(~ATS&)I FORD 4R44E I 4R55E

INDEX

General Description..........................................................3

Vehicle Application...........................................................6

Bearings Bushings and Gaskets......................................7

Computer Sensors............................................................11

Diagnosis and Testing......................................................19

Transmission Disassembly...........................................31

Valve Body.........................................................................53

Pump Assembly.................................................................61

Clutch Drums.....................................................................65

Overdrive Planetary...........................................................81

Torque Converter..............................................................86

Transmission Assembly....................................................87

AUTOMATIC TRANSMISSION SERVICE GROUP9200 S. Dadeland Blvd.Suite 720MIAMI FLORIDA 33156(305) 670-4161

2

..

INTRODUCTIONFORD 4R44E 4R55E

The 4R44E/4R55E is a 4 speed fully computerized transmission. At a first glance it resembles the familiar A4LD. The shift cycles and the transmission oil pressure are computer controlled. These transmissions feature a four element torque converter including the converter clutch. There are three compund planetary gearsets, three bands, three multi-disc clutch packs and two one-way clutch assemblies.

This manual covers the inspection, teardown and assembly of this transmission along with the basic Diagnostic trouble codes. The ATSG PASS books cover computer diagnosing of these transmissions.

We thank the Ford Motor Company for the illustrations and informationthat have made this booklet possible

ROBERT D. CHERRNAYTECHNICAL DIRECTOR

DALE ENGLANDFIELD SERVICE CONSULTANT

WAYNE COLONNATECHNICAL SUPERVISOR

ED KRUSETECHNICAL CONSULTANT

PETELUBANTECHNICAL CONSULTANT

JIM DIALTECHNICAL CONSULTANT

GREGORY LIPNICKTECHNICAL CONSULTANT

JERRY GOTTTECHNICAL CONSULTANT

DAVID CHALKERTECHNICAL CONSULTANT

AUTOMATIC TRANSMISSION SERVICE GROUP9200 S. DADELAND BLVD.SUITE 720MIAMI, FL 33156 (305) 670-4161

I(~ATSGJ

FORD 4R44E/4R55E FULLY COMPUTERIZED A4LD GENERAL DESCRIPTION

The 4R44E/4R55EEautomatic (rear wheel drive) transmissions are four-speed units with electronic shift controls.

The 4R44E is used with 2.3L and 3.0L engine applications. The 4R55Etransmission is used with 4.0L engine applications.

These transmissions feature a four element torque converter including TCC (Torque Conveter Clutch).The gear train includes:

Three compound planetary gear setsThree bandsThree multi-plate clutchesTwo one-way clutchesThe hydraulic functions are directed by electronic solenoids to control: EngagementfeelShift feelShift schedulingModulated TCC applicationsTiming of the 3-2 T>D> and K>D>shiftsEngine braking (with O/D cancelled) utilizing the Coast ClutchManual first timingThermostat bypass and cooler unit

3

I(r:.ifl ATSG ) Service Information 4R44E 4R55E

TRANSMISSION RANGE SELECTOR AND SHIFT PATTERNS

The 4R44E/4R55Etransmission range selector lever has six positions: P exceeds scale set for Either high or low which will(open circuit) temperature -40C (-40F). result in harsh or soft shifts.

IAT temperature higher or Rerun on-board diagnostic114P0114IATIAT out of on-boarddiagnostic rangelower than expected duringKOEO and KOER.at normal operating temperature.

116Pl 116ECTECTout of on-boardECT temperature higher or lower than expected duringRerun on-board diagnostic at normal operating

dis.gnostic rangeKOEO and KOER.temperature.

Voltage drop across ECT Torque converter clutch will117 P0117 ECT

ECT indicates exceeds scale set for125c (254F> temperature 125 C (254 F)

always be off, resulting in(grounded). reduced fuel economy.Voltage drop across ECT Torque converter clutch will118 P0118 ECT

ECT indicates exceeds scale set for-40c C-40F> temperature -40C (40F)

always be off, resulting in(open circuit). reduced fuel economy.

TP voltage TP was not in lhe correct Rerun at appropriate121 Pl 124 TP

high/ low foron-board diagnostic.

position for on-board throttle position per diagnostic. application.P0121, Harsh engagements, firmP0122,122. 123, P0123, PCM has detected an error. shift feel, abnormal shift124, 125, Pl 120, TP TP concern This error may cause a schedule, torque converter167 Pt 121, transmission concern. clutch does not engage.Pl 125, Torque converter clutchP1124 cycling.High/ low EPC pressure,157, 158, P0102, MAF system has a incorrect shift schedule.159, 184, P0103, MAF MAF concerns malfunction which may Incorrect torque converter185 P1100, cause a transmission clutch engagementPl 101 concern. scheduling. Symptomssimilar to a TP failure.212 P0300-P0308 Harsh engagements and211-219 El system has a malfunction221-224 P0320, El El concerns which may cause a shifts, late WOT shifts, no232-239 P0340 transmission concern. torque converter clutch241-243 P1351-P1364 engagement.PCM detected a loss of Torque converter clutch452 P0500 vss Insufficient input vehicle speed signal during engages, shiftfromVSS. operation. engagement I disengage-ment (hunting) on grades.PCM detected on erratic Torque converter clutch- P1500 vss Intermittent VSS vehicle speed signal during engages, shiftoperation. engagement I disengage-ment (hunting) on grades.

522 P1705 TR TR not i

Brake nn PARK. On-board diagnostic in PARK.not runRerun on-board diagnostic in PARK.

Failed ON or not connected

- torque converter clutch

otwill not engage at less than

536P1703actuateBOO on-board during Brake not cycled durd KOER.ing1/3 throttle.Failed OFF or note

diagnostic.connected - torque

converter clutch will not

disengage when brake is applied.

28

I(~RTS6) Service Information4R44E 4R55E

Three-Digit Four-DigitOTC OTC Component Description Condition Symptom

Failed ON or note connected - torque converter clutch will not engage at less than 1 / 3

-P1703 BOO BOO switch circuit Brake ON I OFF circuit throttle.failed. failure during KOEO. Failed OFF or notconnected - torque converter clutch will not disengage when brake is applied.A IC or Defrost ON condition OTC set during on-boardA/C clutch cycling may result from A IC clutch diagnostic - rerun with539 P1460 A/C pressure switch being ON during on-board AICOFF.error diagnostic. Failed ON - EPC pressureslightly low with A IC OFF.Improper gear selection depending on failure orSS1, SS2, mode and manual lever position. Shift errors may645. P07310 SS3or tst gear error No 1st gear.internal parts

also be due to other internal transmission concerns (stuck valves, damaged friction material).Improper gear selection depending on failure orSS1, SS2, mode and manual lever646. P0732" SS3or 2nd gear error No 2nd gear. position. Shift errors may internal parts also be due to otherinternal transmissionconcerns (stuck valves. damaged friction material).Improper gear selection depending on failure orSS1, SS2, mode and manual lever647. P0733'' SS3or 3rd gear error No 3rd gear. position. Shift errors mayinternal parts

also be due to otherinternal transmission concerns (stuck valves, damaged friction material).Improper gear selection depending on failure orSS1. SS2, mode and manual lever648'. P0734'' SS3or 4th gear error No 4th gear. position. Shift errors mayInternal parts also be due to otherinternal transmissionconcerns (stuck valves, damaged friction material).

SS 1 circuit failed to provide Improper gear selection voltage drop across depending on condition621' P0750' SS1 SS 1 solenoid solenoid. Circuit open or mode and manual levercircuit failure shorted or PCM driver position. See Solenoidfailure during on-boarddiagnostic. Ont Off charts.SS2 circuit fails to provide Improper gear selection voltage drop across depending on condition622' P0755' SS2 SS2 solenoid solenoid. Circuit open or mode and manual levercircuit failure shorted or PCM driver position. See Solenoidfailure during on-boarddiagnostic.

On I 011 charts.

Failed ON - Overdrive cancel mode always ON. NO flashing TCIL for EPC631 -

TCIL TCIL circuit failure TCIL circuit open or failure or sensor.shorted. Failed OFF - Overdrivecancel mode never indicated. NO flashing TCIL for EPC sensor failure.

29

I(~RTSli) Service Information 4R44E 4R55E

Three-Digit Four-DigitOTC OTC Component Description Condition SymptomShort Circuit - Causes minimum EPC pressureEPC solenoid Voltage through EPC (minimum capacity) end624 P1747" EPC circuit failure, solenoid is checked. An limits engine torqueshorted circuit. error will be noted if (alternate firm). Zero EPCtolerance is exceeded. - no 2nd and 4th gear.Slips in 1st and 3rd with high torque input.Voltage through EPC Shorted PCM - Causess2s - EPC Shorted PCM solenoid is checked. An maximum EPC pressure, output driver. error will be noted if harsh engagements andtolerance is exceeded. shifts.

The PCM picked up en TCC slippage I erratic or no62s P0741 TCC

TCC slippage excessive amount of TCCdetected. slippage during normal

torque converter clutchvehicle operation. operation. Flash TCIL.

TCS not cycled during self Rerun on-board diagnostic632 P1780 TCS TCS not changing test. TCS circuit open or end cycle switch. No)states.

shorted.

cancel when switch iscycled.

TFTout ofTransmission not et636P1711TFTon-boardoperating temperaturediagnostic range.-40C (-40F)during on-board diagnostic.Voltage drop across TFTWarm vehicle to normal operating temperature.

637 P0713 TFT indicated TFT sensor exceeds scale set Firm shift feel. sensor circuit for temperature -40 Copen. (-40F)157C (315F) Voltage drop across TFT638 P0712 TFT indicated TFT sensor exceeds scale set Firm shift feel. sensor circuit for temperature of 157Cgrounded. (315F)Insufficient input PCM detected a loss of TSS Harsh shifts, abnormal shift639 P07f5 TSS from Turbine Shaft signal during operation. schedule, no torqueSpeed Sensor. converter clutch activation.Short circuit - EngineTCC solenoid circuit fails to stalls in second (OD, 2TCC solenoidcircuit failure provide voltage drop across range) at low idle speeds652 P0743' TCC during on-board solenoid. Circuit open or with brake applied. shorted or PCM drive failure Open circuit - Torquediagnostic.

during on-board diagnostic. converter clutch never engages.Transmission Transmission fluid657 P1783 TFT overtemp temperature exceeded Increase in EPC pressure.conditionindicated.

127C (270F).

667 P0707 TR

TR circuit below TR sensor. circuit or PCM Increase in EPC pressure. minimum voltage. shorted or grounded.

668 P0708 TR

TR circuit above TR sensor, circuit or PCM Increase in EPC pressure. maximum voltage. indicates open.

Shift solenoid No. Mechanical or hydraulic Improper gear selectionNIA P0751 SS1 1 functional failure(California only).

failure of the shift solenoid.

depending on failure modeend manual lever position.

Shift solenoid No. Mechanical or hydraulic Improper gear selectionNIA P0756 SS2 2 functional failure failure of the shift solenoid. depending on failure mode(California only) and manual lever position.

TCC solenoid

TCC solenoid has failed ON

NIA P1743 TCC failed ON. by electric, mechanical or Harsh shifts. hydraulic concern.

30(~RTs&I Service Information 4R44E 4R55E

Three-DigitFour-Digit

DTC

633DTC

P1781Component

4x4LDeacrlptlon4x4-iOW iiwltch Sfailure. dConditionwitch closed or shorted uring KOEO.Symptom

Early or delayed shifts.

691P17294x4L4x4 low switchfailure. Circuit open/ shorted.Early or delayed shifts.

NIA P1751. SS1

Shift solenoid No.1 functional failure(49-State).

Mechanical or hydraulic failure of the shift solenoid.

Improper gear selection depending on failure mode and manuallever position.

NIA P1756 .. SS2

Shift solenoid No.2 functional failure(49-State).

Mechanical or hydraulic failure of the shift solenoid.

Improper gear selection depending on failure mode and manuallever position.

NIA

P0761

SS3

Shift aolenold No.3 functional failure(California).

Mechanical or hydraulic failure of the shift solenoid.

Improper gear selection depending on failure mode and manuallever position.

Shift solenoid No. Mechanical or hydraulic Improper gear selectionNIA P 11e1 SS3 3 functional failure failure of the shift solenoid. depending on failure mode(49-State). and manuallever position.

Failed ON - EPC slightly high, firm engagements, firm shifts, harsh519P1650 PSP PSP circuit open PSP circuit open. coastdown shifts. during KOEO. Failed OFF - EPCpreBSureslightly low duringIncreased loading of vehicle power steering.PSP not changing Operator did not rotate Fault detected. RerunSelf521 P1651 PSP

atateKOER.

steering wheel during Test and rotate steeringKOER. wheel.

SS3 circuit failed to provide Improper gear selection voltage drop acroeeSS3 solenoid solenoid. Circuit open or depending on condition641 P0760 SS3

circuit failure. shorted or PCM driver failure during on-board

mode and manualleverposition. See Solenoiddiagnostic. On/Off chart.

CCS circuit failed to provide Failed on - no coaat voltage drop acro88 braking except In 4th gear.

-643 p1754 ccs

CCS solenold solenoid. Circuit open orcircuit failure. shorted or PCM driver

Delayed 3-2 shifts. Failedfailure during on-board off - coaat braking 2nd, diagnostic.3rd. Firm 3-2 and 4-3 shifts.

Voltage through EPC Open Circuit - Causes e24 P1746 .. EPC EPC aolenold solenoid la checked. Error maximumEPCpreHure,circuit open. la noted If tolerance la harsh engagementsandexceeded. shift a.Reverse EPC preHure la low, no EPCpra11urelow, SS 1 laP1701 Tranaml11ion engagement error drop In TSS rpm, TR off, engine lacks power.Indicates reverse

31

I(rJIRTSGI Service Information 4R44E 4R55E

TRANSMISSION DISASSEMBLY

Transmission

SPECIAL SERVICE TOOL(S) REQUIRED

Description Tool Number

Torque Converter Handles T81P-7902-C Seal Remover T7 4P-77248-A Impact Slide Hammer T50T-100-A Extension Housing Bushing Remover T77L-7697-E A4LD Holding Fixture Adapter T93T-77002-AH Bench-Mounted Holding Fixture T57L-500-B A4LD Transmission Test Plate T86L-7006-A

Disassembly1.WARNING: DO NOT REMOVE THE TORQUE CONVERTER OR TRANSFER CASE FROM THE TRANSMISSION WHILE STILL ON THE JACK. DOING SO COULD CAUSE THE TRANSMISSION TO FALL OFF THE JACK.Relocate the transmission to the top of a flat workbench.

2.

If the vehicle has a transfer case, use a 13mm socket to remove the five transfer case to extension housing bolts. Remove the transfer case and set aside for assembly.

TRANSFER CASE-7A195

3.WARNING: THE TORQUE CONVERTER IS HEAVY, ESPECIALLY WHEN FULL OF FLUID.Remove the torque converter using TorqueConverter Handles T81P-7902-C.

TORQUE CONVERTER HANDLES-T81 P-7902-C

TORQUE CONVERTER7902

32

(f'JIATSG) Service Information 4R44E 4R55E

4.NOTE: The splines on the input shaft are not the same on both ends. The end with the shorter spline goes into the assembly.Remove the input shaft.

INPUT SHAFT7017

5.Remove the extension housing seal using Seal Remover T7 4P- 77248-A and Impact Slide Hammer TSOT-100-A.

6.NOTE: Remove the extension housing bushing only if service is required.Inspect the extension housing bushing and driveshaft slip yoke for nicks, gouges, scoring and wear.Remove the extension housing bushing usingExtension Housing Bushing RemoverT77L-7697-E.

EXTENSION HOUSING7A039

EXTENSION HOUSINGBUSHING REMOVERT??L-7697-E

7. CAUTION: The parking pawl, parking pawl return spring and parking pawl shaft could fall out during removal of the extension housing.Use a 17mm socket to remove the four M 10 x30mm extension housing to transmission case screws and two studs.

EXTENSION HOUSING7A039

SEAL REMOVER T74P-77248-A

IMPACT SLIDE HAMMER T90T-100-A

CASE7005

EXTENSION HOUSING7A039

33(r:.Rts&I Service Information 4R44E 4R55E

8.Remove the parking pawl, parking pawl return spring and parking pawl shaft.

PARKING

10. Attach the fixture arm assembly (part ofT57L-500-B) with two 7I16 x 2-inch bolts and nuts.RODGUIDECUP (PRESS FIT)

PARKINGPAWLRETURNSPRING7D070

FIXTURE ARM (PART OF BENCH MOUNTED HOLDING FIXTURE-T57TL-500-B)

PARKING PAWL7A441

PARKING PAWL SHAFT7D071

9. CAUTION: The parking pawl actuating rod must slip freely into the clearance hole In the adapter plate.NOTE: See the special service tool section for a drawing of this optional adapter plate.Use the four M 10 x 30mm extension housing to transmission case screws to attach the adapter plate to the transmission.

A4LD HOLDING FIXTURE ADAPTER T93T-77002-AH

PARKING PAWL ACTUATING ROD7A232

11. WARNING: MAKE SURE THE LOCK PIN ON BENCH-MOUNTED HOLDING FIXTURE T57L500-B IS SECURE.Install the transmission assembly toBench-Mounted Holding Fixture T57-500-B. Rotate to the position shown. Place a drain pan under the assembly.

BENCH MOUNTED HOLDING FIXTURE T57L-900-B

34

I(~ATS61 Service Information 4R44E 4R55E

12. NOTE: A transmission heat shield is on all 4.0Lapplications.Remove the M6 x 1.0 transmission heat shield nut from the studded bolt.

TRANSMISSION HEAT SHIELD7F013

13. Carefully pry the transmission heat shield off of the fluid pan rail near the retaining clips.

14. WARNING: MAKE SURE THE LOCK PIN ON BENCH-MOUNTED HOLDING FIXTURE T57L-500-B IS SECURE.Rotate the transmission assembly so the converter housing is facing up. 15. Remove the manual control outer lever nut and manual control outer lever.

16. Remove the two M6 x 25 transmission range (TR)sensor bolts and remove the TR sensor.

TRANSMISSION RANGE (TR) SENSOR7A247

17. WARNING: MAKE SURE THE LOCK PIN ON BENCH-MOUNTED HOLDING FIXTURET57L-500-B IS SECURE.Rotate transmission assembly so that the fluid pan is facing up.18. CAUTION: Do not reuse the fluid pan gasket.Use a 13mm socket to remove the eighteen MB x1.4mm fluid pan screws. Remove the fluid panand fluid pan gasket. Discard the fluid pan gasket.

35

I(r:.ATSlil Service Information 4R44E 4R55E

Fluid Pan Removal

FLUID PAN SCREWS W701203-S309M (18 REO'D)

FLUID PAN7A194

WIRE LOOM GUIDE AND PROTECTOR

21. Disconnect the six solenoid connectors from the solenoids by carefully pulling upward and moving side to side.

19. Use a 10mm socket to remove the M6 x 55mm fluid pan filter assembly screw. Remove the fluid pan filter assembly.

Fluid Pan Fiiter Removal

SOLENOID CONNECTOR

20. Carefully lift up on the wire loom guide and protector. Disengage the retaining pins from the solenoid brackets.

36

I (r..aATSGI Service Information 4R44E 4R55E

22. Use a 10mm socket to remove the M6 x 30mm manual valve detent spring screw. Remove the manual valve detent spring.

Part

1EB00156-SScrew, M6 x 20mm270306Reverse Servo Cover37L173Reverse Servo to CaseGasket4EB60167-SRetaining Ring57423Reverse Servo Piston SealRing-Large67E266Reverse Servo Piston77423Reverse Piston Seal Ring - Small870300Rear Servo Cushion SpringRetainer970190Reverse Servo RodItem Number Description

23. Use a 10mm socket to remove the four M6 x20mm reverse servo cover screws. Remove the reverse servo cover, reverse servo piston and rod and reverse servo.

REVERSE SERVO COVER70036

24. NOTE: Refer to the main control disassembly and assembly in this section.Use a 1 Omm socket to remove the seventeen M6 x 40mm, four M6 x 45mm and three M6 x 35mm main control valve body screws.

DO NOT REMOVE THESE BOLTS

37

I(~RTSGI Service Information 4R44E 4R55E

25. Remove the main control assembly.

26. NOTE: The J-hook must be in the appropriate hole for the servo being removed.Install Servo Cover Compressor T95L-77028-A ov.er the intermediate servo cover at the fluid pan rail. Tighten the bolts.

27. Using a 1I2-inch wrench, tighten the nut on the J-hook until there is a gap between the servo cover and the snap ring.

29. CAUTION: The servo cover is under spring tension.Carefully back off the nut on the J-hook until the servo spring is unloaded.30. WARNING: AIR PRESSURE SHOULD NOT BE GREATER THAN 138 KPA (20 PSI). WEAR SAFETY GLASSES WHEN USING COMPRESSED AIR. THE PISTON ASSEMBLY CAN POP OUT UNEXPECTEDLY DUE TO SPRING PRESSURE BEHIND THE PISTON. DO NOT STAND DIRECTLY IN FRONT OF THE PISTON.NOTE: Light tapping on the cover and case, or air pressure applied on the release side may be needed. Use 4R44E/ 4R55E Transmission Test Plate T95L-77000-AH and Transmission Test Plate Gasket T95L-7006A.NOTE: Tag the spring, piston and cover assembly. Label accordingly for assembly. The covers have letters cast on the outer surface for identification.Remove the intermediate servo cover, piston and spring.

INTERMEDIATE SERVO AND SEAL ASSEMBLY-70027

INTERMEDIATE SERVO PISTON SPRING-70028

SERVO COVER COMPRESSOR T95L-77028-A

28. Carefully remove the servo cover snap ring.

INTERMEDIATE SERVO PISTON AND ROD ASSEMBLY-7D021

38I (r:.ATSG) Service Information 4R44E 4R55E

31. Remove Servo Cover CompressorT95L-77028-A.32. NOTE: The J-hook must be in the appropriate hole for the servo being removed.Install Servo Compressor T95L-77028-A over the overdrive servo cover at the fluid pan rail. Tighten the bolts.

33. Using a 1 I 2-inch wrench, tighten the nut on the J-hook until there is a gap between the servo cover and the retaining ring.

SERVO COVER COMPRESSOR T95L- 77028-A

34. Carefully remove the servo cover retaining ring.

RETAINING RING E860343-S

36. WARNING: AIR PRESSURE SHOULD NOT BE GREATER THAN 138 KPA (20 PSI). WEAR SAFETY GLASSES WHEN USING COMPRESSED AIR. THE PISTON ASSEMBLY CAN POP OUT UNEXPECTEDLY DUE TO SPRING PRESSURE BEHIND THE PISTON. DO NOT STAND DIRECTLY IN FRONT OF THE PISTON.

NOTE: Light tapping on the cover and case, or air pressure applied on the release side may be needed. Use 4R44E I 4R55E Transmission Test Plate T95L-77000-AH.NOTE: Tag the spring, piston and cover assembly. Label accordingly for assembly. The covers have letters cast on the outer surface for identification.

Remove the overdrive servo cover, piston and spring.

OVERDRIVE SERVO PISTON AND ROD ASSEMBLY-70021

OVERDRIVE COVER AND SEAL ASSEMBLY-7l493

OVERDRIVE SERVO PISTON SPRING-70028

37. Remove Servo Cover CompressorT95L-77028-A.

35. CAUTION: The servo cover Is under spring tension.

Carefully ~a~k off the nut on the J-hook until the servo spnng rs unloaded.

38. WARNING: MAKE SURE THE LOCK PIN ON BENCH-MOUNTED HOLDING FIXTURE T57L-500-B IS SECURE.Rotate the transmission assembly with the converter housing facing up.

39

I(r.::ilJ:ITS6 ) Service Information 4R44E 4R55E

39. CAUTION: Throw the locknuts away. The locknuts are not reusable for assembly.Remove the overdrive and intermediate band locknuts and back off the band adjusting screws.OVERDRIVE BAND OVERDRIVE BAND LOCKNUTADJUSTING SCREWE825100-S 100 7C492

*II

41. NOTE: Rotate and lift the converter housing so that the clutch assemblies will stay in place.Remove the converter housing and front pump support and gear assembly.CONVERTER HOUSING7976

40.

INTERMEDIATE BAND ADJUSTING SCREW7c492

42. NOTE: Refer to converter housing and pump assembly under subassemblies for service information.Remove the fluid pump gasket and No. 1 front pump thrust washer and discard gasket. Tag the No. 1 front pump thrust washer for identification.

N0.1 FRONTPUMP THRUST WASHER7D014

FRONT FLUID PUMP GASKET7A136

40

I(ea ATS&) Service Information 4R44E 4R55E

43. Compress the overdrive band around the overdrive brake and coast clutch drum. Remove the overdrive band anchor strut and adjusting screw.

OVERDRIVE BAND ANCHOR STRUT7D430

44. CAUTION: Identify which end of the overdrive band Is the anchor side or tht apply side.Remove the overdrive band.

APPLY SIDE

OVERDRIVE BAND7D034

45. Remove the overdrive brake and coast clutch drum.

OVERDRIVE BRAKE AND COAST CLUTCH DRUM7L669

46. Remove the overdrive band apply strut.

OVERDRIVEBANDAPf'L Y STRUT70029

41

(r:.ATsGJ Service Information 4R44E 4R55E

47. NOTE: Tag and identify the overdrive lever for assembly. The overdrive lever has a letter stamped into its side.NOTE: The overdrive band actuating lever shaft is longer than the intermediate shaft.Remove the overdrive band actuating lever shaft.

OVERDRIVE BAND ACTIVATING LEVER SHAFT7D433

48. CAUTION: Do not bend the exciter wheel.

NOTE: No.12 and No. 2 thrust bearings are in this assembly.Remove the planet gear overdrive carrier.

PLANET GEAR OVERDRIVE CARRIER78446

49. Remove the servo band lever and overdrive control bracket.

OVERDRIVE BAND LEVER TO CASE BRACKET-7A653

OVERDRIVE BAND SERVO LEVER .7330

50. Remove the overdrive ring gear, overdrive one-way clutch and overdrive center shaft assembly.

OVERDRIVE RING GEAR OVERDRIVE ONE-WAY CLUTcH AND OVERDRIVE CENTER SHAFT ASSEMBLY

42(r:.RTSlil Service Information 4R44E 4R55E

51. NOTE: Tag and identify the No. 3 center shaft thrust bearing assembly for assembly.Remove the No. 3 center shaft thrust bearing assembly.

I r f'':::::::E;:::::::::::~~if'NO_ 3 CENTER SHAFTTHRUST BEARING ASSEMBLY70014

52. CAUTION: The center support locking nut could fall Into the remaining assembly If not removed.Use a 5mm Allen wrench to remove the M6 x20mm center support capscrew. Remove the locking nut from the center support.CENTER SUPPORT CAPSCREW E804373S

LOCKING NUT AND CAGE EB26160-S76

53. CAUTION: Do not pry on other wires or damage the connector or case surface.Carefully disconnect the turbine shaft speed sensor {TSS) connector from the 16-pin case connector.

l J L ,::=J< J('-----0~~c:'. 0

{

TURBINE SHAFT SPEED(TSS)SENSORCONNECTOR(PART OF 7M101)

..43

I(~RTSGJ Service Information 4R44E 4R55E

54. Use a T30 Torx bit to remove the TSS screw.Remove the TSS.

55.

CASE CONNECTOR RETAINING RING84280020

)

\"'84~DJ/'~~ ---

56. CAUTION: Do not overstretch the case connector retaining ring.

Use a screwdriver to carefully remove the case connector retaining ring.

57. CAUTION: Do not damage the connector or harness.Carefully push down on the top of the connector until it stops. Depress the tab on the back side of the connector and push down on the connector. Remove the connector and harness through the bottom of the case.

58. Remove the center support retaining ring.

CENTER SUPPORT RETAINING RING W702465-S300

44

(~RT56) Service Information 4R44E 4R55E

59. Remove the center support by pulling evenly around the center support web.

CENTER SUPPORT7A130

60. NOTE: Tag and identify the No. 4 intermediate brake drum thrust bearing for assembly.Remove the No. 4 intermediate brake drum thrust bearing.

INTERMEDIATE BAND ADJUSTING SCREW

u17C949

~

~nINTERMEDIATE BAND ANCHOR STRUT

62. CAUTION: Identify which end of the intermediate band is the anchor side or the apply side.

..Remove the intermediate band.

APPLYSIDE

NO. 4 INTERMEDIATE BRAKE DRUM THRUST BEARING7L326

61. Remove the intermediate band anchor strut through the bottom of the case. Remove intermediate band adjusting screw.

ANCHORSIDE

INTERMEDIATE BAND7D034

45

I(r:.RTSGI Service Information 4R44E 4R55E

63. Remove the intermediate band apply strut.

INTERMEDIATE BAND APPLY STRUT7D029

64. NOTE: The intermediate band actuating lever shaft is shorter than the overdrive band actuating lever shaft.

Remove the intermediate band actuating lever shaft.

INTERMEDIATE BAND ACTUATING LEVER SHAFT- 7D433

65. NOTE: Tag and identify the intermediate band servo lever for assembly. The intermediate band servo lever has a letter stamped on its side for identification.Remove the intermediate band servo lever.

66. CAUTION: Make sure the lock pin onBench-Mounted Holding Fixture T57L-500-Bis secure.Rotate the transmission so the fluid pan surface is facing up.

46

I

(~RTSG) Service Information 4R44E 4R55E

67. NOTE: The No. 5 forward clutch cylinder thrust washer may come out with the intermediate brake and direct clutch drum.Remove the intermediate brake and direct clutch drum.

.:

INTERMEDIATE BRAKE AND DIRECT CLUTCH DRUM7D044

68. Remove the No. 5 forward clutch cylinder thrust washer.

69. NOTE: The No. 5 forward clutch cylinder thrust washer may come out with the forward clutch cylinder.Remove the forward clutch cylinder.

FORWARD CLUTCH CYLINDER7A360

70. Remove the forward ring gear and forward ring gear hub.

I

/

FORWARD RING GEAR AND FORWARD RING GEAR HUB

N0.5 FORWARD CLUTCH CYLINDER THRUST WASHER7C096

47

I(r:.ATS61 Service Information4R44E 4R55E

71. Remove the No. 7 forward planet thrust bearing.

FORWARD PLANET THRUST BEARING (NO. 7)7F374

72. NOTE: The forward planet assembly is model dependent.Remove the forward planet assembly.

FORWARD SUN GEAR7D063

INPUT SHELL7D064

7 4. NOTE: 4.0L engines do not have this retaining ring.Remove the reverse planet retaining ring.

IFORWARDPLANET ASSEMBLY7A398

73. Remove the input shell with forward sun gear.

REVERSE PLANET RETAINING RING E860119-S

75. NOTE: The No. 8 reverse planet carrier thrust washer is model dependent.NOTE: Tag and identify the No. 8 reverse planet carrier thrust washer for assembly.Remove the reverse planet assembly and No. 8 reverse planet carrier thrust washer.

48

I(~RT56) Service Information4R44E 4R55E

2.3L, 3.0L

NO. 8 REVERSE PLANET CARRIER THRUST WASHER7A166 REVERSE PLANETASSEMBLY70006

4.0L

NO. 8 REVERSE PLANET CARRIER THRUST WASHER7A166

REVERSE PLANET ASSEMBLY70006

76. NOTE: The No. 9 reverse planet carrier thrust washer is model dependent.Remove the No. 9 reverse planet carrier thrust washer ..

NO. 9 REVERSE PLANET CARRIER THRUST WASHER7A166

77. NOTE: The output shaft sleeve is on 4.0Lapplications only.Remove the output shaft sleeve.

OUTPUT SHAFT SLEEVE-7B176

49

I(~RTSGI Service Information 4R44E 4R55E

78. CAUTION: Discard the output shaft retaining ring. A new retaining ring must be used for assembly.Remove the output shaft retaining ring from inside the case on the output shaft.

/ (//

NO. 10 OUTPUT SHAFT HUB THRUST WASHER70422

OUTPUT SHAFT RETAINING RING E860927-S

79. Remove the output shaft ring gear and output shaft hub.

OUTPUT SHAFT RING GEAR AND OUTPUT SHAFT HUB

80. NOTE: The No. 10 output shaft hub thrust washer is model dependent.NOTE: Tag and identify the No. 10 output shaft hub thrust washer for assembly.Remove the No. 10 output shaft hub thrust washer.

81. NOTE: The inner race of the rear one-way clutch is not removable. It is serviced in the case.Remove the reverse brake drum and the one-way clutch assembly.

Reverse BrakeDrum and One Way ClutchAssemblyRemoval, 2.3L, 3.0L

REPLACING GUIDE TOOL T74P-77193-A

REVERSE BRAKE DRUM7C498

50

I(r.3AT561

Service Information 4R44E 4R55E

Reverse Brake Drum and One Way Clutch AssemblyRemoval, 4.0L

REVERSE BRAKE DRUM7C498

82. Remove the reverse band.

84. Remove the park gear.

REVERSE BAND70095

83. CAUTION:The output shaft Is model dependent. The 4.0L output shaft does not use lube holes.Remove the output shaft.

PARK GEAR7M092

51

I(r.;aRtsGI Service Information4R44E 4R55E

85. NOTE: Tag and identify the No. 11 output shaft thrust washer for assembly.Remove the No. 11 output shaft thrust washer.

N0.11OUTPUT SHAFTTHRUST WASHER78368

PARKING PAWL ACTUATING ROD7A232

MANUAL VALVE INNER LEVER7A115

86. CAUTION: To avoid damage, make sure wrench does not strike the manual valve Inner lever pin.Remove the manual valve inner lever nut.

MANUAL VALVE INNER LEVER7A115

MANUAL VALVE INNER LEVER NUT W701271-S309

87. Remove the manual valve inner lever and parking pawl actuating rod assembly.

88. CAUTION: Do not damage the case fluid pan rail.Using ~small hammer and drift, tap lightly on each side of the manual control lever shaft retaining pin (two or three times). This will loosen the pin prior to removal.

MANUAL CONTROL LEVER SHAFT RETAINING PIN E840125-E

MANUAL CONTROL LEVER SHAFT7A308

52

I(~ATSG) Service Information 4R44E 4R55E

89. CAUTION: Do not damage the case fluid pan rail.Remove the manual control lever shaft retaining pin with a narrow, sharp edged screwdriver from the side as shown.

MANUAL CONTROL LEVER SHAFT RETAINING PIN E840125-S

90. Remove the manual control lever shaft.

91. CAUTION: Do not damage the bore.Remove the manual control lever seal.

53(~RTSG) Service Information 4R44E 4R55EDISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES

Main Control Valve Body

Main Control Valve Body

I

~

54(r:iiRTsGI Service Information 4R44E 4R55EDISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES

PartItem Number Description1 - Manual Valve(Part of 7A100)2 - Valve Plug Retainer(Part of 7A100)3 - Valve Retainer Plug(Part of 7 A 100)4 - Forward Modulator Valve(Part of 7A100)5 - Forward Modulator Spring(Part of 7A100)6 - Valve Plug Retainer(Part of 7A100)7 - Valve Retainer Plug(Part of 7A100)8 - EPC Boost Valve(Part of 7A100)9 - EPC Boost Spring(Part of 7 A 100)10 - Valve Plug Retainer(Part of 7A100)11 - Pressure Boost ValveSleeve(Part of 7A100)12 - Pressure Boost Valve(Part of 7A100)

1415--(Part of 7A100)Oil Pressure RegulatorSpring(Part of 7A100)Main Regulator Spring42-Solenoid Regulator Spring(2.3L, 1 Req'd)Solenoid Regulator Outer Spring (3.0L, 4.0L) Solenoid Regulator Inner16-Retainer(Part of 7A100)Pressure Regulator Valve43-Spring (3.0L, 4.0L)(Part of 7 A 100)Valve Retainer Plug(Part of 7A100)(Part of 7 A 100)17-Valve Retainer Plug44-Coast Clutch Valve(Part of 7 A 100)(Part of 7 A 100)18-Forward EngagementControl Spring45-Coast Clutch Spring(Part of 7 A 100)1920-7M107(Part of 7A100)Forward EngagementControl Valve(Part of 7 A 100)Shift Solenoids and Coast464748---Valve Retainer Plug(Part of 7A100)Solenoid Regulator Valve(Part of 7 A 100)Solenoid Regulator Spring21-Clutch Solenoid (4 Req'd)3-2 Spring496916(Part of 7 A 100)EPC Solenoid22-(Part of 7A100)3-2 Valve50-Valve Plug Retainer(Part of 7 A 100)(Part of 7A100)51-Valve Retainer Plug23-Manual Low Spring(Part of 7 A 100)(Part of 7A100)52-1-2 Shift Valve24-Manual Low Valve(Part of 7 A 100)(Part of 7A100)53-1-2 Shift Valve25-Valve Retainer Plug(Part of 7 A 100)(Part of 7A100)54-1-2 Shift Spring26-3-2 Valve(Part of 7 A 100)(Part of 7 A 100)55-Valve Retainer Plug27-3-4 Shift Valve(Part of 7 A 100)28-(Part of 7A100)3-4 Shift Spring56-2-3 Shift Spring(Part of 7 A 100)(Part of 7A100)57-23 Shift ValveContinued)(Part of 7 A 100)(Continued)13 - Pressure Boost Spring

PartItem Number Description29 - Valve Plug Retainer(Part of 7 A 100)30 - Thermostat Bypass Spring(Part of 7 A 100)31 - Thermostat Bypass Valve(Part of 7 A 100)32 - Thermostat Bypass Valve(Part of 7A100)33 - Thermostat Bypass Spring(Part of 7 A 100)34 - Valve Retainer Plug(Part of 7A100)35 - Cooler Limit Spring(Part of 7A 100)36 - Cooler Limit Valve(Part of 7 A 100)37 7F037 Torque Converter Clutch(TCC) Solenoid38 - Converter Clutch Valve(Part of 7 A 100)39 - Converter Clutch Spring(Part of 7 A 100)40 - Valve Retainer Plug(Part of 7 A 100)41 - Solenoid Regulator Valve(Part of 7A 100)

(

55(r,;aAT56) Service Information 4R44E 4R55EDISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES

PartItem Number Description58 - Valve Retainer Plug(Part of 7 A 100)59 - Reverse Modulation Valve(Part of 7 A 100)60 - Reverse Modulation Spring(Part of 7A 100)61 - Valve Retainer Plug(Part of 7 A 100)62 - Reverse Modulation Valve(Part of 7 A 100)63 - Extension Housing LubeOrifice(Part of 7A 100)64 - Relief Valve - EPC Limit I Converter (Part of 7 A 100)65 - Relief Spring(Part of 7 A 100)66 - Check Balls (4 Req'd) (Part of 7 A 100)

PartItem Number Description67 7L491 Solenoid Bracket - EPC, SS2, SS4, TCC68 7L491 Solenoid Bracket - SS 1, SS369 E800341-S Solenoid Bracket Screws(2 Req'd)70 - Identification Plate(Part of 7A100)71 7A100 Main Control Valve Body72 70100 Control Valve BodySeparating Gasket73 - Valve Body Separating Plate(Part of 7A 100)74 E804357-S76 Separating Plate-to-MainControl Screws(3 Req'd)75 - EPC Limit Circuit Screen(Part of 7A100)(Continued)

Disassembly

PartItem Number Description6 7M107 Shift Solenoid 3

1. NOTE: SS3 may pop out of its bore.Use a 1 Omm socket to remove the SS 1 and SS3 solenoid bracket bolts. Remove the solenoid bracket and the solenoids.

SS1 AND SS3SOLENOIDBRACKET7L491

ItemPartNumberDescription17F037Torque Converter ClutchSolenoid27M107Coast Clutch Solenoid37M107Shift Solenoid 246916EPC Solenoid57M107Shift Solenoid 1(Continued)

56(eaATsGJ Service Information 4R44E 4R55E

2. NOTE: The TCC solenoid may pop out of its bore.The converter modulator valve may come out after the TCC solenoid has been removed.Remove the TCC, CCS, SS2 and EPC solenoid bracket bolt.

TCC, CCS, SS2 AND EPC SOLENOID BRACKET7L491

4. CAUTION: Valves may come out when rotating the main control.Carefully rotate the main control assembly so that the control valve body-to-case gasket is facing up. Remove and discard the control valve body-to-case gasket.

\

CONTROL VALVE BODY-TO-CASE GASKET-7C155

3. Remove the solenoid bracket and the solenoids.

TCC. SS4, SS2 AND EPC SOLENOID BRACKET7L491

5.Use a T30 Torx bit to remove the three separating plate-to-main control screws.

SEPARATING PLATE-TO-MAIN CONTROL SCREWS-EB04357-S76(3 REO'D)

57(~RT56) Service Information 4R44E 4R55E

6. CAUTION: The extension housing lube orifice and relief valves may stick to the separating plate.Remove the valve body separating plate.

-0 aCl

9. Remove the EPC limit relief valve and spring.

EPC LIMIT RELIEF VALVE AND EPC LIMIT RELIEF SPRING

0 00

Oo ...

-i>

VALVE BODY SEPARATING PLATE7A008

7.Remove and discard the control valve body separating gasket.

10. Remove the converter relief valve and spring.

CONTROL VALVE BODY SEPARATING GASKET7D100

8.Carefully remove the extension housing lube orifice.

EXTENSION HOUSING LUBE ORIFICE7D376

11. Remove the EPC limit circuit screen.

58

II (r:..AT56) Service Information 4R44E 4R55E

12. Remove the four check balls.

19. Remove and replace all shift and coast clutch solenoid 0-rings.

SHIFT SOLENOID7M107 (4 REQ'D)

20. Clean and inspect the torque converter clutch(TCC) solenoid.

CHECK BALLS7E195(4 REO'D)

13. CAUTION: Do not lose parts when cleaning or servicing.

Thoroughly clean all parts in solvent and blow dry with moisture-free compressed air.14. Inspect all valve and plug bores for scores. Check all fluid passages for obstructions. Inspect the check valve for free movement. Inspect all mating

Assembly

TORQUE CONVERTER CLUTCH (TCC) SOLENOID-7F037surfaces for burrs or distortion. Inspect all plugs and valves for burrs or scores. Replace thecontrol valve body if the bores are scored or if the valves are scored beyond the point of being able to be cleaned.

15. Inspect all springs for distortion. Check all valves and plugs for free movement in their respective bores. Valves and plugs, when dry, must fall from their own weight in their respective bores.

16. Roll the manual valve on a flat surface to check for a bent condition.17. Clean and inspect the EPC limit circuit screen.

EPC LIMIT CIRCUIT SCREEN7N113

18. Clean and inspect the EPC solenoid screens.

EPC SOLENOID6916

1.CAUTION: Make sure that the screen is properly located.Install the EPC limit circuit screen. Push down on the EPC limit circuit screen to make sure it is fully seated.

EPC LIMIT CIRCUIT SCREEN7N113

59

I(~RTSGI Service Information4R44E 4R55E

2. Install the four check balls in proper locations as shown . ..--------,

CHECK BALLS7E195(4 REO'D)3. NOTE: The springs and valves are interchangeable.Install the converter relief valve and soring.

CONVERTER RELIEF VALVE AND CONVERTER RELIEF SPRING

Install the extension housing lube orifice.

EXTENSION HOUSING LUBE ORIFICE70376

6.Install and align the control valve body separating gasket.

CONTROL VALVE BODY SEPARATING GASKET7D100

7. Install the valve body separating plate. Install the separating plate-to-main control screwsfinger-tight.

VALVE BODY SEPARATING PLATE7A008

.60

II (r:iiRTSG) Service Information 4R44E 4R55E

8. Install the alignment pins in the locations shown.

ALIGNMENT PINST95L-70010C (LARGE) T95L-70010-D (SMALL)

..

"

e

@9. Tighten the separating plate-to-main control screws to 8-11 Nm (71-97 lb-in).

EPC SOLENOID6916..

SHIFT SOLENOID27M107

TORQUE CONVERTERCLUTCH (TCC) SOLENOID7F037

0

.... 0:ebn e

SHIFT SOLENOID47M10714. CAUTION:The solenoid bracket must beInstalled In the TCC and EPCsolenoid0II

SEPARATING PLATE-TO-MAIN CONTROL SCREWS E804357-S76 (3 REQ'D)

10. NOTE: Apply petroleum jelly on the separator surface to hold the gasket in place.Install the control valve body-to-case gasket... -~ 0 ..0

grooves, shift solenoid pockets and the No.204plug.Install the solenoid bracket. Tighten the solenoid bracket screw to 8-11 Nm (71-97 lb-in).

TCC, CCS, 552 AND EPC SOLENOID BRACKET7L491

11. Remove the alignment pins.12. Rotate the main control so that the separator elate is facing down.13. CAUTION:The shift and coast clutch solenoid terminals must face upward.NOTE: The shift and CCS solenoids are interchangeable.NOTE: If the torque converter clutch valve came out, use caution when installing the TCC solenoid.Install the solenoids.

15. Install shift solenoids 1 and ~

SHIFT SOLENOID 17M107

.SHIFT SOLENOID 37M107

61

I(r3ATS6J

Service Information 4R44E 4R55E

16. Install the solenoid bracket. Tighten the bracket screw to 8-11 Nm (71-97 lb-in).

Converter Housing and Pump

SPECIAL SERVICE TOOL(S) REQUIRED

Deacrlptlon Tool NumberSeal Replacer T87L 77248-AH Front Pump Seal Staking Tool T87L-77248-BH Front Pump Seal Staking Tool Adapter T95L-77248-A

Converter Housing and Pump

PartItem Number Description3 7D014 No. 1 Front Pump ThrustWasher4 7A103 Front Pump Support andGear5 W701431-S300 Front Fluid PumpShaft-to-Inner Gear 0-Ring6 7L323 Front Pump Support SealRing7 7A136 Front Fluid Pump Gasket8 78472 Fluid Pump Adapter Plate9 7976 Converter Housing10 E804595-S200 Converter Housing-to-CaseScrews (8 Req'd)11 7A248 Converter Hub-to-ConverterHousing Seal

Disassembly1. Remove the front fluid pump gasket.

~\'FRONT FLUIDPUMP GASKET7A136

PartItem Number Description1 70025 Overdrive Brake Drum SealRings (2 Req'd)2 E804375-S72 Front Pump-to-ConverterHousing Screws(6 Req'd)

62

I(r:.AtsGJ Service Information4R44E 4R55E

2. Remove the front fluid pump square cut seal ring.

FRONT FLUID PUMP SQUARE CUT SEAL RING7A248

3. Remove the two overdrive brake drum seal rings.Remove the front pump support seal ring.

OVERDRIVE BRAKE DRUM SEAL RINGS(2 REC'D)7D025

4. Use a Torx 40 wrench to remove the six MB x35mm front pump-to-converter housing screws. Remove the front pump support and gear and the front pump adapter plate.

FRONTPUMP-TO-CONVERTER HOUSING SCREWS E804375-S72(8 REC'D)

5. NOTE: The pump gears are part of the pump assembly and are not serviced separately. A rough casting on the pump surface crescent is not a flaw. Refer to TSB-91-19A Article 87-2-16Figure 25.Remove the pump gears.

PUMP GEARS (PART OF 7A103)

63

I(r:ilATSGI Service Information 4R44E 4R55E

10. Remove the converter hub-to-converter housing seal using Seal Remover TOOL-117 5-AC or equivalent from the converter housing as shown.0 'C:Q'

7. Inspect the pump gears for scoring and cracks.Replace pump assembly if damaged.8.NOTE: Front fluid pump to converter housing bushing is not serviced separately. If service is required, the converter housing assembly must be replaced.Inspect the front fluid pump to converter housing bushing and converter hub to converter housing seal. Replace converter housing assembly ifnecessary. FRONT FLUID

11. Clean and inspect the front and rear input shaft support bushings. If bushings are worn, scored or damaged, replace the front pump support and gear assembly. Inspect the pump gear pocketsfor scoring and wear. Replace if necessary.

FRONT INPUT SHAFT SUPPORT BUSHING (PART OF 7A103)

orPUMP TO CONVERTER HOUSING BUSHING7B298

1 yZ ~

G'4o~,~;(CONVERTER HUB Q~///. TO CONVERTERHOUSING SEAL7A2489.Using a small chisel, carefully remove the metal displaced by prior staking. This wi!I allow for the removal of the converter hub-to-converter housing seal from the converter housing.

PUMP GEAR POCKETS(PART OF 7A103)

12. Inspect the mating surfaces of the pump body and case for burrs.Inspect the drive and driven gear bearing surface for scores and check the gear teeth for burrs.Inspect the front pump seal for cuts or nicks. Inspect the pump bushing for scoring.Check the fluid passages for obstruction.If any parts are found to be damaged or worn, replace the pump as an assembly. Minor burrs and scores may be removed with a crocus cloth.

64

I

Assembly1. CblAoUckTIoOfN~oPol~ce the converterc?nverter hyd or ~quivalent to housing on aside. rauhc passag protect theNOTE Ch es on the backspring haseek and make surehub-to-con~~:teorppheodusinogff of t~:act otnhveegrtaerrter seal.

NOTE:Sta:k:e~b:e:t====-~~~~~~~~~ Stake a ne ween the old staseal in plac~ c~nvertechub-I ke marks.T87L-77248~A1 thFront Pumpo-Secoanl vSetratekrinhgoTuosoinlg

SEAL REPLTB?L-7724:-~~R

FRONT PUMP SEAL STAKING TOOLT87L-77248-BN

4. Carefully remo

. oolAdapter T95L-~~~~~~tAPump Seal Staking T

FRONTSEAL ST~~~~T TOOL95L- 77248-A

65

I(r;{llRTS61 Service Information 4R44E 4R55E

Coast Clutch

SPECIAL SERVICE TOOL(S) REQUIRED

Description Tool NumberClutch Spring Compressor T65L-77515-A Coast Clutch Outer Seal Sizing Tool T95L-70010-0

Overdrive Brake and Coast Clutch Drum Assembly

Disassembly1.CAUTION: This is a select fit ring. See assembly procedure if the ring or clutch plate pack is replaced.Remove the retaining ring and coast clutch pressure plate from the overdrive brake and coast clutch drum.

SELECT FIT RETAINING RING E860126-129-S

Part

1E860126-SRetaining Ring278066Coast Clutch Pressure Plate378164Coast Clutch Internal Plate- Friction478442Coast Clutch External Plate- Steel5E86125-SRetaining Ring670041Coast Clutch Piston SpringRetainer,77C151Coast Clutch Piston Springs87A258Coast Clutch Piston97A548Coast Clutch Piston OuterSeal Ring1070404Coast Clutch Piston InnerSeal Ring117L669Overdrive Brake and CoastClutch DrumItem Number Description

....._

COAST CLUTCHPRESSUREPLATE78066

OVERDRIVE BRAKE AND COAST CLUTCH DRUM7L669

2. CAUTION: If new clutch plates are being used, they should be soaked in clean transmission fluid for at least 30 minutes before assembly.Remove the coast clutch pack. Inspect for wear, damage or overheating. Replace as necessary.

COAST CLUTCH PACK

66

I(~RTSli) Service Information 4R44E 4R55E

3. WARNING: USE CAUTION WHEN RELEASING TOOL PRESSURE ON THE REAR CLUTCH PISTON SPRINGS.CAUTION: Do not fully compress the clutch spring compressor or damage to the spring retainer may occur.Compress the clutch piston springs with Clutch Spring Compressor T65L-77515-A. Remove the retaining ring.

CLUTCH SPRING COMPRESSOR T65L-77515-A

4. Remove the clutch piston spring retainer and 20 clutch piston springs.

COAST CLUTCH PISTON SPRING RETAINER-7A527

5. WARNING: AIR PRESSURE MUST NOT EXCEED 138 KPA (20 PSI). WEAR SAFETY GLASSES WHEN USING COMPRESSED AIR, AND MAKE SURE DRUM IS FACING DOWN AS SHOWN.Remove the coast clutch piston by using air pressure. Apply air pressure to the one hole on the inside diameter of the overdrive brake and coast clutch drum while blocking the other hole with a finger.

6. Remove the inner and outer coast clutch piston seals. Clean and replace as necessary.

COAST CLUTCH PISTON INNER SEAL RING-70404

COAST CLUTCHPISTON OUTER SEAL RING-7A548

COAST CLUTCH~~~~--t PISTON7A262

Assembly1.CAUTION: The lip seals must be positioned as shown. Care must be taken to prevent roll over of the lip seal.Install new inner and outer coast clutch piston seals on the coast clutch piston

67

I(r;/IRTSG)

Service Information 4R44E 4R55E

COAST CLUTCH PISTON INNER SEAL RING70404

5.Check the fluid passages for obstructions. All fluid passages must be clean and free of obstructions.6.Inspect the clutch plates for wear, scoring and fit on the clutch hub serrations. Replace all plates that are badly scored, worn or do not fit freely in the hub serrations.7. Inspect the clutch pressure plate for scores onthe clutch plate surface. Check the clutch release spring(s) for distortion.8.Make sure the check ball is free and clear of debris prior to installing piston. The check ball is located in the overdrive brake and coast clutch drum.

COAST CLUTCH PISTON INNER SEAL RING70404

COAST CLUTCHPISTON--'"""---- OUTERSEAL RING70548

VIEWA

COAST1..,_..,.:.CLUTCH PISTON7A262

OVERDRIVEBRAKE AND COAST CLUTCH DRUM7L669

-2.CAUTION: Lubricate the inner and outer coast clutch piston seals.Carefully press the coast clutch piston into coastClutch Outer Seal Sizing Tool T95L-70010-0.

COAST CLUTCH OUTER SEAL SIZING TOOL195L-70010-D

/

COAS 1 l0LUTCllPISTCJrl 7A?58

3.Inspect the drum band surface, bushing and thrust surfaces for scores. Minor scores may be removed with a crocus cloth. Badly scored parts must be replaced.4.Inspect the clutch piston bore and the piston and the piston inner and outer bearing surfaces for scores.

9. Carefully remove the coast clutch piston fromCoast Clutch Outer Seal Sizing ToolT95L-70010-0.

COAST CLUTCH OUTER SEAL SIZING TOOL T95L-70010-D

COAST CLUTCH PISTON-7A258

68

II (rJIATSG) Service Information 4R44E 4R55E

10. CAUTION: Care must be taken to prevent damage to the seals during Installation.Carefully install the coast clutch piston into the overdrive brake and coast clutch drum.11. Install the 20 coast clutch piston springs and coast clutch piston spring retainer onto the coast clutch piston.12. CAUTION: Do not fully compress the clutch spring compressoror damage to the coast clutch piston spring retainer may occur.Compress the coast clutch piston springs with Clutch Spring Compressor T65L-77515-A. Install the retaining ring. Release the load on the springs applied by the tool. Remove the tool.

CLUTCH SPRING COMPRESSOR T65L-77515A

D5543C13. CAUTION: If new clutch plates are being used, they should be soaked in clean transmissionfluid for at least 30 minutes before assembly.Install the two steel clutch plates and two friction clutch plates in alternating order, starting with the steel plates first.

FRICTION CLUTCH PLATES78164

14. CAUTION: The retaining ring Is select flt.Install the coast clutch pressure plate. Install the retaining ring on top of the clutch pressure plate.SELECT FIT RETAINING RING E860126 129S

COAST CLUTCH PRESSURE PLATE78066

OVERDRIVE8RAKEAND_coASTCLUTCHDRUM7L669

15. WARNING:AIR PRESSUREMUST NOT EXCEED 138 KPA (20 PSI). WEAR SAFETY GLASSES WHENUSINGCOMPRESSEDAIR. MAKE SUREDRUMIS FACING DOWN AS SHOWN.NOTE: The coast clutch piston must apply withair pressure and release when the air is removed.Air check the assembly. Apply air to the one hole on the inside diameter of the overdrive brake and coast clutch drum while blocking the other hole with a finger. \.......-

If the reading is not within specification, remove the retaining ring and check the thickness. Replace it with a ring that will correct free play.Verify with a feeler gaug:e~.~~~~~

16. Check the free pl~e c utch pack. Push down on the clutch pack. Use a feeler gauge to check the gap between the retaining ring and the pressure plate. Specification: 1.3 to 2.0mm (.051 to .079 inch).

69

I(r:JiRTSGI Service Information 4R44E 4R55ECOAST CLUTCH

ThlckneH Diameter

Part NumbermmInchesmmInches

EB60126-S1.37.0539130.15.122

EB60127-S1.73.0681130.15.122

EB60128-S2.08.0819130.15.122

EB60129-S2.44.0961130.15.122

Intermediate Brake and Direct Clutch DrumAssembly

SPECIAL SERVICE TOOL(S) REQUIRED

RETAINING RING E860126-129-S

DescriptionTool Number

Clutch Spring CompressorDirect Clutch Outer Seal Sizing ToolT65L-77515-A T95L-70010-E

Intermediate Brakeand Direct Clutch DrumAssembly

tem1NumberEB60126-SDescriptionRetaining RingRemove the direct clutch pack. Inspect for wdamage or overheating. Replace the steel orfriction plates as necessary.278066Direct Clw.tch Pressure Plate378164Direct Clutch Internal Plate- Friction478442Direct Clutch External Plate- Steel5EB60125-SRetaining Ring67D041Direct Clutch Piston SpringRetainer77C151Direct Clutch Piston Springs(20 Req'd)87A258Direct Clutch Piston97A54BDirect Clutch Piston OuterSeal Ring107D404Direct Clutch Piston InnerSeal Ring117D044Intermediate Brake andDirect Clutch DrumPartI

2. CAUTION:If new clutch plates are being used, they should be soaked In clean transmission fluid for at least 30 minutes before assembly.ear,

Disassembly1.CAUTION:The retaining ring Is a select flt ring. See aseembly procedure If the ring or clutch pack Is replaced.Remove the retaining ring and direct clutch pressure plate.

70

I(r3ATS61 Service Information 4R44E 4R55E

3.WARNING: AFTER REMOVING THE RETAINING RING, USE CARE WHEN RELEASING THE PRESSURE ON THE SPRINGS.

CAUTION: Do not fully compress the clutch spring compressor or damage to the spring retainer may occur.

6.Remove the inner and outer direct clutch piston seals. Clean and replace as necessary.

DIRECTCompress the direct clutch piston springs with Clutch Spring Compressor T65L-77515-A. Remove the retaining ring. Remove the tool.

~-..-....-, ...

CLUTCH PISTON7A2.62

Assembly

1.CAUTION: The lip seals must be positioned as shown. Care must be taken to prevent rollover of the lip seal.

Install new inner and outer direct clutch piston seals on the direct clutch piston.

DIRECT CLUTCH PISTON OUTER SEAL"\. 7A5484.Rornovs the direct clutch plston spring retainer "'- and W direct dutch piston springs. "'---~.....!..'~~:......;;-:::......~.....!.~~~~~~~~~---,DIRECT CLUTCH PISTON OUTER SEAL-70548

REVERSE AND DIRECT CLUTCH PISTON,~.-r,.-INNER SEAL7D404 VIEWA

2.5. WARNING: DO NOT EXCEED 138 KPA (20PSI). WEAR SAFETY GLASSES WHEN USING COMPRESSED AIR. MAKE SURE DRUM IS FACING DOWN AS SHOWN.Remove the direct clutch piston using compressed air. Apply air pressure to the one hole on the inside diameter of the intermediate brake and direct clutch drum while blocking the other hole with a finger. DIRECTCLUTCH PISTON SPRING RETAINER7A527

DIRECT CLUTCH~~L--- PISTONSPRINGS7A480

71

DIRECT CLUTCf- PISTON INNER SEAL-7D404CAUTION: Lubricate the Inner and outer direct clutch piston seals.Carefully press the direct clutch piston into directClutch Outer Seal Sizing Tool T95L-70010-E.

CLUTCH OUTER SEAL SIZING TOOL --T95L- 70010-E?--

)----

I(r3ATS6) Service Information 4R44E 4R55E

3.Inspect the drum band surface, bushing and thrust surfaces for scores. Minor scores may be removed with a crocus cloth. Badly scored parts must be replaced.4.Inspect the clutch piston bore and the piston and the piston inner and outer bearing surfaces for scores.5.Check the fluid passages for obstructions. All fluid passages must be clean and free of obstructions.6.Inspect the clutch plates for wear. scoring and fit on the clutch hub serrations. Replace all plates that ere badly scored, worn or do not fit freely in the hub serrations.7. Inspect the direct clutch pressure plate forscores on the clutch plate bearing surface. Check the clutch release spring for distortion.8.Make sure the check ball is free and clear of debris prior to installing piston. The check ball is located in the intermediate brake and direct clutch drum.INTERMEDIATE BRAKE AND DIRECT CLUTCH DRUM ASSEMBLY-70044

9. Carefully remove the direct clutch piston from direct Clutch Outer Seal Sizing Tool T95L70010E.CLUTCH OUTER SEAL SIZING TOOL T95L- 70010-E

DIRECT CLUTCH PISTON-7A258

10. CAUTION: Care must be taken to prevent damage to the seals during Installation.Carefully install the clutch piston into the intermediate brake and direct clutch drum.

\

FRICTION CLUTCH PLATES78164

STEELCLUTCH PLATES-78442

11. CAUTION: The number of plates Is model dependent. See specifications at the end of this section. If new plates are being used they should be soaked In clean transmls~lon fluid for at least 30 minutes before assembly.Install the steel clutch plates and friction clutch plates in alternating order, starting with a steel plate and finishing with a friction plate.

EngineSteelFriction

2.3L44

3.0L44

4.0L55

72

I(~ATSGI Service Information 4R44E 4R55E

12. CAUTION: The retaining ring Is a select flt.Install the direct clutch pressure plate on the clutch stack.

RETAINING RING E860126-129-S

DIRECT CLUTCH PRESSURE PLATE'78066

13. WARNING: AIR PRESSURE MUST NOT EXCEED 138 KPA (20 PSI). WEAR SAFETY GLASSES WHEN USING COMPRESSED AIR. MAKE SURE THE DRUM IS FACING DOWN AS SHOWN.NOTE: The direct clutch piston must apply withair pressure and release when the air is removed.Air check the assembly. Apply air to the hole on the inside diameter of the intermediate brake and direct clutch drum while blocking the other hole with a finger.

14. Install the retaining ring on top of the direct clutch pressure plate. Push down on the clutch pack. Use a feeler gauge to check the gap between the retaining ring and the clutch pressure plate. Specification: 1.3 to 2.0mm (.051 to .070 inch).If the reeding Is not within specification remove the retaining ring end check thickness.0Replece w!th a ring that will correct free play, end verify with a feeler gauge.

DIRECT CLUTCH

Part NumbermmlnchHmmlnchHE880128S1.37.0539130.15.122---- 1.73.0681130.15.122E860128S2.08.0819130.15.122E860129S2.44.0961130.15.122ThlckneH Diameter

E880127S

--- ii

73(r:.AT561 Service Information 4R44E 4R55E

Forward Clutch

SPECIAL SERVICE TOOL(S) REQUIRED' Description Tool NumberClutch Spring Compressor T65L-77515-A Lip Seal Protector T74P-77548-B

Disassembly1.CAUTION:The retaining ring Is a select fit ring. See assembly procedure If the retaining ring or clutch pack Is replaced.CAUTION:If new plates are being used, they should be soaked In clean transmissionfluid for at least 30 minutes before assembly.Remove the retaining ring and forward clutch pressure plate.

FORWARD CLUTCH PRESSURE PLATE78066

3.0L 5 5

74I

ItemPartNumberDescription1E860115-SRetaining Ring2.NOTE: The number of clutch plates is model278066Forward Clutch Pressuredependent.Plate378164Forward Clutch InternalPlate - FrictionEngine Steel Friction478442Forward Clutch External2.3L 5 5Plate - Steel57E457Forward Clutch CushionSpring4.0L 6 66E860109-SRetaining Ring770047Forward Clutch Piston Remove the forward clutch pack. Inspect for wear87C151Forward Clutch PistonSprings ( 15 Req 'd)97A262Forward Clutch Piston107A548Forward Clutch Piston OuterSeal Ring117A548Forward Clutch Piston InnerSeal Ring1270424Forward Clutch CylinderAssembly1370019Forward Clutch CylinderSeal Rings147C096No. 5 Forward ClutchCylinder Thrust WasherSpring Retainer

, damage or overheating. Replace as necessary.I (~RTSGJ Service Information 4R44E 4R55E

3.CAUTION: Do not fully compress the clutch spring compressor or damage to the spring retainer may occur.Compress the forward clutch piston springs with Clutch Spring Compressor T65L-77515-A. Remove the retaining ring.

4.WARNING: CAREFULLY RELEASE THE TOOL PRESSURE ON THE FORWARD CLUTCH PISTON SPRINGS AND REMOVE THE TOOL.Remove the clutch spring compressor from the forward clutch cylinder.5. CAUTION: The forward clutch cushion springIs model dependent.Remove the forward clutch piston spring retainer and 15 forward clutch piston springs. Remove the forward clutch cushion spring. Replace as necessary.

6.WARNING: AIR PRESSURE MUST NOT EXCEED 138 KPA (20 PSI). WEAR SAFETY GLASSES WHEN USING COMPRESSED AIR. MAKE SURE THE CYLINDER IS FACING DOWN AS SHOWN.NOTE: This is the middle-sized port.Use the center support to remove the forward clutch piston. Install the center support on the forward clutch cylinder. Apply air pressure to the far left port in the center support as shown.

CENTER SUPPORT7A130

\

MIDOLE- SIZED PORT

7. Remove the inner and outer forward clutch piston seals. Clean and replace as necessary.

FORWARD CLUTCH PISTONFORWARD CLUTCH PISTON OUTERFORWARD

SPRING RETAINER7A527SEAL-7A548CLUTCH PISTON7A262

FORWARD CLUTCH

PISTON SPRINGS

7A480

FORWARD CLUTCH CUSHION SPRING78070

FORWARD CLUTCH CUSHION SPRING78070

75

I(~ATSGI Service Information 4R44E 4R55E

8. Remove the forward clutch cylinder seal rings.

FORWARD CLUTCH CYLINDER SEAL RINGS7D019

FORWARD CLUTCH PISTON OUTER SEAL RING7A548

FORWARD CLUTCH PISTON7A262

9.Inspect the forward clutch cylinder thrust surfaces, piston bore and clutch plate serrationfor scores or burrs. Minor scores or burrs may be removed with a crocus cloth. Replace theforward clutch cylinder if it is badly scored or damaged.10. Check the fluid passages in the forward clutch cylinder for obstructions. Clean out all passages. Inspect the forward clutch piston for scores and replace if necessary. Inspect the piston checkball for freedom of movement and proper seating.11. Check the clutch release springs for distortion and cracks. Replace the springs if they are distorted or cracked.12. Inspect the friction clutch plates, steel clutch plates and clutch pressure plate for worn orscored bearing surface. Replace all parts that are deeply scored.13. Check clutch plates for flatness and fit on the clutch hub serrations. Discard any plate that does not slide freely on the serrations or that is not flat.14. Check clutch hub thrust surfaces for scores and clutch hub splines for wear.15. NOTE: The check ball is located in the piston.Make sure the check ball is free and clear of debris prior to installing the forward clutch piston.

Assembly

1. CAUTION:If there Is evidence of clutch plate burning, replace the forward clutch cushion spring.CAUTION:The forward clutch cushion springIs model dependent.

Install new inner and outer forward clutch piston seals on the forward clutch piston. Install the forward clutch cushion spring.

FORWARD CLUTCH PISTON OUTERSEAL-7A548 FORWARDCLUTCHPISTON7A262

76(~RTs&I Service Information 4R44E 4R55E

2. To prevent damage to the forward clutch piston outer seal, install Lip Seal ProtectorT7 4P-77548-A. To prevent damage to the forward clutch piston inner seal install Lip Seal Protector T7 4P-77548-A into forward clutch cylinder.

r-

3.CAUTION:Care must be taken to prevent damage to the seals.NOTE: Apply petroleum jelly to the inner and outer seals.Carefully install the forward clutch piston into the forward clutch cylinder.4. Carefully remove Lip Seal ProtectorT74P-77548-A and Lip Seal ProtectorT74P-7754-8 from the forward clutch cylinder.5.Install the 15 forward clutch piston springs and forward clutch piston spring retainer.

FORWARD CLUTCH PISTON SPRING RETAINER7A527

6. CAUTION:Do not fully compress the clutch spring compressor or damage to the forward clutch piston spring retainer may occur.Compress the clutch piston springs with Clutch Spring Compressor T65L-77515-A and install the retaining ring. Release the load on the forward clutch piston springs and remove the tool.

7.CAUTION:If new plates are being used, they should be soaked In clean transmission fluld for at least 30 minutes before assembly.CAUTION:The number of clutch plates Is model dependent.Install the steel clutch plates and friction clutch plates in alternating order, starting with a steel plate and finishing with a friction plate.

FRICTION CLUTCH PLATES78164

STEEL CLUTCH PLA TES-78442

Engine StHI Friction2.3L 5 53.0L 5 54.0L 6 6

77

I(~ATSG) Service Information 4R44E 4R55E

8. CAUTION: The retaining ring is a select flt.Install the forward clutch pressure plate on the clutch pack. Install the retaining ring.

FORWARD CLUTCH PRESSURE PLATE78066

9. CAUTION: Front clutch cylinder seal rings must be Interlocked as shown. Interlock the forward clutch cylinder seal rings.

WRONG

11. WARNING: DO NOT EXCEED 138KPA(20PSI). WEAR SAFETY GLASSES WHEN USING COMPRESSED AIR. MAKE SURE THE DRUM IS FACING DOWN AS SHOWN.NOTE: The forward clutch piston must apply With air pressure and release when the air is removed.Install the center support on the forward clutch cylinder. Apply air pressure to the far left port in the center support as shown.

CENTER SUPPORT7A130

INTERLOCKED

FORWARD CLUTCH CYLINDER SEAL RING-70019

12. Push down on the clutch pack. Use a feeler gauge to check the gap between the retaining ring and the clutch pressure plate. Specification: 1.4 to2.1mm (.055 to .083 inch). If the reading is not within specifications, remove the retaining ring10. NOTE: Make sure that the torward clutch cylinder seal ring gaps are placed 180 degrees apart. Install the forward clutch cylinder seal rings on the forward clutch cylinder.

FORWARD CLUTCH CYLINDER SEAL RINGS70019

and check the thickness. Replace the retaining ring with one that will provide correct free play. Verify free play with a feeler gauge.

78

II (r:.RTSli) Service Information 4R44E 4R55E

FRONT CLUTCH CYLINDER

ThlckneBB

DiameterPart NumbermmInchesmmInches

E860115-S1.37.0539125.14.925

E860116-S1.73.0681125.14.925

E860117-S2.08.0819125.14.925

E860118-S2.44.0961125.14.925

79IForward Geartrain AssemblyAssembly

PartItem Number Description1- Intermediate Brake and Direct Clutch Drum Assembly2 7C096 No. 5 Forward ClutchCylinder Thrust Washer3 - Forward Clutch CylinderAssembly4 7D234 No. 6A Forward Ring GearHub Thrust Bearing5 70090 No. 6B Forward ClutchThrust Washer6 70392 Forward Ring Gear7 7F374 No. 7 Forward Planet ThrustBearing8 7A398 Forward Planet Assembly9 70064 Input Shell10 70063 Forward Sun Gear

1.Install the No. 5 forward clutch cylinder thrust washer on the intermediate brake and direct clutch drum. Align the tabs as shown. Use petroleum jelly to hold the washer in place.

TABS

N0.5FORWARD CLUTCH CYLINDER THRUST WASHER7C096

INTERMEDIATE BRAKE AND DIRECT CLUTCH DRUM ASSEMBLY7D044

2.Install the forward clutch cylinder assembly into the intermediate brake and direct clutch drum as shown.

FORWARD CLUTCH CYLINDER ASSEMBLY7A360

INTERMEDIATE BRAKE AND DIRECT CLUTCH DRUM ASSEMBLY7D044

3.Install the No. 6A forward ring gear hub thrust bearing into the forward clutch cylinder as shown.

NO. 6A FORWARD RING GEAR HUB THRUST WASHER70234/

4.NOTE: Use petroleum jelly to hold the washer in place.Install the No. 68 forward clutch thrust washer into the forward ring gear hub.(r:.RtsGI Service Information 4R44E 4R55E

7.NOTE: The forward planet assembly is model dependent.Install the forward planet assembly into the forward ring gear as shown.

FORWARD PLANET ASSEMBLY7A398

NO. 68FORWARDCLUTCHTHRUST WASHER5. NOTE: Make sure the No. 6A bearing and No. 68 thrust washer assembly are inside the forward ring gear.Install the forward ring gear and forward ring gear hub into the forward clutch cylinder as shown.

N0.68FORWARDCLUTCH THRUST WASHER7D090

FORWARD CLUTCH CYLINDER ASSEMBLY7A360

6. Install the No. 7 forward planet thrust bearing into the forward ring gear as shown.

NO. 7FORWARD PLANET THRUST BEARING7F374

FORWARD RING GEAR70392

8. NOTE: 4.0L does not require a bushing inside the forward sun gear or washer on back of inputshell.Inspect the drum gear, bushing and washer. for scoring, wear or damage. Replace as required.9. NOTE: Make sure the forward sun gear aligns with the forward planet assembly. Make sure the input shell aligns with the intermediate brake anddirect clutch drum assembly as shown. Install the input shell with forward sun gearassembly as shown.

INPUT SHELL70064

INTERMEDIATE BRAKE AND DIRECT CLUTCH DRUM ASSEMBLY70044

80

IIr:.t:ITSG I Service Information 4R44E 4R55E

Overdrive Planet and One-Way ClutchAssembly

Overdrive Planet and One-Way Clutch Assembly

ItemPartNumberDescriptionItemPartNumberDescription

1E860119-SRetaining Ring678446Planetary Gear Overdrive

27A658Overdrive Center ShaftCarrier7 70235 No. 12 Sun Gear ThrustBearing Race8 70063 Overdrive Sun Gear9 7660 Coast Clutch Adapter

3-Overdrive One-Way Clutch(Part of 7 A658)

47653Overdrive Ring Gear

57L495No. 2 Overdrive PlanetThrust Bearing

(Continued)

81

I(r'JIATSG) Service Information4R44E 4R55E

Disassembly

1.Remove the overdrive center shaft retaining ring from the overdrive ring gear.

OVERDRIVE ONE-WAY CLUTCH7A089

4.Temporarily insert the planetary gear overdrive carrier assembly into the one-way clutch rollers for verification of the one-way clutch. The planetmust rotate counterclockwise as shown. Removethe planetary gear overdrive carrier assembly.

2.Remove the overdrive center shaft from the overdrive ring gear.

3. CAUTION: Do not remove the overdriveone-way clutch. Damage to the clutch mayoccur If It Is removed.NOTE: The overdrive one-way clutch is serviced with the overdrive center shaft.Clean and inspect the overdrive one-way clutch and overdrive center shaft assembly. Check for cracks in the roller cage and wear on the roller clutch. Inspect the press fit of the one-way roller clutch to the overdrive center shaft.Inspect the rollers and springs for excessive wear or damage.

Inspect the spring and roller cage for bent or damaged spring retainers.

PLANETARY GEAR OVERDRIVECARRIER ASSEMBLY78~46

OVERDRIVE CENTER SHAFT ASSEMBLY7A658

Assembly

1.Install the overdrive center shaft and overdrive one-way clutch into the overdrive ring gear.

82

II (r.aRTSG) Service Information4R44E 4R55E

2. Install the center shaft retaining ring.

CENTER SHAFT RETAINING RING E860119-S

OVERDRIVE CENTER SHAFT7A658

OVERDRIVE1+--- RING GEAR7A153

3. CAUTION: Planets must be replaced. Do not restake.

NOTE: Individual parts of the planet carriers are not serviceable.Check the pins and shafts in the planet assemblies for loose fit and I or complete disengagement. Use a new planet assembly if either condition exists. Before installing a planet assembly, the shaft retaining pins should be checked for adequate staking.Inspect the pinion gears for damaged or excessively worn teeth.Check for free rotation of the pinion gears. Inspect the overdrive one-way clutch inner racetor scoring.Check pinion bearing and gears.

Inspect the inner and outer races for scored or damaged surface areas where the rollers contact the races.

Inspect the needle bearing on the nose of the planetary gear overdrive carrier.

NEEDLE BEARING (PART OF 78446)

PLANETARY GEAR OVERDRIVE CARRIER ASSEMBLY-78446

Inspect the No. 12 needle bearing inside the planetary gear overdrive carrier.

NO. 12 NEEDLE BEARING (PART OF 78446)

4.NOTE: Use petroleum jelly to hold the No. 2 overdrive planet thrust bearing in place.Install the No. 2 overdrive planet thrust bearing between the overdrive center shaft face and the planetary gear overdrive carrier assembly.

5.Install the planet gear overdrive carrier into the overdrive center shaft and overdrive ring gear.

PLANETARY GEAR OVERDRIVE CARRIER ASSEMBLY-78446

OVERDRIVE RING GEAR AND OVERDRIVE CENTER SHAFT

83

I(rJIRTSGI Service Information 4R44E 4R55E

6. CAUTION:Use care not to bend or damage the exciter wheel.CAUTION:Before installing the overdrive sun gear into the planetary gear overdrivecarrier, make sure the No. 12 sun gear thrustbearing race is aligned with the needlebearing inside the planetary gear overdrive carrier. The overdrive sun gear wlll not seat properly if the No. 12 sun gear thrust bearing race Is not aligned In the center of theoverdrive sun gear.

Install the overdrive sun gear into the planetary gear overdrive carrier.

OVERDRIVE{ SUN GEAR7D063

7.Install the coast clutch adapter on the overdrive sun gear.

Center SupportDisassembly

INTERMEDIATE BRAKE DRUM SEAL RINGS70429

CENTER SUPPORT7A130

1.Remove the two intermediate brake drum seal rings from the center support.

INTERMEDIATE BRAKE DRUM SEAL RINGS7D429(2 R~Q'D)

2.Inspect the support thrust surface for wear, scoring or damage. Inspect the forward clutch sealing surface for scoring or damage.Inspect the forward clutch cylinder and intermediate brake drum seal ring grooves in the center support for nicks, burrs or damaged edges.Check the seal rings for damage.

IiIi \DIRECT CLUTCHEXTERNAL SEAL---"'" GROOVE- (PART OF 7A130)

84

I(r;jiAT56) Service Information 4R44E 4R55E

Reverse Brake Drum

SPECIAL SERVICE TOOL(S) REQUIRED DescriptionToolNumberOverrunning Clutch Replacing Guide T74P-77193A

Disassembly

Reverse Brake Drum

2.3L/3.0L 4.0L

PartItem Number Description1 E860120-S Retaining Ring2 70191 Low One-Way Clutch Spring

2. Lift out the cage with the springs and bearing rollers as a unit.

Assembly1. Install the two intermediate brake drum seal rings on the center support and apply a liberal amount of petroleum jelly to the hub and seals.

INTERMEDIATE BRAKE------ DRUM SEAL RINGS70429(2 REQ'D)

2.CAUTION:Do not roll or cut the seals. Allow to stand for several minutes before attempting to remove hub and Install Into the Intermediate brake and direct clutch drum during final assembly.NOTE: This step is for sizing the intermediate brake drum seal rings.

Retainer3 7190 Low One-Wey Clutch Rollers(10Req'd)4 7C498 Reverse Brake Drum -2.3L, 3.0L5 7E193 Reverse Brake DrumAssembly (Rear One-WayClutch) - 4.0L1.NOTE: For 4.0L applications, there is no reta