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tial setting for the WOT upshift is below the opti- mum engine speed. As WOT shifts are repeated, the PCM learns the time required to complete the shifts by comparing the engine speed when the shifts occur to the optimum speed. After each shift, the PCM adjusts the shift point until the optimum speed is reached. The PCM also considers vehicle loading, grade and engine performance changes due to high altitude in determining when to make WOT shifts. It does this by measuring vehicle and engine accelera- tion and then factoring in the shift time.
TRANSFER CASE LOW RANGE OPERATION
On four-wheel drive vehicles operating in low range, the engine can accelerate to its peak more rapidly than in Normal range, resulting in delayed shifts and undesirable engine 9flare.9 The low range governor pressure curve is also higher than normal to initiate upshifts sooner. The PCM compares elec- tronic vehicle speed signal used by the speedometer to the transmission output shaft speed signal to determine when the transfer case is in low range.
AUTOMATIC TRANSMISSION - 46RE
21 - 198
ELECTRONIC GOVERNOR (Continued) REMOVAL(1) Hoist and support vehicle on safety stands. (2) Remove transmission fluid pan and filter. (3) Disengage wire connectors from pressure sen-
sor and solenoid (Fig. 84).
DR
(6) Pull solenoid from governor body (Fig. 86). (7) Pull pressure sensor from governor body. (8) Remove bolts holding governor body to valve
body.
Fig.84GovernorSolenoidAndPressureSensor
1 - PRESSURE SENSOR 2 - PRESSURE SOLENOID 3 - GOVERNOR
(4) Remove
screws holding pressure
solenoid
retainer to governor body.
(5) Separate solenoid retainer from governor (Fig.
85).
Fig.86PressureSolenoidandO-ring
1 - PRESSURE SOLENOID 2 - O-RING 3 - GOVERNOR
(9) Separate governor body from valve body (Fig.
87).
(10) Remove governor body gasket.
Fig.85PressureSolenoidRetainer
1 - PRESSURE SOLENOID RETAINER 2 - GOVERNOR
Fig.87GovernorBodyandGasket
1 - GOVERNOR BODY 2 - GASKET
AUTOMATIC TRANSMISSION - 46RE
21 - 199
(10) Place solenoid retainer in position on governor
(Fig. 90).
(11) Install
screws
to hold pressure
solenoid
retainer to governor body.
Fig.90PressureSolenoidRetainer
1 - PRESSURE SOLENOID RETAINER 2 - GOVERNOR
(12) Engage wire connectors into pressure sensor
and solenoid (Fig. 91).
(13) Install transmission fluid pan and (new) filter. (14) Lower vehicle and road test to verify repair.
DR ELECTRONIC GOVERNOR (Continued) INSTALLATION
Before installing the pressure sensor and solenoid in the governor body, replace o-ring seals, clean the gasket surfaces and replace gasket.
(1) Place gasket in position on back of governor
body (Fig. 88).
(2) Place governor body in position on valve body. (3) Install bolts to hold governor body to valve body.
Fig.88GovernorBodyandGasket
1 - GOVERNOR BODY 2 - GASKET
(4) Lubricate o-ring on pressure sensor with trans-
mission fluid.
(5) Align pressure sensor to bore in governor body. (6) Push pressure sensor into governor body. (7) Lubricate o-ring, on pressure solenoid, with
transmission fluid.
body (Fig. 89).
(8) Align pressure solenoid to bore in governor
(9) Push solenoid into governor body.
Fig.91GovernorSolenoidAndPressureSensor
1 - PRESSURE SENSOR 2 - PRESSURE SOLENOID 3 - GOVERNOR
Fig.89PressureSolenoidandO-ring
1 - PRESSURE SOLENOID 2 - O-RING 3 - GOVERNOR
21 - 200
AUTOMATIC TRANSMISSION - 46RE
DR
EXTENSION HOUSING BUSHING REMOVAL
(1) Remove extension housing yoke seal. (2) Insert Remover 6957 into the extension hous- ing. Tighten tool to bushing and remove bushing (Fig. 92).
Fig.92BushingRemoval-Typical
1 - REMOVER 2 - EXTENSION HOUSING BUSHING
INSTALLATION
(1) Align bushing oil hole with oil slot in extension
housing.
(2) Tap bushing into place with Installer 6951 and
Handle C-4171.
(3) Install new oil seal Installer C-3995-A (Fig. 93).
in housing using Seal
EXTENSION HOUSING SEAL REMOVAL
(1) Raise vehicle. (2) Mark propeller shaft and axle yoke for align-
ment reference.
(3) Disconnect and remove propeller shaft. (4) Remove old seal with Seal Remover C-3985-B
(Fig. 94) from overdrive housing.
Fig.94RemovingTransmissionHousingYokeSeal 1 - SPECIAL TOOL C-3985-B 2 - SEAL
INSTALLATION
(1) Place seal in position on overdrive housing. (2) Drive seal
into overdrive housing with Seal
Installer C-3995-A (Fig. 95).
(3) Carefully guide propeller shaft slip yoke into housing and onto output shaft splines. Align marks made at removal and connect propeller shaft to rear axle pinion yoke.
Fig.93TransmissionExtensionHousingSeal
Installation
1 - SPECIAL TOOL C-3995-A OR C-3972-A 2 - SPECIAL TOOL C-4471
Fig.95InstallingTransmissionHousingSeal
1 - SPECIAL TOOL C-3995-A OR C-3972-A 2 - SPECIAL TOOL C-4471
DR
AUTOMATIC TRANSMISSION - 46RE
21 - 201
FLUID AND FILTER
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - EFFECTS OF INCORRECT FLUID LEVEL
A low fluid level allows the pump to take in air along with the fluid. Air in the fluid will cause fluid pressures to be low and develop slower than normal. If the transmission is overfilled, the gears churn the fluid into foam. This aerates the fluid and causing the same conditions occurring with a low level. In either case, air bubbles cause fluid overheating, oxi- dation and varnish buildup which interferes with valve and clutch operation. Foaming also causes fluid expansion which can result in fluid overflow from the transmission vent or fill tube. Fluid overflow can eas- ily be mistaken for a leak if inspection is not careful.
DIAGNOSIS AND TESTING - CAUSES OF BURNT FLUID
Burnt, discolored fluid is a result of overheating
which has two primary causes.
(1) A result of restricted fluid flow through the main and/or auxiliary cooler. This condition is usu- ally the result of a faulty or improperly installed drainback valve, a damaged main cooler, or severe restrictions in the coolers and lines caused by debris or kinked lines.
(2) Heavy duty operation with a vehicle not prop- erly equipped for this type of operation. Trailer tow- ing or similar high load operation will overheat the transmission fluid if improperly equipped. Such vehicles should have an auxiliary transmission fluid cooler, a heavy duty cooling sys- tem, and the engine/axle ratio combination needed to handle heavy loads.
the vehicle is
DIAGNOSIS AND TESTING - FLUID CONTAMINATION
result of:
checking level
Transmission fluid contamination is generally a † adding incorrect fluid † failure to clean dipstick and fill tube when † engine coolant entering the fluid † internal failure that generates debris † overheat that generates sludge (fluid break- down)† failure to replace contaminated converter after repair The use of non-recommended fluids can result in transmission failure. The usual results are erratic shifts, slippage, abnormal wear and eventual failure
due to fluid breakdown and sludge formation. Avoid this condition by using recommended fluids only.
The dipstick cap and fill tube should be wiped clean before checking fluid level. Dirt, grease and other foreign material on the cap and tube could fall into the tube if not removed beforehand. Take the time to wipe the cap and tube clean before withdraw- ing the dipstick.
Engine coolant in the transmission fluid is gener- ally caused by a cooler malfunction. The only remedy is to replace the radiator as the cooler in the radiator is not a serviceable part. If coolant has circulated through the transmission, an overhaul is necessary. The torque converter should be replaced whenever a failure generates sludge and debris. This is neces- sary because normal converter flushing procedures will not remove all contaminants.
STANDARD PROCEDURE
STANDARD PROCEDURE - FLUID LEVEL CHECK
Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly.
Improper filling can also raise the fluid level too high. When the transmssion has too much fluid, the geartrain churns up foam and cause the same condi- tions which occur with a low fluid level.
In either case, air bubbles can cause overheating and/or fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transmission vent where it may be mis- taken for a leak.
After the fluid has been checked, seat the dipstick
fully to seal out water and dirt.
The transmission has a dipstick to check oil level. It is located on the right side of the engine. Be sure to wipe all dirt from dipstick handle before removing. Fluid level is checked with the engine running at curb idle speed, the transmission in NEUTRAL and the transmission fluid at normal operating tempera- ture. The engine should be running at idle speed for at least one minute, with the vehicle on level ground.
The transmission fluid level can be checked two
ways.
PROCEDURE ONE
(1) Transmission fluid must be at normal operat- ing temperature for accurate fluid level check. Drive
21 - 202
FLUID AND FILTER (Continued)AUTOMATIC TRANSMISSION - 46RE
DR
vehicle if necessary to bring fluid temperature up to normal hot operating temperature of 82°C (180°F).
(2) Position vehicle on level surface. (3) Start and run engine at curb idle speed. (4) Apply parking brakes. (5) Shift transmission momentarily into all gear ranges. Then shift transmission back to NEUTRAL. (6) Clean top of filler tube and dipstick to keep
dirt from entering tube.
(7) Remove dipstick (Fig. 96) and check fluid level
as follows:
mark.
(a) Correct acceptable level is in crosshatch area. (b) Correct maximum level is to MAX arrow
(c) Incorrect level is at or below MIN line. (d) If fluid is low, add only enough Mopart ATF +4, Automatic Transmission fluid, to restore correct level. Do not overfill.
PROCEDURE TWO
(1) Start engine and apply parking brake. (2) Shift the transmission into DRIVE for approxi-
mately 2 seconds.
(3) Shift
the transmission into REVERSE for
approximately 2 seconds.
(4) Shift the transmission into PARK. (5) Hook up DRBt scan tool and select engine.
Fig.96DipstickFluidLevelMarks-Typical
1 - DIPSTICK 2 - MAXIMUM CORRECT FLUID LEVEL 3 - ACCEPTABLE FLUID LEVEL
(6) Select sensors. (7) Read the transmission temperature value. (8) Compare the fluid temperature value with the
figure. (Fig. 97)
(9) Adjust transmission fluid level shown on the
dipstick according to the figure.
NOTE: After adding any fluid to the transmission, wait a minimum of 2 minutes for the oil to fully drain from the fill tube into the transmission before rechecking the fluid level.
(10) Check transmission for leaks.
Fig.9746REFluidFillGraph
AUTOMATIC TRANSMISSION - 46RE
21 - 203
DR FLUID AND FILTER (Continued) STANDARD PROCEDURE - FLUID AND FILTER REPLACEMENT
For proper service intervals (Refer to LUBRICA- TION & MAINTENANCE/MAINTENANCE SCHED- ULES - DESCRIPTION). The service fluid fill after a filter change is approximately 3.8 liters (4.0 quarts).
REMOVAL
(1) Hoist and support vehicle on safety stands. (2) Place a large diameter shallow drain pan
beneath the transmission pan.
(3) Remove bolts holding front and sides of pan to
transmission (Fig. 98).
(4) Loosen bolts holding rear of pan to transmis-
sion.
(5) Slowly separate front of pan and gasket away from transmission allowing the fluid to drain into drain pan.
(6) Hold up pan and remove remaining bolt hold-
ing pan to transmission.
away from transmission.
(7) While holding pan level, lower pan and gasket
(8) Pour remaining fluid in pan into drain pan. (9) Remove screws holding filter to valve body
(Fig. 99).
(10) Separate filter from valve body and pour fluid
in filter into drain pan.
(11) Dispose of used trans fluid and filter properly.
Fig.98TransmissionPan
1 - TRANSMISSION 2 - GASKET 3 - PAN
INSTALLATION
(1) Position a new transmission oil filter onto the
speed.
valve body.
(2) Install the screws to hold the filter to the valve
body. Tighten the screws to 4 N·m (35 in.lbs.).
(3) Clean the gasket surfaces of the transmission
oil pan and transmission pan rail.
Fig.99TransmissionFilter
1 - TRANSMISSION 2 - FILTER
NOTE: The transmission pan oil gasket is reusable. Inspect the sealing surfaces of the gasket. If the sealing ribs on both surfaces appear to be in good condition, clean the gasket of any foreign material and reinstall.
(4) Position the oil pan gasket onto the oil pan. (5) Position the oil pan and gasket onto the trans- mission and install several bolts to hold the pan and gasket to the transmission.
(6) Install the remainder of the oil pan bolts.
Tighten the bolts to 13.6 N·m (125 in.lbs.).
(7) Lower vehicle and fill transmission. (Refer to 21 - TRANSMISSION/AUTOMATIC/FLUID - STAN- DARD PROCEDURE)
STANDARD PROCEDURE - TRANSMISSION FILL
To avoid overfilling transmission after a fluid change or overhaul, perform the following procedure: in
(1) Remove dipstick and insert clean funnel
transmission fill tube.
(2) Add following initial quantity of Mopart ATF
+4, Automatic Transmission Fluid, to transmission:
(a) If only fluid and filter were changed, add 3
pints (1-1/2 quarts) of ATF +4 to transmission.
(b) If transmission was completely overhauled, or torque converter was replaced or drained, add 12 pints (6 quarts) of ATF +4 to transmission. (3) Apply parking brakes. (4) Start and run engine at normal curb idle
service
(5) Apply
transmission through all gear ranges then back to NEUTRAL, set parking brake, and leave engine running at curb idle speed.
brakes,
shift
21 - 204
FLUID AND FILTER (Continued)AUTOMATIC TRANSMISSION - 46RE
DR
(6) Remove funnel, insert dipstick and check fluid level. If level is low, add fluid to bring level to MIN mark on dipstick. Check to see if the oil level is equal on both sides of the dipstick. If one side is noticably higher than the other, the dipstick has picked up some oil from the dipstick tube. Allow the oil to drain down the dipstick tube and re-check.
(7) Drive vehicle until transmission fluid is at nor-
mal operating temperature.
(8) With the engine running at curb idle speed, the gear selector in NEUTRAL, and the parking brake applied, check the transmission fluid level.
CAUTION: Do not overfill transmission, fluid foam- ing and shifting problems can result.
(9) Add fluid to bring level up to MAX arrow
mark.
When fluid level is correct, shut engine off, release park brake, remove funnel, and install dipstick in fill tube.
FRONT CLUTCH DESCRIPTION
The front clutch assembly (Fig. 100) is composed of the front clutch retainer, pressure plate, clutch plates, driving discs, piston, piston return spring,
return spring retainer, and snap-rings. The front clutch is the forward-most component in the trans- mission geartrain and is directly behind the oil pump and is considered a driving component.
NOTE: The number of discs and plates may vary with each engine and vehicle combination.
OPERATION
To apply the clutch, pressure is applied between the clutch retainer and piston. The fluid pressure is provided by the oil pump, transferred through the control valves and passageways, and enters the clutch through the hub of the reaction shaft support. With pressure applied between the clutch retainer and piston, the piston moves away from the clutch retainer and compresses the clutch pack. This action applies the clutch pack, allowing torque to flow through the input shaft into the driving discs, and into the clutch plates and pressure plate that are lugged to the clutch retainer. The waved snap-ring is used to cushion the application of the clutch pack.
When pressure is released from the piston, the spring returns the piston to its fully released position and disengages the clutch. The release spring also helps to cushion the application of the clutch assem- bly. When the clutch is in the process of being released by the release spring, fluid flows through a
1 - INNER PISTON SEAL 2 - CLUTCH PISTON 3 - CLUTCH PISTON SPRING RETAINER 4 - CLUTCH PLATES 5 - CLUTCH PACK SNAP-RING (WAVED) 6 - REACTION PLATE
Fig.100FrontClutchComponents
7 - CLUTCH DISCS 8 - RETAINER SNAP-RING 9 - CLUTCH PISTON SPRINGS (9) 10 - OUTER PISTON SEAL 11 - FRONT CLUTCH RETAINER
AUTOMATIC TRANSMISSION - 46RE
21 - 205
DR FRONT CLUTCH (Continued)
vent and one-way ball-check-valve located in the clutch retainer. The check-valve is needed to elimi- nate the possibility of plate drag caused by centrifu- gal force acting on the residual fluid trapped in the clutch piston retainer.
DISASSEMBLY
(1) Remove the waved snap-ring, reaction plate,
clutch plates, and clutch discs.
(2) Compress clutch piston retainer and piston
springs with Compressor Tool C-3863-A (Fig. 101).
(3) Remove retainer snap-ring and remove com-
pressor tool.
(4) Remove clutch piston springs (Fig. 102). Note
position of piston springs for assembly reference.
(5) Remove clutch piston from retainer with a
(6) Remove and discard clutch piston inner and
twisting motion.
outer seals.
Fig.101RemovingFrontClutchSpringRetainer
Snap-Ring
1 - SPECIAL TOOL C-3863-A 2 - SNAP-RING
1 - INNER PISTON SEAL 2 - CLUTCH PISTON 3 - CLUTCH PISTON SPRING RETAINER 4 - CLUTCH PLATES 5 - CLUTCH PACK SNAP-RING (WAVED) 6 - REACTION PLATE
Fig.102FrontClutchComponents
7 - CLUTCH DISCS 8 - RETAINER SNAP-RING 9 - CLUTCH PISTON SPRINGS (9) 10 - OUTER PISTON SEAL 11 - FRONT CLUTCH RETAINER
21 - 206
FRONT CLUTCH (Continued)AUTOMATIC TRANSMISSION - 46RE
DR
(7) Assemble Tool Handle C-4171 and Bushing
Remover SP-3629 (Fig. 103).
(8) Insert remover tool in bushing and drive bush-
ing straight out of clutch retainer.
ASSEMBLY
NOTE: The 46RE transmission uses three plates and discs for the front clutch.
(1) Mount Bushing Installer SP-5511 on tool han-
dle (Fig. 104).
bushing into retainer.
(2) Slide new bushing onto installer tool and start
(3) Tap new bushing into place until installer tool
bottoms against clutch retainer.
(4) Remove installer tools and clean retainer thor-
oughly.
Fig.103FrontClutchRetainerBushing
ReplacementTools
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL SP-3629
3 - SPECIAL TOOL SP-5511
4 - SPECIAL TOOL C-4171
5 - FRONT CLUTCH RETAINERINSPECTION
Inspect the front clutch components. Replace the clutch discs if warped, worn, scored, burned or charred, the lugs are damaged, or if the facing is flaking off. Replace the steel plates and reaction plate if heavily scored, warped, or broken. Be sure the driving lugs on the discs and plate are also in good condition. The lugs must not be bent, cracked or damaged in any way.
Replace the piston springs and spring retainer if
either are distorted, warped or broken.
Check the lug grooves in the clutch piston retainer. The steel plates should slide freely in the slots. Replace the piston retainer if the grooves are worn or damaged. Also check action of in the piston retainer. The ball must move freely and not stick.
the check ball
Replace the retainer bushing if worn, scored, or
there is any doubt about bushing condition.
Inspect the piston and retainer seal surfaces for nicks or scratches. Minor scratches can be removed with crocus cloth. However, replace the piston and/or retainer if the seal surfaces are seriously scored.
Check the clutch piston check ball. The ball should be securely in place. Replace the piston if the ball is missing, or seized in place.
Fig.104FrontClutchRetainerBushing
ReplacementTools
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL SP-3629
3 - SPECIAL TOOL SP-5511
4 - SPECIAL TOOL C-4171
5 - FRONT CLUTCH RETAINER(5) Soak clutch discs in transmission fluid. (6) Install new inner piston seal onto the outer
diameter of the clutch retainer inner hub.
(7) Install new outer seal onto the clutch piston. Be sure seal lips of both seals face the interior of the retainer.
(8) Lubricate new inner and outer piston seals
with Ru-Glyde™, or Mopart Door Ease.
(9) Install clutch piston in retainer. Use twisting motion to seat piston in bottom of retainer. A thin strip of plastic (about 0.015 - 0.020 in. thick), can be used to guide seals into place if necessary.
AUTOMATIC TRANSMISSION - 46RE
21 - 207
DR FRONT CLUTCH (Continued)
CAUTION: Never push the clutch piston straight in. This will fold the seals over causing leakage and clutch slip. In addition, never use any type of metal tool to help ease the piston seals into place. Metal tools will cut, shave, or score the seals.
(10) Install and position nine clutch piston springs
(Fig. 105).
Fig.105FrontClutchSpringPosition
1 - 9 SPRING CLUTCH
(11) Install
springs.
spring retainer on top of piston
Fig.106TypicalMethodOfMeasuringFrontClutch
PackClearance
1 - FEELER GAUGE 2 - WAVED SNAP-RING 3 - FEELER GAUGE
(12) Compress spring retainer and piston springs
with Tool C-3863-A.
compressor tool.
(13) Install spring retainer snap-ring and remove
(14) Install clutch plates and discs (Fig. 102). Three clutch discs, three steel plates and one reac- tion plate are required.
(15) Install reaction plate followed by waved snap-
ring.
(16) Check clutch pack clearance with feeler gauge (Fig. 106). Clearance between waved spring and pres- sure plate should 1.78 - 3.28 mm (0.070 - 0.129 in.). If clearance is incorrect, clutch plates, clutch discs, snap-ring, or pressure plate may have to be changed.
FRONT SERVO DESCRIPTION
The kickdown servo (Fig. 107) consists of a two- land piston with an inner piston, a piston rod and guide, and a return spring. The dual-land piston uses seal rings on its outer diameters and an O-ring for the inner piston.
Fig.107FrontServo
1 - VENT 2 - INNER PISTON 3 - PISTON 4 - SPRING 5 - RELEASE PRESSURE 6 - APPLY PRESSURE 7 - PISTON ROD
AUTOMATIC TRANSMISSION - 46RE
21 - 208
FRONT SERVO (Continued) OPERATIONThe application of the piston is accomplished by applying pressure between the two lands of the piston. The pressure acts against the larger lower land to push the piston downward, allowing the piston rod to extend though its guide against the apply lever. Release of the servo at the 2-3 upshift is accomplished by a combina- tion of spring and line pressure, acting on the bottom of the larger land of the piston. The small piston is used to cushion the application of the band by bleeding oil through a small orifice in the larger piston. The release timing of the kickdown servo is very important to obtain a smooth but firm shift. The release has to be very quick, just as the front clutch application is taking place. Otherwise, engine runaway or a shift hesitation will occur. To accomplish this, the band retains its hold- ing capacity until the front clutch is applied, giving a small amount of overlap between them.
DISASSEMBLY
(1) Remove seal ring from rod guide (Fig. 108). (2) Remove small snap-ring from servo piston rod. Then remove piston rod, spring and washer from pis- ton.
(3) Remove and discard servo component O-ring
and seal rings.
DR
Fig.109FrontServo
1 - VENT 2 - INNER PISTON 3 - PISTON 4 - SPRING 5 - RELEASE PRESSURE 6 - APPLY PRESSURE 7 - PISTON ROD
INSPECTION
Inspect the servo components (Fig. 110). Replace the springs if collapsed, distorted or broken. Replace the guide, rod and piston if cracked, bent, or worn. Discard the servo snap-ring if distorted or warped.
Fig.108FrontServo
1 - PISTON RINGS 2 - SERVO PISTON 3 - O-RING 4 - SNAP-RING 5 - PISTON ROD GUIDE 6 - SEAL RING 7 - SNAP-RING 8 - SERVO SPRING 9 - WASHER 10 - SPRING 11 - PISTON ROD
CLEANING
Clean the servo piston components (Fig. 109) with
solvent and dry them with compressed air.
Fig.110FrontServo
1 - PISTON RINGS 2 - SERVO PISTON 3 - O-RING 4 - SNAP-RING 5 - PISTON ROD GUIDE 6 - SEAL RING 7 - SNAP-RING 8 - SERVO SPRING 9 - WASHER 10 - SPRING 11 - PISTON ROD
DR FRONT SERVO (Continued)
Check the servo piston bore for wear. If the bore is severely scored, or damaged, it will be necessary to replace the case.
Replace any servo component if doubt exists about
condition. Do not reuse suspect parts.
ASSEMBLY
Clean and inspect front servo components. (1) Lubricate new o-ring and seal rings with petro- leum jelly and install them on piston, guide and rod. (2) Install rod in piston. Install spring and washer on
rod. Compress spring and install snap-ring (Fig. 111).
AUTOMATIC TRANSMISSION - 46RE
21 - 209
(d) NEUTRAL position - Engine running and brakes applied, apply upward force on the shift arm. Transmission shall not be able to shift from neutral to reverse.
REMOVAL
(1) Shift transmission into PARK. (2) Raise vehicle. (3) Disengage cable eyelet at transmission shift lever and pull cable adjuster out of mounting bracket (Fig. 112) or (Fig. 113).
Fig.111FrontServo
1 - PISTON RINGS 2 - SERVO PISTON 3 - O-RING 4 - SNAP-RING 5 - PISTON ROD GUIDE 6 - SEAL RING 7 - SNAP-RING 8 - SERVO SPRING 9 - WASHER 10 - SPRING 11 - PISTON ROD
GEARSHIFT CABLE DIAGNOSIS AND TESTING - GEARSHIFT CABLE
Fig.112GearshiftCableatTransmission-RFE
1 - GEARSHIFT CABLE 2 - RFE TRANSMISSION 3 - MANUAL LEVER
(1) Engine starts must be possible with shift lever in PARK or NEUTRAL positions only. Engine starts must not be possible in any other gear position.
(2) With the shift lever in the:
(a) PARK position - Apply upward force on the shift arm and remove pressure. Engine starts must be possible.
(b) PARK position - Apply downward force on the shift arm and remove pressure. Engine starts must be possible.
(c) NEUTRAL position - Normal position. Engine
starts must be possible.
Fig.113GearshiftCableatTransmission-RE
1 - GEARSHIFT CABLE 2 - RE TRANSMISSION 3 - MANUAL LEVER
21 - 210
GEARSHIFT CABLE (Continued)AUTOMATIC TRANSMISSION - 46RE
DR
(4) Lower the vehicle. (5) Remove the dash panel insulation pad as nec- essary to access the gearshift cable grommet (Fig. 114).
(6) Remove grommet from the dash panel. (7) Remove any steering column trim necessary to
access the gearshift cable and BTSI mechanism.
(8) Disconnect the BTSI wiring connector. (9) Disconnect cable at lower column bracket and shift lever pin and pull the cable through the dash panel opening into the vehicle (Fig. 115).
INSTALLATION
(1) Route the transmission end of the gearshift cable through the opening in the dash panel (Fig. 116).
(2) Seat the cable grommet into the dash panel
opening.
(3) Snap the cable into the steering column bracket so the retaining ears (Fig. 117) are engaged and snap the cable eyelet onto the shift lever ball stud.
Fig.114GearshiftCableattheDashPanel
1 - GEARSHIFT CABLE 2 - GROMMET
Fig.116GearshiftCableattheDashPanel
1 - GEARSHIFT CABLE 2 - GROMMET
Fig.115GearshiftCableatSteeringColumn
1 - STEERING COLUMN 2 - GEARSHIFT CABLE 3 - GEARSHIFT CABLE LOCK TAB 4 - BTSI SOLENOID LOCK TAB 5 - BTSI CONNECTOR
(10) Remove gearshift cable from vehicle.
Fig.117GearshiftCableatSteeringColumn
1 - STEERING COLUMN 2 - GEARSHIFT CABLE 3 - GEARSHIFT CABLE LOCK TAB 4 - BTSI SOLENOID LOCK TAB 5 - BTSI CONNECTOR
DR GEARSHIFT CABLE (Continued)
AUTOMATIC TRANSMISSION - 46RE
21 - 211
(4) Raise the vehicle. (5) Place the transmission manual shift lever in the “PARK” detent (rearmost) position and rotate prop shaft to ensure transmission is in PARK.
(6) Route the gearshift cable through the transmis- sion mounting bracket and secure the cable by snap- ping the cable retaining ears into the transmission bracket and snapping the cable eyelet on the manual shift lever ball stud. (7) Lower vehicle. (8) Lock the shift cable adjustment by pressing the cable adjuster lock tab downward until it snaps into place.
(9) Check for proper operation of the transmission
range sensor.
nism as necessary.
(10) Adjust the gearshift cable and BTSI mecha-
(5) Verify transmission shift
lever is in PARK detent by moving lever fully rearward. Last rearward detent is PARK position.
(6) Verify positive engagement of
transmission park lock by attempting to rotate propeller shaft. Shaft will not rotate when park lock is engaged.
(7) Snap the cable eyelet onto the transmission
manual shift lever. (8) Lower vehicle. (9) Lock shift cable by pressing cable adjuster lock
tab downward until it snaps into place.
(10) Check engine starting. Engine should start
only in PARK and NEUTRAL
ADJUSTMENTS
GEARSHIFT CABLE
is CORRECT if
Check adjustment by starting the engine in PARK and NEUTRAL. Adjustment the engine starts only in these positions. Adjustment is INCORRECT if the engine starts in one but not both positions. If the engine starts in any position other than PARK or NEUTRAL, or if the engine will not start at all, the transmission range sensor may be faulty.
Gearshift Adjustment Procedure
(1) Shift transmission into PARK. (2) Release cable adjuster lock tab (underneath the
steering column) (Fig. 118) to unlock cable.
(3) Raise vehicle. (4) Disengage the cable eyelet from the transmis-
sion manual shift lever.
Fig.118GearshiftCableatSteeringColumn
1 - STEERING COLUMN 2 - GEARSHIFT CABLE 3 - GEARSHIFT CABLE LOCK TAB 4 - BTSI SOLENOID LOCK TAB 5 - BTSI CONNECTOR
21 - 212
AUTOMATIC TRANSMISSION - 46RE
DR
OIL PUMP DESCRIPTION
The oil pump (Fig. 119) is located in the pump housing inside the bell housing of the transmission case. The oil pump consists of an inner and outer gear, a housing, and a reaction shaft support.
OPERATION
(2) Place pump body on two wood blocks. (3) Remove reaction shaft support bolts and sepa-
rate support from pump body (Fig. 120).
the
clearance between the
As the torque converter rotates, the converter hub rotates the inner and outer gears. As the gears rotate, teeth increases in the crescent area, and creates a suction at the inlet side of the pump. This suction draws fluid through the pump inlet from the oil pan. As the clearance between the gear teeth in the crescent area decreases, it forces pressurized fluid into the pump outlet and to the valve body.
gear
DISASSEMBLY
(1) Mark position of support in oil pump body for assembly alignment reference. Use scriber or paint to make alignment marks.
Fig.120ReactionShaftSupport
1 - OIL PUMP 2 - REACTION SHAFT SUPPORT
1 - OIL SEAL 2 - VENT BAFFLE 3 - OIL PUMP BODY 4 - GASKET 5 - REACTION SHAFT SUPPORT 6 - SEAL RINGS
Fig.119OilPumpAssembly
7 - BOLTS (6) 8 - #1 THRUST WASHER (SELECTIVE) 9 - INNER GEAR 10 - OUTER GEAR 11 - “O” RING
DR OIL PUMP (Continued)
AUTOMATIC TRANSMISSION - 46RE
21 - 213
(4) Remove pump inner and outer gears (Fig. 121). (5) Remove o-ring seal from pump body (Fig. 122).
Discard seal after removal.
(6) Remove oil pump seal with Remover Tool
C-3981. Discard seal after removal.
Fig.121PumpGears
1 - GEAR BORE 2 - PUMP BODY 3 - INNER GEAR 4 - OUTER GEAR
1 - OIL SEAL 2 - VENT BAFFLE 3 - OIL PUMP BODY 4 - GASKET 5 - REACTION SHAFT SUPPORT 6 - SEAL RINGS
Fig.122OilPumpAssembly
7 - BOLTS (6) 8 - #1 THRUST WASHER (SELECTIVE) 9 - INNER GEAR 10 - OUTER GEAR 11 - “O” RING
AUTOMATIC TRANSMISSION - 46RE
21 - 214
OIL PUMP (Continued) OIL PUMP BUSHING REMOVALDR
(1) Position pump housing on clean, smooth sur-
face with gear cavity facing down.
(2) Remove bushing with Tool Handle C-4171 and
Bushing Remover SP-3550 (Fig. 123).
REACTION SHAFT SUPPORT BUSHING REMOVAL
(1) Assemble Cup Tool SP-3633, Nut SP-1191 and
Bushing Remover SP-5301 (Fig. 124).
(2) Hold cup tool
firmly against reaction shaft. Thread remover tool into bushing as far as possible by hand.
(3) Using wrench, thread remover tool an addi-
tional 3-4 turns into bushing to firmly engage tool.
(4) Tighten tool hex nut against cup tool to pull bushing from shaft. Clean all chips from shaft and support after bushing removal.
Fig.123OilPumpBushing
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL SP-3550
3 - BUSHING 4 - SPECIAL TOOL SP-5118
5 - SPECIAL TOOL C-4171
6 - PUMP HOUSINGCLEANING
Clean pump and support components with solvent
and dry them with compressed air.
INSPECTION
Check condition of
the seal rings and thrust washer on the reaction shaft support. The seal rings do not need to be replaced unless cracked, broken, or severely worn.
Fig.124ReactionShaftBushing
1 - SPECIAL TOOL SP-1191
2 - SPECIAL TOOL C-4171
3 - SPECIAL TOOL SP-3633
4 - SPECIAL TOOL SP-5301
5 - SPECIAL TOOL SP-5302
6 - BUSHING 7 - REACTION SHAFT 8 - BUSHINGInspect the pump and support components. Replace the pump or support if the seal ring grooves or machined surfaces are worn, scored, pitted, or dam- aged. Replace the pump gears if pitted, worn chipped, or damaged.
Inspect the pump bushing. Then check the reaction shaft support bushing. Replace either bushing only if heavily worn, scored or damaged. It is not necessary to replace the bushings unless they are actually dam- aged.
Clearance between outer gear and reaction shaft housing should be 0.010 to 0.063 mm (0.0004 to 0.0025 in.). Clearance between inner gear and reac- tion shaft housing should be 0.010 to 0.063 mm (0.0004 to 0.0025 in.). Both clearances can be mea- sured at the same time by installing the gears in the pump body and measure pump component clearances as follows:
(1) Position an appropriate piece of Plastigage™
across both gears.
tion shaft housing.
(2) Align the plastigage to a flat area on the reac-
(3) Install the reaction shaft to the pump housing. (4) Separate the reaction shaft housing from the pump housing and measure the Plastigage™ follow- ing the instructions supplied with it.
AUTOMATIC TRANSMISSION - 46RE
21 - 215
DR OIL PUMP (Continued)
Clearance between inner gear tooth and outer gear should be 0.08 to 0.19 mm (0.0035 to 0.0075 in.). Measure clearance with an appropriate feeler gauge (Fig. 125).
Clearance between outer gear and pump housing should be 0.10 to 0.19 mm (0.004 to 0.0075 in.). Mea- sure clearance with an appropriate feeler gauge.
Fig.125CheckingPumpGearTipClearance
1 - FEELER GAUGE 2 - INNER GEAR 3 - OUTER GEAR
ASSEMBLY
OIL PUMP BUSHING
Fig.126OilPumpBushing
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL SP-3550
3 - BUSHING 4 - SPECIAL TOOL SP-5118
5 - SPECIAL TOOL C-4171
6 - PUMP HOUSING(1) Assemble Tool Handle C-4171 and Bushing
Installer SP-5118 (Fig. 126).
(2) Place bushing on installer tool and start bush-
ing into shaft.
(3) Tap bushing into place until Installer Tool SP-5118 bottoms in pump cavity. Keep tool and bush- ing square with bore. Do not allow bushing to become cocked during installation.
(4) Stake pump bushing in two places with blunt punch. Remove burrs from stake points with knife blade (Fig. 127).
Fig.127Staking-DeburringOilPumpBushing
1 - TWO STAKES 2 - NARROW BLADE 3 - BLUNT PUNCH
AUTOMATIC TRANSMISSION - 46RE
21 - 216
OIL PUMP (Continued) REACTION SHAFT SUPPORT BUSHING(1) Place reaction shaft support upright on a clean,
smooth surface.
(2) Assemble Bushing Installer Tools C-4171 and SP-5302. Then slide new bushing onto installer tool (Fig. 128).
(3) Start bushing in shaft. Tap bushing into shaft
until installer tool bottoms against support flange.
(4) Clean reaction shaft support thoroughly after
bushing replacement (to remove any chips).
DR
CAUTION: The reaction shaft support seal rings will break if overspread, or twisted. If new rings are being installed, spread them only enough for instal- lation. Also be very sure the ring ends are securely hooked together after installation. Otherwise, the rings will either prevent pump installation, or break during installation.
(4) Align and install reaction shaft support on
pump body.
(5) Install bolts attaching reaction shaft support to pump. Tighten bolts to 20 N·m (175 in. lbs.) torque. (6) Install new pump seal with Installer Tool C-3860-A (Fig. 129). Use hammer or mallet to tap seal into place.
(7) Install new o-ring on pump body. Lubricate oil
seal and o-ring with petroleum jelly.
(8) Cover pump assembly to prevent dust entry
and set aside for assembly installation.
Fig.128ReactionShaftBushing
1 - SPECIAL TOOL SP-1191
2 - SPECIAL TOOL C-4171
3 - SPECIAL TOOL SP-3633
4 - SPECIAL TOOL SP-5301
5 - SPECIAL TOOL SP-5302
6 - BUSHING 7 - REACTION SHAFT 8 - BUSHINGOIL PUMP BODY
Fig.129OilPumpSeal
1 - SPECIAL TOOL C-3860-A 2 - PUMP BODY 3 - PUMP SEAL
(1) Lubricate pump gears with transmission fluid
and install them in pump body.
(2) Install thrust washer on reaction shaft support hub. Lubricate washer with petroleum jelly or trans- mission fluid before installation.
(3) If reaction shaft seal rings are being replaced, install new seal rings on support hub. Lubricate seal rings with transmission fluid or petroleum jelly after installation. Squeeze each ring until ring ends are securely hooked together.
DR
AUTOMATIC TRANSMISSION - 46RE
21 - 217
OUTPUT SHAFT FRONT BEARING REMOVAL
OUTPUT SHAFT REAR BEARING REMOVAL
(1) Remove overdrive unit from the vehicle. (2) Remove overdrive geartrain from housing. (3) Remove snap-ring holding output shaft front
bearing to overdrive geartrain. (Fig. 130).
(4) Pull bearing from output shaft.
Fig.130OutputShaftFrontBearing
1 - OUTPUT SHAFT FRONT BEARING 2 - SNAP-RING 3 - OUTPUT SHAFT 4 - GROOVE TO REAR 5 - OVERDRIVE GEARTRAIN
INSTALLATION
(1) Place replacement bearing in position on geartrain with locating retainer groove toward the rear.
(2) Push bearing onto shaft until the snap-ring
(3) Install snap-ring to hold bearing onto output
groove is visible.
shaft.
(1) Remove overdrive unit from the vehicle. (Refer to 21 - TRANSMISSION/AUTOMATIC/OVERDRIVE - REMOVAL)
(2) Remove overdrive geartrain from housing. (3) Remove snap-ring holding output shaft rear
bearing into overdrive housing (Fig. 131).
(4) Using a suitable driver inserted through the
rear end of housing, drive bearing from housing.
Fig.131OutputShaftRearBearing
1 - OUTPUT SHAFT REAR BEARING 2 - OVERDRIVE HOUSING 3 - SNAP-RING
INSTALLATION
(1) Place replacement bearing in position in hous-
ing.
(2) Using a suitable driver, drive bearing into
housing until the snap-ring groove is visible.
(3) Install snap-ring to hold bearing into housing
(4) Install overdrive geartrain into housing. (5) Install overdrive unit in vehicle.
(4) Install overdrive geartrain into housing. (5) Install overdrive unit in vehicle.
(Fig. 131).
21 - 218
AUTOMATIC TRANSMISSION - 46RE
DR
OVERDRIVE CLUTCH DESCRIPTION
The overdrive clutch (Fig. 132) is composed of the pressure plate, clutch plates, holding discs, overdrive piston retainer, piston, piston spacer, and snap-rings. The overdrive clutch is the forwardmost component in the transmission overdrive unit and is considered a holding component. The overdrive piston retainer, piston, and piston spacer are located on the rear of the main transmission case.
NOTE: The number of discs and plates may vary with each engine and vehicle combination.
OPERATION
To apply the clutch, pressure is applied between the piston retainer and piston. The fluid pressure is pro- vided by the oil pump, transferred through the control valves and passageways, and enters the clutch through passages at the lower rear portion of the valve body area. With pressure applied between the piston retainer and piston, the piston moves away from the piston retainer and compresses the clutch pack. This action applies the clutch pack, allowing torque to flow through the intermediate shaft into the overdrive planetary gear set. The overdrive clutch discs are attached to the over- drive clutch hub while the overdrive clutch plates, reac- tion plate, and pressure plate are lugged to the overdrive housing. This allows the intermediate shaft to
transfer the engine torque to the planetary gear and overrunning clutch. This drives the planetary gear inside the annulus, which is attached to the overdrive clutch drum and output shaft, creating the desired gear ratio. The waved snap-ring is used to cushion the appli- cation of the clutch pack.
OVERDRIVE SWITCH DESCRIPTION
The overdrive OFF (control) switch is located in the shift lever arm (Fig. 133). The switch is a momentary contact device that signals the PCM to toggle current status of the overdrive function.
OPERATION
At key-on, overdrive operation is allowed. Pressing the switch once causes the overdrive OFF mode to be entered and the overdrive OFF switch lamp to be illuminated. Pressing the switch a second time causes normal overdrive operation to be restored and the overdrive lamp to be turned off. The overdrive OFF mode defaults to ON after the ignition switch is cycled OFF and ON. The normal position for the con- trol switch is the ON position. The switch must be in this position to energize the solenoid and allow a 3-4
upshift. The control switch indicator light illuminates only when the overdrive switch is turned to the OFF position, or when illuminated by the transmission control module.1 - REACTION PLATE
Fig.132OverdriveClutch
2 - PRESSURE PLATE
DR OVERDRIVE SWITCH (Continued)
AUTOMATIC TRANSMISSION - 46RE
21 - 219
Fig.133OverdriveOffSwitch
DIAGNOSIS AND TESTING - OVERDRIVE ELECTRICAL CONTROLS
The overdrive off switch, valve body solenoid, case connectors and related wiring can all be tested with a 12 volt test lamp or a volt/ohmmeter. Check conti- nuity of each component when diagnosis indicates this is necessary.
Switch and solenoid continuity should be checked whenever the transmission fails to shift into fourth gear range.
REMOVAL
(1) Using a plastic trim tool, remove the overdrive
off switch retainer from the shift lever (Fig. 134).
Fig.135RemovetheOverdriveOffSwitch
1 - GEAR SHIFT LEVER 2 - OVERDRIVE OFF SWITCH
INSTALLATION
NOTE: There is enough slack in the wire to pull out the connector from the lever.
(1) Pull the connector out of the lever just enough
to grasp it.
CAUTION: Be careful not to bend the pins on the overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly.
(2) Install the overdrive off switch into the connec-
tor (Fig. 136)
Fig.134OverdriveOffSwitchRetainer
1 - GEAR SHIFT LEVER 2 - OVERDRIVE OFF SWITCH RETAINER 3 - PLASTIC TRIM TOOL
(2) Pull the switch outwards to release it from the
connector in the lever (Fig. 135)
Fig.136InstalltheOverdriveOffSwitch
1 - GEAR SHIFT LEVER 2 - OVERDRIVE OFF SWITCH WIRING CONNECTOR 3 - OVERDRIVE OFF SWITCH
(3) Push the overdrive off switch and wiring into
(4) Install the overdrive off switch retainer onto
the shift lever.
the shift lever.
21 - 220
AUTOMATIC TRANSMISSION - 46RE
DR
OVERDRIVE UNIT REMOVAL
(1) Shift transmission into PARK. (2) Raise vehicle. (3) Remove transfer case, if equipped. (4) Mark propeller shaft universal joint(s) and axle pinion yoke, or the companion flange and flange yoke, for alignment reference at installation, if neces- sary.
(5) Disconnect and remove the rear propeller shaft, if necessary. (Refer to 3 - DIFFERENTIAL & DRIV- ELINE/PROPELLER SHAFT/PROPELLER SHAFT - REMOVAL)
(6) Remove transmission oil pan, remove gasket,
drain oil and reinstall pan.
(7) If overdrive unit had malfunctioned, or if fluid is contaminated, remove entire transmission. If diag- nosis indicated overdrive problems only, remove just the overdrive unit.
(8) Support transmission with transmission jack. (9) Remove bolts attaching overdrive unit to trans-
mission (Fig. 137).
CAUTION: Support the overdrive unit with a jack before moving it rearward. This is necessary to pre- vent damaging the intermediate shaft. Do not allow the shaft to support the entire weight of the over- drive unit.
(10) Carefully work overdrive unit off intermediate shaft. Do not tilt unit during removal. Keep it as level as possible.
(11) If overdrive unit does not require service, immediately insert Alignment Tool 6227-2 in splines of planetary gear and overrunning clutch to prevent splines from rotating out of alignment. If misalign- ment occurs, overdrive unit will have to be disassem- bled in order to realign splines.
(12) Remove and retain overdrive piston thrust bearing. Bearing may remain on piston or in clutch hub during removal.
(13) Position drain pan on workbench. (14) Place overdrive unit over drain pan. Tilt unit
to drain residual fluid from case.
(15) Examine fluid for clutch material or metal fragments. If fluid contains these items, overhaul will be necessary.
(16) If overdrive unit does not require any service, leave alignment tool in position. Tool will prevent accidental misalignment of planetary gear and over- running clutch splines.
DISASSEMBLY
(1) Remove transmission speed sensor and o-ring
seal from overdrive case (Fig. 138).
(2) Remove overdrive piston thrust bearing (Fig.
139).
Fig.137OverdriveUnitBolts
1 - OVERDRIVE UNIT 2 - ATTACHING BOLTS (7)
Fig.138TransmissionSpeedSensor
1 - SOCKET AND WRENCH 2 - SPEED SENSOR 3 - O-RING
DR OVERDRIVE UNIT (Continued)
AUTOMATIC TRANSMISSION - 46RE
21 - 221
(2) Remove intermediate shaft spacer (Fig. 141). Retain spacer. It is a select fit part and may possibly be reused.
Fig.139OverdrivePistonThrustBearingRemoval/
Installation
1 - THRUST BEARING 2 - OVERDRIVE PISTON 3 - THRUST PLATE
OVERDRIVE PISTON
(1) Remove overdrive piston thrust plate (Fig. 140). Retain thrust plate. It is a select fit part and may possibly be reused.
Fig.141IntermediateShaftSpacerLocation
1 - INTERMEDIATE SHAFT 2 - INTERMEDIATE SHAFT SPACER (SELECT FIT)
(3) Remove overdrive piston from retainer (Fig.
142).
Fig.140OverdrivePistonThrustPlateRemoval/
Installation
1 - OVERDRIVE PISTON 2 - OVERDRIVE PISTON SPACER (SELECT FIT)
Fig.142OverdrivePistonRemoval
1 - PISTON RETAINER 2 - OVERDRIVE PISTON
AUTOMATIC TRANSMISSION - 46RE
21 - 222
OVERDRIVE UNIT (Continued) OVERDRIVE CLUTCH PACKDR
(1) Remove overdrive clutch pack wire retaining
ring (Fig. 143).
(2) Remove overdrive clutch pack (Fig. 144). (3) Note position of clutch pack components for
assembly reference (Fig. 145).
Fig.143RemovingOverdriveClutchPackRetaining
Ring
1 - OVERDRIVE CLUTCH PACK RETAINING RING
Fig.144OverdriveClutchPackRemoval
1 - OVERDRIVE CLUTCH PACK
OVERDRIVE GEARTRAIN
(1) Remove overdrive clutch wave spring (Fig.
146).
(2) Remove overdrive clutch reaction snap-ring (Fig. 147). Note that snap-ring is located in same groove as wave spring.
Fig.145OverdriveClutchComponentPosition-
Typical
1 - REACTION PLATE 2 - CLUTCH PLATES (3)
3 - PRESSURE PLATE 4 - CLUTCH DISCS (4)
Fig.146OverdriveClutchWaveSpringRemoval
1 - WAVE SPRING
Fig.147OverdriveClutchReactionSnap-Ring
Removal
1 - REACTION RING 2 - CLUTCH HUB
DR OVERDRIVE UNIT (Continued)
(3) Remove Torx™ head screws that attach access
cover and gasket to overdrive case (Fig. 148).
(4) Remove access cover and gasket (Fig. 149).
AUTOMATIC TRANSMISSION - 46RE
21 - 223
(6) Lift gear case up and off geartrain assembly
(Fig. 151).
Fig.148AccessCoverScrewRemoval
1 - TORX SCREWDRIVER (T25) 2 - ACCESS COVER SCREWS
Fig.151RemovingGeartrain
1 - GEARTRAIN ASSEMBLY 2 - GEAR CASE
(7) Remove snap-ring that retains rear bearing on
(8) Remove rear bearing from output shaft (Fig.
output shaft.
152).
Fig.149AccessCoverAndGasketRemoval
1 - ACCESS COVER AND GASKET
(5) Expand output shaft bearing snap-ring with expanding-type snap-ring pliers. Then push output shaft forward to release shaft bearing from locating ring (Fig. 150).
Fig.150ReleasingBearingFromLocatingRing
1 - EXPAND BEARING LOCATING RING WITH SNAP-RING PLIERS 2 - ACCESS HOLE
Fig.152RearBearingRemoval
1 - OUTPUT SHAFT 2 - REAR BEARING 3 - SNAP-RING
DR
(4) Remove direct clutch pack snap-ring (Fig. 154). (5) Remove direct clutch hub retaining ring (Fig. 155).
AUTOMATIC TRANSMISSION - 46RE
21 - 224
OVERDRIVE UNIT (Continued) DIRECT CLUTCH, HUB AND SPRINGWARNING: THE NEXT STEP IN DISASSEMBLY INVOLVES COMPRESSING THE DIRECT CLUTCH SPRING. IT IS EXTREMELY IMPORTANT THAT PROPER EQUIPMENT BE USED TO COMPRESS THE SPRING AS SPRING FORCE IS APPROXIMATELY 830 POUNDS. USE SPRING COMPRESSOR TOOL 6227-1 AND A HYDRAU- LIC SHOP PRESS WITH A MINIMUM RAM TRAVEL OF 5-6 INCHES. THE PRESS MUST ALSO HAVE A BED THAT CAN BE ADJUSTED UP OR DOWN AS REQUIRED. RELEASE CLUTCH SPRING TENSION SLOWLY AND COMPLETELY TO AVOID PERSONAL INJURY.
(1) Mount geartrain assembly in shop press (Fig. 153). (2) Position Compressor Tool 6227-1 on clutch hub (Fig. 153). Support output shaft flange with steel press plates as shown and center assembly under press ram.
(3) Apply press pressure slowly. Compress hub and spring far enough to expose clutch hub retaining ring and relieve spring pressure on clutch pack snap-ring (Fig. 153).
Fig.154DirectClutchPackSnap-RingRemoval
1 - CLUTCH HUB 2 - SPECIAL TOOL 6227-1
3 - DIRECT CLUTCH PACK SNAP-RING 4 - PRESS PLATES 5 - CLUTCH DRUMFig.153GeartrainMountedInShopPress
1 - PRESS RAM 2 - SPECIAL TOOL C-3995-A (OR SIMILAR TOOL) 3 - CLUTCH HUB 4 - PLATES 5 - PRESS BED 6 - SPECIAL TOOL 6227-1
Fig.155DirectClutchHubRetainingRingRemoval 1 - SPECIAL TOOL 6227-1
2 - CLUTCH HUB RETAINING RING 3 - PRESS BED 4 - PRESS PLATESDR OVERDRIVE UNIT (Continued)
AUTOMATIC TRANSMISSION - 46RE
21 - 225
(6) Release press load slowly and completely (Fig.
156).
(7) Remove Special Tool 6227-1. Then remove
clutch pack from hub (Fig. 156).
Fig.158RemovingSunGear,ThrustBearingAnd
PlanetaryGear
1 - PLANETARY GEAR 2 - PLANETARY THRUST BEARING 3 - CLUTCH SPRING PLATE 4 - SPRING PLATE SNAP-RING 5 - SUN GEAR
(3) Remove overrunning clutch assembly with expanding type snap-ring pliers (Fig. 159). Insert pli- ers into clutch hub. Expand pliers to grip hub splines and remove clutch with counterclockwise, twisting motion.
Fig.156DirectClutchPackRemoval
1 - SPECIAL TOOL 6227-1
2 - DIRECT CLUTCH HUB 3 - DIRECT CLUTCH PACKGEARTRAIN
(1) Remove direct clutch hub and spring (Fig. 157). (2) Remove sun gear and spring plate. Then remove planetary thrust bearing and planetary gear (Fig. 158).
Fig.159OverrunningClutchAssemblyRemoval/
Installation
1 - OVERRUNNING CLUTCH 2 - NEEDLE BEARING
Fig.157DirectClutchHubAndSpringRemoval
1 - DIRECT CLUTCH SPRING 2 - DIRECT CLUTCH HUB
21 - 226
OVERDRIVE UNIT (Continued)AUTOMATIC TRANSMISSION - 46RE
DR
(4) Remove
thrust
bearing
from overrunning
clutch hub.
(5) Remove overrunning clutch from hub. (6) Mark position of annulus gear and direct clutch drum for assembly alignment reference (Fig. 160). Use small center punch or scriber to make alignment marks.
Fig.160MarkingDirectClutchDrumAndAnnulus
GearForAssemblyAlignment
1 - DIRECT CLUTCH DRUM 2 - HAMMER 3 - PUNCH
(7) Remove direct clutch drum rear retaining ring
(8) Remove direct clutch drum outer retaining ring
(Fig. 161).
(Fig. 162).
(9) Mark annulus gear and output shaft for assem- bly alignment reference (Fig. 163). Use punch or scriber to mark gear and shaft.
Fig.162ClutchDrumOuterRetainingRingRemoval 1 - OUTER RETAINING RING
Fig.163MarkingAnnulusGearAndOutputShaft
ForAssemblyAlignment
1 - OUTPUT SHAFT 2 - HAMMER 3 - PUNCH
Fig.161ClutchDrumInnerRetainingRingRemoval 1 - INNER RETAINING RING 2 - DIRECT CLUTCH DRUM 3 - ANNULUS GEAR
DR OVERDRIVE UNIT (Continued)
(10) Remove snap-ring that secures annulus gear on output shaft (Fig. 164). Use two screwdrivers to unseat and work snap-ring out of groove as shown.
(11) Remove annulus gear from output shaft (Fig. 165). Use rawhide or plastic mallet to tap gear off shaft.
Fig.164AnnulusGearSnap-RingRemoval
1 - OUTPUT SHAFT 2 - ANNULUS GEAR 3 - SNAP-RING
Fig.165AnnulusGearRemoval
1 - OUTPUT SHAFT 2 - ANNULUS GEAR
GEAR CASE AND PARK LOCK
(1) Remove locating ring from gear case. (2) Remove park pawl shaft retaining bolt and
remove shaft, pawl and spring.
(3) Remove reaction plug snap-ring and remove
reaction plug.
(4) Remove output shaft seal.
AUTOMATIC TRANSMISSION - 46RE
21 - 227
CLEANING
Clean the geartrain and case components with sol- vent. Dry all parts except the bearings with com- pressed air. Allow bearings to air dry.
Do not use shop towels for wiping parts dry unless the towels are made from a lint-free material. A suf- ficient quantity of lint (from shop towels, cloths, rags, etc.) could plug the transmission filter and fluid pas- sages.
Discard the old case gasket and seals. Do not attempt to salvage these parts. They are not reus- able. Replace any of the overdrive unit snap-rings if distorted or damaged.
Minor nicks or scratches on components can be smoothed with crocus cloth. However, do not attempt to reduce severe scoring on any components with abrasive materials. Replace severely scored compo- nents; do not try to salvage them.
INSPECTION
Check condition of the park lock components and
the overdrive case.
Check the bushings in the overdrive case. Replace the bushings if severely scored or worn. Also replace the case seal if loose, distorted, or damaged.
Examine the overdrive and direct clutch discs and plates. Replace the discs if the facing is worn, severely scored, or burned and flaking off. Replace the clutch plates if worn, heavily scored, or cracked. Check the lugs on the clutch plates for wear. The plates should slide freely in the drum. Replace the plates or drum if binding occurs.
Check condition of the annulus gear, direct clutch hub, clutch drum and clutch spring. Replace the gear, hub and drum if worn or damaged. Replace the spring if collapsed, distorted, or cracked.
Be sure the splines and lugs on the gear, drum and hub are in good condition. The clutch plates and discs should slide freely in these components.
Inspect
the thrust bearings and spring plate. Replace the plate if worn or scored. Replace the bear- ings if rough, noisy, brinnelled, or worn.
Inspect the planetary gear assembly and the sun gear and bushings. If either the sun gear or the bushings are damaged, replace the gear and bush- ings as an assembly. The gear and bushings are not serviced separately.
The planetary carrier and pinions must be in good condition. Also be sure the pinion pins are secure and in good condition. Replace the carrier if worn or dam- aged.
Inspect the overrunning clutch and race. The race surface should be smooth and free of scores. Replace the overrunning clutch assembly or the race if either assembly is worn or damaged in any way.
21 - 228
OVERDRIVE UNIT (Continued)AUTOMATIC TRANSMISSION - 46RE
DR
Replace the shaft pilot bushing and inner bushing if damaged. Replace either shaft bearing if rough or noisy. Replace the bearing snap-rings if distorted or cracked.
Check the machined surfaces on the output shaft. These surfaces should clean and smooth. Very minor nicks or scratches can be smoothed with crocus cloth. Replace the shaft if worn, scored or damaged in any way.
Inspect the output shaft bushings. The small bush- ing is the intermediate shaft pilot bushing. The large bushing is the overrunning clutch hub bushing. Replace either bushing if scored, pitted, cracked, or worn.
(3) Install annulus gear
if removed. Then install annulus gear retaining snap- ring (Fig. 167).
on output
shaft,
(4) Align and install clutch drum on annulus gear (Fig. 168). Be sure drum is engaged in annulus gear lugs.
(5) Install clutch drum outer retaining ring (Fig.
168).
ASSEMBLY
GEARTRAIN AND DIRECT CLUTCH
(1) Soak direct clutch and overdrive clutch discs in Mopart ATF +4, Automatic Transmission fluid. Allow discs to soak for 10-20 minutes.
(2) Install new pilot bushing and clutch hub bush- ing in output shaft if necessary (Fig. 166). Lubricate bushings with petroleum jelly, or transmission fluid.
Fig.167AnnulusGearInstallation
1 - SNAP-RING 2 - OUTPUT SHAFT FRONT BEARING 3 - ANNULUS GEAR
Fig.166OutputShaftPilotBushing
1 - OUTPUT SHAFT HUB 2 - OVERRUNNING CLUTCH HUB BUSHING 3 - INTERMEDIATE SHAFT PILOT BUSHING
Fig.168ClutchDrumAndOuterRetainingRing
Installation
1 - ANNULUS GEAR 2 - OUTER SNAP-RING 3 - CLUTCH DRUM
DR OVERDRIVE UNIT (Continued)
AUTOMATIC TRANSMISSION - 46RE
21 - 229
(6) Slide clutch drum forward and install
inner
retaining ring (Fig. 169).
(7) Install rear bearing and snap ring on output shaft (Fig. 170). Be sure locating ring groove in bear- ing is toward rear.
Fig.169ClutchDrumInnerRetainingRing
Installation
1 - ANNULUS GEAR 2 - INNER SNAP-RING 3 - CLUTCH DRUM
Fig.170RearBearingAndSnap-RingInstallation 1 - REAR BEARING 2 - SNAP-RING
(8) Install overrunning clutch on hub (Fig. 171). Note that clutch only fits one way. Shoulder on clutch should seat in small recess at edge of hub.
(9) Install thrust bearing on overrunning clutch hub. Use generous amount of petroleum jelly to hold bearing in place for installation. Bearing fits one way only. Be sure bearing is seated squarely against hub. Reinstall bearing if it does not seat squarely.
(10) Install overrunning clutch in output shaft (Fig. 172). Insert snap ring pliers in hub splines. Expand pliers to grip hub. Then install assembly with counterclockwise, twisting motion.
Fig.171AssemblingOverrunningClutchAndHub 1 - CLUTCH HUB 2 - OVERRUNNING CLUTCH
Fig.172OverrunningClutchInstallation
1 - CLUTCH DRUM 2 - OVERRUNNING CLUTCH ASSEMBLY
