Part 1

DISASSEMBLY

NOTE: If the transmission is being reconditioned (clutch/seal replacement) or replaced, it is necessary to perform the Quick Learn Procedure using the scan tool Quick Learn Procedure .

NOTE: Tag all clutch pack assemblies, as they are removed, for reassembly identification.

CAUTION: Do not intermix clutch discs or plates as the unit might then fail.

Before disassembling transmission, move the shift lever clockwise as far as it will go and then remove the shift lever.

1. Remove the torque converter (1) from the transmission input shaft (3).

2. Measure input shaft end play using End Play Set 8266A (1, 2). Set up End Play Set 8266A and a dial indicator as shown.
3. Move input shaft in and out to obtain end play reading. End play specifications are 0.13 to 0.64 mm (0.005 to 0.025 inch). Record indicator reading for reference when reassembling the transmission. If endplay exceeds the specified range, the #4 thrust plate needs to be inspected and changed if necessary.

NOTE: It is not necessary to remove the output shaft flange to disassemble the transmission. Perform the following steps only if it necessary to replace a component in the extension housing assembly.

4. Place the transmission in PARK to prepare for the removal of the output shaft nut.
5. Remove the nut holding the propeller shaft flange to the output shaft and remove the flange.
6. Remove the transmission rear oil seal with a suitable slide hammer and screw.
7. Remove the transmission output shaft washer.
8. Remove the transmission rear output shaft bearing retaining ring (1).

9. Position Bearing Remover 9082A (1) over the inner race of the output shaft bearing (3).

NOTE: Due to production variations in the bearing, it may not be possible to slide the collar fully downward. It is only necessary to slide the collar down far enough that the fingers securely grasp the inner bearing race.

10. Slide the collar (3) on the Bearing Remover 9082A (1) downward over the fingers (4) of the tool.

11. Remove the output shaft bearing (3).
12. Remove the geartrain end-play shim from the output shaft. Be sure to tag the shim since it is very similar to the output shaft washer and they must not be interchanged.

NOTE: The four bolts (3) along the bottom of the extension housing (2) have a sealing patch applied from the factory. Note the locations of these bolts and separate these bolts for reuse.

13. Remove the bolts that hold the extension housing (2) onto the transmission case.

14. Remove the extension (2) housing from the transmission case. There are two pry slots located near the bottom corners of the housing for separating the housing from the transmission case.

15. Inspect the lube tube grommet (3) for damage. If the grommet lip is damaged, it will need to be replaced.

NOTE: The speed sensor bolts have a sealing patch applied from the factory. Separate these bolts for reuse.

16. Remove the input speed sensor bolt.

NOTE: The speed sensor bolts have a sealing patch applied from the factory. Separate these bolts for reuse.

17. Remove the output speed sensor bolt.

18. Remove the input and output (2) speed sensors. Identify the speed sensors for re-installation since they are not interchangeable.

NOTE: One of the oil pan bolts has a sealing patch applied from the factory. Separate this bolt for reuse.

19. Remove the transmission oil pan bolts (2).

20. Remove the transmission oil pan (1).

21. Remove the transmission oil filter screws (2).

22. Remove transmission oil filter (1).

23. Remove the oil filter o-ring (2) from the valve body.
24. If necessary, use a suitable tool to push the transmission fill tube grommet and extension from the transmission case from the bottom.