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8HP95 Automatic Transmission (Service Information): Disassembly

CAUTION:

The Transmission Control Module (TCM), or Transmission Control Module Assembly (TCMA) is extremely sensitive to Electrostatic Discharge (ESD). Always use a ground strap and follow the ESD guidelines in ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES. Failure to follow these instructions may result in damage to the TCM/TCMA.

NOTE:

If the transmission is being reconditioned (clutch/seal replacement) or replaced, it is necessary to perform the TCM Adaptation Procedure. Refer to TRANSMISSION CONTROL MODULE (TCM) ADAPTATION .

NOTE:

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

GC0152102Courtesy of CHRYSLER GROUP, LLC
  1. Remove the torque converter (1).
    GC0169779Courtesy of CHRYSLER GROUP, LLC
  2. Using a suitable punch, remove the staking (3) from the transmission output flange nut (2).
  3. Using (special tool #C-3281, Holder, Flange) loosen the transmission output flange nut (2) about 1 thread using a 34 mm 12 point socket.
    GC0152257Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    End play specification is between 0.11 - 0.42 mm (0.0043 - 0.0165 in.). If end play is outside this range, a different selectable end play shim must be used during assembly.

  4. Measure the output shaft (1) end play as follows:
    1. Attach a dial indicator (2) and position the plunger against the end of the output shaft (1).
    2. Zero the dial indicator (2).
    3. Move the output shaft (1) in and out, and record the maximum travel for assembly reference.
  5. Finish removing the transmission output flange nut.
  6. Remove the transmission output flange.
  7. Remove the transmission rear dust seal.
  8. Remove the transmission rear output shaft seal with a suitable slide hammer and screw.
  9. Remove the transmission output shaft washer.
    GC0170254Courtesy of CHRYSLER GROUP, LLC
  10. Remove the 13 transmission oil pan bolts (1).
    NOTE:

    Inspect the gasket for reuse. If the gasket is cut or torn, replace the gasket.

  11. Remove the transmission oil pan (2) and gasket.
    GC0170496Courtesy of CHRYSLER GROUP, LLC
  12. Remove the transmission oil filter (1).
    GC0152103Courtesy of CHRYSLER GROUP, LLC
  13. Remove the valve body assembly end bolts (3).
  14. Lift the electrical connector lock (2) to release the internal harness end from inside the transmission for valve body assembly removal.
  15. Remove the sensor bolt (1) and pull the sensor (4) loose from the case.
    GC0152117Courtesy of CHRYSLER GROUP, LLC
  16. Using (special tool #10377, Remover/Installer, Guide Sleeve) (1) carefully pull the electrical harness insulator (2) straight out from the transmission case (3).
    Fig 1: Valve Body Assembly Bolts Tightening Sequence
    GC0169780Courtesy of CHRYSLER GROUP, LLC
  17. Remove valve body assembly bolts 1-14 (15-18 are already removed).
  18. Remove the valve body assembly from the transmission.
    GC0152241Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The fluid port (1) may be in the transmission or the valve body assembly.

  19. Pull the fluid port (1) from the transmission or valve body assembly.
  20. Remove the two O-rings (2).
  21. Remove the compression seal (3) from the transmission.
    GC0152104Courtesy of CHRYSLER GROUP, LLC
  22. Remove the 13 oil pump housing bolts (2).
    GC0152105Courtesy of CHRYSLER GROUP, LLC
  23. Remove the input shaft O-ring (1) using a small pick (2) or equivalent.
    GC0154661Courtesy of CHRYSLER GROUP, LLC
  24. Pry the oil pump housing (1) away from the case (2) with a small flat blade screwdriver or equivalent through the case opening.
  25. From the front of the transmission, remove the oil pump housing.
    GC0152249Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Apply air pressure slowly because oil may spray when B-piston releases from the assembly.

  26. With one hand above B-piston (1), carefully apply air pressure into the hole (2) directly above the B-piston alignment tab (3) to remove B-piston (1) from the assembly.
    GC0152250Courtesy of CHRYSLER GROUP, LLC
  27. Remove the outer ring (1) (under B-piston).
  28. Remove the snap ring (2).
  29. Remove the clutches and spacers (4).
  30. Remove the hub (3).
    GC0152251Courtesy of CHRYSLER GROUP, LLC
  31. Position the oil pump housing assembly (4) in a suitable arbor press.
  32. Using (special tool #8285, Compressor, Spring) (1), press on the fingers of the piston retaining ring to remove tension, and remove the two halves of the split retainer ring (2, 3).
    GC0152254Courtesy of CHRYSLER GROUP, LLC
  33. Remove the piston retaining ring and piston below it.
    GC0152253Courtesy of CHRYSLER GROUP, LLC
  34. Remove the six bolts (1) and separate the oil pump housing (2) from the oil pump cover (3).
    GC0152247Courtesy of CHRYSLER GROUP, LLC
  35. Using (special tool #9667, Remover, Seal) (2) and (special tool #C-3752, Slide Hammers) (1), remove the oil seal from the front pump cover.
  36. Remove the outer lip seal from the front pump cover.
    GC0152248Courtesy of CHRYSLER GROUP, LLC
  37. Remove the snap ring.
  38. Using (special tool #6787A, Remover, Bearing Cup) (1) and (special tool #C-3752, Slide Hammers) (2) remove the needle bearing from the front cover (3).
  39. Remove the snap ring.
  40. Using (special tool #9585, Remover, Bearing Cup) and (special tool #C-637, Slide Hammer, Universal) remove the needle bearing.
    GC0152243Courtesy of CHRYSLER GROUP, LLC
  41. Remove the Manual Park Release (MPR) lever retaining nut (2) and remove the lever (1).
    GC0152140Courtesy of CHRYSLER GROUP, LLC
  42. Remove the three park pawl lock rod guide plate retaining screws (1) and remove the plate (2).
    GC0152141Courtesy of CHRYSLER GROUP, LLC
  43. Remove the park pawl lock rod (1) from the fork (2).
    GC0152142Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Pay attention to the spring position for installation.

  44. Remove the roll pin from the MPR shaft (4) using a suitable pin punch (3).
  45. Remove the shaft (4), spring (2) and fork (1) from the case.
  46. Remove the MPR shaft seal using a small screwdriver or equivalent.
    GC0152143Courtesy of CHRYSLER GROUP, LLC
  47. Remove the park pawl shaft plug (1) from the rear of the case.
    GC0152144Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Pay attention to the spring position for installation.

  48. Remove the park pawl shaft using a suitable pin punch (3), remove the park pawl (1) and spring (2).
    GC0154476Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The transmission must be in the upright position to remove the assembly to avoid damage to the drums.

  49. Remove the input/output shaft and P4 annulus drum assembly (1) from the case.
    GC0152266Courtesy of CHRYSLER GROUP, LLC
  50. Remove the outer bearing snap ring (1), and the outer ball bearing.
    GC0152267Courtesy of CHRYSLER GROUP, LLC
  51. Remove the oil dam snap ring.
  52. Using (special tool #9664, Remover, Bearing Cup) (1) and (special tool #C-637, Slide Hammer, Universal) (2), remove the oil dam (3).
    GC0152269Courtesy of CHRYSLER GROUP, LLC
  53. Remove the output shaft inner needle bearing snap ring.
  54. Using (special tool #9664, Remover, Bearing Cup) (1) and (special tool #C-637, Slide Hammer, Universal) (2), remove the inner needle bearing (3).
    GC0152139Courtesy of CHRYSLER GROUP, LLC
  55. Position the input/output shaft and P4 annulus drum assembly (1) on (special tool #8925-3, Assembly, Press Fixture) (3) and (special tool #1130, Splitter, Bearing/Gear) (4).
  56. Remove the clutch pack (2).
    GC0152146Courtesy of CHRYSLER GROUP, LLC
  57. Remove the O-ring and 5 squared O-rings.
  58. Remove the P1 annulus/B clutch hub assembly (1) from the P4 annulus drum.
    NOTE:

    The washer may stick to the bottom of the P1 annulus/B clutch hub assembly (1).

  59. Remove the selectable shim from the P1 annulus/B clutch hub.
  60. Remove the needle bearing and holding plate (2) from the P1 planetary carrier.
    GC0152147Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The (special tool #10378, Rings, Support) are three pieces intended to be used in multiple locations around the drum.

  61. Position the (special tool #10378, Rings, Support) (1) on the P4 annulus drum assembly to protect the drum.
    NOTE:

    Pry the snap ring from the opposite side of the snap ring openings to release.

    NOTE:

    When the snap ring is removed the internal clutch drum may drop slightly.

  62. Using a suitable tool (3), release the snap ring (2) by prying in and up from the opposite side of the snap ring openings.
    GC0152148Courtesy of CHRYSLER GROUP, LLC
  63. Remove the P1 planetary carrier (3).
    GC0154685Courtesy of CHRYSLER GROUP, LLC
  64. Remove P1/P2 (1) sun gear from the bottom of the P1 planetary carrier.
    GC0152150Courtesy of CHRYSLER GROUP, LLC
  65. Remove the input shaft with P2 planetary carrier (1) from the drum assembly.
  66. Remove the needle bearing (2) and washer.
    GC0152151Courtesy of CHRYSLER GROUP, LLC
  67. Remove the P2 annulus/P3 sun gear (1) from the drum assembly (2).
    GC0152172Courtesy of CHRYSLER GROUP, LLC
  68. Remove the D clutch drum (1) from the P4 annulus drum (2).
    GC0152152Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The (special tool #10378, Rings, Support) are three pieces intended to be used in multiple locations around the drum.

  69. Position the (special tool #10378, Rings, Support) (4) on the P4 annulus drum assembly to protect the drum.
  70. Using a suitable tool (1), release and remove the snap ring (2).
  71. Remove the P3 planetary carrier (3).
  72. Remove the needle bearing from the planetary carrier.
    GC0152170Courtesy of CHRYSLER GROUP, LLC
  73. Remove the P4 sun gear/C/E clutch retainer (1) from the D clutch drum (2).
    GC0152173Courtesy of CHRYSLER GROUP, LLC
  74. Remove the snap ring (1) from the P4 sun gear/C/E clutch retainer (2).
    GC0152174Courtesy of CHRYSLER GROUP, LLC
  75. Remove the P3 annulus (1) from the P4 sun gear/C/E clutch retainer (2).
    GC0152175Courtesy of CHRYSLER GROUP, LLC
  76. Remove the snap ring (1) from the P4 sun gear/C/E clutch retainer (2).
    GC0152176Courtesy of CHRYSLER GROUP, LLC
  77. Remove the E clutch (1) from the P4 sun gear/C/E clutch retainer (3).
  78. Remove the needle bearing (2) from the E clutch (1).
    GC0152177Courtesy of CHRYSLER GROUP, LLC
  79. Remove the C clutch (1) from the P4 sun gear/C/E clutch retainer (2).
  80. Remove the bearing from top and bottom of C clutch (1).
    GC0152270Courtesy of CHRYSLER GROUP, LLC
  81. Remove the P4 planetary carrier/output shaft (2) from the P4 annulus drum (1).
    GC0152178Courtesy of CHRYSLER GROUP, LLC
  82. Remove the snap ring (1) from the P4 annulus drum (2).
  83. Remove the P4 annulus (3) from the P4 annulus drum (2).
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