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Automatic Transmission (Service Information): Disassembly

  1. Remove the Transmission Control Module (TCM). Refer to MODULE, TRANSMISSION CONTROL (TCM), REMOVAL .
  2. Remove the valve body assembly. Refer to VALVE BODY, REMOVAL .
  3. Remove the external oil cooler. Refer to COOLER, TRANSMISSION OIL, REMOVAL .
    GC0153320Courtesy of CHRYSLER GROUP, LLC
  4. Remove the input speed sensor bolt (1) and remove the input speed sensor (2) from the case.
    GC0153321Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Take note of the position of the longer bolts (1).

  5. Remove the transmission case bolts (1).
    Fig 1: Transmission Case Bolts Loosening Sequence
    GC0153626Courtesy of CHRYSLER GROUP, LLC
  6. Remove the transmission case bolts using the sequence shown.
    GC0153322Courtesy of CHRYSLER GROUP, LLC
  7. Separate the case halves.
    GC0153603Courtesy of CHRYSLER GROUP, LLC
  8. Remove the two transmission case gaskets (1).
    GC0153604Courtesy of CHRYSLER GROUP, LLC
  9. Remove the oil reservoir lock plate bolts (1) and remove the lock plate (2).
    GC0153605Courtesy of CHRYSLER GROUP, LLC
  10. Remove the magnets (1) from the oil reservoir lock plate.
    GC0153606Courtesy of CHRYSLER GROUP, LLC
  11. Remove the bolt (1) and retention tab (2). Using a screw driver or the equivalent, carefully remove the tube (3).
    GC0153309Courtesy of CHRYSLER GROUP, LLC
  12. Remove the oil pump bolts (1, 2). Take note of the longer bolts (2).
    GC0153323Courtesy of CHRYSLER GROUP, LLC
  13. Remove the oil pump.
    GC0153607Courtesy of CHRYSLER GROUP, LLC
  14. Remove the oil strainer bolts (1) and the oil strainer (2).
    GC0153325Courtesy of CHRYSLER GROUP, LLC
  15. Remove the nylon thrust washer (1).
    GC0153326Courtesy of CHRYSLER GROUP, LLC
  16. Remove the B1 brake / C3 clutch assembly (1).
    GC0153327Courtesy of CHRYSLER GROUP, LLC
  17. Remove the front planetary carrier and input shaft annulus gear assembly (1).
    GC0153318Courtesy of CHRYSLER GROUP, LLC
  18. Remove the B1 band bolt (1).
    GC0153324Courtesy of CHRYSLER GROUP, LLC
  19. Remove the B1 brake band (1).
    GC0153319Courtesy of CHRYSLER GROUP, LLC
  20. Remove the B1 brake band servo, spring and piston rod. Discard the O-rings.
    GC0153328Courtesy of CHRYSLER GROUP, LLC
  21. Remove the C1 clutch assembly (1).
    GC0153329Courtesy of CHRYSLER GROUP, LLC
  22. Remove the sun gear input drum (1).
    GC0153330Courtesy of CHRYSLER GROUP, LLC
  23. Remove the thrust washers and bearings.
    GC0153332Courtesy of CHRYSLER GROUP, LLC
  24. Remove the parking pawl actuator bracket bolts (1). Disconnect the actuator rod (2) from the bracket (3).
    GC0153333Courtesy of CHRYSLER GROUP, LLC
  25. Remove the manual shift shaft detent bolt (1), remove the detent (2).
    GC0153334Courtesy of CHRYSLER GROUP, LLC
  26. Remove the parking pawl spring and pivot assembly (1), remove the parking pawl (2).
    GC0153336Courtesy of CHRYSLER GROUP, LLC
  27. Rotate the actuator rod (1) up and turn the manual shift lever (2) so the rod key slot and tabs line up and disconnect.
    GC0153335Courtesy of CHRYSLER GROUP, LLC
  28. Remove the actuator rod (1).
    GC0153341Courtesy of CHRYSLER GROUP, LLC
  29. Remove the plunger from the case (1).
    GC0153337Courtesy of CHRYSLER GROUP, LLC
  30. Remove the manual control lever (1).
  31. Remove the manual control lever seal.
    GC0153338Courtesy of CHRYSLER GROUP, LLC
  32. Remove the counter gear shaft (2) and the differential (1).
    GC0153620Courtesy of CHRYSLER GROUP, LLC
  33. Using (special tool #6055, Thrust Button) and (special tool #5048, Puller, Bearing) remove the right side inner bearing.
    GC0153621Courtesy of CHRYSLER GROUP, LLC
  34. Remove the left side inner bearing.
    GC0153340Courtesy of CHRYSLER GROUP, LLC
  35. Remove the fluid transfer pipe bolts (1) and remove the transfer pipe (2).
    GC0153339Courtesy of CHRYSLER GROUP, LLC
  36. Remove the counter drive gear assembly bolts.
  37. Remove the counter drive gear assembly (1).
    GC0153342Courtesy of CHRYSLER GROUP, LLC
  38. Remove the output speed sensor bolt (1) and speed sensor (2).
    GC0153343Courtesy of CHRYSLER GROUP, LLC
  39. Remove the snap ring (1).
    GC0153344Courtesy of CHRYSLER GROUP, LLC
  40. Remove the large and small rear planetary gears (1).
    GC0153345Courtesy of CHRYSLER GROUP, LLC
  41. Remove the rear planetary carrier and one way clutch as a unit (1 and 2).
    GC0153608Courtesy of CHRYSLER GROUP, LLC
  42. Remove the thrust needle roller bearing and the 2 bearing races.
    GC0153347Courtesy of CHRYSLER GROUP, LLC
  43. Remove the snap ring (1).
    GC0153348Courtesy of CHRYSLER GROUP, LLC
  44. Remove B2 disc pack (1).
    GC0153350Courtesy of CHRYSLER GROUP, LLC
  45. Remove snap ring.
    GC0153349Courtesy of CHRYSLER GROUP, LLC
  46. Remove C2 clutch assembly (1).
    GC0153609Courtesy of CHRYSLER GROUP, LLC
  47. Remove the two oil seal rings from the case.
    GC0153351Courtesy of CHRYSLER GROUP, LLC
  48. Remove the snap ring.
    GC0153352Courtesy of CHRYSLER GROUP, LLC
  49. Remove the 1st gear and reverse brake return spring from the case (1).
    GC0153627Courtesy of CHRYSLER GROUP, LLC
  50. Inspect the return spring. Measure the free length of each of the piston return springs. If the free length of any spring is less than 23 mm (0.91 in) replace the spring.
    GC0153353Courtesy of CHRYSLER GROUP, LLC
  51. Remove the thrust washer (1).
    GC0153354Courtesy of CHRYSLER GROUP, LLC
  52. Remove the 1st gear and reverse brake piston (1).
    GC0153610Courtesy of CHRYSLER GROUP, LLC
  53. Remove the O-rings from the 1st gear and reverse brake piston.
  54. Remove the needle bearing from the case.
    GC0153356Courtesy of CHRYSLER GROUP, LLC
  55. Using (special tool #9664, Remover, Bearing Cup) and (special tool #C-637, Slide Hammer, Universal), remove the case side transfer shaft bearing race.
    GC0153355Courtesy of CHRYSLER GROUP, LLC
  56. Using (special tool #C-3894-A, Puller, Tie Rod) and (special tool #6454, Remover, Bearing Cup) remove the tapered differential side bearing from the case. Do not damage the shim.
    GC0153357Courtesy of CHRYSLER GROUP, LLC
  57. Using (special tool #9664, Remover, Bearing Cup) and (special tool #C-637, Slide Hammer, Universal), remove the bell housing side differential bearing race.
    GC0153358Courtesy of CHRYSLER GROUP, LLC
  58. Using (special tool #9664, Remover, Bearing Cup) and (special tool #C-637, Slide Hammer, Universal), remove the bell housing side transfer shaft bearing race.
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