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E4OD Transmission Disassembly Procedure |
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Done |
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| 1. Fabricate or purchase transmission stand or use a sturdy workbench with transmission adapter. | |||||||||||||
| 2. Locate a large drain pan. (I use a large trash can lid with no holes) | |||||||||||||
| 3. Rotate the transmission to allow any fluid to drain from filler tube in to the drain pan. | |||||||||||||
| 4. Rotate transmission upside down. | |||||||||||||
| 5. Use a 10 mm socket to remove remaining pan bolts. | |||||||||||||
| 6. Remove pan. | |||||||||||||
| 7. Remove pan magnet, clean, and reinstall back in pan for safe keeping. | |||||||||||||
| 8. Grasp "FILTER" and rock it end to end as you pull to remove. (remove seal if it stays in pump) | |||||||||||||
| 9 CAUTION: Protect Valve body mating surfaces at all times. - Always!!!! | |||||||||||||
| 9. Remove LOWER CONTROL VALVE BODY nuts and bolts. (Bolted on top of largest valve body). | |||||||||||||
| 10. Remove lower control valve body and small separator plate. | |||||||||||||
| 11. Remove Check Balls from top of Main Control Valve Body. (record number of check balls) These check balls will be either made of rubber or plastic: 1989-1995 2 each check balls 1996-1998 (3) each 1/4" check balls; and (2) each 5/16" check balls |
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| 12. Remove ACCUMULATOR VALVE BODY nuts and bolts. (very front valve body). | |||||||||||||
| 13. Remove Accumulator Valve Body. | |||||||||||||
| 14. Remove screen in separator plate under Accumulator Valve Body. (Rotate counter-clockwise) | |||||||||||||
| 15. Remove Main Control Valve Body bolts & nuts. (Largest valve body) | |||||||||||||
| 16. Remove Main Control Valve Body | |||||||||||||
| 17. Remove "SOLENOID VALVE BODY" nuts & bolts. | |||||||||||||
| 18. Remove Solenoid Valve Body | |||||||||||||
| 19. CAUTION: Locate EPC 1/4" metal check ball & Spring under separator plate (EPC 1/4" metal check ball & spring are located near round hole hole in case for solenoid connector). |
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| 19. Remove 3 bolts on Valve Body separator Retaining Plate. | |||||||||||||
| 21a. CAUTION: Keep Steel Valve Body plate with gaskets for now to protect plate from damage. | |||||||||||||
| 20. Remove large Valve Body Separator Plate and EPC 1/4" metal check ball and spring. | |||||||||||||
| 21b. CAUTION: Do not use solvent to clean rubber or plastic check balls. | |||||||||||||
| 21. Remove remaining 5/16" Check Balls. Record number of check balls. (14) each 5/16" Early 1989 + EPC Metal 1/4" relief valve & spring (11) each 5/16" Late 1989 + EPC metal 1/4" relief valve & spring (9) each 5/16" 1990-1995 + EPC metal 1/4" relief valve & spring (8) each 5/16" 1996-1998 + EPC metal 1/4" relief valve & spring 1991-1998 Models: Also Remove Accumulator Regulator Filter Screen (very small with spring) (located near single bolt fluid feed bolt in worm tracks.) |
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| 22. Remove snap ring and plate securing band apply "SERVO" (if applicable) & discard both. (updated servo in new kit does not use plate and snap ring). |
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| 23. Remove band apply servo by using high power magnet. (or wait until band is removed later). | |||||||||||||
| 24. Remove "INPUT SHAFT" - Note: Long spline goes inside transmission: ('96 Updated input shaft (center shaft kit) has groove mark at outer end of input shaft) |
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| 25. Remove (9) pump bolts using 10mm socket. | |||||||||||||
| Special Tools: Front pump 8 MM x 1.25 adapters & slide hammer. | |||||||||||||
| 26. Thread 8mm adapters in the two 8 mm threaded bolt holes in pump. Pump bolt holes at 2 and 8 o'clock from bottom / top of case. |
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| 27. Attach slide hammers to 8 mm adapters. | |||||||||||||
| 28 CAUTION: Do not nick or mar the pump surface and edges (ever) | |||||||||||||
| 28. Slide hammer weight outward until pump is popped loose of case. | |||||||||||||
| 29. Lift pump out of case. (PROTECT EDGE SURFACES) | |||||||||||||
| 30. Remove plastic trust washer - usual stuck to back of stator flange. (pump back side) | |||||||||||||
| 31. Remove bearing - usually on coast clutch sun gear. (use magnet if necessary) | |||||||||||||
| 32. Remove case to pump gasket and discard. | |||||||||||||
| 33. Remove Coast Clutch assembly and sun gear. | |||||||||||||
| 34. Remove "CENTER SHAFT" assembly. (Lift Device Available from www.tranYshop.com | |||||||||||||
| 36. Remove bearing if not on Center Shaft. (use magnet if necessary). | |||||||||||||
| 37. Remove large Overdrive Clutch Pack snap ring. | |||||||||||||
| 38. Remove Overdrive pressure plate / clutch pack. (Record number of friction discs). | |||||||||||||
| 39. Using a 13 mm socket remove 1 Bolt retaining OD Cylinder at worm tracks. This bolt is the single bolt nearest front of transmission. |
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| Special Tool: OD / Intermediate Cylinder compressor cage and jack screw. | |||||||||||||
| 40 CAUTION: Do not mar pump to case flange area when attaching compressor. | |||||||||||||
| 40. Install OD Cylinder compressor removal tool and compress 1 revolution of screw. | |||||||||||||
| 41. See if OD Cylinder snap ring can be spun in case using flathead screwdriver. IF NOT, repeat 1 complete turn of jack screw until snap ring can be spun easily. Remove snap ring from case slot. Back off jack screw until loose. Then remove compressor cage tool. |
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| 42. Remove Snap Ring retaining OD cylinder Assembly from case. | |||||||||||||
| 43. Remove OD / Intermediate Cylinder Assembly. | |||||||||||||
| 44. Remove Intermediate Cylinder diaphragm return spring. (large wafer spring) | |||||||||||||
| 42. Using a 13 mm socket remove 2 bolts retaining Center Support at worm tracks. | |||||||||||||
| 43. Remove "CENTER SUPPORT" by grasping cross bar and pulling up. | |||||||||||||
| 44. Remove plastic trust washer. | |||||||||||||
| 45. Remove band apply servo, if not already removed, then remove BAND from case. | |||||||||||||
| 46. Remove bearing in top of drum opening. (use magnet if necessary) | |||||||||||||
| Specialty Tool: Needed to vertically lift drum assembly from transmission. | |||||||||||||
| 47 CAUTION: Shell / Direct Drum / Forward Hub is very heavy. Remove Direct Drum / Forward Hub / and Shell as an assembly. |
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| 47. Tighten handle on the E4OD Drum Lift Tool until cables are tight. (If no lift tool is available, lay transmission horizontal and carefully remove assembly) |
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| 48. Lift Direct Drum / Forward Drum / Shell assembly from case. | |||||||||||||
| 49. Remove metal Trust Washer laying on Reverse Planet if not on bottom of shell. | |||||||||||||
| 50. Remove Snap Ring from Reverse Hub assembly securing Reverse Planet. | |||||||||||||
| 51. Remove Reverse Planet. | |||||||||||||
| 52. Remove metal Thrust Washer from Output Hub if not on bottom of Reverse Planet. | |||||||||||||
| 53. Remove Extension Housing bolts and remove housing. | |||||||||||||
| 54 CAUTION: Place rubber bun gee cord from case around end of output shaft to case This will prevent shaft from falling out of case when c-ring is removed from output shaft. |
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| 54. Remove small c-ring from output shaft. NOTE: Replace this c-ring - DO NOT REUSE ! |
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| 55. Remove Output Ring Gear/Hub assembly from output shaft. | |||||||||||||
| 56. Remove bearing from inner race if not on the back of Ring Gear / output hub. | |||||||||||||
| 57 CAUTION: The Reverse Hub has a one-way clutch. Be careful to pull the Reverse Hub off the Inner Race parallel to case. (do not wobble it) |
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| 57. Remove Reverse Hub and sprag one-way clutch assembly. | |||||||||||||
| 58. Remove Bun gee cord, Output shaft / Park Gear / Trust Washer. (from rear of case) | |||||||||||||
| 59. Remove Large Snap Ring retaining Reverse Clutch Pack. | |||||||||||||
| 60. Remove Reverse Clutch Pack. (record number of friction disc) | |||||||||||||
| 61 CAUTION: if tear down is on a bench use 2 each 5/16" x 3" long guide bolts with | |||||||||||||
| heads cut off to prevent Reverse one-way sprag Inner Race from falling in case. | |||||||||||||
| 61. Remove 5 bolts retaining Reverse Sprag Inner Race. | |||||||||||||
| 62. Remove Reverse sprag Inner Race and Reverse Piston Return Spring assembly. | |||||||||||||
| 63. Reinstall Pressure Plate & Snap Ring for piston removal process: 1st - Reinstall Reverse Clutch Pressure Plate in Case; and then 2nd - Reinstall Reverse Clutch Snap Ring. |
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| 64b CAUTION: You will here a pop-sound and hiss when Reverse Piston is removed. | |||||||||||||
| 64. SEE 64a WARNING & 64b CAUTION above BEFORE APPLYING air to case: 1. Apply air pressure to Reverse Piston apply at worm track. (this hole is about center of case and is the 2nd hole from the rear of case. |
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| 65. Remove Reverse Clutch Pack Snap Ring. | |||||||||||||
| 66. Remove Reverse Clutch Pack Pressure Plate. | |||||||||||||
| 67. Remove Reverse Clutch Piston. | |||||||||||||
| 68. Reinstall pan back on case to protect valve body studs. | |||||||||||||
| 69. Late 1990-1998, remove rear cooling line tap from transmission and Check Converter Anti-drain back check valve.: Check for spring back of ball; and Fill back side fitting with light oil (such as 3-in-1 oil) to verify check valve is sealing. |
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| NOTE: I usually don't remove the following unless there is an obvious problem(s): » Manual lever from case if the seal is not leaking and it feels good. » Parking pawl & parking pawl arm to manual lever if visually looks good. » Lower filler tube going in to case. |
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