Transmission - Disassemble
Disassembly Procedure
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| Required Tools | |||
|---|---|---|---|
| Tool | Part Number | Part Description | Qty |
| A | 138-7575 | Link Brackets | 4 |
| B | 1U-9202 | Lever Puller Hoist | 1 |
| C | 1P-2420 | Transmission Repair Stand | 1 |
| D | 154-6181 | Forcing Screws | 2 |
| E | 203-5581 | Plate | 1 |
| F | 1P-2322 | Combination Puller | 1 |
| 8B-7560 | Step Plate | 1 | |
| G | FT-2769 | Table | 1 |
| H | 5P-4758 | Retaining Ring Pliers As | 1 |
| J | 207-8153 | Shaft Retainer | 1 |
Start By:
- Remove the input speed sensor. Refer to Disassembly and Assembly, "Speed Sensor (Transmission) - Remove".
- Attach Tooling (A) and a suitable lifting device to bell housing (2). The weight of bell housing (2) is approximately 35 kg (75 lb). Remove bolts (1). Remove bell housing (2) and the O-ring seals.
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| Illustration 1 | g01269011 |
- Disconnect harness assemblies (3). Remove bolts (5) and electronic control module (4) .
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| Illustration 2 | g01269023 |
- Use Tooling (A), Tooling (B), and a suitable lifting device in order to reposition transmission (6) onto Tooling (C). The weight of transmission (6) is approximately 1315 kg (2900 lb).
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| Illustration 3 | g01269041 |
- Remove bolt (7) and retainer (10). Remove yoke (9) and O-ring seal (8) .
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| Illustration 4 | g01269046 |
- Reposition harness assembly (13). Attach Tooling (A) and a suitable lifting device to cover assembly (12). The weight of cover assembly (12) is approximately 60 kg (130 lb). Remove bolts (11) and cover assembly (12) .
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| Illustration 5 | g01269055 |
- Remove bolts (14) and Tooling (A) .
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| Illustration 6 | g01269057 |
- Use Tooling (D) in order to remove bearing cage (15). Remove shims (16) .
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| Illustration 7 | g01269063 |
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| Illustration 8 | g01269068 |
- Remove O-ring seals (18) and lip seal (17). Remove bearing cup (19) .
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| Illustration 9 | g01269118 |
- Remove bolt (20) and retainer (21). Use two people in order to remove gear (22). The weight of gear (22) is approximately 23 kg (50 lb).
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| Illustration 10 | g01269176 |
- Remove ring (23). Use two people in order to remove gear (24). The weight of gear (24) is approximately 32 kg (70 lb).
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| Illustration 11 | g01269183 |
- Remove bearing cones (25) from gear (24) .
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| Illustration 12 | g01269221 |
- Remove bolt (28) and tube assembly (29) .
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| Illustration 13 | g01269222 |
- Remove bolt (26) and bearing cage (27) .
- Remove shims (31). Remove bearing cup (30) from bearing cage (27) .
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| Illustration 14 | g01269226 |
- Repeat Steps 13 and 14 for the remaining bearing cages.
- Remove tube assembly (33). Attach Tooling (A) and a suitable lifting device to case assembly (32). The weight of case assembly (32) is approximately 365 kg (800 lb). Remove bolts (34) and case assembly (32). Remove O-ring seal (35) .
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| Illustration 15 | g01269240 |
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| Illustration 16 | g01269241 |
- Remove bearing cup (36) .
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| Illustration 17 | g01269287 |
- Remove bolts (37). Use two people in order to remove clutch assembly (38). The weight of clutch assembly (38) is approximately 25 kg (55 lb).
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| Illustration 18 | g01329460 |
Note: Do not remove bolts (X) .
- Remove O-ring seals (39) from clutch assembly (38) .
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| Illustration 19 | g01269430 |
- Remove bolts (40). Remove reaction plate (41) and ring gear (42) .
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| Illustration 20 | g01269435 |
- Remove disc (43) and plates (44). Remove dowels (45) and springs (46). Remove dowels (50) from housing (51), if necessary.
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| Illustration 21 | g01269438 |
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| Illustration 22 | g01269440 |
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Personal 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. |
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- Remove piston (48) from housing (51). Remove seals (47) and (49) from piston (48) .
- Attach Tooling (E) and a suitable lifting device to shaft assemblies (52). The weight of shaft assemblies (52) is approximately 375 kg (820 lb). Remove shaft assemblies (52) .
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| Illustration 23 | g01269516 |
- Remove ring seals (53) .
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| Illustration 24 | g01269519 |
- Place the shaft assemblies onto Tooling (G). Remove Tooling (E) .
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| Illustration 25 | g01269526 |
- Use Tooling (F) in order to remove bearing cone (54) from shaft assembly (55) .
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| Illustration 26 | g01269638 |
Reverse Shaft | |
- Remove bearing cone (54), spacer (56), spacer (57), gear (58), and spacer (59) from shaft assembly (55) .
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| Illustration 27 | g01269685 |
- Rotate shaft assembly (55) by 180 degrees. Remove bolts (60) and remove seal carrier (61) .
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| Illustration 28 | g01269743 |
- Use Tooling (F) in order to remove bearing cone (62) .
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| Illustration 29 | g01269746 |
- Remove bearing cone (62) and spacer (63). Remove thrust washer (64) and gear (65) .
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| Illustration 30 | g01269751 |
- Remove bearings (66) and thrust washer (67). Use Tooling (H) in order to remove retaining ring (68). Remove clutch plate (69). Remove the friction discs and plates (70) from shaft assembly (55) .
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| Illustration 31 | g01269758 |
- Use a suitable press and Tooling (J) in order to compress spring (72). Remove retaining ring (71) .
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| Illustration 32 | g01269765 |
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Personal 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. |
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- Remove spacer (73), seal assembly (74), and spring (75) from shaft assembly (55) .
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| Illustration 33 | g01269767 |
- Remove piston (77) from shaft assembly (55). Remove seals (76) from piston (77). Remove seal (78) from piston (77) .
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| Illustration 34 | g01270206 |
- Use Tooling (F) in order to remove bearing cone (79) from shaft assembly (80) .
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| Illustration 35 | g01270208 |
Intermediate Shaft | |
- Remove bearing cone (79), spacer (81), spacer (82), thrust washer (83), and gear (84) from shaft assembly (80). Remove bearings (85) and thrust washer (83) .
Note: The procedure for the disassembly of the clutch packs are identical.
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| Illustration 36 | g01270211 |
- Rotate shaft assembly (80) by 180 degrees. Remove bolts (86) and seal carrier (87). Remove bearing cone (88) from shaft assembly (80) .
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| Illustration 37 | g01269959 |
- Use Tooling (F) in order to remove bearing cone (89) from shaft assembly (80) .
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| Illustration 38 | g01269966 |
- Remove bearing cone (89), spacer (90), spacer (91), and gear (92) from shaft assembly (80) .
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| Illustration 39 | g01269968 |
- Remove gear (93), spacer (94), thrust washer (95), and gear (96). Remove bearing (97) and thrust washer (95) from shaft assembly (80) .
Note: The procedure for the disassembly of the clutch packs are identical.
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| Illustration 40 | g01269969 |
- Use Tooling (F) in order to remove bearing cone (98) from shaft assembly (99) .
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| Illustration 41 | g01269974 |
Output Shaft | |
- Remove bearing cone (98), spacer (100), and planetary carrier (101) from shaft assembly (99) .
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| Illustration 42 | g01269976 |
- Drive spring pin (105) into shaft (106). Remove shaft (106), thrust discs (102), gear (104), and bearings (103) from carrier (101) .
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| Illustration 43 | g01269978 |
Note: Drive spring pin (105) into shaft (106) until shaft (106) can be removed. Do not drive spring pin (105) too far.
- Remove thrust washer (107), sun gear (108), spacer (109), thrust washer (110), and gear (111). Remove bearings (112) and thrust washer (110) from shaft assembly (99) .
Note: The procedure for the disassembly of the clutch packs are identical.
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| Illustration 44 | g01269983 |
- Rotate shaft assembly (99). Remove bolts (113), seal carrier (114), bolts (115), and rotor (116) from shaft assembly (99) .
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| Illustration 45 | g01269986 |
- Use Tooling (F) to remove bearing cone (117) from shaft (99) .
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| Illustration 46 | g01270066 |
- Remove bearing cone (117), spacer (118), and planetary carrier (119) from shaft assembly (99) .
Note: The procedure for the disassembly of the planetary carriers are identical.
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| Illustration 47 | g01270067 |
- Remove thrust washer (120), sun gear (121), tube (122), thrust washers (123), and gear (124). Remove bearings (125) and spacer (126) from shaft assembly (99) .
Note: The procedure for the disassembly of the clutch packs are identical.
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| Illustration 48 | g01270078 |
- Use Tooling (F) in order to remove bearing cone (127) from shaft assembly (128) .
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| Illustration 49 | g01270090 |
Input Shaft | |
- Remove bearing cone (127), spacer (129), spacer (130), gear (131), and gear (132) from shaft assembly (128) .
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| Illustration 50 | g01270092 |
- Remove spacer (133), thrust washer (134), and gear (135). Remove bearings (136) and thrust washer (134) from shaft assembly (128) .
Note: The procedure for the disassembly of the clutch packs are identical.
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| Illustration 51 | g01270098 |
- Rotate shaft assembly (128) by 180 degrees. Use Tooling (F) in order to remove bearing cone (137) from shaft assembly (128) .
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| Illustration 52 | g01270099 |
Note: Remove the seal rings before removal of bearing cone (137) .
- Remove bearing cone (137), spacer (138), thrust washer (139), and gear (140). Remove bearings (141) and thrust washer (139) from shaft assembly (128) .
Note: The procedure for the disassembly of the clutch packs are identical.
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| Illustration 53 | g01270555 |
- Remove bolts (142). Use two people in order to remove clutch assembly (143). The weight of clutch assembly (143) is approximately 25 kg (55 lb).
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| Illustration 54 | g01329472 |
Note: Do not remove bolts (Y) .
- Refer to Steps 19 through 22 for disassembly of remaining clutch assemblies.
- Remove bearing cups (144) .
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| Illustration 55 | g01270596 |
- Remove bolts (145) and seal ring housing (146) .
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| Illustration 56 | g01270626 |
- Remove O-ring seals (147) from seal ring housing (146) .
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| Illustration 57 | g01270632 |
- Remove lip seal (148) from seal ring housing (146) .
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| Illustration 58 | g01270685 |
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