62TE Automatic Transmission (Service Information): Disassembly: Disassembly

Fig 1: Speed Sensors

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1. Remove the speed sensors (1, 2 and 3).
   Fig 2: Filter Oil Pan

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2. Remove bolts (1) at the oil filter pan (2).
3. Remove the oil filter pan (2).
   Fig 3: Fluid Filter

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4. Remove the bolts (1) at the oil filter (2).
5. Remove the oil filter (2).
   Fig 4: Oil Filter Seal At Case

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6. Remove the oil filter seal (1) at the case.
   Fig 5: Fasteners And Front Sound Dampener Cover

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   NOTE: Keep the Front Sound Dampener Cover if replacing the unit
7. If equipped remove the fasteners (1) and the Front Sound Dampener Cover (2).
   Fig 6: Top Sound Damper Cover

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   NOTE: Keep the Top Sound Dampener Cover if replacing the unit
8. If equipped remove the Top Sound Damper Cover (1).
   Fig 7: Valve Body Pan

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9. Remove bolts (2) at the valve body oil pan (1).
   Fig 8: Pressure Tap Plug

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10. Remove the pressure tap plug (2) at valve body pan.
11. Remove the valve body pan.
    Fig 9: Connector At Transmission

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12. Remove the electrical connector (1) at the range sensor (4).
13. Remove the bolt (3) holding the detent spring.
14. Remove the detent spring (2).
    Fig 10: Valve Body Bolts

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15. Remove valve body bolts (1).
    Fig 11: Oil Transfer Tubes

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16. Remove valve body (1) from oil transfer tubes and manual valve (3) from rooster comb.
    Fig 12: Transfer Tube O-Rings

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17. Remove oil transfer tubes (2) from the case.
    Fig 13: Accumulators

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    1 - UD ACCUMULATOR	5 - LC ACCUMULATOR
    2 - 2/4 ACCUMULATOR	6 - DC ACCUMULATOR
    3 - LR ACCUMULATOR	7 - OD ACCUMULATOR
    4 - 2/4 CLUTCH OIL SUPPLY SEAL	-

18. Remove all six accumulators (1, 2, 3, 5, 6 and 7) from case along with the accumulator return springs.
19. Remove the 2/4 clutch oil supply seal (4) from the case.
20. Remove the manual lever, TRS and seal. See Transmission and Transfer Case/Automatic - 62TE/SENSOR, Transmission Range - Removal .
    Fig 14: Measure Input Shaft End Play Using End Play Set 8266

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    1 - END PLAY FIXTURES 8266A

    2 - DIAL INDICATOR C-3339A

21. Measure input shaft end play. Place transaxle so input shaft is vertical. Set up end play fixtures 8266A (1,2) and dial indicator (3). Input shaft end play should be within 0.13-0.64 mm (0.005-0.025 in.)  Record indicator reading for reference upon reassembly.
    Fig 15: Front Pump 62TE

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22. Remove the front pump bolts (1).
    Fig 16: Pullers C-3752

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    CAUTION: Be sure input speed sensor is removed before removing oil pump.
23. Install slide hammers C-3752 (1) on oil pump.
    Fig 17: Remove Oil Pump

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24. Remove oil pump assembly (1).
    Fig 18: Oil Pump Gasket

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25. Remove oil pump gasket (2).
    Fig 19: Bypass Valve 62TE

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    CAUTION: If transaxle failure has occurred, the cooler bypass valve must be replaced. Do not re-use or attempt to clean valve.
26. Remove cooler bypass valve (2).
    Fig 20: Remove Caged Needle Bearing

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    1 - #1 CAGED NEEDLE BEARING

    2 - NOTE: TANGED SIDE OUT

27. Remove number one needle bearing (1).
    Fig 21: Remove Input Clutch Assembly

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    1 - INPUT CLUTCH ASSEMBLY

    2 - #4 THRUST WASHER

28. Remove input clutch assembly (1).
    Fig 22: No. 4 Thrust Plate

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    1 - OVERDRIVE SHAFT ASSEMBLY

    2 - #4 THRUST PLATE (SELECT)

    3 - 3 DABS OF PETROLATUM FOR RETENTION

29. Remove number four thrust plate (2).
    Fig 23: Remove Front Sun Gear Assembly

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    1 - FRONT SUN GEAR ASSEMBLY

    2 - #4 THRUST WASHER (FOUR TABS)

30. Remove front sun gear assembly (1) and number four thrust washer (2).
    Fig 24: Remove Front Carrier and Rear Annulus Assembly

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    1 - #6 NEEDLE BEARING

    2 - FRONT CARRIER AND REAR ANNULUS ASSEMBLY (TWIST AND PULL OR PUSH TO REMOVE OR INSTALL).

31. Remove front carrier/rear annulus assembly (2) and number six needle bearing (1).
    Fig 25: Remove Rear Sun Gear

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    1 - #7 NEEDLE BEARING

    2 - REAR SUN GEAR

    NOTE: The number seven needle bearing (1) has three anti-reversal tabs and is common with the number five and number two position. The orientation should allow the bearing to seat flat against the rear sun gear (1) when put together.
32. Remove rear sun gear (2) and number seven needle bearing (1).
    Fig 26: Remove 2/4 Clutch Retainer Snap Ring

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    1 - SPRING COMPRESSING 5058A

    2 - SCREWDRIVER

    3 - SNAP RING

    4 - 2/4 CLUTCH RETAINER

    NOTE: Verify that Compressor 5058A is centered properly over the 2/4 clutch retainer before compressing. If necessary, fasten the 5058A bar to the bellhousing flange with any combination of locking pliers and bolts to center the tool properly.
33. Setup the Spring Compressor 5058A (1), Compress 2/4 clutch return spring (4) (just enough to remove snap ring) and remove snap ring (3).
    Fig 27: 2/4 Clutch Retainer

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    1 - 2/4 CLUTCH RETAINER

    2 - 2/4 CLUTCH RETURN SPRING

    NOTE: The 2/4 Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.
34. Remove 2/4 clutch retainer (1).
    Fig 28: Remove 2/4 Clutch Return Spring

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    1 - 2/4 CLUTCH RETURN SPRING

35. Remove 2/4 clutch return spring (1).
    Fig 29: Remove 2/4 Clutch Pack

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    1 - CLUTCH PLATE (4)

    2 - CLUTCH DISC (4)

36. Remove 2/4 clutch pack (1,2). Tag 2/4 clutch pack for reassembly identification. 
    Fig 30: Remove Tapered Snap Ring

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    1 - LOW/REVERSE CLUTCH REACTION PLATE

    2 - SCREWDRIVER

    3 - LOW/REVERSE TAPERED SNAP RING (TAPERED SIDE UP)

    4 - OIL PAN FACE

    5 - LONG TAB

37. Remove tapered snap ring (3).
    Fig 31: Remove Low/Reverse Reaction Plate

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    1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP)

38. Remove low/reverse reaction plate (1).
    Fig 32: Remove One Disc

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    1 - ONE DISC FROM LOW/REVERSE CLUTCH

39. Remove one low/reverse clutch disc (1).
    Fig 33: Remove Low/Reverse Reaction Plate Snap Ring

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    1 - SCREWDRIVER

    2 - LOW/REVERSE REACTION PLATE FLAT SNAP RING

    3 - DO NOT SCRATCH CLUTCH PLATE

40. Remove low/reverse reaction plate snap ring (2).
    Fig 34: Remove Low/Reverse Clutch Pack

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    1 - CLUTCH PLATES (5)

    2 - CLUTCH DISCS (5)

41. Remove low/reverse clutch pack (1,2).
    Fig 35: Transfer Gear Cover

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42. Remove transfer gear cover-to-case bolts (2).
43. Remove transfer gear cover (1).
    Fig 36: Transfer Gears

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44. Remove the oil scavenger (2).
    Fig 37: Output Nut Retaining Strap

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45. Bend back the locking tabs (2) at the output transfer gear retaining strap (3).
46. Remove the bolts (1) at the output transfer gear retaining strap (3).
47. Remove the output transfer gear retaining strap (3).
    Fig 38: Holder 9739

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48. Install the Gear Holder 9739 (2) onto the output transfer gear (3).
49. Remove the output transfer gear bolt (1).
    Fig 39: Nut At Transfer Gear

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50. Grind the staked tabs (1) from the transfer gear (underdrive compounder side).
51. Install the Gear Holder 9739 (1) onto the transfer gear (underdrive compounder side) and remove the nut.
52. Lift the transfer gear from the underdrive compounder shaft.
    Fig 40: Gear Puller L- 4407 A

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53. Using Gear Puller L-4407A (1) and Thrust Button 6055 (3) remove output shaft transfer gear (2) and select shim.
    Fig 41: Remove Bearing Cone

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    1 - BEARING PULLER 5048 WITH JAWS 5048-5 AND THRUST PAD L-4539-2

    2 - WRENCHES

    3 - OUTPUT GEAR

54. Using Bearing Puller 5048 with Jaws 5048-5 and Thrust Pad L-4539-2 (1) remove output gear bearing cone.
    Fig 42: Compounder Transfer Gear Bearing

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55. Using Press Puller C-293-PA (1), Adaptors 9738 (3) and Press Plug 9678 remove compounder transfer gear bearing cone.
    Fig 43: Rear Carrier

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56. Remove rear carrier assembly (1) from transaxle (2).
    Fig 44: Remove Rear Carrier Bearing Cone

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    1 - BEARING PULLER 5048 WITH JAWS 5048-3 AND THRUST BUTTON 6055

    2 - WRENCHES

    3 - REAR CARRIER ASSEMBLY

57. Remove rear carrier assembly (3) bearing cone using bearing puller 5048 with Jaws 5048-3 and thrust button 6055.
    Fig 45: Low/Reverse Spring Compressor Tool

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    1 - SPRING COMPRESSOR DISC 6057

    2 - SPRING COMPRESSOR 5059-A

    3 - FORCING SCREW 5058A-3

58. Install spring compressor disk 6057 (1), spring compressor 5059-A (2) and forcing screw 5058A-3 (3).
    Fig 46: Compressor Tool in Use

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    1 - LOW/REVERSE CLUTCH RETURN SPRING

    2 - SNAP RING (INSTALL AS SHOWN IN ILLUSTRATION)

    3 - SPRING COMPRESSOR DISC 6057

    4 - SPRING COMPRESSOR 5059-A

    5 - FORCING SCREW 5058A-3

59. Compress low/reverse spring using spring compressor 5059-A (4).
    Fig 47: Remove Snap Ring

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    1 - SNAP RING OPENING MUST BE BETWEEN SPRING LEVERS (AS SHOWN IN ILLUSTRATION)

    2 - SNAP RING PLIERS

    3 - SPRING COMPRESSOR DISC 6057

60. Remove snap ring (1) at low/reverse piston return spring.
    Fig 48: Low/Reverse Piston Return Spring

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    1 - LOW/REVERSE PISTON RETURN SPRING

    2 - PISTON

61. Remove low/reverse spring compressor tool and low reverse piston return spring (1).
    Fig 49: Remove Low/Reverse Clutch Piston

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    1 - LOW/REVERSE CLUTCH PISTON

    2 - BONDED SEAL

    3 - BONDED SEAL

    NOTE: The Low/Reverse Clutch Piston has bonded seals which are not individually serviceable. Seal replacement requires replacement of the piston assembly.
62. Remove low/reverse clutch piston (1).
    Fig 50: Remove Piston Retainer Attaching Screws

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    1 - LOW/REVERSE CLUTCH PISTON RETAINER

    2 - SCREWDRIVER

    3 - TORX-LOC SCREWS

63. Remove low/reverse piston retainer-to-case screws (3).
    Fig 51: Remove Piston Retainer

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    1 - LOW/REVERSE CLUTCH PISTON RETAINER

    2 - GASKET

64. Remove low/reverse piston retainer (1).
    Fig 52: Remove Piston Retainer Gasket

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    1 - GASKET HOLES MUST LINE UP

    2 - LOW/REVERSE CLUTCH PISTON RETAINER GASKET

65. Remove low/reverse piston retainer-to-case gasket (2), gasket holes must line up (1).
    Fig 53: Inner Carrier Cup Out

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66. Using a hammer and suitable drift (2), drive out inner output bearing cup (1).
    Fig 54: Outer Carrier Cup Out

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67. Using bearing cup puller 6062A (1), remove outer output bearing cup (2).
    Fig 55: Snap Ring Underdrive Compounder

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68. Remove the snap ring (1) at the underdrive compounder assembly (2).
    Fig 56: Bolts At Compounder

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69. Remove four bolts (1) at the compounder bearing retainer.
    Fig 57: Tool 9908 Bearing Retainer Assembly

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70. Install puller adapter 9908 (2) to the compounder bearing retainer.
    Fig 58: Slide Hammer To 9908

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71. Install Slide Hammer C-3752 (1) to puller adapter 9908 (2) and pull the underdrive compounder assembly from the case.
    Fig 59: Underdrive Compounder Assembly

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    NOTE: Insure that the planetary gear set / output hub is removed as part of the underdrive compounder assembly.
72. Remove the underdrive compounder assembly (2).
    Fig 60: Bolts At Remote Pinion Cover

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73. Remove the bolts (1) at the remote pinion cover (2).
    Fig 61: Remote Pinion Cover

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74. Remove the remote pinion (1) and the remote pinion cover (2) from the case.
    Fig 62: Cover At Remote Pinion

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75. Remove the remote pinion cover (1) from the remote pinion (2).
    Fig 63: Pinion Cover Cup

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76. Using Remover 8913 (2) and Brace 8915 (1) remove the remote pinion cover bearing cup (3) and selective shim.
    Fig 64: Remote Pinion Cup Out 8912 And 8

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77. Using Remover 8912 and Brace 8915 (1, 2) pull remote pinion small bearing cup (3) from the case.
    Fig 65: Differential Bearing Cover

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78. Remove the differential output bearing cover bolts (1).
79. Remove differential output bearing cover (2).
    Fig 66: Differential Cover

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80. Remove the differential cover bolts (1).
    Fig 67: Differential Cover

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81. Remove the differential cover (1).
82. Remove the out seal (2), oil singer (3) and the small bearing cup (4).
83. Remove the large bearing cup.
    Fig 68: Differential Out And In

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84. Remove the differential.
85. Remove the manual lever and TRS. See Transmission and Transfer Case/Automatic - 62TE/SENSOR, Transmission Range - Removal .
    Fig 69: Set Screw At Park Pawl Shaft

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86. Remove the set screw (1) for the park pawl shaft.
    Fig 70: Park Pawl Tube Snap Ring 2

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87. Remove the snap ring (1) for the park guide assembly (2).
    Fig 71: Park Pawl Tube

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88. Remove the park guide assembly (1).
    Fig 72: Park Pawl Shaft Plug

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89. Remove the plug (1) to allow the park pawl shaft to be removed.
    Fig 73: Park Pawl Shaft

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90. Slide the shaft (1) out of the park pawl (3).
    Fig 74: Park Pawl Shaft 2

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91. Remove the park pawl shaft (1).
    Fig 75: Park Pawl

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92. Remove the park pawl (1) and the park pawl spring (2).