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INDEX
DI AGNOSTI C FAULT CODES 6
HYDRAULI C AND GOVERNOR PRESSURE TESTS 7
ELECTRONI C GOVERNOR COMPONENTS 8
WI RI NG SCHEMATI C 12
~. DI AGNOSTI C CONNECTOR LOCATI ON 14
TRANSMI SSI ON DI AGNOSI S CHARTS 15
TRANSMI SSI ON DI SASSEMBLy 30
TRANSMI SSI ON SUBASSEMBLI ES 38
CHECKBALL LOCATI ONS 59
TRANSMI SSI ON ASSEMBLy 67
BAND ADJ USTMENTS 73
OVERDRI VE SECTI ON DI SASSEMBLY 75
OVERDRI VE SECTI ON ASSEMBLY 82
OVERDRI VE SECTI ON SELECTI VE MEASUREMENTS 92
SPECI FI CATI ONS 98
OI L FLOW CHARTS 99
AUTOMATIC TRANSMISSION SERVICE GROUP
9200 S. DADELAND BLVD. STE 720
MIAMI, FLORIDA33156
(305) 670-4161
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""D
OIL PUMP AND
REACTl ON SHAFT
SUPPORT ASSEMBLY
CHRYSLER
2 WHEEL
TRANSMISSION
OVERRUNNING
CLUTCH
42RE (ASOOSE)
DRI VE MODEL
OVERDRIVE
UNIT
PISTON
RETAINER
OVERDRIVE
CLUTCH
REAR
CLUTCH
FRONT
PLANETARY
GEAR
DIRECT
CLUTCH
SPRING
( ~Q T 5 G )
T OR QUE C ONV E R T E R
A t hr ee el ement t or que conver t er i s used
f or al l appl i cat i ons i n t he 42R E . T or que
conver t er el ement s consi st of t he t ur bi ne,
st at or and i mpel l er . T he conver t er al so
cont ai ns an over r unni ng cl ut ch and a
conver t er cl ut ch pl at e.
T he conver t er cl ut ch i s el ect r oni cal l y
cont r ol l ed. T he conver t er cl ut ch pr ovi des
r educed engi ne R PM and gr eat er f uel econ-
omy when i t i s engaged. C onver t er cl ut ch
engagement al so pr ovi des much r educed
t r ansmi ssi on f l ui d t emper at ur es.
T he conver t er cl ut ch wi l l engage i n 4t h
g~ar , and i n 3r d gear when t he over dr i ve
cont r ol swi t ch i s i n t he OFF posi t i on.
T he over r unni ng cl ut ch i s mount ed i n t he
st at or hub, and pr event s t he st at or f r om
r ot at i ng i n a di r ect i on opposi t e t o t he
engi ne r ot at i on. T hi s r et ai ns t he t or que
mul t i pl i cat i on f eat ur e of t he conver t er .
T he t or que conver t er shoul d be r epl aced
as an assembl y when di agnosi s i ndi cat es
a mal f unct i on has occur ed.
R E C OMME NDE D FL UI D
T he onl y f l ui d r ecommended f or t he 42R E
t r ansmi ssi on i s Mopar AT F Pl us t ype 7176.
Do not use Dexr on I I except i n emer gency
or i f AT F Pl us t ype 7176 i s not avai l abl e.
T he t r ansmi ssi on i dent i f i cat i on number s
and codes ar e st amped on t he l ef t si de of
t he case j ust above t he pan gasket ar ea,
( See Fi gur e 3) . T he f i r st number gr oup i s
t he assembl y par t number . T he next number
gr oup, t he t r ansmi ssi on bui l d dat e. T he
l ast number gr oup i s t he ser i al number .
R ef er t o t hi s i nf or mat i on when or der i ng
r epl acement par t s ( See Fi gur e 3) .
E L E C T R ONI C GOV E R NOR C OMPONE NT S
Gover nor pr essur e i s devel oped and cont -
r ol l ed el ect r oni cal l y i n t he 42R E . T he
component s used f or t he devel opment and
cont r ol of gover nor pr essur e i ncl ude:
Gover nor Body
V al ve Body T r ansf er Pl at e
Gover nor Pr essur e Sol enoi d
Gover nor Pr essur e Sensor
Fl ui d T emper at ur e T her mi st er
T r ansmi ssi on Speed Sensor
T hr ot t l e Posi t i on Sensor
T r ansmi ssi on C ont r ol Modul e ( T C M)
GOV E R NOR PR E SSUR E C UR V E S
T her e ar e f our gover nor pr essur e cur ves
pr ogr amed i nt o t he T C M. T he f our di f f er ent
al l ow t he T C M t o adj ust gover nor pr essur e
f or var yi ng condi t i ons.
C ur ve 1 i s used f or oper at i on when f l ui d
t emper at ur e i s at , or bel ow 30F.
C ur ve 2 i s used f or oper at i on when f l ui d
t emper at ur e i s at , or above 31F, dur i ng
nor mal ci t y, or hi ghway dr i vi ng.
C ur ve 3 i s used dur i ng wi de open t hr ot t l e
oper at i on.
C u~ve 4 i s used when dr i vi ng wi t h t r ansf er
case i n 4WD L ow r ange.
T R ANSMi SSI ON SHI FT I NG
Shi f t val ve oper at i on i n 42R E t r ansmi ssi on
wi t h t he el ect r oni c gover nor mechani sm i s
basi cal l y ~nchanged. T he 1- 2 and 2- 3 up-
shi f t sequence occur s exact l y t he same as
i n hydr aul i c gover nor t r ansmi ssi ons. T he
val ve body shi f t val ves ar e st i l l moved by
a combi nat i on of t hr ot t l e pr essur e and t he
gover nor pr essur e.
T he onl y r eal di f f er ence i s t hat gover nor
pr essur e i s gener at ed by el ect r i cal compon-
ent s i nst ead of a mechani cal val ve and
wei ght assembl y.
T he condi t i ons under whi ch a shi f t t o 4t h
wi l l not occur , al so r emai n t he same. T hey
ar e;
Shi f t t o 3r d not yet compl et ed.
Over dr i ve swi t ch i s i n OFF posi t i on.
T hr ot t l e at 3/ 4 t o wi de open posi t i on.
MPH t oo l ow f or 3- 4 shi f t t o occur .
Fl ui d t emper at ur e i s bel ow 30F, or
above 250F.
A U T O M A T IC T R A N S M IS S IO N S E R V IC E G R O U P
5
( ~Q T 5 G I
C ONV E R T E R C L UT C H E NGAGE ME NT
T he T or que C onver t er C l ut ch ( T C C ) i s en-
gaged by t he T C C Sol enoi d on t he val ve
body. T he T C C can be engaged i n 3r d and
4t h gear , dependi ng on t he over dr i ve con-
t r ol swi t ch posi t i on.
I f t he over dr i ve cont r ol swi t ch i s i n
t he nor mal ( ON) posi t i on, t he T C C wi l l
engage af t er t he shi f t t o 4t h gear , and
above appr oxi mat el y 45 MPH.
t he OFF posi t i on, t he T C C wi l l engage
af t er t he shi f t t o 3r d gear , and above
appr oxi mat el y 35 MPH at l i ght t hr ot t l e.
OV E R DR I V E OFF SWI T C H
T he Over dr i ve OFF Swi t ch i s l ocat ed i n
t he i nst r ument panel . T he OlD OFF swi t ch
i s a moment ar y cont act devi ce t hat si gnal s
t he T C M t o t oggl e cur r ent st at us of t he
over dr i ve f unct i on. At Key- On, over dr i ve
oper at i on i s al l owed.
Pr essi ng t he swi t ch once causes t he OlD
OFF mode t o be ent er ed, and t he over dr i ve
OFF swi t ch l amp t o be i l l umi nat ed. I f you
pr ess t he swi t ch a 2nd t i me, t hi s causes
nor mal over dr i ve oper at i on t o be r est or ed
and t he over dr i ve l amp t o t ur ned of f .
T he nor mal posi t i on f or t he over dr i ve
cont r ol swi t ch i s t he ON posi t i on. T he
swi t ch must be i n t hi s posi t i on t o ener -
gi ze t he OD sol enoi d and al l ow a 4t h gear
upshi f t t o occur .
T he cont r ol swi t ch has an i ndi cat or l amp.
T he l amp i l l umi nat es when t he over dr i ve
swi t ch i s t ur ned t o t he OFF posi t i on, or
when i l l umi nat ed by t he T C M.
T he over dr i ve swi t ch i ndi cat or l i ght i s
al so used t o f l ash f aul t codes f or di ag-
nost i c pur poses.
FAULT
FAULT DESCRIPTION
CODE
11 E ngine R P M input
12 O utput shah sensor input
13 V ehicle speed input
14 G overnor pressure senso~ input
15 T hrottle position sensor input
16 T ransmission fluio temperoture input
17 O verdrive override ( control) switch input
18 S ystem voltage
19 Internal fault in module
21 G overnor pressure solenoid output
22 O verdrive solenoid output
23 C onverter clutch solenoid output
24 O verdrive override ( control switch) lamp output
26 G overnor pressure sensor offset drift
55 E nd of code transmission
R OAD T E ST I NG
Bef or e r oad t est i ng, be sur e t he f l ui d
l evel i s cor r ect and al l cabl e adj ust ment s
have been checked, and adj ust ed i f needed.
Obser ve engi ne per f or mance dur i ng t he r oad
t est . A poor l y t uned engi ne wi l l not al l ow
an accur at e anal ysi s of t he t r ansmi ssi on
oper at i on.
Oper at e t he t r ansmi ssi on i n al l gear s. Be
sur e t o check f or shi f t var i at i ons and eng-
i ne f l ar e, whi ch i ndi cat es sl i ppage.
Sl i ppage i ndi cat ed by engi ne f l ar e usual l y
means cl ut ch, band or over r unni ng cl ut ch
pr obl ems. I f t he condi t i on i s advanced, an
over haul may be necessar y t o r est or e nor mal
oper at i on.
A sl i ppi ng cl ut ch or band can usual l y be
et er mi ned by compar i ng whi ch i nt er nal com-
ponent s ar e_ ~pl i ed i n the ~IiPl~~~
T he Appl i cat i on C har t i n Fi gur e 2 provides
a basi s f or anal yzi ng r oad t est r esul t s.
DI AGNOST I C FAUL T C ODE S

T he l amp i n t he over dr i ve
used t o si gnal ( Fl ash) t he
codes. T he f aul t codes and
i ndi cat ed ar e i n t he Faul t
shown i n Fi gur e 4.
-='-~~#"";=db1~j~V 'zr.c.5 "t"'KUC;KW~ AS FOL L OWS:
1. T ur n i gni t i on key ON and OFF, 3 t i mes
qui ckl y, and r emai n i n ON posi t i on.
2. I mmedi at el y begi n count i ng ~he number
of f l ashes di spl ayed by Dip OFF ~~Lcc~
~4' f u~cat . or ~amp .
of f swi t ch i s
var i ous f aul t
t ype of f aul t
C ode C har t and
C ONV E R T E R C L UT C H E NGA GE ME NT
T he T or que C onver t er C l ut ch ( T C C ) i s en-
gaged by t he T C C Sol enoi d on t he val ve
body. T he T C C can be engaged i n 3r d and
4t h gear , dependi ng on t he over dr i ve con-
t r ol swi t ch posi t i on.
t he nor mal ( ON) posi t i on, t he T C C wi l l
engage af t er t he shi f t t o 4t h gear , and
above appr oxi mat el y 45 MPH.
t he OFF posi t i on, t he T C C wi l l engage
af t er t he shi f t t o 3r d gear , and above
appr oxi mat el y 35 MPH at l i ght t hr ot t l e.
OV E R DR I V E OFF SWI T C H
T he Over dr i ve OFF Swi t ch i s l ocat ed i n
t he i nst r ument panel . T he OlD OFF swi t ch
i s a moment ar y cont act devi ce t hat si gnal s
t he T C M t o t oggl e cur r ent st at us of t he
over dr i ve f unct i on. A t Key- On, over dr i ve
oper at i on i s al l owed.
Pr essi ng t he swi t ch once causes t he OlD
OFF mode t o be ent er ed, and t he over dr i ve
OFF swi t ch l amp t o be i l l umi nat ed. I f you
pr ess t he swi t ch a 2nd t i me, t hi s causes
nor mal over dr i ve oper at i on t o be r est or ed
and t he over dr i ve l amp t o t ur ned of f .
T he nor mal posi t i on f or t he over dr i ve
cont r ol swi t ch i s t he ON posi t i on. T he
swi t ch must be i n t hi s posi t i on t o ener -
gi ze t he OD sol enoi d and al l ow a 4t h gear
upshi f t t o occur .
T he cont r ol swi t ch has an i ndi cat or l amp.
T he l amp i l l umi nat es when t he over dr i ve
swi t ch i s t ur ned t o t he OFF posi t i on, or
when i l l umi nat ed by t he T C M.
T he over dr i ve swi t ch i ndi cat or l i ght i s
al so used t o f l ash f aul t codes f or di ag-
nost i c pur poses.
DI A GNOST I C FA UL T C ODE S
T he l amp i n t he over dr i ve
used t o si gnal ( Fl ash) t he
codes. T he f aul t codes and
i ndi cat ed ar e i n t he Faul t
T O V I E W FA UL T C ODE S, PR OC E E D A S FOL L OWS:
1. T ur n i gni t i on key ON and OFF, 3 t i mes
qui ckl y, and r emai n i n ON posi t i on.
2. I mmedi at el y begi n count i ng ~he number
of f l ashes di spl ayed by OlD OFF swi t ch
i ndi cat or l amp.
3. R ef er - t o t he char t i n Fi gur e 4 f or t he
f aul t code i ndi cat ed .
. . . .:.
of f swi t ch i s
var i ous f aul t
t ype of f aul t
C ode C har t and
FAULT
FAULT DESCRIPTION
CODE
11 Engine RPM input
12 Output shaft sensor input
13 Vehicle speed input
1<1
Governor pressure senso~input
15 Throttle position sensor input
16 Transmission fluiCl temperature input
17 Overdrive override (control) switch input
18 System voltage
19 Internol fault in module
21 Governor pressure solenoid output
22 Overdrive solenoid output
23 Converter clutch solenoid output
2<1
Overdrive override (control swifch) lamp output
26 Governor pressure sensor offset drift
55 End of code transmission
R OA D T E ST I NG
Bef or e r oad t est i ng, be sur e t he f l ui d
l evel i s cor r ect and al l cabl e adj ust ment s
have been checked, and adj ust ed i f needed.
Obser ve engi ne per f or mance dur i ng t he r oad
t est . A poor l y t uned engi ne wi l l not al l ow
an accur at e anal ysi s of t he t r ansmi ssi on
oper at i on.
Oper at e t he t r ansmi ssi on i n al l gear s. Be
sur e t o check f or shi f t var i at i ons and eng-
i ne f l ar e, whi ch i ndi cat es sl , ' ppage.
Sl i ppage i ndi cat ed by engi ne f l ar e usual l y
means cl ut ch, band or over r unni ng cl ut ch
pr obl ems. I f t he condi t i on i s advanced, an
over haul may be necessar y t o r est or e nor mal
oper at i on.
A sl i ppi ng cl ut ch or band can usual l y be
det er mi ned by compar i ng whi ch i nt er nal com-
ponent s ar e appl i ed i n t he var i ous gear s.
T he A ppl i cat i on C har t i n Fi gur e 2 pr ovi des
a basi s f or anal yzi ng r oad t est r esul t s.
6
HY DR A UL I C PR E SSUR E T E ST
T her e ar e pr essur e t est por t s at t he acc-
umul at or , f r ont ser vo and r ear ser vo. A l so
gover nor and over dr i ve cl ut ch pr essur e can
be checked wi t h gauges.
L i ne pr essur e i s checked at t he accumu-
l at or t est por t , but must be i n t he dr i ve
posi t i on, as i t i s r ear cl ut ch oi l t hat i s
bei ng measur ed. Fr ont cl ut ch oi l ( 3r d&R ev)
i s avai l abl e at t he f r ont ser vo pr essur e
por t . A l l pr essur e por t l ocat i ons ar e seen
i n Fi gur e 5.
Use t he char t i n Fi gur e 6 t o det er mi ne
cor r ect oi l pr essur es. Use a 100 PSI gauge
f or t est i ng l i ne pr essur e and gover nor pr e-
ssur e. A 300 PSI gauge wi l l be r equi r ed
f or t est i ng r ever se.
C ompar e r esul t s of pr essur e t est s wi t h t he
anal ysi s char t i n Fi gur e 7 .
GOV E R NOR PR E SSUR E T E ST
T hi s t est checks gover nor oper at i on by
measur i ng gover nor or es sur e r esponse t o
changes i n vehi cl e speed. T hi s t est shoul d
be per f or med on a hoi st t hat wi l l al l ow t he
r ear wheel s t o r ot at e f r eel y.
1. C onnect 100 PSI gauge t o t he gover nor
pr essur e por t ( See Fi gur e 5) .
2. St ar t engi ne and pl ace sel ect or l ever
i n t he Dr i ve posi t i on. A t i dl e wi t h t he
vehi cl e st opped, pr essur e shoul d be 0
t o 1- 1/ 2 PSI maxi mum. I f pr essur e does
exceed t hi s f i gur e, a f aul t exi st s i n
t he gover nor pr essur e cont r ol syst em.
3. Sl owl y i ncr ease engi ne speed, obser ve
speedomet er and pr essur e gauge. T he
gover nor pr essur e shoul d i ncr ease i n
por por t i on t o vehi cl e speed, or appr ox-
i mat el y 1 PSI f or ever y 1 MPH.
4. Pr essur e shoul d dr op back t o 0 t o 1- 1/ 2
PSI when wheel s st op r ot at i ng.
SHI FT
L E V E R
POSI T I ON
MI NI MUM T V
PR E SSUR E
MA XI MUM T V
PR E SSUR E
GOVERNOR
TEST PORT
5. C ompar e r esul t s of pr essur e t est wi t h
t he anal ysi s char t i n Fi gur e 7 .
DR I V E 55- 6 5 PSI 9 0- 9 6 PSI A C C UMUL A T OR 100 PSI
MA N- 2 55- 6 5 PSI 9 0- 9 6 PSI A C C UMUL A T OR 100 PSI
MA N- 1 55- 6 5 PSI 9 0- 9 6 PSI A C C UMUL A T OR 100 PSI
R E V E R SE 145- 17 5 PSI 230- 28 0 PSI R E A R SE R V O 300 PSI
D- 4T H GE A R 6 8 - 7 2 PSI 9 0- 120 PSI OV E R DR I V E 300 PSI
7
[~~T SG)
T E S T CONDmON INDICAT ION
Linepreuure OK during Pump and regulator valve OK
anyone le$t
LinePressure OK in R Leakage in rear clutch area (servo,
but low in D, 2, 1 clutch seals, governor support
seal rings)
Preuure Lowin D Overdrive clutch piston seal, or
Fourth Gear Range check ball problem
Pressure OK in 1, 2 but
Leakage in front ~utch area (servo,
law in D3 and R
clutch seals, retoiner bare, pump
seal rings)
Pressure OK in 2 but low Leakage in rear servo
in Rand 1
Front servo pressure law Leakage in servo; broken servo
in 2 ring or crocked servo piston
Pressure law in all positions CI~ged filter, stuck regulator
valve, worn or faulty pump,
plugged Auidcooler
Governor pressure too high Governor pressure solenoid
at idle speed valve foulty
Governor p'ressure low Faulty governor pressure solenoid,
at all mph ngures transmission control module, or
governor pressure sensor
Lubrication/line pressure Clog
1
edAuidcooler or lines, seal
low at all throttle positions rin~s eaking, output shaft plugged
wi debris, worn bushings in
pump or clutch retainer
E L E C T R ONI C GOV E R NOR C OMP ONE NT S
Gover nor pr essur e i s devel oped and cont -
r ol l ed el ect r oni cal l y i n t he 42R E . R ef er
t o Fi gur e 9 f or component l ocat i ons. T he
component s used f or t he devel opement and
cont r ol of gover nor pr essur e i ncl ude:
GOV E R NOR BODY.
V AL V E BODY T R ANS FE R P L AT E .
GOV E R NOR P R E S S UR E S OL E NOI D.
GOV E R NOR P R E S S UR E S E NS OR .
FL UI D T E MP E R AT UR E T HE R MI S T E R .
T R ANS MI S S I ON S P E E D S E NS OR .
T HR OT T L E P OS I T I ON S E NS OR .
T R ANS MI S S I ON C ONT R OL MODUL E ( T C M) .
R ef er t o Fi gur e 9 f or component l ocat i ons.
GOVE RNOR
BODY
GOV E R NOR BODY AND NE W T R ANS FE R P L AT E
A new T r ansf er P l at e i s used wi t h t he 42R E
val ve body. T he t r ansf er pl at e i s desi gned
t o suppl y l i ne pr essur e t o t he gover nor
pr essur e sol enoi d, and t o r et ur n gover nor
pr essur e t o t he val ve body.
T he gover nor pr essur e sol enoi d i s mount ed
i n t he gover nor body, and t he body i s bol t -
ed t o t he l ower si de of t he new t r ansf er
pl at e ( S ee Fi gur e 9) .
T R ANS MI S S I ON S P E E D S E NS OR
T he T r ansmi ssi on S peed S ensor i s l ocat ed
i n t he over dr i ve gear case ( S ee Fi gur e 10) .
T he sensor i s posi t i oned over t he par k gear
and moni t er s t r ansmi ssi on out put shaf t r o-
t at i ng speed. T he sensor used wi t h t he 42R E
t r ansmi ssi on i s t he same as i s used i n t he
41T E ( A604) and 42L E ( A606) .
S peed sensor si gnal s ar e t r i gger ed by t he
par k gear l ugs as t hey r ot at e past sensor
pi ckup f ace. I nput si gnal s ar e sent t o t he
t r ansmi ssi on cont r ol modul e ( T C M) f or pr o- i
cessi ng.
T he vehi cl e speed sensor ( V S S ) al so ser ves
as a backup f or t he T r ansmi ssi on S peed S en-
sor . S i gnal s f r om t hi s sensor ar e shar ed ~
wi t h t he power t r ai n cont r ol modul e ( P C M) .
T HR OT T L E P OS I T I ON S E NS OR ( T P S )
T he T P S pr ovi des t hr ot t l e posi t i on si gnal s
t o bot h t he T C M and P C M. T hi s i nput si gnal
i s used t o det er mi ne 3- 4 and T C C shi f t sch-
edul e, and t o sel ect t he pr oper gover nor
cur ve, pr ovi ded by t he T C M.
AUT OMAT IC T RANS MIS S ION S E RVICE GROUP
8
(~~T 5G)
C ONV E R T E R C L UT C H S OL E NOI D
T HE R MI S T E R I S L OC AT E D ON T HE
UNDE R S I DE OF T HI S S OL E NOI D.
GOV E R NOR P R E S S UR E C UR V E S
T her e ar e f our gover nor pr essur e cur ves
pr ogr amed i nt o t he T C M. T he f our di f f er ent
gover nor cur ves al l ow t he T C M t o adj ust
gover nor pr essur e f or var yi ng condi t i ons.
C UR V E 1, i s used f or oper at i on when f l ui d
t emper at ur e i s at , or bel ow 30 F.
C UR V E 2, i s used f or oper at i on when f l ui d
t emper at ur e i s at , or above 31 F, dur i ng
nor mal ci t y, or hi ghway dr i vi ng.
C UR V E 3, i s used dur i ng wi de open t hr ot t l e
oper at i on.
C UR V E 4 i s used when dr i vi ng wi t h t r ansf er
case i n 4WD L ow r ange.
OV E R DR I V E
S OL E NOI D
SPEED
SENSOR
T RANSMISSION
OUT PUT
SHAFT
SPEED
SENSOR
o
AUT OMAT IC T RANS MIS S ION S E RVICE GROUP
9
[~~T 5G)
VI EW LOOKI NG I NTO THE
GOVERNOR PRESSURE
SOLENOI D CONNECTOR
GOVERNOR PRESSURE
SOLENOI D HARNESS
GOVERNOR PRESSURE SOLENOI D
The Gover nor Pr essur e Sol enoi d gener at es
t he gover nor pr essur e needed f or upshi f t s
and down shi f t s. I t i s a Pul se Wi dt h Mod-
ul at ed ( PWM) sol enoi d and i s l ocat ed i n
t he gover nor body on t he val ve body t r an-
sf er pl at e, as shown i n Fi gur e 9.
The i nl et si de of t he sol enoi d i s exposed
t o nor mal l i ne pr essur e. The out l et si de
of t he sol enoi d l eads t o t he val ve body
gover nor ci r cui t .
The sol enoi d r egul at es l i ne pr essur e t o
pr oduce gover nor pr essur e. The aver age
cur r ent suppl i ed t o t he sol enoi d, f r om t he
TCM, cont r ol s gover nor pr essur e. One Amp
cur r ent pr oduces zer o ( 0) PSI gover nor
pr essur e. Zer o Amps set s t he maxi mum gov-
er nor pr essur e.
The Tr ansmi ssi on Cont r ol Modul e ( TCM)
suppl i es el ect r i cal power , l 2V ( DC) t o t he
gover nor pr essur e sol enoi d, and i s pr ovi ded
t hr ough t he bat t er y t er mi nal on t he TCM.
The sol enoi d i s pol ar i t y sensi t i ve. The
TCM ener gi zes t he sol enoi d by gr oundi ng i t
t hr ough t he gr ound t er mi nal on t he TCM.
Ref er t o Fi gur e 11 f or t he sol enoi d and
i t s connect or .
Ref er t o Fi gur e 13 f or compl et e vehi cl e
wi r i ng schemat i c f or t he t r ansmi ssi on r e-
l at ed component s.
A U T O M A T I C T R A N S M I S S I O N S E R V I C E G R O U P
10
( ~Q T S G )
GOVERNOR PRESSURE
SENSOR CONNECTOR
GOVERNOR PRESSURE
SENSOR HARNESS
GOVERNOR PRESSURE SENSOR
The Gover nor Pr essur e Sensor out put si gnal
pr ovi des t he necessar y f eedback t o t he TCM.
Thi s f eedback i nf or mat i on i s needed by t he
TCM, t o adequat el y cont r ol gover nor pr ess-
ur e f or var yi ng condi t i ons.
11
TRANSMI SSI ON CASE CONNECTOR
VEHI CLE HARNESS CONNECTOR
r--------- ---------- ----- ------ -----.,
I I
I I
I I
I
I I
I 0.0. Tee I
I
I
I
I
I.
I
I
I
I
I
I
I
I
I
I
I
I
J
f
I
I
I
I
~ I
. . . J I
e l l I
GOVERNOR
PRESSURE
SENSOR
( REAR OF I NSTRUHENT
P A N E L L E f T O f C O L U M N )
A UTOMATIC TR ANS MIS S ION S E R VIC E GR OUP
12
CASE
CONNECTOR
TERMI NAL
1 -----------------
2 - - - - - - - - - - - - - - - - -
3 -----------------
4 - - - - - - - - - - - - - - - - -
5 -----------------
6 - - - - - - - - - - - - - - - - -
7 -----------------
8 - - - - - - - - - - - - - - - - -
F UNCTI ON
12V POWER I N F OR TCC, O. D. , &GOVERNOR PRESSURE SOLENOI D.
5V F EED TO GOVERNOR PRESSURE SENSOR.
GROUND F OR GOVERNOR PRESSURE SENSOR AND THERMI STER.
GOVERNOR PRESSURE SENSOR SI GNAL TO THE TCM.
GROUND ( VARI ABLE F ORCE) TO GOVERNOR PRESSURE SOLENOI D.
GROUND F ROM TCM TO OVERDRI VE SOLENOI D.
GROUND F ROM TCM TO CONVERTER CLUTCH SOLENOI D.
TEMP SENSOR ( THERMI STER) SI GNAL TO THE TCM. '
F LUI D TEMPERATURE THERMI STER
Tr ans mi s s i on f l ui d t e mpe r at ur e r e adi ngs ar e
s uppl i e d t o t he TCM by t he t he r mi s t e r ( Se e
F i gur e 13) . The t e mpe r at ur e r e adi ngs ar e
us e dt o cont r ol t he 3- 4 s hi f t , t he conve r t e r
cl ut ch, and gove r nor pr e s s ur e . The nor mal
r e s i s t ance val ue f or t he t he r mi s t e r at r oom
t e mpe r at ur e i s appr oxi mat e l y 1000 ohms .
The TCM pr e ve nt s a 3- 4 s hi f t and pr e ve nt s
e ngage me nt of t he conve r t e r cl ut ch, whe n
t he f l ui d t e mpe r at ur e i s be l ow appr oxi mat e
30 F .
I f f l ui d t e mpe r at ur e e xce e ds 260 F , t he
TCM wi l l caus e a 4- 3 downs hi f t and e ngage
t he conve r t e r cl ut ch. Engage me nt i s now
accor di ng t o t he 3r d ge ar conve r t e r cl ut ch
e ngage me nt s che dul e .
The ove r dr i ve OF F l amp on t he i ns t r ume nt
pane l , al s o i l l umi nat e s whe n t he s hi f t back
t o 3r d occur s . The TCM wi l l not al l ow 4t h
ge ar ope r at i on unt i l f l ui d t e mpe r at ur e de -
cr e as e s t o appr oxi mat e l y 230 F .
The t he r mi s t e r i s mount e d on t he unde r s i de
of t he conve r t e r cl ut ch s ol e noi d, as s hown
i n F i gur e 9, and i s i mme r s e d i n f l ui d at
al l t i me s .
THERMI STER - - - - - - - - - - - - - - - - - - - - - - - APPROX. 1000 Ohms at l O a F .
OVERDRI VE SOLENOI D - - - - - - - - - - - - - - - 25- 40 Ohms at l O a F .
CONVERTER CLUTCH SOLENOI D - - - - - - - - 25- 40 Ohms at l O a F .
GOVERNOR PRESSURE SOLENOI D - - - - - - - 3. 0- 5. 0 Ohms at l O a F .
AUTOMATIC TR ANS MIS S ION S E R VIC E GR OUP
13
(~Q T 5G I
T echnical Service I nformation
ceoDAT A UNK CONNECT OR
(BEHI ND DASH, RI G HT SI DE OF COlUMN)
TRANSMI SSI ON CONTROL MODULE ( TCM)
The TCM cont r ol s oper at i on of t he TCC
Sol enoi d, t he Over dr i ve Sol enoi d, and t he
Gover nor Pr essur e Sol enoi d. The TCM i s l o-
cat ed behi nd i nst r ument panel t o t he l ef t
of t he st eer i ng col umn ( Fi gur e 16) .
The TCM, det er mi nes t r ansmi ssi on shi f t
poi nt s based on i nput si gnal s f r om t he
t her mi st er , t r ansmi ssi on speed sensor ,
cr ankshaf t posi t i on sensor , vehi cl e speed
sensor , and t hr ot t l e posi t i on sensor .
Oper at i ng vol t age i s suppl i ed t hr ough t he
bat t er y t er mi nal on t he TCM. The i gni t i on
vol t age si gnal i s suppl i ed t hr ough a t er m-
i nal on t he ABS cont r ol modul e.
The DRB I I scan t ool can be used t o check
oper at i on of t he TCM and t r ansmi ssi on el ec-
t r i cal component s. The Di agnost i c Connect or
f or t he scan t ool i s l ocat ed under t he i n-
st r ument panel j ust t o t he r i ght si de of
st eer i ng col umn ( See Fi gur e 14) .
The Di agnost i c Connect or has a si x- way
t er mi nal and i s Bl ue i n col or ( Fi gur e 15) .
CCDOATAUHK
CONNECTOR
CAV COLOR FUNCT I ON
2 RO 6+
: s WT/GY CCOBUS (.)
4 VT I BA ceo BUS (+)
8 BKI TN G ROUND
TRANSMI SSI ON
CONTROl MODULE
P
TOI NSTRU~NT
PANel WI RI NG
AUT OMAT I C T RANSMI SSI ON SERVI CE G ROUP
14
Condition Possible Cause Correction
HARSH ENGAGEMENT
1.
Engine idle s peed too high
1.
Check/adjos t idle s peed
(FROM NEUTRAL TO DRI VE
2. Driver "riding" accelerator pedal during s hif! 2. Advis e owner/operator
OR NEUTRAL TO REVERSE)
3. Throttle coble mis odjus ted or binding 3. Adjus t coble s elling
(revers e only)
4. Bond adjus tment needed
N 4. Adjus l rear bond
"
5. Loos e mounting bolts 5. Check en~ne, trans mis s ion, propeller s haft,
cros s mem er, and axle bolt torbe; lighten
loos e bolts and replace mis s ing olts
6. Worn or damaged U-joints 6. Remove propeller s haft and replace
..
U-joinls
7. Loos e axle pinion nut 7. Rer: lace nut and check pinion threads
be ore ins talling new nut; replace pinion
gear if threads are damaged
8. Hydraulic pres s ure is incorrect
\i
8. Check pres s ures ; remove, overhaul, or
adjus l valve body as needed; repair oil
Note: The s hift from neutral to pump if neces s ary
~.
revers e is normally quite firm.
9. Engineltrans mis s ion mounts worn or 9. Replace as neces s ary
Hydraulic pres s ure at the rear
damaged
s ervo can approach 300 ps i
in revers e gear. Do not
10. Faulty converter lockup clutch (if equipped) rr, 10. Replace converter and flus h cooler and
confus e a firm engagement
lines before ins talling new converter
with a truly hars h engagement 11.
Clutch, bond, or planetary component is
11.
Remove, dis as s emble, and repair
damaged
-"J
trans mis s ion as neces s ary
DELAY ED ENGAGEMENT
1.
Engine idle s peed too low
-
1.
Adjus t idle s peed
(fROM NEUTRAL TO DRI VE
2. Low fluid level 2. Correct level and check for leaks
OR REVERSE)
-
3. Gears hift linkage out of adjus tment 'i 3. Adjus t linkage and repair linkage jf worn
or damaged
4. Rear bond out of adjus tment 4. Adjus 1 bond
5. Valve body filter plugged 5. Replace fluid and filter. I f oil pan and old
fluid were full of clutch dis c material
and/or metal particles , overhaul will be
neces s ary
6. Oil pump gears worn or damaged or pump 6. Remove trans mis s ion and replace oil pump
body or s eal is damaged, allowing pump to
toke in air, co us ing fluid aeration
7. Reaction s haft s eal rings worn or broken
"J
7. Remove trans mis s ion, remove oil pump,
"-
and replace s eal rings '
8. Governor pres s ure s olenoid valve or electrical 8. Check electrical functions wi,h ORB s can
circuit fault
'I
1001or flas h codes and repair as neces s ary
9. Low hydraulic pres s ure 9. Perform pres s ure tes t, remove trans mis s ion,
and repair as needed
10. Clutch, bond, or s ervo damaged
'v
10. Remove and dis as s emble trans mis s ion and
repair as neces s ary
11.
Torque converter drain down after s everal ',/
11.
No repair required
days out of s ervice
AUT OMAT I C T RANSMI SSI ON SERVI CE G ROUP
15
Cewtlltl_ Iltl. c . . _
CofToc tI_
NO DRIVERANGE 1. Gearshift linkage either loose, damaged 0<"out of
1.
Repair 0<"replace linkage compooenn
(REVERSEOK) adjustment
2. LowAuid level 2. Correct Auid level and check for leaks
3. Valve body malfunction (manual valve 0<"shaft 3. Remove and di50ssemble valve body; reploce as
damaged or 12 shift valve stuckI assembly if any valves 0<"wes are damaged
4. Rear clutch failure 4. Remove and di50ssemble transmission and rear
clutch; repair/replace worn, domoged ports os
noeded
5. Transmission overrunning clutch failure 5. Remove and di50ssemble transmiuion; replace
overrunning clutch
6. Input shaft ~I rings worn or damaged 6. Remove and di$Ossemble transmiuion; replace
seal rings and any olher worn 0<"damaged ports
NO DRIVE0R REVERSE 1 . LowAuid level 1 . Add Auid and check for leaks if drive is restored
(VEHICLEWlU NOT MOVEI
2. Gearshift linkage loose, damaged, or mi50ssembled 2. Inspect, adjust, and reassemble linkage as noeded;
replace worn, damaged ports
3. Failure of driveline component, such as U'joint, axle 3. Perform preliminary ii15pection procedure for
shaft, transfer case component, etc. vehicle that will no! move; refer to procedure in
diognosi s section
4. LowAuid pressure due to worn or damaged oil 4. Perform pressure test to confirm low preuure;
pump replace pump body and/O<" gears if necessary
5. Transmission internal component damaged 5. Remove and di50ssemble transmission; repair 01"
replace failed components as noeded
6. Volve body malfunction (seized volve, damaged 6. Remove, di$Ouemble, and in5pecl valve body;
monuollever, volve body screws loose or replace valve body (as ossemblyl if Obi; valve 0<"
overtightened cousing distortion and bind) bore is damaged; clean and reassem e correctly
if all ports are in good condition
Fi gur e 18
A U T O MA T IC T R A NS MIS S IO N S E R V IC E G R O U P
16
(~Q TSG]
Condition POlllble Cau Correc tion
SHIFTS DELAYED OR
1.
low fluid level 1. Correct fluid level and check for leaks
ERRATIC (SHIFTS ALSO
2. Throllie coble out of adjustment 2. Adjust cable as described in service section
HARSH AT TIMES)
3. Thrallie cable binding 3. Adjust cable, replace if worn, or damaged
4. Gearshift linkage out of adjustment 4. Adjust linkage as described in service
section
S . Fluid filter partially clogged S . Replace filter. If filter and fluid contained
clutch material or metal particles, on
overhaul may be necessary
6. Air in fluid due to overfill condition or air 6. Drain fluid to correct level if overfilled. If
leakage into pump suction passages fluid is highly aerated (full of bubbles and
foa7)' oil pump gasket or seal may have
faile , or pump body is porous or crocked
7. Clutch or servo problem 7. Remove valve body and air test clutch,
bond and servo operation; disassemble and
repa'ir transmission as needed
8. Front bond out of adjustment (may couse harsh 8. Adjust bond
12 shift)
9. Accumulator springs/seals worn or damaged 9. Inspect/replace as required
10. Governor pressure control system faull 10. Check with DRB II scan tool or flash code,
and repair 0' necessary
NO REVERSE (0 RANGES
1.
Gearshift linkage is either aut of adjustment or
1.
Repair or replace linkage port, os needed
OK) damaged
Ht~
:'A \ J , Ht: I\j t()P , A
2. Ritar bond is out of adjustment 2. Adjust bond
3'1t-P e,~Hv ! 1'0. b 3. Valve body malfunction (stuck/damaged manual 3. Remove and service valve body; replace
nO~"(/:\ id~
valve, regulator valve, or check boll) valve body if any valve, or valve bore, are
worm or damaged
4. Rear servo or front clutch malfunction 4. Remove and disassemble transmission;
reploce worn, damaged servo and clutch
ports as necessary
S . Overdrive unit direct clutch malfunction S . Remove and disassemble overdrive unit.
Repair dire" clutch as needed
HAS FIRST-REVERSE ONLY 1. Governor component fault' J
1.
Te,' electrical component, with DRB " scon
(NO 1-2 OR 2-3 UPSHIFT)
-
1001 or fla,h codes and repair os needed
2. front servo problem
'\ )
2. Pressure check and repair as needed
17
[~Q T 5 G )
Condition POlilbl. Cau Corr.ctlon
MOVES IN 2ND OR 3RD
1.
Governor circuit fault \v
1.
Test governor components with DRB " scan
GEAR, ABRUPTLY tool
DOWNSHIFTS TO LOW
2. Valve body malfunction .J 2. Remove, clean, and inspect; look for stuck
1-2 valve or governor plug
SLIPS IN LOW GEAR D
1.
Transmission overrunning clutch faulty, not
1.
Replace overrunning clutch
ONL Y, BUT NOT IN 1
holding
POSITION
SLIPS FORWARD DRIVE
1.
Low Auid level 1.
Add fluid and check for leaks
RANGES
2. Air in fluid (fluid is foamy, full of bubbles),
2. Check for bod pump gasket or seals, dirt
shifts are spongy, caused by air gelling into
between p'ump halves, and loose pump bolts
pump suction passages
or defective O-ring at filler tube
3. Gearshift linkage or throttle coble out of
3. Adjust as needed
adjustment
4. Low hydraulic pressure due to worn pump,
4. Perform hydraulic and air pressure tests to
incorrect control pressure adjustment, valve
determine couse
body warpage or malfunction, sticking
r.0vernor, leaking seal rings, clutch seals
eaking, servo leaks, clogged filter, or cooler
lines
5. Accumulator piston crocked, spring broken or
5. Inspect and repair as necessary
seal worn
6.
Clutch or servo malfunction, leaking seals or
6. Air pressure check c1utch.servo operation
worn plates
and repair as required
7.
Overrunning clutch worn, not holding (slips in
1 7. Replace clutch
only)
SLIPS IN REVERSE ONLY
1.
low Auid level
1. Add fluid and check for leaks
2. Aerated fluid; see Slips in forward Drive
Ranges
2. See Slips in Forward Drive Ranges
3. Gearshift linkage out of adjustment
3. Adjust linkage
4. Rear bond out of adjustment
4. Adjust bond
5.
Hydraulic pressure too low due to worn pump,
5. Perform hydraulic pressure test. to
worn ,eol rings, clutch or servo .eol leakage
determine cou.e
6.
Worn front clutch, leaking rear servo, or worn
6. Air pressure check clutch-servo operation
rear bond
and repair a, required
7. Band.linkage binding
7. Inspect and repair as required
8.
Overdrive unit direct clutch slipping
8. Remove and disassemble overdrive unit.
Repair clutch as needed
AUT OMAT IC T R ANS MIS S ION S E R VIC E G R OUP
18
(~QT51i)
Condition Possible Cause
Correction
NO KICKDOWN OR
1.
Incorrect throttle coble adjustment
1.
Adjust coble
NORMAL DOWNSHIFT
2. Incorrect gear shift linkage adjustment 2. Adjust linkage
3. Front bond out of adjustment 3. Adjust bond
4. Hydraulic pressure too high or too low due to 4. Perform hydraulic pressure tests to
valve body malfunction, or incorrect hydraulic determine couse and repair as required.
control pressure adjustment
Correct valve body pressure adjustments as
required
5. Front servo, bond, or linkage malfunction 5. Air pressure test operation and repair as
necessary
6. Clutch or servo malfunction 6. Air pressure test operation and repair as
necessary
7. Governor fault 7. Check with ORB \I scan tool or flash codes and
repair as needed
8. TPS fault 8. Check for TPS fault at transmission control
module with DRB \I scan tool or flash codes
, . . . . . "
STUCK IN LOW GEAR (WILL
1.
Gearshift linkage or thrallie coble out of
1.
Adjust and repair linkage or coble if worn
NOT UPSHIFT) adjustment. or damaged
2. Front bond out of adjustment 2. Adjust bond
3. Governor component fault, loose output shaft 3. Check operating pressures, and test ~overnor
support, worn pump, leaking seal rings, or component with DRB II scan tool or f ash
valve body problem (i.e., stuck 1-2 shift valve codes. Repair as needed
or governor plug)
4. Clutch or servo malfunction 4. Air pressure check operation of clutches and
bonds; repair faulty component
NO LOW GEAR (MOVES IN
1.
Governor circuit fault
1.
Test governor components with DRB II scan
2ND OR 3RD GEAR ONLY) tool
2. Valve body malfunction 2. Remove, clean, and inspect. Look for
stickin~ 12 valve, 23 valve, governor plug,
or bra en springs
3. Front servo piston cocked in bore 3. Inspect servo and repair as required
4. Front bond linkage malfunction 4. Inspect linkage and look for bind in linkage
5. Incorrect throttle or gearshift linkage adjustment 5. Adjust linkage
19
Condition
Possible Cause
Correction
CREEPS IN NEUTRAL
1.
Gearshift linkage out of adjustment
1. Adjust linkage
2 .
Valve body malfunction (warped body, cross
2 .
Perform hydraulic pressure test to del ermine
leakage, loose screws)
cause and repair as required
3. Clutch dragging
3.
Air pressure check operation of clutches and
repair as required
DRAGS OR LOCKS UP
1.
Front or rear band out of adjustment 1. Adjust bands
2 . Servo band or linkage malfunction (i.e., 2 . Air pressure check servo operation and
binding linkage, warped band, servo piston repair as required
stuck)
3. Dragging clutch (does not release fully) 3. Air pressure check clutch operation and
repair as required
4. Broken or seized planetary gears 4. Remove, insbect, and repair as required
(look for de ris in oil pan)
5. Overrunning clutch worn, broken, or seized 5. Remove and inspect clutch, repair as
required
GROWLING, GRATING OR
1.
Planetary gear set broken or seized 1. Check for debris in oil pan and repair as
SCRAPING NOISES required
2. Overrunning clutch worn, seized, or broken 2 . Inspect and check for debris in oil pan;
repair as required
3. Oil pump components scored, binding, or 3. Remove, inspect, and repair as required
broken
4. Output shaft bearing or bushing damaged 4. Remove, inspect, and repair as required
5. Faulty clutch operation 5. Perform air pressure check and repair as
required
6. Front and rear bands out of adjustment 6. Adjust bands
BUZZING NOISE
1.
low fluid level
1.
Add fluid and check for leaks
2. Air being drawn into pump suction passages 2 . Check pU";fc For porous casting, scores on
maling sv aces, and excess rotor c1eorance;
repair 01 required
3. Overrunning clutch damaged 3. Replace clutch
4. Valve body misassembled, bolts loose, weak 4. Remove, disassemble, inspect valve body;
spring, or mispositioned valve or check ball reassemble correctly if necessary; replace
assembly if valves or springs are damaged
A UT O MAT IC T R ANS MIS S IO N S E R VIC E G R O UP
2 0
1~~T5GI
OIL COMES OUT FILLER TUBE 1. Transminion overfilled
1.
Drive fluid to correct level; remove neutral
switch and drain through switch hole with
suction gun
2. Breather vent in oil pump blocked 2. Inspect and clear blockage
3. Fluid cooler or cooler lines plugged 3. Flush cooler and lines
4. Air in fluid (aerated) 4. See "Slips In Forward Drive Ranges"
5. Oil filter clogged 5. Replace filter; determine the reason for
clogged condition and repair
6. Rear servo piston or seal failure 6. Check hydraulic pressure of servo in
reverse (will register low or fluctuate
rapidly). Repair/replace servo piston and
seal. Replace case if servo bar. is damaged
7. Valve body switch valve sticking 7. Remove and clean valve
OIL LEAKS (ITEMS LISTED
1.
Speedometer adopter
1.
Replace both adopter seals
REPRESENT POSSIBLE LEAK
2. Pan gasket 2. Tighten pan screws to 150 inch-pounds; if
POINTS AND SHOULD All
BE CHECKED)
leaks persist, replace gasket; do not
overtighten screws
3. Filler tube (where tube enters case) 3. Replace O-ring seal
4. Fluid lines and fiMings 4. Tighten fillings; if leaks persist, replace
fillings and lines if necenary
5. Valve body manual lever shaft seal 5. Replace shaft seal
6. Prenure port plug loose 6. Tighten to correct torque; rep,lace plug if
leak persists
7. Rear bearing accen plate 7. Replace gasket
8. Gasket damaged or bolts are loose 8. Replace bolts or gasket or tighten bolts
9. Adopter/extension gasket damaged 9. Replace gasket
10. Neutral switch 10. Replace switch and gasket
11.
Converter housing area
11.
Check for leaks at seal caused by worn
seal or burr on converter hub (cuMing
seal), worn bushing, missing oil return, oil
in front pump housing, or hole plugged.
Check for leaks post Orign seal on pump,
or post pump.to-case bolts; pump housinft
porous, oil coming out vent due to overfi I
or leak post front bond shaft access plug
12. Cooler line fiMings and hoses 12. Replace fillings and hoses
13. Pump seal 13. Replace seal
14. Torque converter 14. Replace converter
AUT O MAT IC T R ANS MIS S IO N S E R VIC E G R O UP
21
I~QT51i)
OVERHEAT DURING
COMMERCIAL OP ERATION
OR WHILE TRAILERTOWING
(FLUID DARK AND BURNED
WITH SOME SLUDGE
FORMATION)
OVERHEAT DURING NORMAL
OP ERATION (FLUID
DISCOlORED, SMELlS
BURNED)
1. Vehicle not property equipped for trailer towing or
com~cial u~
3. Exlensive idling time or operation in heavy traffic in
hot weather
A. Tow vehicle overloaded {exceeding vehicle tow
capacityl
5. Air Row 10 auxiliary cooler blocked by mow plow,
front mounted ~pore tire, bug ~reen, or ~imilar item
1. LowRuid level
2. Fluid cooler, line~blocked, or cooler crocked (oil in
engine coolant)
3. Switch valve ~ticking
A . Clutch pock clearance incorrect (too tight)
5. Sands 100 tight
1. Besure vehicle is equipped with recommended
optional components (i.e, HD springs,
tran~ission, axle, larger C1Dengine, auxiliary
cooler, correct axle ratio, elc.l. If vehicle i~not ~
equipped, it ~hould not be u~ lor severe
service operation
2. Drain Auid, change filter, and install auxiliary
cooler
3. Cut down on idling time; shih into neutral every
so often and run engine at 1000 rprn 10 help
circulate Ruid through cooler
A . Besure vehicle is property equipped 10 handle
load; do nol tow Closs III-type loads with a
vehicle that is only rated lor Closs I or II
operation
5. Remove or repo~ition item cou~ing air Row
blockage
1. Add Ruid and check for leaks
2. Flush cooler and lines and replace radiator if
tran,mission Auid ha, ente<ed coolant
3. Remove, disassemble, c1eon valve body
4. Check and correct os required
5. Adiust bonds
Fi gur e 24
22
(~Q T5 GJ
Condition Posslbl. Cau Correction
NO START IN PARK OR
1.
Gearshift linkage out of adjustment
1.
Adjust linkage
NEUTRAL
2. Pork/neutral position swilch wire broken or 2. Check continuity with lest lamp; repair as
open required
3 . Faulty park/neutral position switch 3 . Refer to service section for test and
replacement procedure
4. Valve body manual lever assembly bent, worn, 4. Inspect lever assembly and replace if
broken, or not aligned with switch damaged
SLUGGISH ACCELERATION
1.
Poor engine performance: 1. Check engine and repair as required
AT LOW SPEEDS OR
2. Gearshift linkage or throttle cable out of 2. Adjust as needed
REQUIRES EXCESSIVE
THROTILE OPENING TO
adjustment
/"
MAINTAIN HIGHWAY 3 . Transminion clutches slipping 3 . Perform stoll test and repair as required
SPEEDS
4. Overrunning clutch in converter stator not 4. Perform stoll lest and replace converter if
holding clutch has foiled
5. Converter stator overrunning clutch seized 5. Replace converter as assembly
---
FLUID CONTAMINATED 1. If cantaminalion occurred shortly after 1. If contamination is severe, cooler flushing,
(DISCOLORED, FULL OF overhaul, fluid cooler and lines were not converter replacement, and another
SLUDGE AND/OR METAL flushed and flow tested. This il especially true overhaul may be necelsary; particularly
AND FRICTION MATERIAL when original overhaul was fa correct a if shift problems were also pre,enl.
PARTICULAR)
problem that generated a large amount of
debris, such as a gear failure or a clutch pock
failure
Note: Flushing the cooler and lines is mandatory
after a failure of the converter clutch
2. Incorrect fluid used in transmission 2. If transmission is operating properly, drain
fluid, reverse flush cooler and lines, and
chanr,e fluid and filter. However, if shift
prob em has developed, converter
replacement and transmission overhaul may
be required.
3 . Main cooler in radiator is cracked, allowing 3 . Replace radiator (and cooler) and flush
engine coolant to enter transmission lines. If problem was diagnosed early
enough, fluid and filter change may only be
necessary. If contamination period was
prolonged, overhaul and converter
replacement may be required
4. Severe overload results in overheat, fluid 4. Repair transmission, flush cooler, and lines.
breakdown, and accelerated wear, especialiy Replace ccnverter if necenarf,' Install
in high ambient temperatures. Most frequent auxiliary cooler if needed. A so install HD
causes are: cooling system if needed. if tow vehicle and
Vehicle is not properly equipped for heavy

unit being towed are both overloaded, the
duty service
only repair is to reduce Ihe load to rated
Tow vehicle and boot or trailer are bath

limits. However, if trailer or boat is loa
overloaded
large for two vehicle, the only 0F-tion is for
Trailer or boal are 100 large for low vehicle

the owner to move up to r.roper y-equipped
(load exceeds rated capacity of tow vehicle)
and load-rated tow vehic e
AUTOMATIC TRANSMISSION SERVICE GROU P
23
SLIPS IN OVERDRIVE
FOURTH GEAR
1. Fourth geor overdrive switch (in dosh) in OFF
1.
Turn control switch to ON position
position
3. Fourth gear overdrive switch shorted, open, 3. Replace switch if shorted or open and
wires loose repair loose or damoged wires
4. Overdrive solenoid or circuit wire loose, 4. Check wires/connections with 12V test lamf
shorted, open and voltmeter; repoir damaged or loose
wires/connections as necessary
5. Solenoid feed orifice in valve body is blocked 5. Remove, disassemble, c1eon valve body
or blown out
thoroughly
6. Fourth gear overdrive solenoid failure 6. Verify solenoid failure with test lamp and
replace solenoid
7. Sensor or fluid temperature Ihermi"er fault 7. Test with ORB II scan tool or ohmmeter.
Replace sensor or thermister as needed
8. Overdrive pislon seol failure 8. Replace bOlh seals
9. Wrong overdrive piston spacer 9. Remove unit, check end ploy, and install
correct spacer
10. Low hydraulic pressure
10. Pressure lest transmission to determine
couse
11. Transmission fluid overheat (aver 260 0Fl
11. See overheal information in transmission
diagnosis charlS
1. Low fluid level
2. Overdrive piston or seal malfunction
1. Add fluid and check for leaks
2. Remove overdrive unit; replace pislon Sf
if worn; replace piston if damaged; if
piston retainer is da,:"aged, il will be
necessary to remove and disassemble th
transmission
3. Overdrive clutch pock worn
4. 3-4 shift valve, timing valve, or accumulator
malfunction
3. Remove overdrive unit and rebuild clutch F
4. Remove and overhaul valve body. Rep!
accumulator seals. Make sure all valves
operate freely in bores and do not bind
stick. Make sure valve body screws are
correctly tightened and separator plate'
are properly positioned.
5. Disassemble transmission, remove retair
and replace orifice
6. Disassemble overdrive unit and replace
thrust bearing (No. 1 thrust bearing is
between overdrive piston and clutch hu
No.2 thrust bearing is between the
planetary gear and the direct clutch sp.
plote; No.3 thrust bearing is between
.overrunning clutch hub and output shal'
A U T O MA T IC T R A NSMISSIO N SE R V IC E G R O U P
24
(~~T5G)
Condition Possible Cause
Correction
OELA YEO 34 UPSHIFT
1.
Low fluid level
1.
Add fluid ond check for leoks
(SLOW TO ENGAGE)
2. Overdrive solenoid or wiring is faulty 2. Test solenoid and check wiring for
loose/corroded connections, or
shorh/ground; replace solenoid if faulty and
repair wiring if necessary
3. Overdrive piston spacer too thin 3. Remove unit; measure end play and select
proper spacer
4. Overdrive clutch pock worn 4. Remove unil and rebuild clutch pack
5. T.P.S. faulty 5. Replace T.P.s.
6. Overdrive clutch bleed orifice in retoiner
6. Disossemble transmission and replace orifice
plugged or blown out
~
''- .. -
34 UPSHIFT OCCURS
1.
Overdrive solenoid connector or wiring 1. Test connector and wiring for loose connections,
BEFORE COMPLETION OF problem
shorts, or ground, and repair as needed
23 UPSHIFT
2. Overdrive solenoid malfunction 2. Replace solenoid
3. Coolant temperature or T.P.S. malfunction 3. Tesl sensor at TeM with DRB II scan tool
and replace as necessary
4. Valve body malfunction 4. Remove, disassemble, clean, and inspect
valve body components; make sure all
valves and plugs slide freely in bores; polish
valves with crocus cloth if needed
5. Transmission control module malfunction 5. Test module with DRB II scan tool and
replace if faulty
,
A U T O MA T IC T R A NSMISSIO N SE R V IC E G R O U P
25
(~
QTSG] Technical Service Information
TRANSMISSION DIAGNOSIS
NO 4-3 DOWNSHIFT
1.
Circuit wiring and/or connectors shorted
1.
Tesl wiring and connectors with lest lamp
and volt/ohmmeter; repair wiring as
necessary; replace connectors and/or
harness as required
2. Converter clutch solenoid nol venling 2. Remove valve body and replace solenoid if
seized or shorted
3. Overdrive solenoid nol venting 3. Remove valve body and replace solenoid if
seized or shorted
4. 3-4 shift or accumulator malfunction 4. Remove valve body; remove and disassemble
lower housing and 3-4 accumulator housing;
replace seals and clean valves as necessary;
b. sur. all valv.s slid. freely in bor.s
5. Transmission conlrol module malfunction 5. Check operation with DRB II scan tool,
replace module only if faulty
6. T.P.S. malfunctian 6. Check operation with DRB II scan 1001.
Replace TPS only if faulty i
I
I
I
I
NO 43 DOWNSHIFT
1.
Overdrive solenoid wiring or conneclors faulty
1.
Check solenoid wiring and connections for
WHEN CONTROL SWITCH
2. Overdrive or lockup solenoid nol venling
shorts/grounds; repair as necessary
IS TURNED OFF
I
(OVERDRIVE OFF AND
2. Tesl solenoids and replace if seized or
shorled
!
LAMP IS ILLUMINATED)
3. Transmission control module 3 Tesl wilh DR B II scan 1001, replace coni roller
if faulty
NO 4-3 DOWNSHIFT
1.
Overdrive off switch (in dash) open, sharled,
1.
Tesl switch function wilh DRB " scan tool can
WHEN OVERDRIVE OFF
or wiring is open, or shorled
nected 10 TCM. Replace swilCh or repair wiring
I
SWITCH IS TURNED OFF
oS necessary
(OVERDRIVE OFF AND
lAMP NOT IllUMINATED)
i
Fi gur e 28
AUTOMATIC TR ANS MIS S ION S E R VIC E GR OUP
26
(~Q TS G)
HARSH 12,23, OR 32
1.
Converter clutch solenoid failure
1.
Remove valve body and replace solenoid
SHIFTS. MAY STALL WHEN
GEAR SHIFT LEVER IS
PLACED IN D POSITION
ONLY
TORQUE CONVERTER
1.
Converler clutch solenoid or wiring problem
1.
Tesl solenoid and wiring for continuity,
CLUTCH ENGAGES IN
shorts, or grounds; replace solenoid and
SECOND AND/OR THIRD
relay if faulty; repair wiring and connectors
GEAR
as necessary
NOISY OPERATION IN
1.
Overdrive clutch discs, plates, or snap rings
1.
Remove unit and rebuild clutch pack
FOURTH GEAR ONLY damaged
2. Overdrive piston or planetary thrust bearing 2 Remove and disassemble unit; replace either
brinnelled, installed wrong, or damaged thrust bearing if damaged
3. Output shah bearings brinnelled, scored, 3. Remove and disassemble unit; replace either
damaged bearing if damaged
4. Planetary gears worn, chipped, damaged 4. Remove and overhaul overdrive unit
5. Overdrive unit overrunning clutch rollers rough, 5. Remove and overhaul overdrive unit
scored, or output bushings ore worn
A U T O M A T I C T R A N S M I S S I O N S E R V I CE G R O U P
27
[~Q T 5 G )
Condition Poulbl. Cau Corr.ctlon
NO REVERSE (OR SLIPS IN
1.
Direct clutch spring collapsed or broken 1. Remove and disassemble unit; check clutch
REVERSE) pock and replace spring
2. Direct clutch pock worn 2. Disassemble unit and rebuild clutch pack
3. Rear band out of adjustment 3. Adjust band
4. Front clutch malfunction 4. Air pressure test clutch operation; remove
and rebuild if necessary
5. Overdrive thrust bearing failure 5. Disassemble geartrain and replace bearings
NO 1-2 OR 2-3 UPSHIFT 1. Governor fault
1.
Test governor components with ORB II scan
(HAS LOW AND REVERSE tool and repair as needed
ONLY)
AUT OMAT IC T RANS MIS S ION S E RVIC E G ROUP
28
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SOCKET
4. Remove shi f t l ever and t hr ot t l e l ever
f r om val ve body manual l ever shaf t .
5. Remove t he t r ansmi ssi on speed sensor
and " 0" r i ng seal f r om t he over dr i ve
uni t , as shown i n Fi gur e 2.
6. Pl ace t r ansmi ssi on i n upr i ght posi t i on.
7. Remove over dr i ve uni t t o case at t ach i n
bol t s, usi ng an I l mm socket , as shown
i n Fi gur e 3.
8. Not e posi t i on of al l wi r i ng cl i ps f or
i nst al l at i on r ef er ence.
Li f t over dr i ve uni t up and of f of t he
t r ansmi ssi on i nt er medi at e shaf t , as
T R A N S M I S S I O N DI S A S S E MB LY
1. B ef or e r emovi ng t or que conver t er , sur f ace
of conver t er l ugs shoul d be 1/ 2" t o t he
r ear of st r ai ght edge when t he conver t er
i s f ul l y seat ed. Thi s shoul d be checked
f or di agnosi s pur poses ( S ee Fi gur e 1) .
2. Remove t he t or que conver t er f r om t he t r ans- g.
mi ssi on.
3. Cl ean t he t r ansmi ssi on ext er i or wi t h st eam
gun or wi t h sol vent bef or e di sassembl y.
' A U T O M A T I C T R A N S M I S S I O N S E R V I C E G R O U P
30
I ~Q T5G )
10. I f over dr i ve uni t does not r equi r e any
ser vi ce, i nst al l al i gnment t ool 6227- 2
i n over r unni ng cl ut ch and t he pl ant ar y
spl i nes t o mai nt ai n al i gnment , shown
i n Fi gur e 5.
11. Remove t he t hr ust bear i ng and sel ect i ve
t hr ust washer f r om over dr i ve pi st on,
as shown i n Fi gur e 6.
12. Remove t he over dr i ve pi st on f r om t he
r et ai ner , as shown i n Fi gur e 7.
13. Pl ace t r ansmi ssi on i n a hor i zont al po-
si t i on, wi t h pan f aci ng up.
14. Remove t he bot t om oi l pan and gasket ,
and di scar d pan gasket .
15. Remove t he oi l f i l t er f r om val ve body,
16. Keep f i l t er scr ews seper at e f r om ot her
val ve body scr ews, as t hey ar e l onger
and shoul d be kept seper at e.
T HRUST
BEARI NG
OVERDRI VE
PI ST ON
FI L T ER
SCREWS
(3)
A U T O M A T I C T R A N S M I S S I O N SERVI CE G ROU P
31
(~Q T S G )
,
i
17. Remove t he Par k/ Neut r al swi t ch f r om t he!
case ( See Fi gur e 9) . !
18. Remove ONLY t he t en val ve body r et ai n-
i ng bol t s shown i n Fi gur e 10. Not e t he
di f f er ent bol t l engt hs f or r eassembl y
r ef er ence.
19. Remove val ve body assembl y f r om case by!
pushi ng on har ness connect or , and at
same t i me l i f t i ng on val ve body. Then
wor k par k r od and val ve body out of t he
case ( See Fi gur e 12) .
20. Excer ci se car e dur i ng r emoval as bot h
gover nor pr essur e sol enoi d and sensor
can be damaged by r ough handl i ng.
21. Remove t he accumul at or pi st on and bot h
i nner and out er spr i ngs ( Fi gur e 13) .
22. Remove f r ont band l ever shaf t access
pl ug t hr ough conver t er housi ng, shown
i n Fi gur e 11.
32
FRONT
BAND
L E V E R
SHAFT
ACCESS
PL UG
\
V AL V E
BO DY
A C C U M U LA T O R
P I S T O N
Fi gur e 12
ACCUMUL AT OR
PI STON
OUT E R
SPRI NG
(~Q T 5G ]
OIL PUMP AND R E ACT ION
S HAFT S UPPOR T ~S S E MBL Y
Fi gur e 15
23. Loosen f r ont band l ocknut , and t i ght en
band adj ust i ng scr ew al l t he way i n, so
t he band i s t i ght ar ound dr um. Thi s i s
pr event t he dr ums f r om comi ng out wi t h
t he pump and possi bl e damage.
24. Remove f r ont pump r et ai ni ng bol t s.
25. Remove t he f r ont pump assembl y usi ng
sl i de hammer s, as shown i n Fi gur e 14.
26. Remove f r ont band adj ust i ng scr ew.
27. Squeeze f r ont band t oget her and r emove
band st r ut , as shown i n Fi gur e 15.
28. Remove f r ont band l ever shaf t usi ng a
penci l magnet ( See Fi gur e 16) .
29. Remove f r ont band l ever , as shown i n
Fi gur e 17.
30. Remove f r ont and r ear cl ut ch dr ums as
an assembl y, by l i f t i ng st r ai ght up on
t he t ur bi ne shaf t , and r emove t hem f r om
t he case ( See Fi gur e 18) .
Cont i nued on Page 34.
AUT OMAT IC T R ANS MIS S ION S E R V ICE G R OUP
33
INPUT
SHA FT
Fi gur e 20
31. Seper at e f r ont and r ear cl ut ch dr ums,
as shown i n Fi gur e 19, and set bot h of
t he dr ums asi de f or over haul dur i ng
subassembl y.
__\'r
I NTERM EDI A TE
SHA FT
THRUST PL A TE
32. Remove i nt er medi at e shaf t t hr ust washer
f r om f r ont end of shaf t , or f r om r ear
cl ut ch dr um ( See Fi gur e 20) .
33. Remove i nt er medi at e shaf t t hr ust pl at e
f r om t he i nt er medi at e shaf t hub, shown
i n Fi gur e 21.
34. Sl i de t he f r ont band of f of t he dr i vi ng
shel l ( See Fi gur e 22) , and r emove f r om
t he case.
A UTO M A TIC TR A NSM ISSIO N SE R V IC E G R O UP
34
[~Q T S G )
35. Remove t he pl anet ar y gear t r ai n as an
assembl y as shown i n Fi gur e 23. Suppor t
t he gear t r ai n wi t h bot h hands as you
r emove i t , t o ensur e t her e i s no damage
done t o t he over dr i ve pi st on r et ai ner .
36. Loosen t he r ear band adj ust i ng scr ew
5 or 6 f ul l t ur ns.
37. Remove t he l ow/ r ever se dr um snap r i ng
usi ng snap r i ng pl i er s, as shown i n
Fi gur e 24.
E T AINE R
BOlTS
Fi gur e 26
38. Remove t he bol t s at t achi ng over dr i ve
pi st on r et ai ner t o r ear of case, as
39. Remove t he over dr i ve pi st on r et ai ner
f r om t he case, remove and di scar d t he
r et ai ner t o case gasket .
40. Remove t he r ear band pi vot and r eact i on
pi ns, as shown i n Fi gur e 26. I nser t
and spr ead snap r i ng pl i er s i n t he pi n
bor e, t hen t wi st and pul l pi ns as you
r emove t hem f r om case.
41. Remove t he r ear band l ever f r om case.
AU T O MAT IC T R ANS MIS S IO N S E R V IC E G R O U P
35
I ~Q T 5 G ]
'~ ~
AUGN MARKS
IDENTIFYING
ON-THREADED HOLE OVERRUNNING
IN CAN. AND CASE ~CLUT CH ASSEMBLY /
Fi gur e 29
42. Remove t he l ow/ r ever se dr um and r ear
band as an assembl y, as shown i n Fi gu
27. Tur n dr um cl ockwi se and pul l out
r emove i t f r om over r unni ng cl ut ch.
43. Remove t he bol t s at t achi ng over r unni ng
cl ut ch cam t o case, as shown Fi gur e 28
44. Check t he over r unni ng cl ut ch cam f or
" Al i gn Mar ks" on t he cam and case, as
shown i n Fi gur e 29. These mar ks ar e to
i dent i f y t he Non- t hr eaded hol e i n t he
over r unni ng cl ut ch cam.
45. I f t her e ar e no pai nt mar ks t o i dent i f
t he non- t hr eaded hol e, put some t her e
f or r eassembl y pur poses, bef or e r emova
Ref er t o Fi gur e 29.
46. Remove over r unni ng cl ut ch cam and t he
r ol l er cl ut ch assembl y as a uni t . Turn
cam back and f or t h and t i l t i t i nwar d
t o r emove i t f r om case ( Fi gur e 29) .
47. Compr ess f r ont ser vo r od gui de about
1/ 8" wi t h compr essor , as shown i n Fi g-
ur e 30, and r emove snap r i ng.
48. Exer ci se caut i on when r emovi ng snap
r i ng as ser vo bor e can be damaged.
49. Remove compr essor t ool s and r emove t he
f r ont ser vo par t s.
50. Compr ess t he r ear ser vo spr i ng r et ai ne
about 1/ 16" wi t h spr i ng compr essor , as,
shown i n Fi gur e 31, and r emove t he sna
r i ng.
51. Remove t he compr essor t ool s and r emove'
r ear ser vo pi st on and spr i ng.
52. Cl ean and i nspect al l t r ansmi ssi on and~
component par t s.
36
(~Q T S G ]
OVERHAUL SERVI CE I NFORMATI ON
I nspect t he t r ansmi ssi on bushi ngs dur i ng
over haul . Bushi ng condi t i on i s i mpor t ant
as wor n or scor ed bushi ngs cont r i but e t o
l ow pr essur es, cl ut ch sl i ppage and wear of
r el at ed par t s. Repl ace bushi ngs onl y when
t hey ar e act ual l y wor n or scor ed.
Use r ecommended t ool s t o r epl ace bushi ngs
as t hey ar e desi gned t o r emove and i nst al l
bushi ngs cor r ect l y.
Pr e- si zed ser vi ce bushi ngs ar e avai l abl e
f or r epl acement pur poses. Onl y t he sun gear
bushi ngs ar e not ser vi ced. The sun gear i s
r epl aced as an assembl y i f t he bushi ngs ar e
damaged.
Hel i - Coi l i nser t s can be used t o r epai r
damaged, st r i pped or wor n t hr eads i n any
al umi num par t s. These i nser t s ar e avai l abl e
f r om most aut omot i ve j obber s. The st ai nl ess
st eel i nser t s ar e r ecommended.
The use of cr ocus cl ot h i s per mi ssi bl e i f
i t i s used car ef ul l y. When used on shaf t s,
or val ves, use ext r eme car e t o avoi d r ound-
i ng of f shar p edges. Shar p edges ~r e vi t al
as t hey pr event f or ei gn mat er i al f r om get t -
i ng bet ween t he val ve and val ve bor e.
Do not r euse oi l seal s, gasket s, " 0" r i ng,
seal r i ngs or f i l t er dur i ng over haul . These
ar e mandat or y r epl acement par t s. Al so don' t
r euse snap r i ngs or " E- Cl i ps" t hat ar e bent
or di st or t ed. Repl ace t hese par t s as wel l .
Lubr i cat e t r ansmi ssi on par t s wi t h Dexr on
or 7176 t r ansmi ssi on f l ui d dur i ng assembl y.
Use Tr ans- J el t o pr el ubr i cat e seal s, " 0"
r i ngs, and t hr ust washer s. Tr ans- J el can
al so be used t o hol d par t s i n pl ace dur i ng
t he r eassembl y pr ocess.
37
CL UTCH
CAM
TRANSMI SSI ON CASE
1. Cl ean t he t r ansmi ssi on case i n
t ank wi t h cl ean sol vent . Fl ush al l of
t he bor es and passages t hor oughl y, a
dr y wi t h compr essed ai r .
2. I nspect t he case car ef ul l y f or cr acks
por ous spot s, wor n bor es, or damaged
t hr eads.
3. Damaged t hr eads can be r epai r ed wi t h
Hel i - Coi l t hr ead i nser t s.
4. Lubr i cat e t he f r ont band adj ust i ng sc
ew t hr eads wi t h a smal l amount of t he
Tr ans- J el , and t hr ead t he scr ew par t
way i nt o t he case. Be sur e t he scr ew
t ur ns f r eel y.
5. Cl ean t he over r un cl ut ch par t s wi t h
cl ean sol vent , and dr y wi t h compr ess
ai r .
6. I nspect al l par t s f or . damage.
7. I nst al l t he r ol l er s i nt o over r un
cage, as shown i n Fi gur e 32.
8. I f t he over r unni ng cl ut ch and cam ca
out wi t h t he l ow/ r ever se dr um, t hr ead
t wo cam bol t s i nt o t he cam, as shown
Fi gur e 33.
9. Li f t t he cl ut ch and cam out of t he d
wi t h t he bol t s ( See Fi gur e 33) . Rot at
t he cam i f necessar y t o ease r emoval .
10. Exami ne t he bol t hol es i n t he over r un
cl ut ch cam. Not e t hat one hol e i s not
t hr eaded ( See Fi gur e 34) .
11. Thi s hol e MUST al i gn wi t h bl ank ar ea,
mar ked wi t h an " X" as shown i n Fi gur e
35.
12. Thi s hol e shoul d have been mar ked wi t
pai nt bef or e di sassembl y, as shown i n
Fi gur e 34, wi t h a cor espondi ng mar k 0
t he case.
13. Not i ce al so t hat t he over r un cl ut ch c
t hr eaded hol es ar e sl i ght l y count er s
on one si de ( See Fi gur e 34) .
14. Be sur e t hi s si de of t he cam f aces t h
r ear of t he t r ansmi ssi on case.
15. I nst al l t he over r unni ng cl ut ch i n t he
over r un cl ut ch cam.
16. Al i gn and i nst al l over r unni ng cl ut ch
and ear n i nt o t r ansmi ssi on case ( See
Fi gur e 36.
17. Ver i f y t hat non- t hr eaded hol e i n cl ut
cam i s pr oper l y al i gned, by t hr eadi ng
a bol t i nt o each hol e. Adj ust cl ut ch
cam posi t i on as necessar y.
A UTO M A TI C TR ANS MIS S ~ON S E R V I CE G R O UP
38
(~Q TS G )
18. I nst al l t he f i ve over r unni ng cl ut ch cam
bol t s i n t he posi t i ons shown i n Fi gur e
37.
19. Ver i f y t hat your mar ks ar e al i gned as
20. Tor que t he f i ve over r un cl ut ch bol t s
t o 13 f t . l bs. ( See Fi gur e 37) . Not e
t hat t he cam bol t s ar e shor t er t han t he
pi st on r et ai ner bol t s.
21. Lubr i cat e t he over r un cl ut ch r ol l er s
wi t h t r ansmi ssi on f l ui d.
NON-THR EADED
HOlE
AUG N MAR KS
IDENTIFYING
NON-THR EADED HOLE /' OVER R UNNING
IN CAM AND CAS E / /CLUTCH AS S EMBLY /
AUTOMATIC TR ANS MIS S ION S ER VICE G R OUP
39
CUSHION
SPRING
PISTON
PLUG
SNAP 0
RING
l ~S E R V O
PISTON
Fi gur e 38
22. Assembl e r ever se ser vo pi st on pl ug, t he
cushi on spr i ng and pi st on, as shown i n
Fi gur e 38. Lubr i cat e wi t h f l ui d.
23. Compr ess cushi on spr i ng i n vi se, and
i nst al l t he snap r i ng on pi st on pl ug,
24. I nst al l new l i p seal on pi st on, wi t h
t he l i p f aci ng away f r om cushi on spr i ng
BE SURE
SE AL UP
IS TOWARD
SE RVO
RE AR
SE RVO
PIS T~
25. Lubr i cat e t he r ever se ser vo pi st on an
seal wi t h l i ber al amount of Tr ans- J el .
26. Lubr i cat e t he r ever se ser vo bor e i n
t he case, wi t h a l i ber al amount of t h
Tr ans- J el .
27. Thi s i s done t o pr event t hi s pi st on
f r om cocki ng and st i cki ng i n t he bor e
of t he case.
28. I nst al l t he r ever se ser vo pi st on ass-
embl y i nt o t he case.
29. I nst al l t he r ever se ser vo r et ur n spr i
and r et ai ner on t op of t he pi st on.
30. I nst al l spr i ng compr essor , compr ess t
spr i ng, and i nst al l snap r i ng, as sho
i n Fi gur e 39.
31. Remove t he compr essor t ool s.
AUTOM ATIC TRANSM ISSION SE RVICE GROUP
40
I~Q TS G I
Technical Service Information
32. I nst al l new seal r i ngs ( 2) , on f r ont
ser vo pi st on and l ubr i cat e wi t h smal l
amount of Tr ans- J el ( See Fi gur e 42) .
33. I nst al l new " 0" r i ng seal on t he ser vo
pi st on r od, and l ubr i cat e wi t h smal l
amount of Tr ans- J el ( See Fi gur e 42) .
34. I nst al l ser vo pi st on r od i nt o t he f r ont
ser vo pi st on and i nst al l snap r i ng, as
35. Lubr i cat e t he f r ont ser vo case bor e
wi t h a smal l amount of Tr ans- J el .
36. I nst al l t he f r ont ser vo pi st on assembl y
i nt o t he case bor e.
37. I nst al l t he ser vo pi st on r et ur n spr i ng
on t op of t he f r ont ser vo pi st on.
38. I nst al l new " 0" r i ng on pi st on r od
gui de and l ubr i cat e wi t h smal l amount
of Tr ans- J el .
39. I nst al l pi st on r od gui de, compr ess t he
assembl y wi t h compr essor t ool , shown
i n Fi gur e 43.
40. I nst al l snap r i ng on t op of pi st on r od
gui de, as shown i n Fi gur e 43.
41. Remove t he compr essor t ool s.
42. Set t he t r ansmi ssi on case assembl y
asi de f or f i nal assembl y.
PISTON
ROD
SERVO
S NAP
RING
A U TOM A TIC TRA NSM ISSION SERVIC E GROU P
41
( ~Q T 5G l
o-RING
SEAl
SP E CIAL
TOOL
( -4171
SP E CIAL
TOOL
( -4171
SP E CIAL
TOOL
SP -5117
OI L PUMP AND REACTI ON SHAFT SUPPORT
1. Cl ean and i nspect al l oi l pump par t s
and component s ( See Fi gur e 44) .
2. Remove t he pump body bushi ng usi ng t he
dr i ver shown i n Fi gur e 45, dr i vi ng t he
bushi ng out t owar ds t he pump pocket .
REA CTION SHA FT
SUPPORT
THRUST
WA SHER
3. I nst al l t he new pump body bushi ng f r o
t he pump pocket si de, as shown i n Fi g~'
ur e 45.
4. Bushi ng shoul d be f l ush wi t h t he pump'
housi ng bor e.
5. St ake t he new pump bushi ng i n 2 pl aces
wi t h a bl unt punch, as shown i n Fi gur e
46, and r emove bur r s f r om st ake poi nt s
wi t h a smal l kni f e bl ade ( Fi gur e 46) .
6. I nst al l bot h pump gear s i nt o t he pump
housi ng and measur e cl ear ance wi t h a
f eel er gauge and st r ai ght edge, as sh-
own i n Fi gur e 48. Cl ear ance shoul d be
. 0015" - . 0035" .
A UTOM A TIC TRA NSM ISSION SERV ICE GROUP
42
~QT5G)
PREVI OUS
DESI GN
7: Measur e cl ear ance bet ween t he out er
gear and t he pump body, as shown i n
Fi gur e 49, wi t h a f eel er gauge. The
cl ear ance shoul d be . 0035" - . 007" .
8. Not e t hat t he i nner gear used i n t he
42RE oi l pumps has a new desi gn dr i ve
l ug. The new desi gn uses " Fl at s" , as
opposed t o t he pr evi ousl y used squar e
l ug ( See Fi gur e 47) .
9. I f i t i s necessar y t o r epl ace r eact i on
shaf t suppor t bushi ng, r ef er t o Fi gur e
50 f or t he speci al t ool s r equi r ed.
NEW
DESI GN
SP E CIAL
TOOL
SP 1191
SP E CIAL
TOOL
( .4171
SP E CIAL
TOOL
SP 532A
SP E CIAL
TOOL
SP -5325
BUSHING
INSTALLATION
AUTOMATIC TR ANSMISSION SE R VICE GR OUP
43
- [~~T SG )
OUTER
10.
GEAR
11.
12.
13.
14.
OUTER
GEAR
INNER
GEAR
16.
17.
18.
19.
Fi gur e 52
20.
2l .
PUMP
HOUSING
22.
23.
24.
Fi gur e 53
25.
Lubr i cat e t he pump pocket i n t he p
body wi t h t r ansmi ssi on f l ui d.
Lubr i cat e bot h i nner and out er pump
gear s wi t h t r ansmi ssi on f l ui d.
Suppor t t he pump body on wooden bl o
I nst al l t he out er pump gear i nt o p
pocket ( See Fi gur e 51) . The out er g
can be i nst al l ed ei t her si de up.
I nst al l t he i nner pump gear i nt o p
pocket ( See Fi gur e 52) .
CAUTI ON: The i nner pump gear i s a 0
way f i t . The bor e on one si de of t he.
gear s i nsi de di amet er i s chamf er ed.
sur e t he chamf er ed si de f aces down,
t owar ds t he bushi ng.
15. I nst al l t hr ust washer on t he r eact i
shaf t suppor t , and r et ai n wi t h a s
amount of Tr ans- J el .
CAUTI ON: The t hr ust washer i s one- wa
f i t . The washer i nsi de di amet er i s
chamf er ed on one si de. Be sur e wash
i s i nst al l ed wi t h t he chamf er ed si de
f aci ng t owar ds pump cover .
I nst al l t he r eact i on shaf t suppor t
t he pump body as shown i n Fi gur e 53.
Al i gn or r ot at e r eact i on suppor t unt
bol t hol es i n suppor t and pump housi
ar e al l al i gned. I t onl y f i t s one wa
I nst al l al l si x bol t s t hat at t ach t
suppor t t o pump body " Fi nger Ti ght " .
I nst al l t he pump assembl y i nt o case
bor e i n t he r ever sed posi t i on so t ha
bol t s ar e f aci ng out and accessi bl e. 1
Thi s wi l l al i gn t he pump hal ves.
Secur e t he pump assembl y i n case wi t
2 or 3 bol t s, or wi t h pi l ot st uds.
Tor que t he si x bol t s t hat at t ach t h
suppor t t o pump body t o 15 f t . l bs, as,
Remove t he oi l pump assembl y f r om t h.
t r ansmi ssi on case.
I nst al l new f r ont seal i nt o
usi ng seal dr i ver , as shown
55.
I nst al l 2 new seal i ng r i ns ont o pump
r eact i on shaf t suppor t . Squeeze each
r i ng unt i l r i ng ends ar e secur el y
hooked t oget her ( See Fi gur e 56) .
I nst al l new seal r i ng ar ound pump bod
as shown i n Fi gur e 57. Ensur e t hat s
i s pr oper l y seat ed i n gr oove, and not
t wi st ed.
26. Lubr i cat e seal r i ng, 2 met al seal i ng
r i ngs, and f r ont seal l i p wi t h smal l
amount of Tr ans- J el .
AUTOMATIC TRANSMISSION SERVIC E GROUP
44
( ~Q TSG)
27. Lubr i cat e spl i nes on r eact i on shaf t
wi t h a smal l amount of Tr ans- J el t o
hel p on conver t er i nst al l at i on.
28. Ensur e t hat f r ont pump gear s r ot at e
f r eel y i n oi l pump.
29. Set oi l pump assembl y asi de f or f i nal
assembl y.
SPEC IAL
TOOL
Co4193
PUMP
BODY
PUMP
SEAL
SEAL
RINGS
SUPPORT
HUB
PUMP
HOUSING
SEAL
RING
RET A I NER HU B
SEAL
CLUTCH
PISTON
PISTON
SPRING
RET A I NER
CHECK BALL
Fi gur e 59
FRONT CLUTCH HOUSI NG ASSEMBLY
1. Cl ean t he f r ont cl ut ch component s wi t h
cl ean sol vent and dr y wi t h compr essed
ai r ( See Fi gur e 58) .
2. Check t he bal l capsul e i n f r ont cl ut ch
housi ng f or f r ee movement and ver i f y
t hat i t does not l eak ( See Fi gur e 59) .
Leak check wi t h smal l amount sol vent .
3. I nspect t he bushi ngs i n f r ont cl ut ch
housi ng f or wear or damage. Bushi ngs
f or t hi s l ocat i on ar e not ser vi ced.
( See Fi gur e 60) .
SNAP RING
(WAVED)
SPRING
RETAINER
SNAP RING
PRESSURE
PLATE
SPRING
RETAINER
FRONT
CLUTCH
RETAINER
BUSHINGS
(NON.SERVICEABLE)
Fi gur e 60
4. Soak t he l i ned pl at es i n t r ansmi ssi on
f l ui d whi l e assembl i ng ot her par t s.
5. I nst al l new l i p seal ont o t he f r ont
cl ut ch pi st on, and l ubr i cat e wi t h smal
amount of Tr ans- J el . Ensur e t hat l i p 1
f aces away f r om spr i ng si de of pi st onl
6. I nst al l new l i p seal i nt o f r ont cl ut ~
housi ng and l ubr i cat e wi t h smal l amo
of Tr ans- J el . Ensur e t hat l i p f aces
i nt er i or of cl ut ch dr um.
7. Lubr i cat e t he f r ont cl ut ch pi st on
wi t h smal l amount of Tr ans- J ~' .
46
12. Remove compr essor t ool s.
13. I nst al l t he cl ut ch pl at es begi nni ng wi t h
a st eel pl at e and al t er nat i ng wi t h l i ned
pl at es unt i l you have i nst al l ed f our of
p.ach (Sp.p' FiRlirp ')8).
14. Af t er i nst al l i ng pr essur e pl at e and t he
waved snap r i ng, check cl ut ch cl ear ance
wi t h f eel er gage ( Fi gur e 65) . Cl ear ance
shoul d be . 060" - . 080" .
1 ,~2~- 2 , D : > o 2
47
FRONT
CLUTCH
RET A I NER
CLUTCH
PI ST ON
SMA ll T A BS
ON RET A I NER
FACE
UPWARD
8. I nst al l t he f r ont cl ut ch pi st on i n t he
f r ont cl ut ch housi ng wi t h a t wi st i ng
mot i on unt i l f ul l y seat ed ( See Fi gur e
61) .
9. Posi t i on t he f r ont cl ut ch r et ur n spr i ng
on pi st on, as shown i n Fi gur e 62.
I nst al l t he r et ai ner on t op of spr i nR
wi t h smal l r ai sed Labs l aci ng up, as
Compr ess t he r et ur n spr i ng and i nst al l
snap r i ng ( See Fi gur e 64) .
SPRI NG
RET A I NER "'"
(~~T 5G)
P ISTON
SP RING
WAVE
SP RING
REAR CLUTCH HOUSI NG ASSEMBLY
1. Cl ean al l r ear cl ut ch component s wi t h
cl ean sol vent and dr y wi t h compr essed
ai r ( See Fi gur e 66) .
2. I nspect al l r ear cl ut ch component s f or
any damage or wear , r epl ace as needed.
3. Soak t he r ear cl ut ch l i ned pl at es i n
! f r ansmi ssi on f l ui d whi l e assembl i ng
ot her par t s.
INP UT
SHAFT
SNAP
RING
REAR
CLUTCH
RETAINER
REAR
CLUTCH
THRUST
SHAFT WASHER
FRONT (FIBER)
SEAL
RING
(TEFLON) CLUTCH
P ACK
SNAP
RING
(SELECTIVE)
/
RETAINER
SEAL RING
4. I nst al l new l i p seal s on r ear cl ut ch
pi st on, wi t h l i ps f aci ng t he i nt er i or '
of dr um, and l ubr i cat e wi t h Tr ans- J el
48
l ~~T SG) .
BE SURE
RI NG ENDS
ARE HOOKED
TOGETHER
AFTER INSTALLATION
METAl
REAR
SEAl
RING .
TEflON
FRONT
SEAL
RING
(SQUEEZE RING
TOGETHER SLIGHTLY
BEFORE INSTALLATION
FOR BmER FIT)
Fi gur e 69
5. I nst al l t he r ear cl ut ch pi st on i n t he
r ear cl ut ch dr um wi t h a t wi st i ng mot i on
unt i l f ul l y seat ed.
6. I nst al l bel l vi l l e spr i ng i n dr um on t op
of t he pi st on, wi t h concave si de f aci ng
up ( See Fi gur e 67) .
7. I nst al l t he waved snap r i ng i n gr oove
on t op of bel l vi l l e spr i ng ( Fi gur e 67) .
8. I nst al l bot t om pr essur e pl at e, r i dged
si de f aci ng down ( See Fi gur e 66) .
9. I nst al l cl ut ch pl at es begi nni ng wi t h a
l i ned pl at e and al t er nat i ng wi t h st eel
pl at es, unt i l you have 4 l i ned and 3
st eel pl at es i nst al l ed ( Fi gur e 66) .
10. I nst al l t op pr essur e pl at e and sel ec-
t i ve snap r i ng ( See Fi gur e 68) .
REAR
CLUTCH
THRUST
WASHER (FIBER)
Fi gur e 71
o 162 ~ 1.2J
11. Check cl ut ch cl ear ance wi t h a f eel er
gauge as shown i n Fi gur e 68. Cl ear ance
shoul d be . 030" - . 050" .
12. I nst al l one st eel seal i ng r i ng and one
scar f - cut t ef l on seal r i ng, as shown i n
Fi gur e 69.
13. I nst al l f i ber t hr ust washer on t he r ear
cl ut ch dr um as shown i n Fi gur e 70, and
r et ai n wi t h Tr ans- J el .
14. I nst al l t he f r ont cl ut ch housi ng ont o
t he r ear cl ut ch housi ng, as shown i n
Fi gur e 70, r ot at i ng t he f r ont cl ut ch
unt i l f ul l y seat ed, and set assembl y
49
(~~T SG )
Technical Service Information
I
DRIVING L((il~
SHELL~
REAR
THRUST
PLATE
SUN GEAR REAR PLANETARY ANNULUS GEAR
LOCK RING THRUST WASHERS GEAR SUPPORT
7
mut
[iny CI$!()
INTERMEDIATE INTERMEDIATE
SHAFT THRUST SHAFT
PLATE
SELECT
F IT
PLANETARY
SUPPORT
SNAP
RING
FRONT
ANNULUS
GEAR
FRONT
ANNULUS
THRUST
WASHER
PL ANETARY GEARTRAI N ASSEMBL Y
1. Cl ean al l pl anet ar y gear t r ai n compon-
ent s wi t h cl ean sol vent ( Fi gur e 72) .
2. I nspect al l pl anet ar y component s f or
any wear and/ or damage.
3. Be sur e t he sel ect i ve spacer gr oove on
t he i nt er medi at e shaf t has no wear or
damage.
4. I nst al l r ear t hr ust washer on t he r ear
pl anet ar y, as shown i n Fi gur e 73, and
5. I nst al l t he r ear r i ng gear and suppor t
over and ont o t he r ear pl anet ar y and
engage on pl anet ar y gear s ( Fi gur e 73) .
6. I nst al l assembl ed r ear pl anet ar y and
r i ng gear ont o i nt er medi at e shaf t , as
7. I nst al l f r ont t hr ust washer on t he r ear
pl anet ar y, as shown i n Fi gur e 75, and
8. I nst al l sun gear spacer on t he sun gear
9. I nst al l t hr ust pl at e over t he sun gear
and on t op of spacer ( See Fi gur e 77) .
Not e t hat t hr ust pl at es ar e t he same,
bot h f r ont and r ear .
CLUTCH
CAM
CLUTCH
CAM BOLTS
REAR
ANNULUS
GEAR
TABBED
THRUST
WASHER
REAR
PLANET ARY
10. I nser t sun gear i nt o t he dr i vi ng shel l
as shown i n Fi gur e 78, and i nst al l t hE
r ear t hr ust pl at e ( See Fi gur e 78) .
11. Posi t i on wood bl ock on bench, as shaWl
i n Fi gur e 79, and suppor t sun gear on
t he wood bl ock. Thi s makes i t easi er
t o i nst al l sun gear l ocki ng r i ng.
AUTOMATIC TRANSMISSION. SERVICE GROUP
50
(~Q T5 G)
REAR ANNULUS
AND PLANETARY GEAR
ASSEMBLY
F RONT
TAB8ED
THRUST
WASHER
SUN
GEAR
SUN GEAR
SPACER
REAR
HRUST
PL ATE
SUN
GEAR
WOOD
BLOCK
DRIVING
SHELL
(~Q T S G ]
DRIVING
SHELL
REAR
THRUST
PLATE
FRONT
PLANETARY
GEAR
12. Wi t h t he sun gear and shel l set t i ng on
wood bl ock, al i gn r ear t hr ust pl at e and
i nst al l t he sun gear l ocki ng r i ng, as
13. Keep t he wood bl ock handy as i t wi l l
al so be used f or t he gear t r ai n endpl ay
check.
14. I nst al l t he assembl ed sun gear / dr i vi ng
shel l ont o t he i nt er medi at e shaf t , as
shown i n Fi gur e 81, engagi ng i t i n t he
r ear pl anet ar y gear s.
15. I nst al l r ear t hr ust washer ont o f r ont
pl anet ar y and r et ai n wi t h Tr ans- J el ,
16. I nst al l f r ont t hr ust washer ont o f r ont
pl anet ar y and r et ai n wi t h Tr ans- J el .
17. I nst al l t he f r ont pl anet ar y ont o t he
i nt er medi at e shaf t , engagi ng t he spl i ne
ar ea and t he gear s ( See Fi gur e 84) .
18. Posi t i on t he t hr ust pl at e on t he f r ont
r i ng gear , as shown i n Fi gur e 83, and
19. I nst al l f r ont r i ng gear ont o t he f r ont
pl anet ar y, engagi ng t he gear s, shown
i n Fi gur e 84.
20. I nst al l f r ont r i ng gear t hr ust washer
ensur i ng t he f l at on washer i s al i gned
wi t h f l at on' pl anet ar y hub, and t he t ab
on washer i s f aci ng f or war d, as shown
i n Fi gur e 85.
21. Ret ai n t he t hr ust washer wi t h Tr ans- l el
22. I nst al l t he snap r i ng ont o i nt er medi at e
shaf t usi ng snap r i ng pl i er s, as shown
i n Fi gur e 86.
52
[~Q TSG)
SNAP RING
FRONT
PLIERS
ANNULUS
GEAR
Fi gur e 84
Fi gur e 86
WASHER
FRONT
FLAT
ANNULUS
ALIGNS
THRUST
WITH FLAT
WASHER
ON PLANETARY
HUB
"I
REAR
TAB ANNULUS
FAC ES GEAR
FRONT
FRONT
PLANETARY
GEAR
I
I
I
\ 23. Tur n t he pl anet ar y gear t r ai n assembl y
over so dr i vi ng shel l i s f aci ng bench,
Then suppor t gear t r ai n on wood bl ock
posi t i oned under f or war d end of t he
i nt er medi at e shaf t . Thi s i s necessar y
so gear t r ai n par t s wi l l move up and
down ( See Fi gur e 87) .
~5. Check pl anet ar y gear t r ai n endpl ay wi t h
a f eel er gauge as shown i n Fi gur e 87.
Feel er gauge goes get ween t he shoul der
on i nt er medi at e shaf t and t he end of
r ear ' r i ng gear suppor t ( Fi gur e 87) .
6. Gear t r a. f r l ' . - endpl ayshoul d be bet ween
. 005" and . 045" . I f endpl ay i s not
cor r ect , snap r i ng ( or t hr ust washer s)
may have t o be r epl aced.
7~ Snap r i ng i s avai l abl e i n 3 di f f er ent
t hi cknesses f or adj ust ment pur poses.
SELEC TIVE
SNAP
RING
28. Set compl et ed pl anet ar y gear t r ai n Asm.
53
i ~Q T S G ]
U PPE R
HOUSING
LIMIT
VALVE
? SING
V A L V E B ODY R E A S S E MB L Y
UPPE R HOUS I NG V A L V E I NS TA L L A TI ON
1. Posi t i on upper val ve body housi ng wi t h
wor m t r ack si de f aci ng up and t he shi f t
val ve si de f aci ng as shown i n Fi gur e
88.
2. I nst al l t hr ot t l e pr essur e spr i ng a~d
val ve, l i ne pr essur e pl ug and sl eeve,
and cover pl at e as shown i n Fi gur e 88.
Tor que cover pl at e scr ews t o 35 i n. l bso
3. I nst al l l i mi t val ve, l i mi t val ve spr i ng
and r et ai ner i nt o l i mi t vafvy housi ng,
4. I nst al l 2- 3 t hr ot t l e pl ug i nt o I t mi t
val ve housi ng ( S ee Fi gur e 88) .
5. I nst al l 1- 2 shi f t cont r ol val ve~nd t he
spr i ng i nt o upper housi ng ( Fi gur ~ 88) .
6. I nst al l 1- 2 and 2- 3 shi f t , val ves and
spr i ngs i n upper housi ng ( ~~~4r e 88) .
7. I nst al l l i mi t val ve housi ng assembl y
on t op of t he 3 spr i ngs, compr ess a~d
i nst al l 3 scr ews wi t h cover pl at ej as
8. Tor que t he 3 scr ews t o 35 i n. l bs.
9. L ubr i cat e al l val ves wi t h t r ansmi ssi on
f l ui d or L ube- Gar d spr ay as~embl y l ube.
10. Tur n upper - val ve body housi n~ over and
posi t i on as shown i n Fi gur e 89.
11. I nser t t he pl ast i c gui des i n each end
of shut t l e val ve secondar y spr i ng and
i nst al l spr i ng on t he end of val ve as
12. I nst al l t he assembl y i nt o bor e of t he
upper housi ng ( S ee Fi gur es 89 and 90) .
13. Compr ess t he secondar y spr i ng, i nst al l
t he " E " cl i p i n gr oove at end of t he
shut t l e val ve ( S ee Fi gur ~ 90) .
14. I nst al l t he shut t l e val ve cov~r and i n-
st al l t he si x r et ai ni ng scr e~~, shown
i n Fi gur e 89. . .
15. Tor que t he si x scr ews t o 35 i n. l bs.
16. I nst al l t he boost val ve, boost val ve
spr i ng, and r et ai ner , ~s shown Fi gur ~
89.
17. I nst al l t he boost val ve cover pl at e as
shown i n F- 'I : ur e 89, and t or que t hr ee
scr ews t o ~5 i n. l bs.
18. I nst al i t he 1- 2 gover nor pl ug i nt o t he
upper housi ~g ( S ee Fi gur e 91) .
AUTOMATIC TR ANSMISSION SER VIC E GR OUP
54
~QTSG)
BOOST
VALVE
C OVER
D
/
UP P ER
HOUSING
BOOST
VALVE
C OVER
SP R ING
A ND
VALVE
R ETAINER
BOOST
VALVE
SP R ING
? ~~r~l
BOOS T
VA L VE
Fi gur e 89A
19. I nst al l t he 2- 3 gover nor pl ug i nt o t he
upper housi ng ( S ee Fi gur e 91) .
20. I nst al l t he shut t l e val ve pr i mar y spr -
i ng and t hr ot t l e pl ug, as shown Fi gur e
89.
21. I nst al l gover nor pl ug cover pl at e and
f i ve scr ews as shown i n Fi gur e 91.
22. Tor que 5 scr ews t o 35 i n. l bs.
SHUTTLE
~VALVE
~ C OVER
23. Do not i nst al l any val ves i n r emal nl ng
f our bor es i n t he upper val ve body.
24. These f our val ve t r ai ns wi l l be i nst al l -
ed af t er t he compl et e assembl y.
A U T O M A T I C TR ANSMISSION SER VIC E GR OUP
55
(~~T 5G ]
THROTTlE
P LUG
Technical Servi -ce-I n-f-e-fm at ion
~)~.,'
REGULATOR
VALVE
SP RING
SHVffiE
VALVE
P RI/v\ARY
SP RING
2-3
GOVERNOR
P LUG
GOVERNOR ~
P LUG ~
COVER
3- 4 ACCUMULATOR ASSEMBLY
1. I nst al l new seal s on 3- 4 accumul at or
pi st on, as shown i n Fi gur e 92.
2. Lubr i cat e 3- 4 accumul at or bor e i n t he
3- 4 accumul at or housi ng wi t h Tr ans- J el ,
l ubr i cat e pi st on seal s, and i nst al l t he
pi st on i nt o t he housi ng ( See Fi gur e 92)
3. I nst al l t he 3- 4 accumul at or spr i ng i n
t he housi ng on t op of pi st on as shown
i n Fi gur e 92.
4. I nst al l t he cover pl at e and t he f i ve
scr ews, as shown i n Fi gur e 92.
5. Tor que cover pl at e scr ews t o 35 i n. l bs.
3-4
ACCUMULATOR
HOUSING
ACCUMULATOR
P ISTON
COVER
P LATE
AND
SCREWS
56
[~Q TSG)
TIMING
VALVE _
COVER
CONVERTER
CLUTCH.
VALVE AND
SP RING
CONVERTER CLUTCH
TIMING VALVE
AND SP RING
CONVERTER
CLUTCH
SOlENOID
SOLENOID
GASKET
CASE
CONNECTOR
OVERDRIVE
SEP ARATOR P LATE
Fi gur e 93
LOWER HOUSt N~ VALVE I NSTALLATI ON
1. Posi t i on l ower val ve body housi ng as
2. Lubr i cat e l ower housi ng val ves and t he
housi ng bor es wi t h cl ean t r ansmi ssi on
f l ui d, or Lube- Gar d spr ay l ube.
3. I nst al l 3- 4 t i mi ng val ve spr i ng, and
3- 4 t i mi ng val ve i n l ower housi ng~ as
4. I nst al l 3- 4 qui ck- f i l l val ve spr i ng,
qui ck- f i l l val ve, and t hr ot t l e pl ug,
5. I nst al l t i mi ng val ve cover pl at e and
scr ews as shown i n Fi gur e 93. Tor que
scr ews t o 35 i n. l bs.
6. I nst al l conver t er cl ut ch t i mi ng val ve,
spr i ng and r et ai ner ( See Fi gur e 93) .
7. Do not i nst al l t he t wo r emai ni ng val ve
t r ai ns unt i l bot h hal ves of t he val ve
body have been assembl ed t oget her .
3-4 SHIFT
VALVE AN
SP RING
SP RING
RETAINER
3- 4 QUI CK FI LL VALVE OPERATI ON
The 3- 4 shut t l e val ve i s r epl aced by a
3- 4 Qui ck Fi l l Val ve i n t he 42RE val ve
body. The val ve mai nt ai ns a pr e- f i l l pr e-
ssur e of appr oxi mat el y 5 PSI i n t he O. D.
cl ut ch ci r cui t . Pr ef i l l pr essur e i s mai n-
t ai ned i n al l f or war d r anges. The pur pose
of t he val ve i s f ast er engagement of t he
over dr i ve cl ut ch dur i ng 3- 4 upshi f t s.
I n oper at i on, t he val ve t empor ar i l y by-
passes t he cl ut ch pi st on f eed or i f i ce at
t he st ar t of a 3- 4 upshi f t . Thi s exposes
a l ar ger passage i nt o t he pi st on r et ai ner
r esul t i ng i n a much f ast er cl ut ch f i l l
and over dr ~ve cl ut ch appl y sequence.
'. ot~~~~. "
....
57
REAR
CLUTCH
CHECK
BALL
REAR
SERVO
CHECK
BALL
ASSEMBLE UPPER AND LOWER HOUSI NGS
1. Posi t i on t r ansf er pl at e on bench wi t h
wor m t r ack si de f aci ng up, as shown i n
Fi gur e 94.
2. I nst al l t he r ear cl ut ch and r ear ser vo
checkbal l s ( 1/ 4" bal l s) i n t he t r ansf er .
pl at e, i n t he posi t i ons shown i n Fi gur
98.
3. I nst al l t he f i l t er scr een i nt o spacer
pl at e, as shown i n Fi gur e 95.
4. Al i gn and posi t i on t he spacer pl at e on
t r ansf er pl at e as shown i n Fi gur e 96.
5. I nst al l t he t ensi on pl at e w~t h scr ews
and t he 3 r emai ni ng spac~r ~pl at e at t ac
i ng scr ews, as~shown i n Fi gur e 96,
6. Tor que t he 5 scr ews t o 35 i n. l bs.
7. Posi t i on upper housi ng so t he i nt er nal
passages and checkbal l pocket s ar e f ac~
i ng upwar d, as shown i n Fi gur e 98.
8. I nst al l t he checkbal l s i nt o t he upper
housi ng i n t he posi t i ons shown i n Fi g-
ur e 98.
9. Not e t hat one of t he checkba+J s i s a
l ar ger di amet er t han: t he ot her si x ( Se
Fi gur e 98) .
10. I nst al l t he assembl ed t r ansf er pl at e
and spacer pl at e on t he upper housi ng
11. Ensur e t hat f i l t Br scr een i s seat ed i n
t he pr oper upper housi ng r ecess.
AUTOMATIC TRANSMISSION SERVICETGROUP
58
~QT5G)
1/4" DIAMETER
CHECKBALLS ( 6)
11/ 32" DIAMETER
CHECKBALL ( 1)
REAR SERVO
CHECKBALL ( 1/ 4" )
Fi gur e 98
AU T O M AT I C T RAN S M I S S I O N S ERV I C E G RO U P
59
( ~Q T 5G l
TRANSFER
PLATE
LOWER
HOUSING
(OVERDRIVE)
SEPARATOR
PLATE
Fi gur e 99
"~
LOWER
12.
HOUSING
13.
14.
15.
Fi gur e 100
16.
LOWER
HOUSING
17.
18.
~
,,-
19.
Now ver y car ef ul l y gr asp bot h hal ves at
once and t ur n t he ent i r e assembl y over
and l ay i t as shown i n Fi gur e 99.
Posi t i on t he l ower housi ng spacer pl at e
on t r ansf er pl at e and al i gn, as shown
i n Fi gur e 99.
I nst al l l ower val ve body housi ng on t op
of spacer pl at e ( See Fi gur e 100) .
I nst al l and st ar t by hand t he 13 val ve
body scr ews, maki ng sur e t hat t he t ube
br ace i s i nst al l ed i n pr oper posi t i on,
Tor que val ve body scr ews t o 35 i n. l bs,
st ar t i ng at t he cent er and wor ki ng out
t o t he si des.
Lubr i cat e boost val ve t ube ends wi t h
t r ansmi ssi on f l ui d or Tr ans- J el .
Posi t i on boost val ve t ube behi nd t ube
br ace, as shown i n Fi gur e 102.
St ar t t he t ube i n l ower housi ng por t
f i r st , and t hen swi ng t ube downwar d and
wor k opposi t e end of t he t ube i nt o t he
upper housi ng por t ( See Fi gur e 102) .
20. Seat bot h ends of t he boost val ve t ube
once t hey ar e i n posi t i on.
21. Not e t hat t ube br ace may be bent sl i -
ght l y t o ease t he i nst al l at i on and
t hen r esecur ed i See Fi gur e 102) .
22. I nst al l t he 3- 4 shi f t val ve and spr i ng
as shown i n Fi gur es 93 and 103.
23. I nst al l t he conver t er cl ut ch val ve, t he
conver t er cl ut ch val ve spr i ng and pl ug,
as shown i n Fi gur es 93 and 103.
24. Loosel y at t ach t he accumul at or housi ng
usi ng onl y t he r i ght si de scr ew, shown
i n Fi gur e 104.
25. I nst al l onl y one scr ew at t hi s t i me,
as accumul at or housi ng must be f r ee t o
pi vot up f or easi er i nst al l at i on.
60
~QT5G)
~6. Posi t i on pl ug on end of t he conver t er
cl ut ch val ve spr i ng ( See Fi gur e 103) .
~7. Swi ng accumul at or housi ng upwar d over
t he val ve spr i ngs and pl ug, whi l e you
ar e hol di ng t he spr i ngs and pl ug comp-
r essed.
28. Hol d accumul at or housi ng f i r ml y i n
pl ace, and i nst al l t he t wo r emai ni ng
at t achi ng scr ews ( See Fi gur e 105) .
29. Be sur e t hat spr i ngs and t he conver t er
cl ut ch val ve pl ug ar e seat ed pr oper l y.
30. Tor que t he 3 accumul at or housi ng scr ews
t o 35 i n. l bs. ( See Fi gur e 105) .
C ONVERTER
C LUTC H
VALVE
SPRI NG AND
PLUG
3-.(
SHIFT
VALVE
SPRI NG
3.( AC C UMULATOR
Fi gur e 104
AC C UMULATOR
BOSS
61
PRESSURE
REGULATOR
VAL VE SPRING
ADJ USTING
SCREW
BRACKET
THROTILE
PRESSURE
ADJ USTING
SCREW
125
TOR X
B I T
BRACKET
Fi gur e 107
DETENT
SPRING
DETENT
BALL
PENCIL
MAGNET
/
SPECIAL
TOOL 6583
POSITIONED
ON DETENT
HOUSING
Fi gur e 109
I nst al l t he manual val ve i nt o t he bor e
i n t he upper housi ng ( See Fi gur e 91) .
I nst al l t he t hr ot t l e val ve and spr i ng,
ki ckdown val ve, and ki ckdown det ent as
I nst al l t he pr essur e r egul at or val ve
i n t he bor e i n upper housi ng as shown
i n Fi gur e 91.
I nst al l t he swi t ch val ve i nt o t he bor e
i n t he upper housi ng ( See Fi gur e 91) .
Posi t i on l i ne pr essur e adj ust i ng scr e~
i n t he adj ust i ng scr ew br acket .
I nst al l pr essur e r egul at or spr i ng on
t he end of pr essur e r egul at or val ve, a5
I nst al l swi t ch val ve spr i ng on t ang at
end of adj ust i ng scr ew br acket ( See
Fi gur e 106) .
Posi t i on adj ust i ng scr ew br acket ont o
val ve body, al i gni ng val ve spr i ngs, i
and pr ess br acket i nt o pl ace. Ref er t i
Fi gur e 106 and 107.
I nst al l t he shor t , upper br acket scr e,
f i r st , and l ong bot t om ~cr ew l ast ( Set
Fi gur e 107) .
Tor que al l 3 scr ews t o 35 i n. l bs.
I nst al l manual l ever det ent spr i ng anI
bal l i n upper housi ng, ( Fi gur e 108) .
1
Ret ai n det ent bal l and spr i ng i n t he i
housi ng wi t h Ret ai ner Tool 6583, showl
i n Fi gur e 109.
I nst al l t hr ot t l e l ever i n t he upper
housi ng, t hen i nst al l t he manual l eve
over t hr ot t l e l ever and st ar t manual
l ever i nt o housi ng ( See Fi gur e 110) .
Ensur e t hat manual l ever i s al i gned
wi t h det ent bal l and engaged pr oper l y
i nt o t he manual val ve, as shown i n
Fi gur e 111.
40.
41.
62
( ~Q TSG)
45. Pr ess down on manual l ever unt i l i t i s
f ul l y seat ed, whi l e hol di ng up on t he
t hr ot t l e l ever .
46. Remove t he det ent bal l r et ai ner t ool
af t er l ever i s f ul l y seat ed.
47. Then i nst al l t hr ot t l e l ever seal over
t he shaf t , and i nst al l t he washer and
" E" cl i p as shown i n Fi gur e 112.
48. Lubr i cat e t he manual l ever wi t h l i ght
coat of Tr ans- J el .
49. Ver i f y agai n t hat t he t hr ot t l e l ever
i s al i gned wi t h end of ki ckdown val ve
st em, and t hat manual l ever ar m i s en-
gaged i n manual val ve ( See Fi gur e I l l ) .
~E~UP __
/~ ~
PA RK
ROD
MANUAL
LEVER
ASSEMBLY
< -
MANUAL
LEVER
\ VALVE
.\ ARM
ECL lP AND_.....- ::==::::!':- ::;~_I
WASHER ~
63
( r : ; ; i I l " 1 ni l J
GOVERNOR
SENSOR
WIRE
OVERDRIVE/CONVERTER
CLUTCH SOLENOID
ASSEMBLY
3-4
ACCUMULATOR
COVER
PLATE
SOLENOID
HARNESS CASE
CONNECTOR
~
3-4
CCUMULATOR
HOUSING \
Fi gur e 116
I nst al l Over dr i ve/ Conver t er
gasket on upper housi ng and
Tr ans- J el ( See Fi gur e 113) .
I nst al l t he sol enoi d and wi r i ng har ne
assembl y, and t or que t he 3 r et ai ni ng
scr ews t o 72 i n. l bs ( See Fi gur e 114) .
Rout e t he wi r e har ness, as shown i n I
Fi gur e 115, and hook i nt o t he 3- 4 ace- I '
umul at or cover pl at e. 1
At t ach t he sol enoi d case connect or t o 1
3- 4 accumul at or housi ng wi t h shoul der I
t ype scr ew ( See Fi gur e 116) .
Case connect or has smal l l ocat i ng t ang
t hat f i t s i nt o di mpl e at t he t op of 3-
accumul at or housi ng. Seat t he t ang i n
di mpl e bef or e t i ght eni ng scr ew.
Ver i f y t hat wi r e har ness i s pr oper l y
r out ed. Har ness must be cl ear of t he
manual l ever and par k r od.
I nst al l new " a" r i ng on t he gover nor
pr essur e sensor , and l ubr i cat e wi t h a j
smal l amount of Tr ans- J el , as shown i n!
Fi gur e 117. .
I nst al l gover nor pr essur e sensor i nt o j
t he gover nor body wi t h t wi st i ng mot i on
and i nst al l t he r et ai ni ng cl i p, shown
i n Fi gur e 118.
I nst al l new " a" r i ngs on t he gover nor
pr essur e sol enoi d, and l ubr i cat e wi t h 1
smal l amount of Tr ans- J el , as shown i n:
Fi gur e 1 1 9, :
I nst al l gover nor pr essur e sol enoi d i n j
t he gover nor body wi t h t wi st i ng mot i onl
as shown i n Fi gur e 120. I
I nst al l gasket , gover nor body assembl y,
and r et ai ner pl at e on t r ansf er pl at e,
,
sol enoi d I
r et ai n wi t t
64
( ~Q TSG)
CAUTION: DO NOT TURN
THIS SCREW FOR ANY REASON.
DOING SO WILL RUIN
SOLENOID VALVE CALIBRATION
CAUSING FAILURE.
SOLENOID VALVE
O-RINGS
( SERVICEABLE)
RETAINING
CLIP
" 'w
GOVERNOR
PRESSURE
SENSOR
SOLENOID VALVE
FILTER ( t!Q ! SERVICEABLE)
VENT
PORTS
Figure 119
SOLENOID
BORE AND
SEAT
SENSOR -------
WIRES
SPRING
CLIP
Figure 118
TRANSFER
PLATE
65
I ~Q T 5 G )
RETAINER
PLATE
64.
65.
66.
SCREW (2)
./
Fi gur e 122
GOVERNOR I
PRESSURE
SENSOR
AND
WIRES
III
~
GOVERNOR
PRESSURE
SOLENOID
VALVE
AND
WIRES
Fi gur e 123
61. Al i gn t he scr ew hol es i n t he gover nor
body, gasket , and t r ansf er pl at e, and
i nst al l t he t wo r et ai ni ng scr ews, as
62. Tor que t he t wo gover nor body scr ews t
35 i n. l bs. ( See Fi gur e 122) .
63. Connect t he wi r e har ness t o gover nor
pr essur e sol enoi d, usi ng car e so as
not t o bend t he t er mi nal s. Ref er t o
Fi gur e 123.
Connect t he wi r e har ness t o gover nor
pr essur e sensor , usi ng car e so as not
t o bend t he t er mi nal s ( Fi gur e 123) .
The Ohms r eadi ngs f or al l el ect r i cal
component s i s f ound on Page 13.
The val ve body i s now r eady f or t he
f i nal l i ne pr essur e and t hr ot t l e pres
sur e adj ust ment checks, and can t hen
be set asi de f or f i nal assembl y.
SPECI AL
T OOL
CJ76J
AUTOM ATIC TRANSM ISSION SERVICE GROUP
66
~Q T 5 G )
TRANSMI SSI ON RE ASSE MB L Y
1. E nsur e t hat r ol l er cl ut ch assembl y has
been i nst al l ed i nt o t he r ol l er cl ut ch
cam, as shown i n Fi gur e 127.
2. I nst al l r ear band r eact i on pi n i n case
as shown i n Fi gur e 126, and ensur e i t
i s f ul l y seat ed.
3. I nst al l r ear band i n case, as shown i n
Fi gur e 127, and ensur e t he t wi n l ugs
on band ar e seat ed agai nst t he r eact i on
pi n.
Ther e ar e t wo cont r ol pr essur e adj ust ment s
on t he val ve body whi ch ar e, l i ne pr essur e
and t hr ot t l e pr essur e.
L i ne and t hr ot t l e pr essur e wor k t oget her ,
as each af f ect s shi f t qual i t y and t i mi ng.
B ot h adj ust ment s must be per f or med pr oper l y
and i n t he cor r ect sequence. L i ne pr essur e
i s adj ust ed f i r st and t hr ot t l e pr essur e i s
adj ust ed l ast .
L I NE PRE SSURE ADJ USTME NT
1. Measur e di st ance f r om t he val ve body t o
t he i nner edge of t he adj ust i ng scr ew
wi t h an accur at e st eel scal e, as shown
i n Fi gur e 124.
2. Di st ance shoul d be 1 and 5/ 16 i nches.
, 3. I f adj ust ment i s r equi r ed, t ur n adj ust -
i ng scr ew i n, or out , t o obt ai n t he
desi r ed set t i ng.
4. The ( 1- 5/ 16 i nch) set t i ng i s appr oxi -
mat e. B ecause of manuf act ur i ng t ol er -
ances, i t may be necessar y t o var y f r om
t hi s demensi on t o obt ai n desi r ed pr es-
sur es .
. . 5. One compl et e t ur n of t he adj ust i ng sc-
r ew changes l i ne pr essur e appr oxi mat el y
2 PSI . Tur ni ng t he adj ust i ng scr ew i n
count er cl ockwi se di r ect i on i ncr eases
pr essur e, and cl ockwi se wi l l decr ease
pr essur e. '
THROTTL E PRE SSURE ADJ USTME NT
1. I nser t gauge C- 3763 bet ween t he t hr o-
t t l e l ever cam and t he ki ckdown val ve
st em as shown i n Fi gur e 125.
2. Push t he gauge t ool i nwar d t o compr ess
t he ki ckdown val ve agai nst t he spr i ng
and bot t om t he t hr ot t l e val ve.
3. Mai nt ai n pr essur e agai nst t he ki ckdown
val ve spr i ng.
4. Tur n t hr ot t l e l ever st op scr ew unt i l
t he scr ew head t ouches t hr ot t l e l ever
t ang and t he t hr ot t l e l ever cam t ouchs
gauge t ool .
5. The ki ckdown val ve spr i ng must be f ul l y
compr essed and t he ki ckdown val ve comp-
l et el y bot t omed t o obt ai n t he cor r ect
adj ust ment ( See Fi gur e 125) .
REAR
BA ND
REACT I ON
PI N
o 0~c=J 0~-l-~
REAR
BA ND
AU T OM AT I C T RANSM I SSI ON SERV I CE G ROU P
67
( ~Q T 5 G J
REA R
~ B~D =O=c:=:=:J =""> 0
HOLES IN
CASE AND
A SKET A RE A UGNED
4. Lubr i cat e over r unni ng cl ut ch r ace t hat
i s on t he l ow/ r ever se dr um, wi t h smal l
amount of t r ansmi ssi on f l ui d.
5. I nst al l t he l ow/ r ever se dr um t hr ough
t he band, use sl i ght pr essur e r ear war d
and t ur n i t i n cl ockwi se di r ect i on un-
t i l dr um seat s i n over r unni ng cl ut ch.
6. Tur n t he l ow/ r ever se dr um back and f or -
t h. Dr um shoul d r ot at e f r eel y i n cl ock
' wi se di r ect i on, and l ock when r ot at ed
count er cl ockwi se di r ect i on ( As vi ewed
f r om f r ont of case) .
7. I nst al l new gasket on r ear of t he case,
as shown i n Fi gur e 129, and r et ai n wi t h
smal l amount of Tr ans- J el .
8. Ensur e hol es i n t he new gasket al i gn
wi t h t he hol es i n case ( Fi gur e 129) .
9. I nst al l t he over dr i ve r et ai ner t hr ough:
case and al i gn bol t hol es i n r et ai ner ,
gasket , and case ( See Fi gur e 130) .
10. I nst al l t he si x Ol D r et ai ner bol t s i n
case, as shown i n Fi gur e 130.
11. Tor que t he r et ai ni ng bol t s t o 13 f t . l b. '
12. I nst al l t he snap r i ng t hat hol ds t he 1
l ow/ r ever se dr um t o t he hub of t he 0. 0.
r et ai ner ( See Fi gur e 131),
68itl.- _
fl-~-r:l-T S -G)
13. I nst al l t he r ear band l ever and pi vot
pi n, as shown i n Fi gur e 132 .
. 14. Al i gn t he r ear band l ever wi t h t he pi n
bor es i n case, and push t he pi vot pi n
i nt o pl ace ( See Fi gur e 132) .
15. I nst al l t he pr eassembl ed pl anet ar y
gear t r ai n assembl y i nt o t he case usi ng
bot h hands, unt i l i t i s f ul l y seat ed
16. Ensur e t hat t he t hr ust pl at e i s st i l l
i n pl ace on i nt er medi at e shaf t , shown
i n Fi gur e 134. Ret ai n wi t h Tr ans- J el .
I N T E R M E D I A T E
S HAFT HUB
Fi gur e 135
17. Ensur e t hat t he sel ect i ve t hr ust wash-
er i s i n pl ace on t he r ear cl ut ch dr um
18. Be sur e gr ooved si de of t he washer i s
f aci ng out ( t owar d out put shaf t ) , as
shown i n Fi gur e 135. Al so not e t hat
washer onl y f i t s one way i nt o t he r ear
cl ut ch hub ( See Fi gur e 135) .
69
(~Q T 5 G )
FRONT
BA ND
L EV ER
PI V OT
22.
SHA FT
I;~fRONT
23.
CL UTCH
RETA I NER
24.
)9321470
25.
26.
27.
FRONT
BAND
L EV ER
"'-. ~
\ ~
FRONT
BA ND
L E V E R
SHA FT
ACCESS
PL UG
\
Fi gur e 139 1
Fr om t hi s poi nt , i t wi l l be best i f wej
have t he t r ansmi ssi on st andi ng upr i ght ,
We r ecommend usi ng an ol d 904 " Baby 8
lt
j '
case wi t h bel l housi ng f aci ng f l oor .
Your t r ansmi ssi on can now be st ood up I
on t he ol d case wi t h i nt er medi at e shaf (
goi ng t hr ough t he ol d case. i
I nst al l t he pr eassembl ed f r ont and r e~
cl ut ch housi ng assembl y i nt o t he case.
as shown i n Fi gur e 136. j
Car ef ul l y t wi st assembl ed cl ut ches ba~
and f or t h t o engage and seat t he r ear j
cl ut ches on f r ont r i ng gear hub. Al so
be sur e f r ont cl ut ch housi ng dr i ve l u~
ar e f ul l y engaged i n t he sl ot s of t he I
dr i vi ng shel l af t er i nst al l at i on. j
Sl i de t he f r ont band over f r ont cl ut e
housi ng as shown i n Fi gur e 137.
I nst al l t he f r ont band l ever pi vot sh-
af t par t way i nt o t he case, as shown'
Fi gur e 137.
Al i gn t he f r ont band l ever wi t h bor esj
i n t he case and push pi vot shaf t al l 1
t he way i nt o t he case( See Fi gur e 138: 1'
I nst al l t he f r ont band st r ut , as sho
i n Fi gur e 140. .
Ver i f y t hat bot h cl ut ch dr ums ar e st i
seat ed i n t r ansmi ssi on pr oper l y. j
Coat t he f r ont band pi vot pi n access 1
pl ug wi t h seal er , and i nst al l pl ug i n
conver t er housi ng ( See Fi gur e 139) . I
Ti ght en f r ont band adj ust i ng scr ew, sd
t hat f r ont band j ust gr i ps t he f r ont I
cl ut ch housi ng. I
Check t he seal i ng r i ngs on pr eassembl J
f r ont pump assembl y ( See Fi gur e 141) . I
Ver i f y t hat seal r i ngs ar e hooked t o- '
get her and t hat t hr ust washer i s pr oP] l
er l y posi t i oned. Ret ai n t hr ust washer
wi t h Tr ans- J el .
Thi s washer i nsi de di amet er bor e i s
chamf er ed on one si de, and chamf er ed
si de goes t owar d t he f r ont .
AUT O MAT IC T R ANS MIS S IO N S E R V IC E G R O UP
70
(~Q T5G l T ee hnic a-l-S ervie e I nfor mat ion
----------
SEA L
RINGS
Fi gur e 141
32. I nst al l t wo t hr eaded pi l ot st uds i nt o
t he case, as shown i n Fi gur e 142.
33. Al i gn and i nst al l a new f r ont oi l pump
gasket over t he pi l ot st uds, as shown
i n Fi gur e 142.
34. Lubr i cat e t he f r ont pump bor e i n case
wi t h Tr ans- J el t o ease i nst al l at i on.
35. Lubr i cat e t he f r ont oi l pump " 0" r i ng
wi t h Tr ans- J el t o ease i nst al l at i on.
36. Al i gn and i nst al l f r ont oi l pump over
t he pi l ot st uds and i nt o t he case, as
37. I nst al l 2 or 3 pump bol t s by hand and
r emove t he pi l ot st uds.
38. I nst al l t he r emai ni ng oi l pump bol t s
and t i ght en al t er nat i ng f r om one si de
t o t he ot her .
39. Af t er pump i s snug t or que al l of t he
oi l pump bol t s t o 15 f t . l bs.
CAU TI ON:
TRANSMI SSI ON END PLAY WI LL BE CHECKED AFTER
THE OVERDRI VE U NI T SECTI ON I S I NSTALLED ON
THE TRANSMI SSI ON.
TRANSMI SSI ON END PLAY CANNOT BE PROPERLY
CHECKED WI TH THE OVERDRI VE U NI T SECTI ON
OFF OF THE TRANSMI SSI ON.
AUT O MAT IC T R ANS MIS S IO N S E R V IC E G R O UP
71
( ~Q T S G )
------"
J
ACCUMULAT OR
PI STON
OUTER
SPRI NG
\
;~ 40.
,"-
4l .
42.
43.
44.
45.
Per f or m ai r t est s on t he cl ut ch packs,
and t he f r ont and r ear ser vos. The
passages ar e i dent i f i ed i n Fi gur e 144.
I nst al l accumul at or pi st on, and i nner
and out er spr i ngs i nt o t he case, as
Ver i f y t hat Par k/ Neut r al swi t ch has not
been i nst al l ed i n case. Val ve body can-
not be i nst al l ed i f swi t ch i s i n case.
Ver i f y t hat val ve body wi r i ng har ness
i s secur ed i n 3- 4 accumul at or cover pl -
at e.
Al i gn and car ef ul l y i nser t par ki ng r od
i n case as shown i n Fi gur e 146.
Al i gn and seat val ve body on case. Be
sur e manual l ever shaf t and case conn-
ect or ar e f ul l y seat ed i n case. Al so
be sur e wi r e har ness i s not pi nched or
ki nked.
VALVE
BODY
ACCUMULAT OR
PI STON
Fi gur e 146
Fi gur e 147
46. I nst al l and st ar t t he 10 val ve body
bol t s i n l ocat i ons shown i n Fi gur e 147. \
47. Tor que t he t en val ve body bol t s down t o
105 i n. l bs. ( See Fi gur e 147) .
48. I nst al l a new oi l f i l t er on val ve body
and t or que scr ews t o 35 i n. 1bs, shown
i n Fi gur e 148.
49. I nst al l neut r al saf et y swi t ch as shown
i n Fi gur e 149 and 150.
AUT OMAT IC T RANS MIS S ION S ERVICE G ROUP
72
( ~Q T S G )
F I L T E R
SCREWS
( 3)
50. Loosen f r ont and r ear band scr ew l ock-
nut s ( See Fi gur e 151) .
51. Ti ght en each band adj ust i ng scr ew down
t o 72 i n. l bs. wi t h t or que wr ench.
52. Back FRONT band adj ust i ng scr ew out ,
Exact l y 3 and 5/ 8 t ur ns.
53. Back t he REAR band adj ust i ng scr ew out ,
Exact l y 4 f ul l t ur ns.
54. Ti ght en each adj ust i ng scr ew l ocknut ,
whi l e hol di ng adj ust i ng scr ew wi t h a
wr ench t o pr event t ur ni ng whi l e you ar e
t i ght eni ng l ocknut .
55. I nst al l cl ean magnet on smal l t ab at
cor ner of bot t om oi l pan.
56. I nst al l a new bot t om pan gasket on t he
case, and i nst al l t he bot t om pan.
57. Tor que t he bot t om pan bol t s t o 13 f t . l b.
AUT OMAT IC T RANS MIS S ION S ERVICE G ROUP
73
PISTON
LOCATIN
LUGS
Fi gur e 152
I nst al l a new manual shaf t seal i n t he
case usi ng a 15/ 16" socket , as shown
i n Fi gur e 155.
I nst al l new i nner and out er l i p seal s
on over dr i ve cl ut ch pi st on, l ubr i cat e
wi t h a smal l amount of Tr ans- J el .
Al i gn l ocat i ng l ugs on pi st on wi t h t he
l ocat i ng bor es i n t he r et ai ner , shown
i n Fi gur e 152.
Use wi r e l i p seal i nst al l er and i nst al l
over dr i ve pi st on i nt o t he r et ai ner .
I nst al l sel ect i ve spacer on i nt er med-
i at e shaf t ( See Fi gur e 153) .
I nst al l sel ect i ve t hr ust pl at e on t he
over dr i ve pi st on and r et ai n wi t h a
l I ber al amount of Tr ans- J el , as shown
i n Fi gur e 154.
64. I nst al l t hr ust bear i ng on t op of t he
sel ect i ve t hr ust pl at e wi t h t he bl ack
si de f aci ng t he pi st on, and r et ai n wi t h
a l i ber al amount of Tr ans- J el , as shown
i n Fi gur e 154.
65. You ar e now r eady t o i nst al l t he over -
dr i ve uni t ont o t he t r ansmi ssi on.
THRUST
BEARING
15/16" SOCK1
I
2.
\\ \
Fi gur e 2
,
3.
I
I
4.
5.
~
CL UTCH
DISC (3)
f :
6.
I
REACTION
PL A TE
(TO REAR)
WAVE
SPRI NG
REACTION
RING
OV E R DR I V E SE C TI ON DI SASSE MB L Y
1. R emove t he speci al t ool f or al i gni ng
t he over r unni ng cl ut ch and pl anet ar y
gear spl i nes, i f i t was pr evi ousl y
i nst al l ed ( See Fi gur e 1) .
R emove t he over dr i ve cl ut ch pack wi r e
snap r i ng. Thi s snap r i ng i s R OUND, as
R emove t he over dr i ve cl ut ch pack and
not e posi t i on of cl ut ch pack component s
R emove t he over dr i ve cl ut ch WAV E snap
r i ng, as shown i n Fi gur e 4.
R emove t he over dr i ve cl ut ch FL AT snap
r i ng, as shown i n Fi gur e 5. Not e t hat
t he FL AT snap r i ng i s l ocat ed i n t he
same gr oove as t he WAV E snap r i ng.
Keep r ecor d of t hese t hr ee snap r i ngs,
R OUND, WAV E , and FL AT snap r i ngs, as
put t i ng t hse i n t he wr ong l ocat i on i s
a ver y common mi s- assembl y pr obl em.
A UTO M A TIC TR A N SM ISSIO N SERVICE GROUP
75
TORX
SCREWDRIVER (T25)
ACCESS
COVER
SCREWS
EXPAND BEARING
LOCATING
RING
WITH SNAP
RING PUERS
- - -
PUSH OUTPUT SHAFT
FORWARD TO FREE
BEARING FROM RING
REAR
BEARING
7. Remove t he t wo Tor x head scr ews t hat
at t ach t he access cover t o over dr i ve
case, as shown i n Fi gur e 6.
8. Remove t he access cover and
gasket ( See Fi gur e 6) .
9. Expand out put shaf t bear i ng snap r i ng
wi t h snap r i ng pl i er s, and push out put
shaf t f or war d t o r el ease bear i ng f r om
spap r i ng ( See Fi gur e 7) .
10. Li f t t he over dr i ve case up and of f of
t he gear t r ai n assembl y ( See Fi gur e 8) .
11. Remove t he snap r i ng t hat r et ai ns t he
r ear bear i ng on out put shaf t , as shown
i n Fi gur e 9.
12. Remove t he r ear bal l bear i ng f r om t he
out put shaf t ( See Fi gur e 10) .
76
WARNING: THE NEXT STEP IN DISASSEMBLY IN-
VOLVES COMPRESSING THE DIRECT CLUTCH
SPRING. IT IS EXTREMELY IMPORTANT THAT
PROPER EQUIPMENT BE USED TO COMPRESS
THE SPRING AS SPRING FORCE IS APPROXI
MATELY 830 POUNDS. USE SPRING COMPRESSOR
TOOL 6227-1 AND A HYDRAULIC SHOP PRESS
WITH A MINIMUM RAM TRAVEL OF 5-6 INCHES.
THE PRESS MUST ALSO HAVE A BED THAT CAN
BE ADJ USTED UP OR DOWN AS REQUIRED. RE-
LEASE CLUTCH SPRING TENSION SLOWLY AND
COMPLETELY TO AVOID PERSONAL INJ URY.
PRESS
RAM
SPECIAL
TOOL
C-3995-A
(OR SIMILAR
TOOL)
SPECIAL TOOL
6ml
13. Mount t he gear t r ai n assembl y i n a shop
pr ess, as shown i n Fi gur e 11.
14. Posi t i on Compr essor Tool 6227- 1 on t he
cl ut ch hub, as shown i n Fi gur e 11.
Suppor t out put shaf t f l ange wi t h st eel
pr ess pl at es as shown i n Fi gur e 11 and
cent er assembl y under pr ess r am.
15. Use Speci al Tool C- 3995- A, or a si mi l ar
si ze t ool , at t op of 6227- 1 t o hel p
di st r i but e l oad and pr ovi de t he needed
ext r a pr ess l engt h ( See Fi gur e 11) .
DIRECT
CLUTCH
PACK
SNAP
RING
CLUTCH
DRUM
16. Appl y pr essur e sl owl y, compr essi ng hub
and spr i ng f ar enough t o expose cl ut ch
hub r et ai ni ng r i ng and r el i eve spr i ng
pr essur e on t he cl ut ch pack snap r i ng.
17. Remove t he di r ect cl ut ch pack snap r i ng
18. Remove t he di r ect cl ut ch hub r et ai ni ng
19. Rel ease t he pr ess l oad sl owl y and comp-
l et el y.
77
SP ECIAL
TOOL
6227-1
DIRECT
CLUTCH
P ACK
DIRECT
CLUTCH
HUB
DIRECT
CLUTCH
SP RING
P LANETARY P LANETARY
GEAR THRUST
BEARING
DIRECT
CLUTCH
HUB
CLUTCH
SP RING
P LATE
SP RING
P LATE
SNAP RIN
Fi gur e 17
20. Af t er t he pr ess i s f ul l y r el eased, r e-
move t he Speci al Tool 6227- 1,
i n Fi gur e 14.
21. Remove t he di r ect cl ut ch pack
22. Remove t he di r ect cl ut ch
23. Remove sun gear , pl anet ar y t hr ust bea
i ng, and over dr l ve car r i er , as shown
Fi gur e 16.
24. Remove t he over r unni ng
wi t h snap r i ng pl i er s,
17. Remove cl ut ch wi t h count er cl ockwi
t wi st i ng mot i on ( See Fi gur e 17) .
25. Remove over r unni ng cl ut ch f r om cl ut ch
hub, as shown i n Fi gur e 18.
26. Mar k posi t i on of annul us gear and di r -
ect cl ut ch dr um f or assembl y al i gnment
r ef er ence, as shown i n Fi gur e 19, wi t h
a smal l cent er punch or scr i be.
27. Remove t he di r ect cl ut ch dr um i nner r
t ai ni ng r i ng ( See Fi gur e 20) .
28. Tur n t he assembl y over and r emove t he
di r ect cl ut ch out er r et ai ni ng r i ng, as
29. Mar k posi t i on of annul us gear and t he
out put shaf t f or assembl y al i gnment
r ef er ence, as shown i n Fi gur e 22, wi t h
a smal l cent er punch or scr i be.
78
OVERRUNNING
C UTCH
CLUTCH
H U B
THRUST
BEARING
INNER
RETAINING
RING
79
( ~Q T S G )
ANNULUS
GEA R
30. Remove t he snap r i ng t hat secur es t he
annul us r i ng gear on t he out put shaf t ,
as shown i n Fi gur e 23. Use t wo scr ew-
dr i ver s t o unseat and wor k t he snap
r i ng out of i t s gr oove, as shown i n
Fi gur e 23.
31. Remove t he annul us gear f r om t he out put
shaf t usi ng a pl ast i c mal l et t o t ap t he
gear of f of t he shaf t ( See Fi gur e 24) .
32. Do not r emove par ki ng pawl and spr i ng
unl ess t hey ar e damaged.
Cl ean t he gear t r ai n and al l component s i
good cl ean sol vent ( See Fi gur e 25) . Dr y a
par t s, except t he bear i ngs, wi t h compr ess
ai r . Al l ow t he bear i ngs t o ai r dr y.
Do not use shop t owel s f or wi pi ng par t s
dr y unl ess t he t owel s ar e made f r om l i nt
f r ee mat er i al .
I nspect t he gear t r ai n and al l component s
f or any wear and/ or damage, and r epl ace
necessar y.
80
l>
C
~
o
~
l>
~
n
~
:IJ
l>
Z
en >T j
(Xl ~ ;;-
>-' en c
en ~
o
z
en
m
:IJ
<
n
m
G)
:IJ
o
C
Ll
CD
OVE R DR IVE P IS T ON T HR US T P LAT E
ill
OVE R DR IVE P IS T ON T HR US T BE AR ING
CD
OVE R DR IVE C LUT C H P AC K R E T AINING R ING
@ OVE R DR IVE C LUT C H P AC K
CD
OVE R DR IVE C LUT C H R E AC T ION R ING
OVE R DR IVE C LUT C H S NAP R ING

CD
DIR E C T C LUT C H P AC K S NAP R ING
'CD
DIR E C T C lUT C H P AC K
C LUT C H HUB R E T AINING R ING

@ DIR E C T C lUT C H HUB
@ DIR E C T C LUT C H S P R ING
@
S UN G E AR AND S P R ING P lAT E AS S E MBLY
@
P LANE T AR Y T HR US T BE AR ING
P LANE T AR Y G E AR
@ OVE R R UNNING C LUT C H HUB
@ OVE R R UNNING C LUT C H
OVE R R UNNING C LUT C H T HR US T BE AR ING
@ R E T AINING R ING ( C LUT C H DR UM INNE R )
@ DIR E C T C LUT C H DR UM
@ R E T AINING R ING ( C LUT C H DR UM OUT E R )
ANNULUS G E AR . OUT P UT S HAFT .
AND S NAP R ING AS S E MBLY
@ R E AR BE AR ING
@ R E AR BE AR ING S NAP R ING
( ~Q T 5 G ]
OUT PUT
SHA FT
H U B
OV E R DR I V E S E C T I ON A S y E MB L Y
1. S oak di r ect cl ut ch and over dr i ve
pl at es i n t r ansmi ssi on f l ui d f or
mi nut es.
2. I nspect t he bushi ngs i n t he out put sh
af t as shown i n Fi gur e 1, and r e~l ace
as necessar y .
3. L ubr i cat e bot h bushi ngs wi t h a sma12
amount of T r ans- J el ( S ee Fi gur e 1) .
4. I nst al l t he bal l : bear i ~ng~nd snap r i
on out put shaf t . B e sur e l ocat i ng
gr oove i n bear i ng i s t owar d r ear ,
5. A l i gn and i nst al l out put shaf t i n t he
annul us gear , and i nst al l t he snan r '
6. A l i gn and i nst al l annul us gear i n t he
di r ect dr um, and i nst al l t he out er s
7. T ur n t he assembl y ~ver and i nst al l t
i nner snap r i ng i n di r ect dr um, shown
i n Fi gur e 5.
82
~~T 5 G )
C LUT C H
HUB
OVE R R UNNING
C LUT C H
BE S UR E
T HR US T BE AR ING
IS S E AT E D S Q UAR E LY
AG AINS T C LUT C H HUB
~
C LUT C H
HUB
8. I nst al l t he over r unni ng cl ut ch on t he
hub ( I nner ear n) , as shown i n Fi gur e 6.
Not e t hat r ol l er cl ut ch onl y f i t s one
way . S houl der on r ol l er cl ut ch shoul d
seat i n smal l r ecess at edge of hub.
9. I nst al l t hr ust bear i ng on over r unni ng
r , cl ut ch hub, as shown i n Fi gur e 7, and
'
I r et ai n wi t h l i ber al amount of T r ans- J el
( S ee Fi gur e 7) . B e sur e bear i ng i s
I seat ed Fl at agai nst hub ( S ee Fi gur e 7) .
10. I nst al l over r unni ng cl ut ch i n out put
shaf t , usi ng snap r i ng pl i er s, wi t h a
count er cl ockwi se t wi st i ng mot i on, as
11. Over r unni ng cl ut ch assembl y shoul d
f r ee- wheel count er cl ockwi se and l ock
cl ockwi se.
OVE R R UNNING
C LUT C H
AS S E MBLY
E XPANDING - T YP
S NAP R ING
PLIE R S
OVE R R UNNING
LUT C H AS S E MBLY
S E AT E D IN
OUT PUT S HAFT
ANNULUS
G E AR
PLANE T AR Y
G E AR
12. I nst al l t he over dr i ve car r i er i nt o t he
r i ng gear , as shown i n Fi gur e 9.
13. B e sur e pl anet ar y pi ni ons ar e f ul l y
seat ed i n r i ng gear bef or e pr oceedi ng.
83
14. I nst al l di r ect cl ut ch spr i ng pl at e on
t he sun gear , wi t h t he shoul der si de
of t he pl at e f aci ng out , as shown i n
Fi gur e 10, and secur e pl at e t o t he sun
gear wi t h t he snap r i ng.
15. I nst al l t he bear i ng ont o t he spr i ng
pl at e usi ng a l i ber al amount Tr ans- J el
t o r et ai n. Be sur e bear i ng si t s squar e
agai nst pl at e as i t onl y f i t s one way
16. I nst al l compl et ed sun gear assembl y i n
over dr i ve car r i er unt i l f ul l y seat ed,
1~. Mount t he assembl ed out put shaf t , ~nd
di r ect dr um i n shop pr ess, as di r ect
cl ut ch spr i ng and di r ect cl ut ches ar e
easi er t o i nst al l .
18. Al i gn t he spl i nes i n hubs of pl anet ar y
car r i er and over r unni ng cl ut ch usi ng
Tool 6227- 2, as shown i n Fi gur e 13.
19. I nst al l di r ect cl ut ch spr i ng down on
t he spr i ng pl at e ( See Fi gur e 13) .
20. I nst al l t he di r ect cl ut ch r eact i on pl -
at e on di r ect cl ut ch hub f i r st .
Not i ce t hat one si de of r ~pct i on pl at e
i s count er bor ed on t he i nsi de di amet er .
as shown i n Fi gur e 15. Be sur e t hi s
si de f aces r ear war d. Spl i nes at r ear 0
di r ect cl ut ch hub ar e sl i ght l y r ai sed.
The count er bor e i n r eact i on pl at e f i t s
over r ai sed spl i nes.
Pl at e shoul d be FLUSH wi t h t hi s
hub, as shown i n Fi gur e 15.
84
SPRING
PLATE
DIR E C T
C LU T C H
SPRING
S P E C IA L
T O O L
(-6227-2
(~Q T 5 G )
ROLLE RS AND
SPRI NGS
WHI LE HOLDI NG THE OUTPUT SHAFT,
THE I NNE R CAM SHOULD:
FRE E WHE E L I N COUNTE RCLOCKWI SE DI RE CTI ON
AND LOCK I N A CLOCKWI SE DI RE CTI ON.
DIR E C T
C LU T C H DIS C S (6)
P R E S S U R E
--- P LA T E
DIR E O
C LU T C H
R E A O IO N
P LA T E
(FLU S H WIT H
E ND O F HU B)
C LU T C H
HU B
85
(~Q T S G l '
21. I nst al l t he f i r st l i ned di r ect cl ut ch
pl at e over t he hub and agai nst r eact i
pl at e, f ol l owed by a st eel pl at e unt i l
6 l i ned pl at es and 5 st eel pl at es have
been i nst al l ed ( See Fi gur e 16) .
22. I nst al l t he di r ect cl ut ch pr essur e pl -
at e on t op of t he l ast l i ned pl at e wi
t he shoul der si de of pr essur e pl at e up
23. I nst al l cl ut ch hub and di r ect cl ut ch
pack assembl y on t he di r ect cl ut ch sp-
r i ng, and be sur e hub i s st ar t ed on t
sun gear spl i nes ( See Fi gur e 17) .
WARNING: THE NEXT STEP IN GEARTRAIN ASSE
BLY INVOLVES COMPRESSING THE DIRECT CLUTC
HUB AND SPRING. IT IS EXTREMELY IMPORTA
THAT PROPER EQUIPMENT BE USED TO COMPRESS
THE SPRING AS SPRING FORCE IS APPROXIMATEL
830 POUNDS. USE SPRING COMPRESSOR TO
C62271 AND A HYDRAULIC-TYPE SHOP PRE
WITH A MINIMUM RAM TRAVEL OF 5-6 INCHES. T
PRESS MUST ALSO HAVE A BED THAT CAN BE A
JUSTED UP OR DOWN AS REQUIRED. RELEAS
CLUTCH SPRING TENSION SLOWLY AND COfll.
PLETELY TO AVOID PERSONAL INJURY.
24. Posi t i on Compr essor Tool 6227- 1 on the
cl ut ch hub, as shown i n Fi gur e 18.
25. Posi t i on speci al t ool or si mi l ar t ype
t ool on t op of Tool 6227- 1, as shown
i n Fi gur e 18.
26. Compr ess t he cl ut ch hub and spr i ng
enough t o pl ace t ensi on on hub and
i t i n pl ace.
27. Sl i de di r ect cl ut ch pack upwar ds on h
and set cl ut ch pack on edge of t he co
r essor t ool as shown i n Fi gur e 19.
28. Sl owl y compr ess cl ut ch hub and spr i ng
enough t o expose r i ng gr ooves f or t he
cl ut ch pack snap r i ng and t he cl ut ch
hub r et ai ni ng r i ng.
29. I nst al l t he di r ect cl ut ch pl at es and
pr essur e pl at e i nt o di r ect
30. I nst al l di r ect cl ut ch snap r i ng, shown
i n Fi gur e 20, and be VERY sur e snap
r i ng i s f ul l y seat ed i n gr oove.
31. I nst al l cl ut ch hub r et ai ni ng r i ng, as
shown i n Fi gur e 21, and be VERY sur e
t hat snap r i ng i s f ul l y seat ed i n t he
gr oove.
32. Sl owl y r el ease pr ess r am, r emove t he
compr essor t ool s and gear t r ai n.
86
'SPECIAL TOOL
, MB9908Q1
SPECIAL
TOOL
6m2
SPECIAL
TOOL
62271
CLUTCH
DRUM
DIRECT
lUTCH
PACK
LUTCH
HUB
CLUTCH
DRUM
SPECIAL
TOOL
C6m2
DIRECT
CLUTCH
PACK
/
S NAP
RING
SPECIAL
TOOL
C62272
AUTOMATIC TRANSMISSION SERV ICE GROUP
87
(~Q T 5G l
REACTION
PLUG SNAP .
RING (DO --c:
NOT OVERCOMPRESS ...
TO INSTALL)
PARK
LOCK
REACTION
PLUG
4x4
GEAR
CASE
Posi t i on par ki ng pawl and spr i ng i nt o
over dr i ve housi ng and i nst al l t he par k
pawl pi vot shaf t . Ver i f y t hat end of
spr i ng wi t h t he 90 bend i s hooked t o
par k pawl and st r ai ght end of spr i ng
i s seat ed agai nst housi ng.
I nst al l par ki ng pawl shaf t r et ai ni ng
bol t , and t or que t o 20 f t . l bs.
I nst al l par k l ock r eact i on pl ug i nt o
over dr i ve housi ng ( See Fi gur e 22) . Be
pi n i s seat ed i n t he hol e i n housi ng
bef or e i nst al l i ng snap r i ng.
I nst al l t he r eact i on pl ug snap r i ng as
shown i n Fi gur e 23, and compr ess snap
r i ng onl y enough f or i nst al l at i on. Do
not di st or t snap r i ng.
I nst al l new r ear seal i n t he over dr i ve
housi ng, as shown i n Fi gur e 24, usi ng
pr oper si ze seal dr i ver .
88
[~Q T 5G ]
EXPAND BEARING
LOCAT ING
RING
WIT H SNAP
RING PLIERS
~~.,.. -
PUSH OUT PUT SHAFT
FORWARD T O FREE
BEARING FROM RING
,,.._'_""'ll4 I ,
38. Ver i f y t hat t he t ab ends of r ear bear -
i ng l ocat i ng r i ng ext end i nt o access
hol e i n over dr i ve housi ng, as shown i n
Fi gur e 25.
39. I nst al l t he over dr i ve housi ng ont o t he
gear t r ai n, and st ar t on r ear bear i ng,
40. Expand t he r ear bear i ng snap r i ng wi t h
snap r i ng pl i er s, as shown Fi gur e 27,
and sl i de housi ng downwar d unt i l t he
l ocat i ng r i ng snaps i nt o gr oove i n t he
b
. ~
ear 1ng.
41. I nst al l new l ocat i ng r i ng access cover
gasket , and i nst al l access cover , as
42. At t hi s poi nt , you shoul d have t hr ee
snap r i ngs l ef t , one FLAT snap r i ng,
one WAVED snap r i ng, and one ROUND
( Wi r e) snap r i ng, shown i n Fi gur e 29.
43. I nst al l t he FLAT snap r i ng f i r st i nt o
t he gr oove i n t he over dr i ve housi ng as
shown i n Fi gur e 30, and ensur e t hat i t
i s f ul l y seat ed.
44. I nst al l t he WAVE snap r i ng on t op of
t he FLAT snap r i ng, and i nt o t he same
gr oove, as shewn i n Fi gur e 31, ensur e
t hat i t i s f ul l y seat ed.
45. The FLAT snap r i ng and t he WAVE snap
r i ng f i t i nt o t he same gr oove.
, T ORX
SCREWDRIVER (T25)
ACCESS
COVER
SCREWS
WAVE
SPRING
REACT ION
RING
RET AINING RING
(WIRE-T YPE)
REACT ION
RING
WAVE
SPRING
AUT OMAT IC T RANSMISSION SERVICE G ROUP
89
(~Q T 5G ]
OD CL UTCH F L AT SNAP RI NG.
OD CL UTCH ~ SNAP RI NG.
OD CL t r r CH REACTI ON P L ATE ( THI N) .
OD CL t r r CH P RESSURE P L ATE ( THI CK) .
OD CL t r r CH ROUND SNAP RI NG.
DI RECT CL UTCH SNAP RI NG.
DI RECT CL UTCH REACTI ON P L ATE.
DI RECT CL UTCH P L ATES ( SEE CHART BEL OW) .
DI RECT CL UTCH P RESSURE P L ATE ( L I P DOWN) .
DI RECT CL UTCH HOUSI NG.
-( ------.,-,----",
I I
I I
I ,
. ,
, I
I
I I
- T .- - - - - - - - - - - .;",-
: I
1 1
, I
I I
_ ~I~ . I __ --'--'--- _
90
r
f
t .
49.
!
I
I
50.
1 .
/ ~
I
I
f
I
(~~T 5G )
OVERDRIVE
CLUTCH DISCS (3)
REACTION
PLATE
\
CLUTCH PLATES (2)
F i gur e 33
46. I nst al l t he over dr i ve cl ut ch r eact i on
pl at e i nt o over dr i ve housi ng on t op of
t he snap r i ngs as shown i n F i gur e 33.
Not e t hat r eact i on pl at e i s t hi nner
t han t he pr essur e pl at e ( F i gur e 33) .
47. I nst al l t he f i r st l i ned cl ut ch pl at e,
f ol l owed by a st eel pl at e, al t er nat i ng
unt i l t he over dr i ve cl ut ches have al l
been i nst al l ed ( See F i gur e 33) .
48. CAUTI ON: Some model s. r equi r e 3 l i ned
pl at es, 2 st eel pl at es, I r eact i on pl -
at e, and I pr essur e pl at e.
Ot her model s r equi r ~ 4 l i ned pl at es,
3 st eel pl at es, I r ' e, q. ~1: . , ~~m pl at e, and
1pr essur e pl at e. : : , ' .
' Be sur e you put back " t ; t \ ~' ; ' ; s, ame amount
of over dr i ve cl ut ches t nat you t ook
out of t he uni t .
I nst al l t he ROUND ( Wi r e- Type) snap
r i ng on t op of t he pr essur e pl at e, as
shown i n F i gur e 34.
Thi s r i ng i s onl y used t o r et ai n t he
over dr i ve cl ut ches i n pl ace whi l e t he
over dr i ve sect i on assembl y i s bei ng
i nst al l ed on t he t r ansmi ssi on.
Remove t he spl i ne al i gnmer i t t ool f r om
t he over dr i ve sect i on ( See F i gur e 35) .
AUTOM ATIC TRANSM ISSION S E R V IC E G R O U p
91
[~Q T 5G ]
SELECTIVE SPACER1
SPACER
G ROOVE
Fi gur e 36
SPECIAL
T OOL C-4962 -
SPECIAL
T OOL 6311
52.
SPECIAL
53.
T OOL 6312
54.
55.
J 9221-47
Fi gur e 37
End Play
Measurement Spacer Thickness
(Inches) (Inches)
.7336 . .7505 19.06
If, 0I
.158 .159
Y,03
It/,M .7506 . .7675
i9.yi(
lj.lfVr .175 - .176 't.l.fb
if/. ,(4'l
.7676 - .7855 1'/. ff
"1,9()~ .193 _ .194 \{,'1N
rtlt(rY .7856 - .8011 2iP.3Y ~.3s9 .211 - .212 5.~&C;
51. Pl ace over dr i ve uni t i n ver t i cal posi -
t i on and mount i n vi se, or on bench,
wi t h t he appr opr i at e si ze mount i ng hol e
cut i nt o i t . Be sur e uni t i s f aci ng up-
war d f or access t o di r ect cl ut ch hub,
WARNI NG: THE NEXT STEP I N ASSEMBLY I NVOLVES
CHECKI NG THE SELECTI VE SPACER AND SELECTI VE
WASHER. THI S I S A MANDATORY STEP, AND THI S
REQUI RES SPECI AL TOOLS. THESE SPECI AL TOOLS
CAN BE MANUFACTURED, AND WE HAVE PROVI DED
THE DI MENSI ONS TO MAKE THE NEEDED SPECI AL
TOOLS ON PAGE 94.
The spacer on t he i nt er medi at e shaf t i s
sel ect i ve, and set s t he end pl ay on t he.
i nt er medi at e shaf t ( See Fi gur e 36) .
I nser t Speci al Tool 6312 t hr ough t he
sun gear and i nt o pi l ot bushi ng i n t he
out put shaf t ( See Fi gur e 37) .
Posi t i on Gauge Tool 6311 acr oss f ace of
t he over dr i ve housi ng, as shown i n Fi g-
ur e 37.
Then posi t i on di al cal i per over gauge
t ool , as shown i n Fi gur e 37. Ext end t he
sl i di ng scal e of di al cal i per downwar d
t hr ough gauge t ool sl ot unt i l t he scal e
cont act s t he end of Gauge Tool 6312.
Lock t he scal e i n pl ace, r emove di al
cal i per and not e di st ance measur ed.
Sel ect t he pr oper t hi ckness sel ect i ve
spacer f r om t he spacer char t as shown
i n Fi gur e 38, based on t he di st ance
measur ed.
I nst al l t he pr oper sel ect i ve spacer
i nt er medi at e shaf t ( See Fi gur e 39) .
Remove speci al t ool 6312 f r om over dr i ve'
sect i on.
Posi t i on Gauge Tool 6311
t he over dr i ve housi ng, shown i n Fi gur e
40. Then posi t i on di al cal i per over t he
gauge t ool ( See Fi gur e 40) .
Measur e t he di st ance t o t he cl ut ch hub
seat ( Bear i ng Must Be Removed) , at f our
poi nt s 90 apar t . Then aver age t hese
measur ment s by addi ng t hem and di vi de
by 4.
Sel ect t he pr oper t hi ckness sel ect i ve
washer f r om t he i nf or mat i on i n t hr ust
pl at e char t , shown i n Fi gur e 41.
I nst al l t he pr oper t hi ckness sel ect i ve
t hr ust pl at e on over dr i ve pi st on, and
r et ai n wi t h Tr ans- J el ( See Fi gur e 42) .
58.
\
92
[~~T5G)
SPECIAL
T OOL 6311
63. Rot at e t he t r ansmi ssi on and st and i t
up on t he bel l housi ng, as shown i n
Fi gur e 43, i n pr epar at i on t o i nst al l
t he over dr i ve sect i on.
64. I nst al l t hr ust bear i ng on t op of t he
sel ect i ve t hr ust pl at e wi t h t he bl ack
si de f aci ng t he pi st on, and r et ai n wi t h
a l i ber al amount of Tr ans- J el , as shown
i n Fi gur e 43.
End Play
Measurement Spacer Thickness
(Inches) (Inches)
1.7500 . 1.7649 .108 - .110
1.7650 . 1.7799 .123 - .125
1.7800 - 1.7949 .138 .. 140
1.7950 - 1.8099 .153 .. 155
1.81001.8249 .168 - .170
1.8250 . 1.8399 .183 .. 185
1.8400 1.8549 .198 .. 200
1.8550 . 1.8699 .213 .. 215
1.8700 . 1.8849 .228 .. 230
1.8850 1.8999 .243 .. 245
THRU ST
BEARING
93
[~~T 5G)
94
(~Q T 5 G )
65. Rai se over dr i ve uni t , car ef ul l y sl i de
i t st r ai ght ont o i nt er medi at e shaf t as
66. Al i gn and car ef ul l y i nser t par k r od
i nt o par ki ng pawl . Rod wi l l make cl i ck
noi se as i t ent er s par k pawl . Move t he
r od r ear war d sl i ght l y.
67. Wor k over dr i ve uni t down on i nt er med-
i at e shaf t unt i l f ul l y seat ed on t he
t r ansmi ssi on case.
11mm
SOCKET
68. I f uni t i s not f ul l y seat ed, t i ght en
over dr i ve bol t s t o dr aw t he uni t up t o
case.
69. Appl y Lock- Ti t e 242 t o t he t hr eads of
over dr i ve bol t s, i nst al l and t or que t o
25 f t . l bs ( See Fi gur e 45) .
70. Lay t r ansmi ssi on assembl y down on t he
bot t om pan as shown i n Fi gur e 46.
CAUTI ON: I t i s possi bl e f or t he par k
r od t o di spl ace i nt o a cavi t y j ust over
t he pawl spr ag when. i nst al l o. D. uni t .
Make sur e t he r od i s act ual l y engaged
i n t he pawl and has not di spl aced i nt o
t hi s cavi t y.
A U T O M A T I C T R A N S M I S S I O N SER V I CE G R OU P
9S
( ~Q T S G ]
SPEED
SENSOR
78. I nt er medi at e shaf t t hr ust washer t hat
i s i n hub of r ear cl ut ch dr um cont r ol s
endpl ay. Thr ust washer i s sel ect i ve
and can be changed t o adj ust endpl ay.
79. I f endpl ay t ur ns out t o be i ncor r ect ,
r emove oi l pump, cl ut ch dr ums, i nst al l
t hi nner / t hi cker washer as necessar y.
80. I nst al l out put shaf t speed sensor i nt o
t he over dr i ve housi ng, as shown Fi gur e
48, wi t h new "a" r i ng, and t or que t he
sensor t o 20 f t . l bs.
81. I nst al l t he t or que conver t er as shown
i n Fi gur e 49.
82. Sur f ace of conver t er l ugs shoul d be
1/ 2" t o t he r ear of st r ai ght edge when
t he conver t er i s f ul l y seat ed as shown
i n Fi gur e 49.
71. Be sur e t he wi r e har ness cl i ps ar e pl -
aced on appr opr i at e over dr i ve bol t s.
72. Measur e and i f necessar y, cor r ect i nput
shaf t endpl ay ( See Fi gur e 47) .
73. Be sur e over dr i ve uni t i s i nst al l ed on
t r ansmi ssi on. End- pl ay cannot be pr op-
er l y checked wi t h O. D. uni t of f .
74. At t ach di al i ndi cat or t o bel l housi ng,
75. Posi t i on i ndi cat or pl unger agai nst t he
end of i nput shaf t and zer o i ndi cat or .
76. Move t he i nput shaf t i n and out and
r ecor d t he r eadi ngs.
77. End- pl ay shoul d be . 022" - . 091" .
0.55 - ~.3~M.
AUTOMATIC TRANSMISSION SERVIC E G ROUP
96
l~Q J 5~L
-. . . . . ~"'. ,.
ITEM TORQ UE
A 23 N-m (1527 in. Ibs. l
B 10-12 N-m (90-110 in. lbs. )
VEHIC L E
S PEED
~SENSOR
~~~,.
jf; . ',
: ti : \ l ; . . . ::. - " 1 : .; :
l~''; ",. ~1"t}
{. '~
1~~t;l:;;~4~ EED0METE R
1 .
Thor oughl y cl ean adapt er f l ange and t he
adapt er mount i ng sur f ace i n t he housi ng.
Sur f aces must be cl ean f or pr oper adap-
t er al i gnment and speedomet er oper at i on.
2. I nst al l new " 0" r i ngs on vehi cl e speed
sensor and speedomet er adapt er , shown
i n Fi gur e 50.
3. Lubr i cat e " a" r i ngs wi t h Tr ans- J el .
4. I nst al l vehi cl e speed sensor i n adapt er
and t or que scr ew t o 15- 27 i n. l bs.
( See Fi gur e 50).
5. Count t he number of t eet h on t he speed-
omet er pi ni on, bef or e i nst al l i ng i nt o
t he housi ng.
6. I nst al l t he speedomet er pi ni on i n t he
speedomet er adapt er ( See Fi gur e 50).
7. Not e i ndex number s on adapt er body, as
shown i n Fi gur e 51. These number s wi l l
cor es pond t o t he numb. er of t eet h on t he
speedomet er pi ni on.
8. I nst al l speedomet er assembl y i nt o t he
housi ng. Ext ensi on housi ng on 2WD model
and t r ansf er case on 4WD model s.
9. Rot at e adapt er unt i l r equi r ed r ange of
number s ar e at 6 a- Cl ock posi t i on. Be
sur e r ange i ndex number s cor r espond t o
number of t eet h on sp~edomet er pi ni on.
I nst al l speedomet er adapt er cl amp and
t or que t o 90- 1 1 0 i n. l bs.
SPEEDOMETER
PINION
AUTOMATIC TRANSMISSION SERVIC E G ROUP
97
(~~T 5G)
SPECI FICA TIONS
42RE GENERAL SPECIFICA TIONS 42RE THRUST WASHER/SPACER/SNAP RING
DIMENSIONS
TRANSMISSIONMODel 42 RE
Oil PumpClearances (all) 0.089-0.190 mm
(0.0035-0.0075 in)
Planetary End Ploy 0.127-1.22 mm
(0.005-0.048 in)
Input Shaft End Ploy 0.56-2.31 mm
(0.022-0.091 in)
Clutch PockClearance:
Front Clutch (4 Disc) 1.70-3.40mm
(0.067-0.134 in)
Rear Clutch (4 Disc) 0.81-1.40 mm
(0.032-0.055 in)
Clutch Disc Usage:
Front Clutch 4
Rear Clutch 4
Overdrive Clutch 3
Direct Clutch 6
Bond Adjustments:
(backed off form 72 in. Ibs.)
Front Bond 3-5/8 Turns
Rear'Bond 4 Turns
Recommended (and preferred) Fluid MOPAR ATF.Plus,
Type 7176
Automatic Trammission
Fluid
TRANSMISSION MODEL 42 RE
Front Clutch ThrustWasher 0.061 in.
(on reaction shaft support hub)
Rear ClutchThrust Washer 0.061 in.
(on dutch retainer)
Intermediate' Shaft Thrust Plate 0.060-0.063 in.
(on shaft pilot hub)
Intermedioie Shaft Thrust. Select fit io set.
Washer (in rear clutch hub) overall end ploy
.
Rear Clutch PockSnap Ring 0.060 in.
0.076 in.. '
0.098 in.
Planetary Geartrain Snap Ring
Select fit
(3 thicknesses
(at front end of intermediateshaft)
available)
Overdrive PistonThrustPlate Thrustplate and spacer
are selectfit components..
Intermediate Shaft Spacer
Referto size charts and
selectionpr;;edures in
"Overdrive Unit.Assembly
and Adjustment. .' .
. '.,
42RE TORQUE SPECIFICA TIONS
______ D_ESC_R_IPTJ _O_N --' T_O_R_Q_U_E_~I I DE_S_C_RI_PT_IO--'-N_. _--'-~ TO_R_Q_U_E_~':
Cooler line Fittings (at transmission) .... ;... 18 N-m (13ft. Ibs.) Overdriveto Tronsmission I
Converter Bolts: Case Bolts.... . ,....... 34 N-m (25 ft Ibs)
10.75 in., Alug converter 31 N-m (270 in.lbs.) Overdrive PistonRetainer Bolts 17 N-m (150 in.lbs.)
Crossmember Bolts/Nuts ....................... 68 N-m (50 ft.lbs.) PressureTestPort Plugs.. 14N-in (10ft.lbsl .
.Driveplate Bolts 75 N-m (55 ft. Ibs.) Propeller Shaft Clomp Bolts. 19 N-m (170in.lbs.) .
Front Bond lever Pivot Shaft Reaction Shaft SuppOrtBolts 20 N-m( 15 ft. Ibs.J
Access Plug 17 N-m(13ft. lb.) Rear Bond Adjusting Screw Locknut.. .41 N-m (30 ft Ibs)
Front Bond Adjusting Screw Locknut 34N-m (25 ft. Ibs) Solenoid Wiring ConneCtor Sc~ew.. 4 N. m(35'in Ibl.)
Pork/Neutral Position Switch : 34 N-m (25 ft. Ibs.) Solenoid.to.Tronsfer PlateScrew. 4 N~m (35 in.lbs.)
OiLFilter SCrews.. .:......... 4 N-m (35 in. Ibs.) S ed Ad' B I 11 N-m'(8 ft. Ibs.)
pe ometer opter at .
Oil PanBolt 17 N-m (1.3ft. Ibs.)
........................................... Valve Body/GovernorBody Screws.. 4 N-m (35 in.,1bs.) .
Oil PumpBoIt..
j
h' 20 N-m (15ft. Ibs) yalve Body.t~.Case Bolts.... 12 N-m (l00in.lbs.)
Overrunning C utc Com Bolts................ 17 N-m (150 in. Ibs.) . Transmission 'speed sensor 27 N _m(20 h. Ibs:)
AUTOMATIC. TRANSMISSION SERVICE GROUP.
93
c:
--1
o
~
--1
("")
--1
::0
z
(J )
~
" ' ( J )
" ' ( J )
o
z
(J )
m
::0
<
("")
m
(;)
::0
o
c:
-0
-
UNE PRESSURE
(160- 270 psi)
~
1-2 SHIFT
CONTROL
(25-70 psi)
~
UNE PRESSURE
TOTHROTTlf
VALVE
(50-100 psi)
Imiof;tl.tiif~~f1;111.
CONVERTER/
LUBE PRESSURE
(95-130 psi)
1:::;:;:::::::::::::l .
PUMP
SUCTlON
.... ' Cf)
OCf )
0-
o
z
Cf)
m
::0
<
o
m
G1
::0
o
C
\J
-
UNE P RESSURE
(70-78 psi)
I I I !I I I I I I I I I I I
GOVERNOR
P RESSURE
(0-75 psi)
V;~~:~;;}N:n;,H j
TH ROmE
P RESSURE
(To40 psi)
CONVERTER/
LUBE P RESSURE
(5-75 psi)
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DI AGNOST I C FAUL T C ODE S

Vehicle is not properly equipped for heavy

Tow vehicle and boot or trailer are bath

Trailer or boal are 100 large for low vehicle

OVE R DR IVE C LUT C H S NAP R ING

C LUT C H HUB R E T AINING R ING

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