Here are pictures from the first few steps of disassembling my transmission. So far I don't really see anything wrong:

https://picasaweb.google.com/lh/photo/M ... directlink
https://picasaweb.google.com/lh/photo/M ... directlink
https://picasaweb.google.com/lh/photo/M ... directlink
https://picasaweb.google.com/lh/photo/P ... directlink
https://picasaweb.google.com/lh/photo/l ... directlink
https://picasaweb.google.com/lh/photo/- ... directlink
https://picasaweb.google.com/lh/photo/r ... directlink

As a quick refresher. I had some burt oil, metal dust all throughout and a split flat filter. The jeep wouldn't move.

Have you disassembled the pump? Metal shavings could be coming from a worn pump.
What do the clutch packs look like?

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U.S. Army Retired

I'm not sure yet. This is as far as I got last night. I need to finish pulling stuff out. There was metal in the pan so something is busted somewhere.

There are in-case snap rings which I need to figure out how to remove. With regular vice grips maybe? Looks like I have to pull them IN not squeeze them OUT.

I have never taken apart a 545RFE.
Usually, with an INSIDE snap ring (that doesn't have the little holes for normal snap ring pliers),
you have to push in on the piston, drum or whatever, and use a small hook to grab the ring and
gently pry it out. Hopefully not bending and mangling the ring in the process.
And be careful as you are trying the grab/pull out the ring so you dont damage the area the ring snaps into.

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U.S. Army Retired

Some more advice:

It looks like you have the front drum assembly removed. It also looks like the shaft coming out of the
front drum, into the rear drum has a machined recess for a one way clutch. Make sure you get that
one way clutch installed in the correct direction.
When trying to disassemble the clutch packs, you will probably encounter more inside snap rings.
Sometimes you need a special tool to compress the piston spring and remove the snap ring.

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U.S. Army Retired