
9. Install ring (99) on the outside diameter of bearing (98). Put No. 1 clutch housing and planetary carrier on tool (A).
10. Install teflon rings (86) on piston (85) for the No. 1 clutch. Make sure the lip of the teflon rings are toward the clutch housing. Put clean transmission oil on the rings.
11. Install piston (85) in No. 1 clutch housing (88).
12. Install two 1/2 " - 13 NC guide bolts (101) 355 mm (14 in) long and ring gear (84) in the No. 1 clutch housing.
NOTE: A disc has friction material on both sides. A plate is a smooth steel plate and does not have friction material on either side. Put clean transmission oil on all discs and plates before assembly.
14. Install plates (83) and discs (82) in the No. 1 clutch housing. Start with a plate and stop with a disc. Alternate the plates and discs. The tangs on plates (83) must be positioned as shown.
15. Install plate (81) on the No. 1 clutch housing.
16. Install bearings (77) in gears (76) for planetary carrier (67). Install gears (76) in the planetary carrier with thrust washers (79 and 80) on both sides of the gears. Install shafts (75). Make an alignment of the hole in the shaft with the hole in the planetary carrier and install pins (78).
17. Install sun gear (74) in planetary carrier (67).
18. Install bearing (73) in planetary carrier (67) with a soft hammer.
| NOTICE |
|---|
Make sure the notch in bearing (73) is in alignment with dowel (102) in sun gear (72). |
19. Install sun gear (72).
20. Turn the planetary carrier over and put it on wooden blocks. Use tool (F) and install retaining ring (71) that holds the sun gear in place.
21. Install ring (69) on planetary carrier (67).
| NOTICE |
|---|
Ring gear (68) can be installed incorrectly. Make sure the groove in ring gear (68) is toward the top as shown in illustration B01572P4. |
22. Put ring gear (68) in position on wooden blocks. Put planetary carrier (67) in position in ring gear (68). Use tooling (D) to push the ring in the groove in the planetary carrier. Push the planetary carrier into the ring gear until ring (69) moves into place in the groove in the ring gear.
23. Turn the planetary carrier over. Put clean grease on plate (70) to hold it in place. Install plate (70).
24. Install planetary carrier (67) and ring gear (68) as a unit.
25. Install ring gear (66) on the planetary carrier.
NOTE: Do not install the top plate at this time.
26. Install discs (65) and plates (59). Start and stop with a disc.
27. Install three guide rods (63), three springs (64) and top plate (59).
28. See illustration B1579P1 for correct position of the tangs on plates (59).
29. Remove top plate (59).
30. Install teflon rings (62) on piston (61) from the No. 3 clutch. Make sure the lip of the teflon rings are toward the clutch housing. Put clean transmission oil on the rings. Install piston (61) in No. 2 and No. 3 clutch housing (58).
| NOTICE |
|---|
Do not let piston (61) fall when the clutch housing is turned over. |
31. Turn the clutch housing over. Install teflon rings (103) on piston (60) for the No. 2 clutch. Make sure the lip of the teflon rings is toward the clutch housing. Put clean transmission oil on the rings. Install piston (60) in No. 2 and 3 clutch housing (58).
32. Install top plate (59) in No. 2 and 3 clutch housing (58).
33. Install tooling (C) to hold piston (60) and plate (59) in the clutch housing. Turn the clutch housing over.
34. Install No. 2 and 3 clutch housing (58). Remove tooling (C). Make sure the tangs on the plates are in the correct position.
35. Install bearings (50) in gears (51) for planetary carrier (39). Install gears (51) in the planetary carrier with thrust washers (49) and (52) on both sides of the gears. Install shafts (53). Make an alignment of the hole in the shaft with the hole in the planetary carrier.
36. Install pins (54) that holds shafts (53) in planetary carrier (39).
37. Install bearing (48) in planetary carrier (39) with a soft hammer as shown.
38. Install ring (47) on planetary carrier (39).
39. Put ring gear in position as shown. Put planetary carrier (39) in position in ring gear (44). Use tooling (D) to push the ring in the groove in the planetary carrier. Push the planetary carrier into the ring gear until ring (47) moves into place in the groove in the ring gear.
40. Put plate (43) in position in the ring gear.
41. Use a punch and a hammer and install pins (42) and (45) that hold plate (43) in ring gear (44).
42. Install bearings (41) in output shaft (37) with tooling (G). Install the bearings to a depth of 2.26 ± 0.25 mm (.089 ± .010 in) below the outside surface.
43. Slide planetary carrier (39) into position on output shaft (37).
44. Install sun gear (46) in the planetary carrier.
45. Install hub (38) on the output shaft and use tool (F) to install retaining ring (40) that holds the hub on the output shaft.
46. Install output shaft (37) planetary carrier (39) and hub (38) as a unit.
47. Install the four plates and four discs (57) for the No. 3 clutch. Start with a plate and stop with a disc. Note the correct position of the tangs on the plates. Install plate (56) on the No. 2 and 3 clutch housing.
48. Put plate (36) in position in ring gear (32). Install ring (35) that holds the plate in the ring gear.
NOTE: Do not install the top plate at this time.
49. Install ring gear (32), three discs (21), two plates (18) and three springs (55), for the No. 4 clutch. Start and stop with a disc.
50. Install teflon rings (20) on piston (19) and make sure the lip of the teflon rings are toward the clutch housing. Put clean transmission oil on the rings and install piston (19) in No. 4 clutch housing (17).
51. Install top plate (18) in No. 4 clutch housing (17).
52. Install tooling (C) to hold piston (19) and top plate (18), install No. 4 clutch housing (17). Remove tooling (C).
53. Install five discs (33) and four plates (34) for the No. 5 clutch.
54. Heat seal carrier (105) to a temperature of 138° to 165° C (280° to 330° F) for ten minutes. Install seal carrier (105) on housing (107). Make sure the groove (slot) in the seal carrier is in alignment with the hole in the housing.
55. Install pin (106) that holds the seal carrier in place.
56. Install the O-ring and smaller teflon ring (30) on the piston. Install larger teflon ring (30) on the piston. The larger teflon ring has a lip on the ring and the lip must be toward the housing. Install piston (26) in housing (107).
57. Install shaft (25) into housing (107). Install one spacer (29), spring (27) and other spacer (29).
58. Put housing assembly (22) in a press. Use tooling (E) and the press and put spring (27) under compression until the groove for the retaining ring is above spacer (29).
59. Install retaining ring (28) with tool (B).
60. Install seal rings (24) on the seal carrier.
61. Install housing assembly (22) and use tooling (F) to install retaining ring (23) that holds the housing assembly in the ring gear.
62. Heat bearing (16) to a maximum temperature of 135° C (275° F). Install bearing (16) in rear manifold (14). Make sure the notch in the bearing is down. Install retaining ring (15).
| NOTICE |
|---|
Make sure notch (108) in bearing (16) is in alignment with the dowel in the housing. |
| NOTICE |
|---|
Be extra careful not to cause damage to the seal rings. |
63. Install rear manifold (14) and the bolts (12) that hold No. 4 clutch housing together, except for the two that the guide bolts are installed.
64. Install two 5/16 " - 18 NC bolts (109) into the housing assembly. Use two screwdrivers to lift up the housing assembly.
65. Use tooling (F) and install retaining ring (13) on the housing assembly.
66. Remove guide bolts (101) and install bolts (12).
67. Check, to make sure the pistons are free in their clutch housings, [except for the number five clutch], with tool (H) as follows:
a. Put air (free of water) under pressure of 690 to 1030 kPa (100 to 150 psi) into each of the oil passages.
b. If the pistons do not move, put a small amount of clean SAE 30 oil in each passage. Check for movement again. If the pistons still do not move, the transmission must be disassembled and the pistons and seals checked.
68. Install shaft (11) in the input shaft as shown. Turn the transmission so the rear manifold is against tool (A).
69. Lower the temperature of bearing cups (9). Install ring (10) and bearing cups (9) in pump drive gear (6).
70. Install spacer (5) and bearing cone (4) on shaft (3). Install shaft (3), bearing cone (7) and spacer (8) into gear (6).
71. Install pump drive gear assembly (2).
72. Install bolt (1) that holds the pump drive gear assembly in place.
End By:
a. install torque converter