Disassembly
DISASSEMBLENOTE: When disassembling transmission and removing thrust washers, identity washers clearly. Some thrust washers are very similar and could be installed improperly during transmission assembly.
1. On models with 4WD, remove transfer case.
Exploded View Of Transmission, (Part 1 Of 2):
Exploded View Of Transmission, (Part 2 Of 2):
2. On all models, remove torque converter, then the input shaft.
3. Remove extension housing seal using seal remover tool No T74P-77248-A and slide hammer tool No. T9OT-1OO-A or equivalents.
4. Inspect extension housing bushing, remove bushing using puller tool No. T77L-7697-E or equivalent if necessary.
5. Remove extension housing, then remove parking pawl and spring.
6. Remove governor assembly.
7. Install mounting fixture plate tool No. T93T-77002-AH or equivalent to transmission, then place transmission onto a suitable swivel overhaul fixture.
8. On models with 4.0L engines, remove heat shield.
9. On all models, remove oil pan and filter.
10. Disconnect connectors from two solenoids on control valve body.
11. Remove manual lever detent spring, then the reverse servo from control valve body.
12. Remove control valve body bolts.
13. Remove control valve body and place aside.
Overdrive And Intermediate Band Servo Removal:
14. Remove intermediate and overdrive servo assemblies using servo cover compressor tool No. T95L-77028-A, or equivalent.
15. Remove and discard intermediate and overdrive band adjusting screw lock-nuts, then loosen band adjusting screws
16. Remove and discard converter housing bolts, then use a rotating and rocking motion to allow clutch assemblies to stay in place, lift converter housing out of transmission.
17. Remove and discard front pump gasket. Mark No. 1 thrust washer and position aside.
18. Remove overdrive band, anchor strut, and screw. Mark anchor strut side of band and place aside.
19. Remove overdrive brake/coast clutch drum assembly.
20. Remove and mark overdrive band actuator strut and overdrive band actuator lever shaft.
21. Remove planet gear overdrive carrier, use caution not to bend exciter wheel (base) of assembly
22. Remove overdrive band servo lever and lever to case control bracket.
23. Remove overdrive ring gear, one way clutch, and center shaft assembly.
24. Remove No. 3 thrust bearing assembly, mark bearing for later assembly and place aside.
Center Support Removal:
25. Remove center support cap screw.
26. Remove center support snap ring, then lift center support from case.
27. Locate, remove, and mark No. 4 thrust bearing and position aside.
28. Remove intermediate band anchor strut, then the intermediate band. Mark band to identify anchor and apply sides.
29. Remove remaining intermediate band linkage. Mark these components for assembly reference.
30. Remove intermediate brake and direct clutch drum, then locate, remove and mark No. 5 thrust washer.
31. Remove forward clutch assembly, then locate, remove, and mark No. 7 thrust washer.
32. On models equipped with 2.3L and 3.0L engines, remove reverse planet retaining snap ring.
33. On all models, locate, remove, and mark No.8 thrust washer.
34. Remove reverse planet assembly, then locate, remove, and mark No. 9 thrust washer.
35. On models equipped with 4.0L engine, remove output sleeve/lubricant guide.
36. On all models, remove and discard output shaft retaining snap ring.
37. Remove output shaft ring gear and hub, then locate, remove, and mark No. 10 thrust washer.
38. Remove reverse brake drum and one way clutch, then the reverse brake band.
39. Remove output shaft and park gear, then locate, remove, and mark No. 11 thrust washer.
40. Proceed as follows:
a. Remove governor oil collector body.
b. Remove vacuum diaphragm assembly, actuator pin and throttle valve.
c. Remove Park Neutral Position (PNP) switch.
d. Remove kick down lever and 0-ring seal.
e. Depress lock tab on case electrical plug, then pull plug from case.
41. Remove manual lever inner nut.
42. Remove manual control lever shaft retaining pin.
43. Remove manual lever, inner kick down lever, park pawl actuator rod, and inner manual lever with Z link.
44. Pry out manual lever seal.