Beruflich Dokumente
Kultur Dokumente
V.1 N. CODE
1&V
Exhaust Pipe To Manifold
Bolts . . . . . . . . . . . . .
Nuts
. . . . . . . . . . . . .
U-H-L
19 N-m
(14 ft. lb.)
21 N*m
(1 5 ft . lb .)
19 N*m
(14ft.lb.)
R&K
(Exc. Toro.)
K
Toronado
30 N=m
(22ft.lb.)
19 N*m
(14ft.lb.)
21 N*m
(15 ft. lb.)
4
19 N*m
(14ft.lb.)
. . . . . . . . . . . . .
19 N-m
(14ft.lb.)
19 N*m
(14ft.lb.)
19 N-m
(14ft.lb.)
21 N-m
(15ft.lb.)
STARFIRE
OMEGA
CUTLASS
28 N-m
(21 ft.1b.)
28 N-m
(21 ft. Ib.)
47 N*m
(3.5ft.lb.)
23 N*m
(17 ft. lb.)
28 N*m
(21 ft. lb.)
41 N-m
(30 ft . lb .)
31 N-m
(23 ft . lb .)
'
88-98
TORONADO
54 Nom
(40ft.lb.)
41 Nom
(30 ft. Ib.)
20 N-m
(15 ft. Ib.)
27 N*m
(20 ft. lb.)
29 N*m
(21 ft.1b.)
41 N-m
(30 ft. lb.)
Muffler Hanger
Right U -301t
. . . . . . . . . .
Left U-Bolt
. . . . . . . . . .
Right Screw
Left Screw
. . . . . . . . . .
. . . . . . . . . .
17 N*m
(13 ft. lb.)
41 N-m
(30 ft . lb .)
Fully Driven
14 N*m
(10 ft. lb.)
14 N*m
(10 ft . Ib.)
. . . . . .
. . . . . . . . .
41 N=m
(30 ft. lb .)
31 N*m
(23 ft . lb .)
10 N-m
(7 ft. Ib.)
TORQUE SPECIFICATIONS
I
V.1 N. CODE
1&V
Exhaust Pipe To Manifold
Bolts . . . . . . . . . . . . .
Nuts
. . . . . . . . . . . . .
U-H-L
19 N-m
(14 ft. lb.)
21 N*m
(1 5 ft . lb .)
19 N*m
(14ft.lb.)
R&K
(Exc. Toro.)
K
Toronado
30 N=m
(22ft.lb.)
19 N*m
(14ft.lb.)
21 N*m
(15 ft. lb.)
4
19 N*m
(14ft.lb.)
. . . . . . . . . . . . .
19 N-m
(14ft.lb.)
19 N*m
(14ft.lb.)
19 N-m
(14ft.lb.)
21 N-m
(15ft.lb.)
STARFIRE
OMEGA
CUTLASS
28 N-m
(21 ft.1b.)
28 N-m
(21 ft. Ib.)
47 N*m
(3.5ft.lb.)
23 N*m
(17 ft. lb.)
28 N*m
(21 ft. lb.)
41 N-m
(30 ft . lb .)
31 N-m
(23 ft . lb .)
'
88-98
TORONADO
54 Nom
(40ft.lb.)
41 Nom
(30 ft. Ib.)
20 N-m
(15 ft. Ib.)
27 N*m
(20 ft. lb.)
29 N*m
(21 ft.1b.)
41 N-m
(30 ft. lb.)
Muffler Hanger
Right U -301t
. . . . . . . . . .
Left U-Bolt
. . . . . . . . . .
Right Screw
Left Screw
. . . . . . . . . .
. . . . . . . . . .
17 N*m
(13 ft. lb.)
41 N-m
(30 ft . lb .)
Fully Driven
14 N*m
(10 ft. lb.)
14 N*m
(10 ft . Ib.)
. . . . . .
. . . . . . . . .
41 N=m
(30 ft. lb .)
31 N*m
(23 ft . lb .)
10 N-m
(7 ft. Ib.)
7AI-1
7A1-7
7A3-1
7A4-1
70-1
7C-1
TORQUE CONVERTER
ALL TURBO HYDRA-MATICS
GENERALDESCRIPTION
The torque converter couples the engine to the planetary
gears t h r o u g h oil and provides hydraulic torque
multiplication when required. The compound planetary gear
set produces three forward speeds and reverse.
The 3element torque converter consists of a pump or
driving member, a turbine or driven member, and a stator
assembly. The stator is mounted on a one-way roller clutch
which will allow the stator to turn clockwise but not
counterclockwise.
The torque converter housing is filled with oil and is
attached to the engine crankshaft by a flex plate and always
rotates at engine speed. The converter pump is an integral
part of the converter housing, therefore the pump blades,
rotating at engine speed, set the oil within the converter into
motion and direct it to the turbine, causing the turbine to
rotate.
As the oil passes through the turbine it is traveling in
such a direction that if it were not redirected by the stator it
would hit the rear of the converter pump blades and impede
its pumping action. So at low turbine speeds, the oil is
redirected by the stator to the converter pump in such a
manner that it actually assists the converter pump to deliver
power or multiply engine torque.
AS turbine speed increases, the direction of the oil
leaving the turbine changes and flows against the rear side of
the stator vanes in a clockwise direction. Since the stator is
now impeding the smooth flow of oil, its roller clutch
releases and it revolves freely on its shaft. Once the stator
becomes inactive, there is no further multiplication of engine
torque within the converter. At this point, the converter is
merely acting as a fluid coupling as both the converter pump
and turbine are being driven at approximately the same
Speed, or at one-to-one ratio.
A hydraulic system pressurized by a gear type pump
Provides the working pressure required to operate the
ffiction elements and automatic controls.
C A U T I O N : After
C O N V E R T E R T R O U B L E DIAGNOSIS
leak testing,
pressurized a i r from
J-2 1369-2 before removing from
converter.
O
w STATOR
~
~OPERATION
~
~ DIAGNOSIS
~
The torque converter stator assembly and its related
clutch can possible have one of two different type
malfunctions.
1. The stator assembly freewheels in both directions.
2. The stator assembly remains locked up at all times.
Checking Converter
1. Check converter for leaks as follows:
a. Install J-21369-2 and J-213694 and tighten hex
nut on 5-21369-2. (Fig. 7A1-1)
b. Fill converter with air; 55 1 kilopascals (80 psi).
c. Submerge in water and check for leaks.
bleed
TORQUE CONVERTER
CONNECT NOZZLE
TO PARTS CLEANER
OSED-END POP
CONDITION : Contaminated O i l
CONDITION: Vibration
CONDITION: Leaks
transmission
THROTTLE L E V E R &
BRACKET ASSEMBLY
7A1-6 T.V.CA3
downshifts.
DIAGNOSIS PROCEDURE
1. Check transmission oil level and correct as requir
2. Be sure engine is operating properly and brakes
not dragging.
3 . Check for correct T.V. cable, according to the par
catalog.
4. Check that the T.V. cable is connected at both end
5 . Adjust the T.V, cable as follows:
a. Unlock the "snap lock" on the T.V. cable.
b. Rotate the carburetor lever to the wide o
position. (Engine Off)
c. While holding the carburetor lever at wide o
throttle, push the "snap lock" flush to secure the c
housing.
d. Return the carburetor lever to the clo
posit ion.
6. Check T.V. cable for sticking and binding.
7. When the T.V. cable adjustment is made and lot
the cable housing will extend t h r o u p the cable snap
assembly about 1.57 - 7.95 mm (1116 -5116"). (Fig. 7A1
idle
speed.
.
b. Record or1 pressures m Neutral and YarK.
4
down as the lifter does. Also, be sure lifter spring holds the
lifter rod up against the bottom of the controI valve
assembly. Make sure T.V. plunger is not stuck. Inspect
transmission for correct throttle lever t o cable link. (Fig.
7A 1-18)
TE: Neutral
-,.
a T -
11 NeULliiJ
.+
'
11
SUBJECT
PAGE
. . . . . . . . . . .
V 1 I . \
. . . . . . . .
. . . .
. . .
SUBJECT
PAGE
Maintenance
. . . . . . . . . . . . . . . .7A18
Manual Linkage
. . . . . . . . . . . . . . 7A 1- 18
. . . . . . . . . . . . . 7A 1-9
Oil Cooler Servicing
Oil Cooler Pipes . . . . . . . . . . . . . . 7A1-10
Oil Pan and Screen . . . . . . . . . . . . . 7A 1-23
Oil Passages . . . . . . . . . . . . . . . . 7A 1-3 1
Oil Pressure Checks
. . . . . . . . . . . . 7A1-11
OilPump . . . . . . . . . . . . . . . . .7A1-150
Oil Sea1,Rear . . . . . . . . . . . . . . . 7A1-18
. . . . . . . . . . 7A1-19
Pressure Regulator Valve
Selective Spacer/Washer/Pin
Front Unit Washer . . . . . . . . . . . . 7A1-53
. . . . . . . 7A 1-55
Intermediate Band Apply Pin
Rear Unit Spacer . . . . . . . . . . . . . 7A1-43
Service Precautions . . . . . . . . . . . . . 7A1- 17
Shift Rod and Cable Adjustment . . . 7A1-18 & 7A1-20
Speedometer Driven Gear . . . . . . . . . . 7A1-18
Tools
Hand Tools . . . . . . . . . . . . . . . 7A1-63
. . . . . . . . . . . . . . 7A1-63
Special Tools
Torque Converters . . . . . . . . . . . . . . 7A1-1
Torque Specifications
. . . . . . . . . . . 7A1-62
Transmission Mounts . . . . . . . . . . . . 7A1-18
Transmission Removal
. . . . . . . . . . . 7A1-20
T.V.CableAdjustment
. . . . . . . 7A1-6&7A1-20
ValveBody . . . . . . . . . . . .7A1-56-7A1-61
(
I
'
GENERAL DESCRIPTION
The Turbo Hydra-Matic 200 transmission is a fully
automatic unit consisting primarily of a 3element hydraulic
torque converter and a compound planetary gear set. Three
MAINTENANCE
MAINTENANCE SCHEDULE
CONVERTER
IF
bfjng '0
to the "FULL
use
C8(9O0 F.').
'
t
~ T E DO
: NOT OVERFILL. It takes only one pint to
"iie level from "ADD" to "FULL" with a hot transmission.)
zey~
-
1. Raise car.
2. With drain pan placed under transmission oil pan,
remove oil pan attaching bolts from front and side of pan.
3. Loosen rear pan attaching bolts approximately four
(4) turns,
4. Carefully pry transmission oil pan loose with
screwdriver, allowing fluid to drain.
5. Remove remaining bolts and remove oil pan and
gasket. Discard gasket.
6. Drain fluid from oil pan. Clean pan with solvent and
dry thoroughly with clean compressed air.
7. Remove two (2) screen-to-valve body bolts, screen
and gasket . Discard gasket.
8 . Thoroughly clean screen assembly in solvent and dry
thoroughly with clean compressed air.
9. Install new gasket on screen and two (2) bolts.
Tighten bolt to 8 to 14 N*m (6 to 10 ft . lbs.)
10. Install new gasket on oil pan and install oil pan.
Tighten attaching bolt and washer assemblies to 14 .O-18.0
N*m (10-1 3 ft. lbs.).
1 1. Lower car, add approximately 2.8 litres (3 quarts) of
DEXRO@-11 automatic transmission fluid or its equivalent
through filler tube.
12. With selector lever in PARK position, apply hand
brake, start engine and let idle (carburetor off fast idle step).
DO NOT RACE ENGINE.
13. Move selector lever through each range and, with
selector lever in PARK range, check fluid level.
14. Add additional fluid to bring level between the
dimples on the dipstick.
ADDING FLUID TO FILL DRY TRANSMISSION AND
CONVERTER
In cases of transmission overhaul, when a complete fill is
required, including converter, proceed as follows:
1 . Add 6.6 litres (7 quarts) of transmission fluid
through filler tube.
2. With manual control lever in park (P) position, start
engine and place on cold idle cam. DO NOT RACE ENGINE.
Move manual control lever through each range.
3. Immediately check fluid level with selector lever in
park (P), engine running and car on LEVEL surface and add
additional fluid to bring level to a point between the two
dimples on the dipstick. Do not overfill.
TRANSMISSION FLUID
FLUID LEVEL AND CAPACITY
The transmission dipstick is located in a filler tube at
right rear of the engine. To bring fluid level from ADD mark
to FULL mark requires .5 litres (one pint) of fluid. Fluid
level should be checked at every engine oil change.
Fluid level should be to FULL mark with transmission
fluid at normal operating temperature 93' C. (200' F .). With
warm fluid room temperature 2 1" C. (70" F.) level will be
between the two dimples on the dipstick. The normal
operating temperature is obtained only after at least 24 km
(15 miles) of highway type driving or equivalent of city
driving.
empty container.
3 . Flush clean oleum solvent or equivalent through the
return line (from the bottom of the cooler) using an oil
suction gun until clean solvent comes out of the hose. This
will "back flush" the cooler.
4. Remove the hose from the inlet cooler line and place
it on the return line.
5. Flush clean oleum solvent or equivalent through the
inlet line until clean solvent comes out the return line.
Remove remaining solvent from cooler with compressed air
applied to the return line and flush with transmission fluid.
6. Reconnect oil cooler lines and torque nuts to 12 ft.
Approximately 2.8 litres (3 quarts) of fluid are required
to refill transmission after the oil pan has been drained; The
fluid capacity of the Turbo Hydra-Matic 200 transmission
and converter assembly is approximately 8.4 litres (9 quarts)
but correct level is determined by mark on the dipstick
rather than by amount added. Use only DEXRON@-11
automatic transmission fluid or its equivalent (with a " D
prefix to the numbers on top of the can).
OF ENG lNE
MOUNTING BRACKET
FRONT OF CAR
,,,,,
DIAGNOSIS
OIL LEAKS
The suspected area should be wiped clean of al
before inspecting for the source of the leak. Red dye is
in the transmission oil at the assembly plant and will
if the oil leak is from the transmission.
When an oil leak is found the following procedure
assist in locating the leak.
1. Clean the area with solvent to remove all traces
oil.
2. Remove the flywheel lower cover, if leak
suspected at rear of engine or front of the transmission,
3. Spray suspected leak areas with a pressurized
powder (to aid in detection).
4. Start engine and run at high idle.
5 . Repair any leaks which are detected and rechea
necessav. Reinstall previously removed Parts.
The use of a "black light" to identify the oil at'
source of the leak is also helpful. Comparing the oil from
leak to that on the engine or Wmsmission dipstick
dewedb~blacklight)willdeterminethesourceofth
Oil leaks around the engine and
generally carried toward the rear of the car
For example, a transmission "oil filler tube
sometimes appear as a leak at the rear of th
determining the source of an oil leak, it i
keep the engine running.
A "black light" testing unit such as 5-6640 rn
obtained from service tool suppliers.
6. Degrease underside of transmission.
7. Road test to get unit at operating temperatu
C . (180" F.).
8. Inspect for leak with engine running.
9. With engine off, check for oil leaks due to the r
oil level caused by drain back.
POSSIBLE POINTS OF OIL LEAK
I . Transmission Oil Pan Leak
a. Attaching bolts not correctly torqued.
b. Improperly installed or damaged pan gasket*
c. Oil pan gasket mounting face not flat.
2. Case Leak
a. Filler pipe "0" ring seal damaged or
misposition of filler pipe bracket to engine "1
one side of "0" ring.
b. T.V. cable "0" ring seal missing, dam8
improperly installed.
c. Rear seal assembly damaged or imPf
installed.
d. Governor cover and "0"rings dama
missing.
e. Speedometer driven gear "0" ring damage
f. Manual shaft lip seal damaged or impr
installed.
g. Line pressure tap plug.
h. Porous casting.
i, Intermediate servo "0" ring damaged.
3. Leak at Front of Transmission.
Front pump seal leaks.
1. Seal lip cut. Check converter hub for nicks,
,,
kmg,
d t
DRNE IN NEUTRAL
1 . Manual Linkage
a. Misadjusted or disconnected.
2. Forward Clutch
a. Clutch does not release. Exhaust check ball
sticking. Plates burned together.
3. Pump
a. Cross leakage in pump passages.
4. Case
a. Cross leakage to forward clutch passages.
NO DRIVE IN REVERSE OR SLIPS IN REVERSE (Refer
to Oil Pressure Checks)
1. Throttle Valve Cable
a. Binding or misadjusted.
2. Manual Linkage
a. Misadjusted.
3. Pump Assembly
a. Pressure regulator valve binding or stuck with
chips.
b . Check ball missing or mislocated.
c. Pump to case gasket mislocated or damaged.
d. Direct clutch feed holes leaking, cross-feeding or
not drilled.
e . Cup plugs missing.
f. Oil rings damaged or missing.
4. Control Valve Assembly
a. Throttle valve binding.
b. Shift T.V. valve binding.
c. Reverse boost valve binding.
8. Case
a. Porosity.
m ~ ~ N BRAKING
E
IN LOW RANGE-1ST GEAR
colltrol Valve Assembly
LOW overrun clutch valve binding.
FoTE
thrkfollowing conditions.)
a. Broken or missing.
4. Governor Cover "0" Rings
a. Broken or missing.
(;mECOOLANTIN TRANSMISSION
~f
,,
w
a
g
e .I
200
TRANSMISSION
i
i
PISTON
'6
MANUAL LINKAGE
Manual linkage adjustment and the associated neu
start switch are important from a safety standpoint.
The neutral start switch should be adjusted so that
engine will start in the Park and Neutral positions only.
With the selector lever in the Park position, the p
engage and prevent the car from
pawl
The pointer on the indicator quadrant should lin
properly with the range indicators in all ranges.
If the linkage is not adjusted properly, an internal
which "'ld
cause a
Occur at the
or band failure,
EVER IN THE
POSITION,
~
~THE
hwability
to withstand normal car vibrations.
" Steel tubing should be flared using the double flare
i
method.
'r
*y?%
1
GOVERNOR
Removal
1. Before raising the car, disconnect the negative
battery cable and remove the air cleaner.
'.
ot
9. Refer
to
overhaul
operations
for
inspection
CA U T I O N : I n termediate band
anchor p i n must locate on
intermediate band or damage to
transmission will result.
Refer to Refilling of Transmission portion of this section
for correct fluid level.
T.V. CABLE
1. Remove air cleaner.
2. Push up on bottom of snap-lock and release lock and
Installation
1. Place transmission on locating pilots. I
downshift cable in clip on transmission, insert oil
dipstick tube and bolt tube in place. Install transmissio
engine bolts and torque to 54 N-m (40 ft. lbs.).
(NOTE: Rotate converter to permit coupling of
and converter in the original position by aligning t
made before removal.)
2. Install transmission support and torque sUPP
frame nuts to 34 N*m (25 ft . lbs.). Torque sUPP
transmission mount bolts to 61 N*m (45 ft. lbs.). Re
POS ITION.
TRANS. OUTER
HlNG
A
B RACKET
WASHER
(SEEVIEW)
I \
27 N. m
120 FT. LBS.
i 3 'VVITti i:KAtci
ro hlAiif
2. PLACE SHIFT LEVER I N "PARK" POS ITION. PLACE TRANSM I S S I O N MANUAL LEVER I N "PARK" POS I T I O N AND I G N I T I O N
KEY I N LOCK POSITION.
3. T I GHTEN CABLE P I N NUT TO 20 FT. LBS.
4. ROTATE THE TRANSMISSION MANUAL LEVER FULLY AGAINST
THE "PARK" STOP. THEN RELEASE THE LEVER.
5. PULL SHIFT ROD DOWN AGAINST LOCK STOP TO ELIMINATE
LASH AND T I GHTEN CLAMP SCREW TO 20 FT. LBS.
SHIFT ROD
6. CHECK OPERATION:
TRANSMISS ION
CABU
PIN
c LAMP
CLAMP SCREW
7 ~ 1 - 3 2 Also,
)
make sure rings are seated in the grooves
iFFrevent damage to the rings during reassembly of mating
over rings. Retain with petrolatum.
4. New angle cut or full circle teflon seal rings may
to be distorted after being installed. Once exposed to
oil temperatures, the new seal rings will
return to their normal shape and fit freely in their bores.
5. The teflon Seal rings allow for a free fit in their bores
after erati ti on. The free fit of the rings in their bores does
not indicate leakage during operation.
,,,
RIGHT
WRONG
I
EXTERNAL PARTS
Removal
1. Remove oil pan and discard gasket.
2. Remove oil screen and discard gasket. (Fig. 7A1-33)
Fig. 7 A l - 3 3 - ~ e m o v i nOil
~ Screen
f.
snap ring.)
INTERMEDIATE BAND
APPLY PIN SELECTION CHART
APPLY PIN
DIAL INDICATOR TRAVEL
IDENTIFICATION
0 mm-2.16mm
2.16mm-2.88rnm
(.00OV-.086")
(.086" -.I 14")
2 Rings
Wide Band
-.
ERMEDIATE BAND
THICKNESS
IDENTIFICATION
Number and/or Color
2.463-2.59Omm
290-3.01mm
3.08-3.19mm
326-3.37mm
3.44-355mrn
3.62-3.73rnm
3.80-391mm
3.984.09mm
4.164.27mrn
4.344.45rnm
(0.097"0.102")
(0.1 14" 0 . 1 19")
(0.121" 0.126")
(0.128" 0.133")
(0.135" 0.140")
(0.143" 0.147")
(0.150" 0.154")
(0,157" 0 . 1 61 ")
(0.164" 0.168")
(0.171"-0.175")
0
1
2
3
4
5
6
7
8
9
- Orange
White
Yellow
Blue
Red
Brown
- Green
- Black
- Purple
OUTPUT SHAFT
4
SLOTTED SPRING PIN
PARKING
PAWL CUP PLUG
E4ik
7 $a RETAINING
IDENTIFICATION
GROOVE
T P I N GROOVE
MANUAL
SHAFT
SPEEDOMETER
DRIVE GEAR CLIP
\
\Y
SNAP R I N G
SPEEDOMETER
DRIVE GEAR
OUTPUT SHAFT
Fig. 7A1-90
tput Shaft
I
I
Removal
Inst allation
1. Place front end of output shaft on block of wood to
prevent damaging the front end.
SPEEDOMETER
DRIVE GEAR
SPEEDOMETER
CIRIVE GEAR
OUTPUT SHAFT
THRUST WASH
REAR CARRIER
REAR C A R R I E R
11 f
I
/
I
I
L
ROLLER
17:- 7 A 1 1 n3
1.1s.
I nl-luL
T-~+~II:-,.
a-r.-+
Urnohfir
OUTPUT SHAFT
RRlER
PARKlNG PAWL
LUGS
RlNG
(HOUSING
TO CASE)
HOUSING
TO CASE
SPACER
LO & REVERSE
LO & REVERSE CLUTCH
LO&REVERSE
CLUTCH APPLY SPRING
STEEL CLUTCH
RING
RETAINER
PLATE
LO & REVERSE
PISTON
ASSEMBLY
WAVE
RELEASE
SPRING
SNAP
RING
LO & REVERSE
COMPOSITIONFACED PLATE
1'
Inspection
1 . Inspect low and reverse clutch housing for d
plugged feed hole.
2. Inspect low and reverse clutch housing bushino c,damage or scoring.
3. Inspect low and reverse clutch splines and
groove for damage or burrs. Remove any burrs on
snap ring groove.
4. Inspect low and reverse clutch piston a
apply ring assembly for distortion, cracks or damage.
--ubba'
b11 V U L b L
Cnql
LJbUL
ir
i'
Reassembly
1 . Install clutch apply ring on low and rev
piston.
2. Install new outer and inner seals on piston with lips
facing away from clutch apply ring side. (Figs. 7A 1-109 and
7A1-110)
3. Install seal protector 5-2501 1 .
C A U T I O N : F l a t screwdriver
surface area must be smooth to
prevent damaging outer sea/.
LO & REVERSE
CLUTCH HOUSING
J-25011
LO & R E V
CLUTCH HOUSING
Fig. 7Al-112-Installing Low and Reverse Fig. 7Al-113-Installing Low and Reverse
Clutch Retaining Snap Ring
Clutch Wave Release Spring
I-
.-
E
E r
E
E z
E
E r
E
E^
$ $ 3% 29 9 : $g
8 9 $5 $ 2 R 2 $0
->.
2 2 :m
r
E
E-
*
*
a. Remove toolJ-25012.
b. Using rear sun gear and input drum as twl
install input drum and rear sun gear in case.
c. Rotate rear sun gear back and forth, tapp
lightly with input drum, to align roller clutch race
low and reverse clutch hub splines. (Fig. 7A1-117)
d . Remove tool (input drum and rear sun gear),
INPUT DRUM
SNAP RING
(INPUT DRUM TO
REAR SUN GEAR)
THRUST WASHER
(DRUM TO HOUSING)
Inspection
1 . Inspect rear sun gear for cracks, splits, d
spline, worn gear or journals and plugged lubrication
(Fig. 7Al-118)
2. Inspect rear sun gear bushing for damage or scar
3. If necessary, remove input drum to rear sun
snap ring and remove sun gear from input drum.
4. Inspect input drum for damage. (Fig. 7A1-118)
5 . Inspect 4 tanged input drum to low and re
clutch housing thrust washer for scoring or distorted t
(Fig. 7A1-118)
6. If damaged, replace rear sun gear to input drum
ring.
Reassembly
1 . Install rear sun gear into input drum, spline si
first, and retain with snap ring. (Fig. 7A1-118)
2. Install 4 tanged thrust washer on input drum
sun gear end; align tangs into input drum and retain
petrolatum. (Figs. 7A1-118 and 7A1-119)
3. Install rear sun gear and input drum assembly (
7A1-117)
R E A R SUN
GEAR
I .
s
Fig. 7Al-119-Installing Thrust Washer
or wear.
RACE ASSEMBLY
NEEDLE BEARfNGS
GAINST GEAR)
Reassembly
1 . Install front carrier to front internal gear thrust
bearing assembly by placing the smaller diameter race against
carrier. Retain with petrolatum. (Fig. 7A1-124)
Install front carrier and thrust bearing assembly.
(Fig. 7A1-125)
;i
--I
CA U T I 0 N : The rear
thrust washer must be
with the iden tification
t o w a r d the front
transmission.
I'I1'1r
'I
selective
installed
number
o f the
r i
, ,
f
I!
"
Slfi
4
9
/ /I
--
THICKNESS
IDENTIFICATION
Number and/or Color
2.463-2.59Omm
290-3.Olmm
308-3.19mrn
326-3.37mm
3.44-35 5 mm
3.62 -3.73mm
380-39 1 mrn
3984.09rnm
4.16427mm
4.344.45 mm
0
I
2
3
4
5
6
7
8
9
Orange
Whte
Yellow
Blue
Red
Brown
Green
Black
Purple
.
D lR ECT
CLUTCH
PISTON
DIRECT
CLUTCH
HOUSING
DIRECT
CLUTCH
APPLY
DIRECT CLUTCH
PISTON ASSEMBLY
DIRECT
CLUTCH
RETAINER
SPRING
GUIDE
RING
FLAT
STEEL
PLATE
FACED PLATE
DIRECT
CLUTCH
BACKING
RING
PISTON
Piston Outer Se
(LIP UP)
TE:
CLeen
-- CLUTCI-%
HOUSING
SNAP ./
W BNG
L 1.5-3 mm R. (.06*-.12'')
Fig. 7A 1-142-Piston Installing Tool
FORWARD
CLUTCH
CLUTCH
RETAINER & STEEL
HOUSING
UTCH PISTON
O R W A R D CLUTCH
FEED HOLE
bsembly
#'
with lips
_ 2. Install new outer and inner seals on piston
f a h g away from clutch apply ring side. ( F ~ G 7A1-150
.
and
%I-15 1)
k
f
1
E
'
'On:
FORWARD CLUTC
Fig. 761-163.)
3. Grasp direct and forward clutch assemblies to
prevent their separation and position on bench, with the
turbine shaft up.
4. Install 5-2502 1 as shown in Fig. 7Al-164.
5. Install direct and forward clutch assemblies, using
J-25021,and rotate into position. (Fig. 7A1-164)
r
6. Remove 5-2502 1.
HY DRA-MATIC 200
PUMP BODY
PRESSURE REGULATOR
REGULATOR GUIDE
GULATOR VALVE
d'
F&
QQ ;
&
j%
7~ 1-169-Removing Pump
Drive Gear
PUMP COVER
Inspection
1. Inspect for open oil passages. (Figs. 7A1-174A and
ORIFICE
CONVERTER
TO COOLER
CONVERTER
lA1-175)
2. inspect seven (7) cup plugs. If a plug is missing, drive
'new cup plug to .79mm (1132") below top of hole, using a
7e14mm (9132 I) diameter rod on the two smaller plugs and a
?92mm (51 16") diameter rod on the four larger plugs. Stake
@ofhole two places, directly opposite each other, to retain
plug.
htness.
b,.
PUMP COVER
HYDRA-MATIC 200
UVCl Wll m
retain with
(Fig. 7A1-180)
1 1. Remove holding bolt or screwdriver. (Fig. 7Al-180)
12. Install new pump t o case gasket on pump 2lnd retain
with petrolatunl.
. . .
f3. Install 2 pump to case alignment plns ln case as
shown in Fig. 7A1-18 1.
U W U ~ W "
Bit
Reassembly
1 . Place pump body over hole in bench.
2. Assemble pump cover to pump body with attaching
bolts, finger tight.
3. ~ l ;n
i, l pump ,cover and pump body using J-25015
-'t or screwdriver through pump
(Fig. 7A1-176) ana place- 'DUL
t o case bolt hole and bench.
PUMP
ASSY.
PUMP COVER
THRUS: WASHER
Fig. 7 A
RIGHT
HOLDING BOL:
.\
PUMP O I L
em
THICKNESS
I
1.66-1.77 mm
1.79-1 9 0 mm
192-2.03 mm
2,05-2.16 mm
2.18-2.29mm
2.31-2.42mm
2.44-2.55 mm
2.57-2.68 mm
2.70-2.81 mm
2.83-294mm
296-3.07 mm
3.09-3.20 mm
3.22-3.33 mm
3.35-3.46 rnrn
3.48-3.59 mm
(he&
IDENTIFICATION
Number and/or Color
1
(0.065 "-0.070")
2
(0.070" -0.075")
(0.076" 4.080")
3
(0.081~'-0.085")
4
(0.086"-0.090")
5
(0.091~~-0.095~~) 6
(0.096"-0.100")
7
(0.101"-0.106")
8
(0.106"-0.111")
9
(0.111"-0.116")
10
(0.1 17"-0.12 1") 11
(0.122"-0.126")
12
(0.127"-0.13lV)
13
(0.132"-0.136")
14
(0.137t1-0.141") 15
- Black
Light Green
Scarlet
Purple
Cocoa Brown
Orange
Yellow
LightBlue
Pink
- Green
- Gray
INTERMEDIATE BAND
APPLY PIN SELECTION CHART
I
APPLY PIN
DJAL INDICATOR TRAVEL
IDENTIFICATION
0 mm-2.16mm
2.16mm-2.88mm
(.000" -.086")
(.086" -.I 14")
2 Rings
Wide Band
Disassembly
1. Using 5-22269-01 , compress intermediate servo
piston spring. (Fig. 7A1-19 1)
2 . Using small flat edge screwdriver, remove
intermediate pin to piston snap ring.
3. Remove J-22269-01 and separate band apply pin,
spring and washer from intermediate servo piston.
Reassembly
1 . Install washer on snap ring end of band apply pin.
(Fig.7Al-187)
2. Install spring on washer.
3. Install band apply pin, spring end first through
intermediate servo piston.
4 . Using 5-22269-01, compress intermediate servo
piston spring. (Fig. 7A1-191)
5. Using small pliers, install intermediate servo pin t o
piston snap ring. Remove 5-22269-01.
II
:
, +La
111 1.I I G
o n m o
aalllc
r ~ l ~ + ; n n a h ;OnP
I C I I U L I U I I J I U ~ UJ
pll+
CIUL.
/Kin
7 A 1,197) Make
\A 15. t A x z r / r I "'""'
nlrp
"UI"
3
-
RIGHT
WRONG
y 1I
I:
1
4
42
43 44 45
1. MANUAL VALVE
31. ROLL P I N
2. ROLL P I N
17. ROLL P I N
18. ROLL P I N
34.
5. 2 - 3 SHIFT VALVE
6. 2 - 3 THROTTLE VALVE
21.
7. 2 - 3 THROTTLE SPRING
22.
INNER ROLL P I N
9. ROLL P I N
24. ROLL P I N
10. ROLL P I N
25. ROLL P I N
27. 1 - 2 ACCUMULATOR
15. 1-2THROTTLEVALVESPRlNG
~ T E The
: 2-3 throttle valve spring and 2-3 throttle valve
may be inside the 2 -3 throttle valve bushing.)
(NOTE: The 1-2 throttle valve spring and the 1-2 throttle
valve may be inside the 1-2 throttle valve bushing.)
7. From next bore down, remove roll pin and bore
plug. Remove reverse boost spring and reverse boost valve.
8. Check the operation of the shift T.V. valve in the
next bore down, by moving the valve against the spring. If it
is necessary to remove the valve, proceed as follows: (Figs.
7A1-197 and 7A1-198)
a. Remove roll pin and place valve body on shop
towel with rough casting surface up.
b. Using needle nose pliers, compress the shift T.V.
Inspection
1 . Wash control valve body, valves, springs, and ot
parts in clean solvent and air dry.
2 . Inspect 1-2 accumulator piston for damage.
3 . Inspect 1-2 accumulator piston seal for damage
free fitting groove. Do not remove seal unless replacing.
4. Inspect valves for scoring, cracks and free rnovemrn
in their bores.
5. Inspect bushings for cracks or scored bores,
6. Inspect valve body for cracks darnage or sco
bores.
7. Inspect springs for distortion or collapsed coils.
8. Inspect bore plugs for damage,
Reassembly
(NOTE: The size of the 5 check balls used in the case and
control valve assembly is 6.35 mm (-250"). The size of the
check ball used in the pump is 7.14 mm (.281ff). Do not
interchange.)
4 . Install 5th check ball in case as shown. (Fig.
7A 1-204)
FOR I D E N T I F I C A T I O Q
5th CHECK
{T.V. EXHA
Oil Screen
1. Thoroughly clean, air dry and inspect oil screen
assembly.
2. Install new oil screen gasket on screen and retain
with petrolatum.
3 . Install oil screen assembly and attaching bolts. (Fig.
7Al-210) Torque bolts to 17.0 N-m (12 ft. Ibs.).
%
-'
IV EXHAUST
OIL SCREEN
TORQUE SPECIFICATIONS
DESCRIPTION OF USAGE
QUANTITY
M8 x 1.25 x 4 5
20.0-27.0 N-m
M8 x 1.25 x 35
TORQUE ASSEMB
M8 x 1.25 x 20
20.0-27.0 N*m
M8x 1 . 2 5 16
~
1/4-18NPSF
1/4-18 NPSF
20.0-27.0 Nmm
(15-20 ft. lbs.)
1/8-27 NPTF
7.0-14.0 N-m
(5-10 ft. lbs.)
M6.3 x 1.O x 45
13.0-17.0N*m
(9-12 ft. lbs.)
M6.3 x 1.O x 45
13.0-17.0N*m
(9-12 ft. lbs.)
M6.3x 1 . 0 ~ 5 5
13.0-17.0 N*m
(9-12 ft . lbs.)
M6.3 x 1 . 0 16
~
8.0-14.0 N*m
(6-10 ft . lbs.)
(NOTE: All critical torque specifications are listed in each section, where appropriate.)
Converter L e a k - ~ e s~i i x t i r e
Rear Seal Installer
Dial Indicator Set
Pressure Regulator Valve Remover
Converter Holding Tool
Speedometer Drive Gear Remover
Puller (Use with 5-2142741)
Speedometer Drive Gear Installer
Pliers.
Medium Chisel.
tw
Rear Bushing
1 . Using Tool 5-25019 -14 with Slide Hammer 5-7004-1,
remove bushing. (Fig. 7A1-215)
2. Using Tool 5-250 19-6 with Driver Handle 5-8092,
drive or press new bushing until tool bottoms. (Fig.
7A1-216)
,
,
3-250
- 1 9-14
R E A R SUN GEAR
TURBO HYDRA-MATIC 3 5 0
INDEX
PAGE
sity
. . . . . . . . . . . . . . . 7A3-52
. . . . . . . . . . . . . . . . .7A3-2
. . . . . . . . . . . . . . . . . .7A3-2
. .
. . . . .
. . . .
. . . .
Clutch
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
7A3-37
7A340
7A3-15
7A3-15
h Accumulator
SUBJECT
PAGE
. . . . . .
Oil Leak Diagnosis
. . . . . . . . . .
Oil Pump
. . . . .
Periodic Maintenance
Sun Gear and Sun Gear Drive Shell
Teflon Seal Replacement . . . .
Tools . . . . . . . . . . . .
. . . . .
Torque Specifications
. . . .
Transmission Assembly
. . .
Transmission Disassembly
Transmission Removal . . . . .
Turbo Hydra-Matic 350 Inf. Chart
. . . . . . . . .
Valve Body
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
. . . . . . 7A3-2
. . . . . 7A3-34
. . . . . . 7A3-1
. . . . . 7A342
. . . . . 7A340
. . . 7A3-59 & 60
. . . . . 7A3-52
. . . . . 7A344
. . . . . 7A3-23
. . . . . 7A3-17
. . . . . . . 7A3-16
. . . . . . .
7A3-33
PERIODIC MAINTENANCE
(NOTE: Many of the bolts in the exterior of the
WINTENANCE SCHEDULE
The fluid level should be checked at each oil change see
below). When adding or changing fluid, use DEXRON -11
with a "D" prefix and about five numbers on the top of the
can, or equivalent automatic transmission fluid. Under
normal driving conditions, change transmission fluid every
&
%S
check is made using an available tool, BT-6733. The
@ge Compares the load of a known good modulator with a
"dulator being checked.
1. Install the modulator that is known to be acceptable
On either end of the gage.
2. Install the modulator in question on the opposite
end of the gage. (Fig. 7A3-2)
(NOTE: Do
between channels.
2. Intermediate Clutch
b . Low line pressure.
between channels.
3 . Direct Clutch
a, Restriction in vacuum line to modulator (poor
vacuum response).
b . Clutch piston seals damaged or missing.
c. Case valve body face not flat or porosity
between channels.
GEAR
PARK-NEUT.
FIRST
REV.
DIRECT
CLUTCH CLUTCH
OFF
OFF
OFF
OFF
OFF
ON
FORWARD
REVERSE
ROLLER
ROLLER
CLUTCH
CLUTCH
CLUTCH
CLUTCH
OFF
OFF
INEFFECTIVE
INEFFECTIVE
OFF
INEFFECTIVE
LOCKED UP
OFF
INEFFECTIVE
LOCKED UP
OFF
ON
INEFFECTIVE
INEFFECTIVE
OFF
OFF
OVERRUN
BAND
T U R B O HYDRA-MATIC 350
DIAGNOSIS CHART
2.
3.
4.
5.
** CAUTION:
Total test running time for these four (4) tests not to exceed two (2) minutes.
0" vacuum
to modulator
**Brakes
Drive
Applied
1OOORPM
#=# Reverse
Brakes
Applied
1OOORPM
** Super or
Neutral
Brakes
Applied
1000RPM
Lo Brakes
Applied
1000RPM
Brakes on
Detent*
Drive
Idle
(11 Drive
30MPH
Closed
Throttle
Drive-from
1000 to
3000 RPM
Wheels free
55-70
Pressure
drop of 10
PSI or more
Activated
**1000
Drive
RPM
Pressure Test
Conditions
to move
I
60-90
85-150
85-110
55-70
90-110
60-85
DROP
r
Normal Results
Note (2)
Malfunction in Control
Valve Assembly
I
NO DROP
Malfunction in
Governor or
Goyernor Feed System
ALL PRESSURES HlGH WlTH LESS THAN 35 PSI BETWEEN PRESSURE READINGS
ALL PRESSURES HlGH WlTH MORE THAN 35 PSI BETWEEN PRESSURE READINGS
Malfunction in
Modulator
Low
---
--
Low
Low to
Normal
Low to
Normal
-. -- - ---
Low to
Normal
Low to
Normal
Low
Detent System
I
_I
Malfunction in
Detent System
--
1 2 PART THROTlil
=
-
3 7 PhRT T H R O T I L t
M A N U A l VALVE
D I T I N I VALVE
RAL-ENGINE
RUNNING
, 7n
A
-
COOLER O U T
'RAL
-4 D 1
EXHAUST
--
EXHAUST
DIRECT CLUTCH
DIRECT C L U T C H
F O R W A R D CLUTCH
PUMP PRESSURE
CObIVERTER FEED
COOLER O U T
( F R O M RADIATOR )
COOLER IN
( TO RADIATOR ) 7
INTERMEDIATE CLUTCH
CONVERTER FEED
COOLER OUT
( FROM RADIATOR
INTERMEDIATE
PRIMING VALVE
FROM RADIATOR
TO RADIATOR )
MP LIP SEAL D R A I N
- CHART C -
- CHART D -
1. ENGINE
A. TUNE UP
B. LOOSE VACUUM FITTINGS
C. VACUUM OPERATED UNIT LEAK
(HOSES, VACUUM ADVANCE, ETC.)
2. VACUUM LINE TO MODULATOR
A. LEAK
B. LOOSE FITTING
C. CARBON BUILD UP A T MOD. VAC.
FITTING
D. PINCHED LlNE
E. GREASE I N PIPE (NO OR DELAYED
UPSHIF T-COLD)
C
CHECK MOD.
- CHART A
6. Internal C i r c u i t Leaks.
a. Forward c l u t c h leak (pressure n o r m a l i n neutral a n d reverse-pressure
l o w in drive.
(1) Check p u m p rings.
(2) Check f o r w a r d c l u t c h seals.
b- Direct c l u t c h leak (pressure n o r m a l i n neutral, l o w , i n t . a n d drivePressure l o w i n reverse).
(1) Check direct c l u t c h outer seal f o r damage.
(2) Check 1-2 accumulator a n d 2-3 accumulator pistons a n d rings
f o r damage o r missing.
CHART B -
CAUSE OF H I G H L I N E PRESSURE
1. V a c u u m Leak
a. F u l l leak-vacuum line disconnected.
b. Partial leak i n line f r o m engine t o modulator.
c. I m p r o p e r engine vacuum
d. V a c u u m operated u n i t leak, (hoses, vacuum
advance, etc.)
2. Damaged M o d u l a t o r
a. S t u c k valve
b. Water in m o d u l a t o r
c. N o t operating properly.
3. P u m p
a.
4. C o n t r o l Valve Assembly
a. Pressure reg. and/or boost valve stuck.
b. Pressure boost valve sleeve b r o k e n o r otherwise
defective.
I 1ST
-1
IPARK.
--
---
TRANSMISSION NOISY (
PUMP CAVITATION
0 IL L N EL LOW
PLUGGED OR RESTRICTED SCREEN
WRONG F ILTER
POROS ITY I N P U M P INTAKE CASE
PASSAGE
WATER I N O I L
POROS I T Y OR VOIDS AT TRANS. CASE
( PUMP FACE) INTAKE PORT.
PUMP TO CASE GASKET OFF LOCATION
INTERNAL LINKAGE
PUhIP ASSEMBLY
NO ENGINE BREAKING-LO
L_T__I
CASE ASSEMBLY
CONVERTER
VALVE STUCK
-1
I
NO ENGINE BREAKING SUPER
RANGE-SECOND GEAR
LNOTENGAGED ON SERVO P I N
SQUEAL AT LOW
CAR SPEEDS
I
I
SPEEDOMETER DRIVEN GEAR SHAFT SEAL
1
%;
T R A N S M I S S I O N a n d ASSEMBLY O F THE
TRANSMISSION will apply.
Oil pan and gasket.
Oil filter
Valve body assembly.
Direct clutch accumulator and servo (requires valve body
removal).
Manual control linkage and parking pawl.
Extension housing and seal.
Vacuum modulator.
Speedometer drive gear.
"Governor assembly.
"Intermediate clutch accumulator.
"Requires a procedure different than described under
Disassembly and Assembly.
GOVERNOR (WITHOUT REMOVING TRANSMISSION)
Removal
1 . H o i s t car, disconnect speedometer cable at
transmission.
2. Remove governor cover retainer and governor cover.
ERTER ASSEMBLY
OUTPUT SHAFT
VALVE
BODY
INPUT SHAFT
SUCTION
Transmission
Code
Engine
DIRECT CLUTCH
FORWARD CLUTCH
Speedometer
Drive
Gear
No. of
Faced
Plates
No. of
Steel
Plates
Clutch
Piston
Thickness
No. of
Faced
Plates
No. of
Steel
Plates
Clutch
Piston
Thickness
No. of
Faced
Plates
No. of
Steel
Plates
Clutch
Piston
Thickness
No. of
Faced
Plates
No. of
Steel
Plates
Clutch
Piston
Thickness
KL
*Starfire
231 V-6
2 Bbl. VIN A
7 Tooth
1.184"
1.014"
1.405"
3.091 "
KG
**Starfire
231 V-6
2 Bbl. VIN A
9 Tooth
1.184"
1.014"
1.405"
3.091"
Omega
231 V-6
2 Bbl. VIN A
17 Tooth
1.184"
1.014"
1.405"
3.091"
Omega &
Cutlass
305 V-8
2 Bbl. VIN U
305 V-8
4 Bbl. VIN H
19 Tooth
.992"
.833"
1.223"
2.906"
JD
Omega &
Cutlass
350 V-8
4 Bbl. VIN L
18 Tooth
.992"
.833"
1.223"
2.906"
KE
Cutlass
& 88
231 V-6
2 Bbl. VIN A
17 Tooth
1.184"
1.014"
1.405"
3.091"
LD
Cutlass
& 88
260 V-8
2 Bbl. VIN F
19 Tooth
1.184"
1.014"
1.405"
3.091"
LA
***88
350 V-8
4 Bbl. VIN R
19 Tooth
,992"
.833"
1.223"
2.906"
LH
a88
350 V-8
4 Bbl. VIN R
19 Tooth
.992"
,833"
1.223"
2.906"
LC
-88
403 V-8
4 Bbl. VIN K
19 Tooth
,992"
333"
I .223"
2 .9Obw
LK
-88
403 V-8
4 Bbl. VIN K
18 Tooth
,992"
.833"
1.223"
2.906"
---
--
1
-
LE
088
403 V-8
4 Bbl. VIN K
19 Tooth
.992"
,833"
1.223"
2.906"
LJ
Custom
Cruiser
350 V-8
Diesel
VIN N
19 Tooth
.992"
.833"
1.223"
2.906"
WC
Starfire
305 V-8
2 Bbl. VIN U
9 Tooth
1.184"
1.014"
1.405"
3.091 "
High Altitude
2.41,2.56,2.73,3.08 Axle Ratios Except High Altitude
3.23 Axle Ratio Except High Altitude
3. Install retainer.
4. Connect speedometer cable, lower car and check
transmission oil level.
INTERMEDIATE CLUTCH ACCUMULATOR
,''A
/-"/
Removal
1. Remove two transmission oil pan bolts below the
intermediate clutch accumulator cover. Install 5-23069 in
place of bolts removed.
2 . Press in on cover and remove retaining ring with an
awl as shown in Fig. 7A3-16.
3. Remove cover "0" ring seal, spring and intermediate
clutch accumulator.
ring.
Removal
1. At the carburetor end of the detent cable, lift the
"snap-lock", then slacken the cable from the carburetor
bracket and linkage. (Fig. 7A3-17)
2. Remove transmission oil level dipstick and upper
bolt on dipstick tube (from above).
V A C U U M MODULATOR
VIEW OF P I P E
INSTALLATION
"IEW @
S PR I N G
WITHSHIFTRODCLAMPSCREW LOOSENED,
SET TRANSMISS ION OUTER LEVER I N NEUTRAL
POS ITION.
TRANS. OUTER
(20FT. LBS.)
"
SHIFTER ASSEMBLY
SHIFT ROD
6. CHECK OPERATION:
TRANSM l SS ION
M A N U A L LEVER
CABLE P I N
CLAMP
C L A M P SCREW
TRANSMISSION CONTROL
-CABLE
ASSEMBLY
C----
TRANSMISSION CONTROL
SHl FTER ASSEMBLY
lel
TRANSMISSION
TRANSM(SSI0N CONTROL
CABLE BRACKET
TRANSMISSION DISASSEMBLY
Ic.
NUT
LEVER ASSEMBLY
BRACKET
Fig. 7A3-29-Transmission in
Holding Fixture
V A C U U M MODULATOR
'
I
!+
ii
I
I
ER DRIVE G E A
RETAINING CLIP
gj:i
Itd
'
14. Lift valve body while guiding manual valve link from
(J-8001)
DIAL INDICATOR
TER
5-2
'
I
Fig. 7A3-64-Intermediate Clutch Plates
INTERMEDIATE OVERRUN
BRAKE BAND
Fig. 7A3-66-Intermediate Overrun
Brake Band
TO OUTPUT SHAF
r
Fig. 7A3-73-Sun Gear Drive Shell
I2
OUTPUT R I N G
GEAR TO CASE
NEEDLE B E A R I N G
'11
7A384)
5 6. Remove low and reverse clutch piston assembly.
(Fig. 7A3-85)
57. Remove low and reverse clutch piston outer seal.
(Fig. 7A386)
I
!i
ncv t ~ a LLUTCH
t
J-23327-2
\
S P R I N G RETAINER
1 CLUTCH PISTON
'
Ill i
INTERMEDIATE CLUTCH
\ACCUMULATOR PISTON
Inspection
1 . Wash all parts in cleaning solvent , air dry and blow
1 - 2 S H I F T VALVE
1 - 2 S H I F T CONTROL VALVE
1 - 2 S H I F T CONTROL SPRING
1 - 2 SHIFT CONTROL S L E E V E
RETAINING P I N
MANUAL LOW CONTROL VALVE
MANUAL LOW CONTROL SPRING
PLUG
RETAINING PIN
D E T E N T REGULATOR VALVE
DETEP:T REGULATOR SPRING SEAT
D E T E N T REGULATOR SPRING
RETAINING P I N
11f
I/
/i
I
t
Disassembly
1. Position valve body assembly with cored face up and
direct clutch accumulator piston pocket positioned as shown.
2. Remove manual valve from lower left hand bore (A).
3. From lower right hand bore (B), remove the pressure
regulator valve train' retaining pin, -boost valve' sleeve,
intermediate boost valve, reverse and modulator boost valve,
pressure regulator valve spring, and the pressure regulator
valve.
4 . From the next bore (C), remove the 2-3 shift valve
train retaining pin sleeve, control valve spring, 2-3 s h f t
control valve, shift valve spring, and the 2-3 shift valve.
5. ~ r o mthe next bhre YD), remove the 1-2 s i f t valve
train retaining pin, sleeve, shift control valve spring, 1-2 shift
control valve and the 1-2 shift valve.
6. From the next bore (E), remove retaining pin, plug,
manual low control valve spring, and the manual low control
valve.
7. From the next bore (F), remove the retaining- pin,
spring, seat, and the detent regdator valve.
8 . From the upper left hand bore (G), remove the
detent actuating leve; retaining pin, actuating lever, bracket
bolt, bracket, stop, spring retainer, seat, outerspring, and the
detent valve.
9. Install tool 5-22269 on direct clutch accumulator
piston (H) and remove retaining "E" ring. (Fig. 7A3-99)
10. Remove direct clutch accumulator piston with
teflon oil seal ring" and s ~ r i n"g .
stoi
'
1.
I/'
OIL PUMP
Disassembly
1. Remove pump cover to body attaching bolts. (Fig.
7A3-100)
2. Remove intermediate clutch return spring and
retainer assembly and the intermediate clutch piston
assembly.
3 . - ~ e m o v eintermediate clutch piston inner and outer
seals. (Fig. 7A3-101)
4. ~ e m o v e(3) direct clutch to pump hub hook type oil
rings. (Fig. 7A3-102)
, ?
INTERMEDIATE
CLUTCH SPRING
h
Jnsnect
If- -r-i--na ~-is- cut
or -frozen -in-a. --. ---r - - - steadv -rest
- - - -ring.
--groove, it must be removed and replaced with the same color
ring.
..
- -
- -
.
.
-.
Im mN T F R M F n l A Tm F f I l l Tu f mUI
~
nL
ULV I
F
f
iron rings.
8. Install intermediate clutch piston inner and out
seals.
9 . Install pump cover on pump body.
10. Install intermediate clutch piston into pump
with the aid of a piece of .020" music wire crimped in
copper tubing .
SHAFT ASSEMBLY
AND PUMP.
P U M P COVER TO P U M P BODY
A T T A C H I N G BOLTS ( 5 )
/
A
.,
RETAINER RING
4I
pig.7A3-116)
RRUN CLUTCH
INTERMEDIATE OVERRU
- 1 1
1
"
I lllr
r
. .-
INTERMEDIATE OVERRUN
I ~%
,STEEL P L A T E S
PRESSURE PLATE
DIRECT CLUTCH D RUM
ASSEMBLY
RE
DIRECT CLUTCH
DIRECT C L U T C H DRUM
STEEL SEPARATOR
DIRECT CLUTCH
PISTON ASSEMBLY
RETAINING RING
FACED PLATE
DIRECT CLUTCH PRESSURE PLATE
RETAINING RING
DIRECT CLUTCH DRUM
AND INTERMEDIATE CLUTCH
OVERRUN INNER CAM
CLUTCH PISTON
C E N T E R SEAL
IIII
11,'
$ 1
Removal
1 . Remove seal with a sharp pointed knife by inserting
under the seal and cutting, making sure not to damage the
seal land area. (Fig. 7 ~ 3 - 1 3 5 )
I
~ 1 1 O L U U 1lb
vv
O"UA,
--A
7-1 7,)
'n"-'""J
U1lLu
g1
'lLU
,I
I
.T
l-"&*La
lrino .
1-77974
and J-9392-01 (six
,
com~ressor
t 001s). Position J -22974
- - with large open end on top of input shaft chamfer. (Fig,
IL
rvlinAer
2ir
- - - -,--------- conditioner
II
I
-
,.,
-
,LUTCH
a - -
PISTON
-- .
Fig. 7A3-133-Forward
n.
n .Clutch
_l_
riston 3ea1s
L -
I
SCORED AREAS
STEEL SEPARATOR PL
CUSHION SPRING
RETAINING RING
FACED PLATE
FORWARD CLUTCH PRESSURE PLATE
1
1
1
FORWARD CLUTCH
BALL CHECK
EXHAUST
ti,!
I
11
-SUN
GEAR
m s s e mbly
1. Remove low and reverse clutch to sun gear shell
thrust
washer. (Fig. 7A3-145)
2. Remove low and reverse overrun clutch i m e r race.
(Fig. 7 ~ 3 - 1 4 6 )
3. Remove low and reverse roller clutch retaining ring.
(Fig. 7A3-147)
' " 4. Remove low and reverse roller clutch assembly. (Fig.
7~3-149)
!f
I
LOW A N D REVERSE
/CLUTCH
SUPPORT
I N N E R RACE
I@
Ii
/
i
ij
I
i\
THRUST WASHER
IF ROLLER F A L L SOUT, ~ N S T A L CR O L L E R
FROM 'OUTSIDE IN ' A S S H O W N 1 0
--
TRANSMISSION ASSEMBLY
1 . Install intermediate clutch accumulator piston
assembly. (Fig. 7A3-150)
2. Install intermediate clutch accumulator piston
spring. (Fig. 7A3-15 1)
3. Place "0" ring seal on intermediate clutch
accumulator piston cover.
4. Install accumulator piston cover. (Fig. 7A3-152)
5 . Install tool 5-23069 to compress intermediate clutch
accumulator cover and install retaining ring. Remove tool
5-23069. (Fig. 7A3-153)
6. Install low and reverse clutch piston center and inner
seal on piston. (Fig. 7A3-154)
7. Install low and reverse clutch piston outer seal. (Fig.
7A3-155)
8. Install low and reverse clutch piston assembly. (Fig.
7A3-156)
(NOTE: Make sure correct low and reverse clutch piston
assembly is installed. Refer to Turbo Hydra-Matic 350, Fig.
7A3-15, information chart for dimensions and model usage.
Notch in low and reverse clutch piston must be installed
adjacent to parking pawl .)
INTERMEDIATE CLUTCH
\ ACCUMULATOR PISTON
TEFLON SEAL R l NG
ilu.
Fig.
- 7A3-15 1-Accumulator Piston
Springs
SEAL
PRlNG COMPR
OUTF'UT RING
ASSEMBLY
CLUTCH PACK
'
INTERMEDIATE OVERRUN
Fig. 7A3-174-Intermediate
Overrun Band
INTERMEDIATE CLUTCH
Fig. 7A3-175-Intermediate Clutch
Pressure Plate
TO CASE ATTACHING
IF REPLACEMENT IS REO
ALUMlNUM QI L SEAL R I N
IMTERNIEaIATE SERVO
MANUAL
LEVER TO M A N U A L
ALL
ER DRIVE GEAR
SEAL
RETAINING CLIP
Fig. 7 A 3 - 2 0 5 - ~ ~ t ~ ~ sHousing
ion
TORQUE SPECIFICAT
APPLICATION
Pump Cover to Pump Body Bolts . . . . . . . . . . . . . . . .
Pump Attaching Bolts . . . . . . . . . . . . . . . . . . . . .
. . . . . . .
Range Selector Inner Lever to Manual Shaft Jam Nut
. . . . . . . . . . . . . . .
Park Lock Bracket Attaching Bolts
Valve Body to Case Attaching Bolts . . . . . . . . . . . . . . .
Oil Pump Screen (Strainer) Attaching Screws . . . . . . . . . . .
Extension Housing to Case Attaching Bolts . . . . . . . . . . . .
Crossmember to Frame Bolts . . . . . . . . . . . . . . . . . .
Crossmember to Mount Bolts . . . . . . . . . . . . . . . . . .
Starfire . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pan Attaching Bolts
V8
. . . . . . . . . . . . . . . . . . . . . . . . . . .
V-6
. . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
Converter to Flywheel
. 48 N*m
17 N - m
EXTENSION
4 HOUSING
SLIDE HAMMER
PUMP COVER
AND STATOR
SHAFT ASSEMBLY
PUMP COVER
AND STATOR
SHAFT ASSEMBL
ADAPTER
i
Fig. 7A3-217-Installing Stator Shaft Rear Bushing
PUMP BODY
\PUMP COVER
A N D STATOR
SHAFT ASSEMBLY
J-8092
DRIVE
HANDLE
j
f
t
J-23062-14
or
PUMP COVER
AND STATOR
OUTPUT SHAFT
SLtDE HAMMER
1
I
II,[
;
!
!/I
/i I
!/
i'i
'1
II
1,
fj',
h r
~p a m ~ r ~ .
~ v u l ~ a-------
rlrv
will insure ,
correct
location
other towards the. .bottom. This
---l t - I , , : , ,
,
,
Of bushing slots wltn governor rleeu
11ult;;s111 Ldac.
Drive bushing in until flush with top of governor bore.
. _ .
DW G
UU3111115
TOOLS 7A3-59
SLIDE HAMMER
ADAPTER, SL IDE HAMMER
SLI DE HAMMER
DR IVER HANDLE
BUSHING REMOVER
CASE BUSHING REMOVER AND INSTALLER
STATOR SHAFT BUSHING INSTALLER (BOTH REAR)
SUN GEAR BUSHING INSTALLER
DIRECT CLUTCH BUSHING REMOVER AND INSTALLER
INPUT R ING GEAR BUSHING REMOVER AND INSTALLER
OUTPUT SHAFT BUSHING INSTALLER
DR IVER HANDLE EXTENS ION
STATOR SHAFT AND SUN GEAR BUSHING REMOVER
O I L PUMP BUSHINGS, REMOVER AND INSTALLER
EXTENS ION HOUSING BUSHING REMOVER AND INSTALLER
ALIGNMENT FIXTURE
AL IGNMENT ARBOR
REAMER
Fig. 7A3-230-Bushing Tools
TURBO HYDRA-MATIC
TRANSMISSION
DIAGNOSIS GUIDE THM 400 AND 425
INDEX
In many of the following diagnosis procedures, it is
recommended that air pressure be applied. The purpose of
this is to help determine if seals, rings or pistons are stuck,
missing or damaged.. Therefore, when air is applied, it is
important to listen carefully for escaping air and piston
action as air is applied to a particular area.
In the event of a major transmission failure, replace the
filter assembly and flush the oil cooler and lines.
PAGE
Case Porosity Repair
Diagnosis Guide Chart
Downshift Switch
.
. . . . . . . . . . . . . 7A4-1
. . . . . . . . . . . . 7A4-7
. . . . . . . . . . . . 7A4-2 1
OIL LEAKS
The suspected area should be wiped clean of all oil
before inspecting for the source of the leak. Red dye is used
in the transmission oil at the assembly plant and will
indicate if the oil leak is from the transmission.
When an oil leak is found the following procedure will
assist in locating the leak.
1. Clean the area with solvent to remove all traces of
SUBJECT
Information Chart
Oil Leak Diagnosis
Oil Pressure Charts
PAGE
. . . . . . . . . . . . . 7A4-14
. . . . . . . . . . . . . . 7A4-1
. . . . . . . . . . . . . . 7A4-6
to
"Periodic
1111
FRON
VENT
SPACER PLATE
70 CASE GASKET
MODULATOR OR
INTERMEDIATE
MODULATOR OR
INTERMEDIATE
PRESSURE REGULA
FEED HOLE
P U M P INTAKE
CONVERTER RETURN
LOIRNIEF I C E
LINE
EX
&ND
L ~ N ~
IN1
/-
--
M O D TO I 2 A C C U M
r\-
.-. . ,
CONVERTER FEED
LINE,
DRIVE
MODULATOR
I
LUBE (FROM COOL
INTERMEDIATE
SERVO OIL
THRU EXHAUST
LINE
/\
/\ MOPULATOR
~ffi!
J\k
111;
[Iil1
,
d ,:
PART NO.
STAMPED
HERE
VACUUM CONNECTOR
S EAM
i111
/
-
VACUUM P O R i s o d
BOTH AIOUULATORS
Mus7~pEh
/[ (:/ :;
I{,
' 5
J
Fig. 7A4-16-Checking Modulator
ij '
i;',
I1
I/!i
I
I\
'
CHECKING PROCEDURES
2.
3.
4.
5.
Drive
Idle
Drive
Brakes
Applied
1000 RPM
Super or Lo
Brakes
Applied
1000 RPM
Reverse
Brakes
Applied
1000 RPM
Drive-Brakes
Applied 1000 RPM
Downshift
Switch Activated*
55-70
60-85
60-90
135-160
95-150
90-110
Drop of
10 PSI or More
55-70
Normal
Normal
Normal
Normal
Normal
Normal
10 PSI Drop
or More
Normal
Neutral
Brakes
Applied
1000 RPM
(1 Drive
30 MPH
Closed
Throttle
Possible Cause
of Malfunction
Normal
Oil Pressure
No 1-2 Upshift
Andlor Delayed
Upshift
Slipping-~everse
Normal
Normal
Normal
Normal
Normal
Normal
Less Than
10 PSI Drop
Normal
Normal
High
High
Normal
Normal
Normal
Drop
High
High
High
High
Normal
High
Normal
Normal
Normal
Normal
Low
Normal
Drop
Normal
Malfunction in
Control Valve Assy.
Malfunction in
Governor or
Governor Feed
System
Malfunction in
Detent System
Malfunction in
Modulator or
Vacuum Feed System
to Modulator
Oil Leak in Feed
System to the
Direct Clutch
J
Slipping-1st Gear
No Detent
Downshifts
Normal
Normal
Low to
Normal
Low to
Normal
Low to
Normal
Normal
Normal
Normal
Normal
Normal
Low t o
Normal
Low
Normal
Low to
Normal
Normal
'L
1
DISCONNECT ELECT. PLUG
FROM TRANS. AND TEST CAR
I
NO UPSHIFT
I
C J
60-90 PSI
90-15.0 PSI
70-160 PSI
55-70 PSI
DETENT SYS.
I
CHECK DETENT VALVE TRAIN
- CHART C
LlNE
--
1 CHECK TRANS.
+
CHECK ENGINE TUNE
4
WITH BRAKES APPLIED
C H K K LlNE PRESSURE I N DR. AT 1OW RPM
I +-?
NORMAL
NORMAL
AND SOLENOID
s
-
CHART B
1 V A C W M LEAK
A NU U * K V A C W M LINE M X O N N K T I D
m PARTIAL U A K I N UN FROM NOIN TO MODUUTOR
C I M m W R I N G I N VACUUM
0 V A C W Y m A l O U N I T LEAK (HOSS. V A C W M
ADVANCE WC I
1 DAMbQD MODULATOR
A STUCK VALm w b n a IN r r o w i r r o n
c MOT O r r r r n m m o r n ~ r
3 D n m T SYSTEM
A
s m r c N A n u A n D OR s ~ o l r t o
I DCIH~w l n l r n %O.TH)
C D m N l SOLENOID STUCK O R N
D DCRNT rao or~ncr
IN KACH
n*n uocrn,
DCRNT I O o l D L O O I (
6 DCIHn V U W U W UW D N A G DmM R W V A L W PIN SHOlll
4 N U *
A P R E S M I RG AND/OR WOOST VALVE STUCK
I I N C O I R ~ m m w f i REQ ~ I M G
C T O 0 MANY PRESSUIS R W V A L V I SPACERS
D PUMP CASnNO B 4 D
1 CMKY
v u n rsrtvur
A cwu
v A L n ASSY TO YAQR a s a n ow LOCATION
mw
m orvnr rmicmD
II
1
I M O D U U I O R bSS&?MUY
REHR TO CWCKINQ CIOCEWRE
1
I
a
EXCESSIVE
4 4
W MNOT
P
NUJOU Y A C H S I N RESSUm I K W U T O I
8 m u s u n REOUUTO~
IIWO,
TOO WEAK
C Q A I C L U R A K L DAM*-.
WORN
I IWIIBNAL C l K U T U A K l
A FORWARD CLUTCH LEAK ( m c s s u a c NORMAL IN NEUTRAL AND REVERYPRESSURE LOW I N D I f V I
1 C M K K W M P RlWOS
a CWK FOIWARD crvtcn l u ~ s
m DIRECT CLUTCH UAK lmrrrut NORMAL IN NCUTRAL, LOW. SWR
AND n n I V t - m E s w a E LOW IN WVIRYI
a
NORMAL
- CHART A -
- CHART B -
C A U S E O F L O W L I N E PRESSURE
C A U S E O F HIGH L I N E PRESSURE
3. FILTER
A. BLOCKED OR RESTRICTED.
B. "0" RING O N INTAKE PIPE OMITTED OR DAMAGED.
C. SPLIT OR LEAKING INTAKE PIPE.
4. PUMP
A. NOT ENOUGH SPACERS I N PRESSURE REGULATOR.
B. PRESSURE REGULATOR SPRING, TOO WEAK.
C. GEAR CLEARANCE, DAMAGED, WORN.
5. INTERNAL CIRCUIT LEAKS
A. FORWARD CLUTCH LEAK (PRESSURE NORMAL I N NEUTRAL AND REVERSEPRESSURE LOW I N DRIVE).
1. CHECK PUMP RINGS.
2. CHECK FORWARD CLUTCH SEALS.
B. DIRECT CLUTCH LEAK (PRESSURE NORMAL I N NEUTRAL, LOW, SUPER
AND DRIVE-PRESSURE LOW I N REVERSE).
1. VACUUM LEAK
A FULL LEAK-VACUUM LlNE DISCONNECTED.
B. PARTIAL LEAK I N LlNE FROM ENGINE TO MODULATOR.
C. IMPROPER ENGINE VACUUM.
D. VACUUM OPERATED UNIT LEAK. (HOSES, VACUUM
ADVANCE, ETC.)
2. DAMAGED MODULATOR
A. STUCK VALVE.
B. WATER I N MODULATOR.
C. NOT OPERATING PROPERLY.
3. DETENT SYSTEM
A. DETENT SWITCH ACTUATED OR SHORTED.
B. DETENT WIRING SHORTED.
C. DETENT SOLENOID STUCK OPEN.
D. DETENT FEED ORIFICE I N SPACER PLATE BLOCKED.
E. DETENT SOLENOID LOOSE.
F. DETENT VALVE BORE PLUG DAMAGED.
G. DETENT REG. VALVE PIN SHORT.
4. PUMP
A. PRESSURE REG. AND/OR BOOST VALVE STUCK.
8. INCORRECT PRESSURE REG. SPRING.
C. TOO MANY PRESSURE REG. VALVE SPACERS.
D. PUMP CASTING BAD.
5. CONTROL VALVE ASSEMBLY
A. CONTROL VALVE ASSY. TO SPACER GASKET OFF LOCATION.
B. GASKETS SWITCHED.
s
c
TRANSMISSION
NOISY
11
I
1
NO
ENGINE BRAKING
RANGE IS7 GEAR
LO
PUMP ASSEMBLY
.*
1'
INTERNAL LINKAGE
PUMP CAVITATION'
0 IL LEVEL LOW
PLUGGED OR RESTRICTED FILTER
WRONG FILTER
INTAKE PIPE "0" R I N G DAMAGED
INTAKE PIPE SPLIT, POROSITY I N CASE INTAKE
P I P E BORE.
WATER I N O I L
POROSITY OR VOIDS AT TRANS. CASE (PUMP FACE]
l NTAKE PORT,
PUMP TO CASE GASKET OFF LOCATION.
CONVERTER
LOOSE BOLTS (CONVERTER TO FLYWHEEL)
CONVERTER DAMAGED.
[PLANETARYGEAR SET
GEARS OR THRUST BEARINGS DAMAGED.
FRONT l NTERNAL GEAR R l NG DAMAGED.
THPOUGHLY CLEAN THRUST BEARINGS AND
RACES. INSPECT NEEDLES FOR ROUGH
SURFACE AND PITTING.
CASE ASSEMBLY
LO-REVERSE CHECK BALL M I SPOS ITIONED OR
MISSING. CASE DAMAGED AT LO - REVERSE
CHECK BALL AREA.
J
I
REAR SERVO
OIL SEAL RING, BORE OR PISTON DAMAGED
REAR BAND APPLY P I N SHORT, IMPROPERLY
ASSEMBLED
DURING A C C E L E R A T I O ~
ANY GEAR
1.
REAR BAND
BROKEN, BURNED (CHECK FOR CAUSE]
NOT ENGAGED ON ANCHOR P I N S AND/OR
SERVO PIN.
SQUEAL AT LOW VEHICLE
SPEEDS
I
FRONT BAND
NO DETENT DOWNSHIFTS
I
1.
DETENT SWITCH
MALADJUSTED - REFER TO DETENT SWITCH
ADJUSTMENT PROCEDURES.
CHECK CAUSE
w
I
I
WlTH BRAKES APPLIED, CHECK LlNE PRESSURE
IN REVERSE AT 1000 R.P.M.
2.
3.
I
FORWARD CLUTCH
CLUTCH DOES NOT RELEASE (WILL ALSO
2.
3.
DRIVE IN,NEUTRAL
- I
/
I
CENTER SUPPORT
OIL SEAL RINGS OR GROOVES DAMAGED
OR WORN
PUMP ASSEMBLY
TRANS. LUBE PRESSURE LEAKING INTO
FORWARD CLUTCH APPLY PASSAGE
FORWARD CLUTCH
BURNED PLATES CHECK CAUSE
INCORRECT CLUTCH PLATE USAGE
SEE CHART IN SERVICE MANUAL
_T1
,,
ARGA~
?, INTERMEDIATE CLUTCH
3. DIRECT CLUTCH
A. RESTRICTED ORIFICE IN VACUUM L I N E T O MODULATOR (POOR VACUUM RESPONSE).
B. CHECK BALL I N DIRECT CLUTCH PISTON DAMAGED, STUCK OR MISSING.
C . DEFECTIVE MODULATOR BELLOWS.
D. CENTER SUPPORT BOLT LOOSE. (BOLT MAY BE T I G H T IN SUPPORT BUT NOT HOLDING SUPPORT
TIGHT TO CASE).
E. CENTER SUPPORT OIL RINGS OR GROOVES DAMAGED OR MISSING.
F. CLUTCH PISTON SEALS DAMAGED OR MISSING.
G. FRONT AND REAR SERVO PISTONS AND SEALS DAMAGED.
H. MANUAL VALVE B E N T AND CENTER LAND NOT CLEANED UP.
I. CASE VALVE BODY FACE NOT FLAT OR POROSITY BETWEEN CHANNELS.
J. INTERMEDIATE SPRAG CLUTCH INSTALLED BACKWARDS.
K. 3-2 VALVE, 3-2 SPRING OR 3-2 SPACER PIN INSTALLED IN WRONG
LOCATION I N 3-2 VALVE BORE.
NOTE: IF DIRECT CLUTCH PLATES A N D FRONT B A N D ARE BURNED, CHECK MANUAL LINKAGE.
NOTE: BURNED CLUTCH PLATES C A N BE CAUSED BY INCORRECT USAGE OF CLUTCH PLATES. ALSO, ANTI-FREEZE IN
TRANSMISSION FLUID C A N CAUSE SEVERE DAMAGE, SUCH AS LARGE PIECES OF COMPOSITION CLUTCH PLATE MATERIAL PEELING OFF.
THREAD SIZE
IDENTIFICATION
Manual Shaft
MI0 x 1.5-6g
Groove on metric
end of shaft with
drill point in end
of shaft.
TransmisionCase:
Speedometer
Attaching Bolt Hole
M6.3~1-6H
NONE
Case Extension:
Transmission
Mount
Bolt Holes
M10x1.5-6H
Letter"MVInk
Stamped on case
extension.
FORWARD CLUTCH
DIRECT CLUTCH
INTERMEDIATE CLUTCH
I
Flat Steel
Plates
No. of
Waved
' Steel
Thickness Plates
No. of
Dished
Steel
Plates
No. of
Composition
Plates
No.of
Flat
Steel
Plates
No.of
Waved
Steel
Plates
No. of
Composition
Plates
No.of
Flat
Steel
Plates
No.of
Waved
Steel
Plates
No. of
Composition
Plates
Body Type
Engine
Converter
identification
Number
OB
(400)
98
OD*
(400)
98
OC**
(400)
98
18 Tooth
0775"
0J
(425)
Toronado
4 & Green
Dot
14Tooth
.0915"
Transmission
Code
Speedometer
Drive Gear
No.
.O77Sn
'I
*
**
TURBO HYDRA-MATIC
400 TRANSMISSION
FOR ADDING AND CHECKING OIL, REFER TO SECTION 7 A 3
INDEX
PAGE
Bushing Service . . . . . . .
Case Porosity Repair . . . . .
. . . . . . .
Center Support
. . . . .
Converter C h e c h g
Description of Operation
. . .
magnosis . . . . . . . . . .
Direct Clutch . . . . . . . .
~ownshift~witchAdjustments
Forward Clutch . . . . . . .
Governor . . . . . . . . . .
~nformationChart . . . . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
. . . . 7A4-131
. . . . . 7A4-1
. . . . 7A4-52
. . . . 7A4-58
. . . . 7A4-15
. . . . .7A4-1
. . . . 7A4-47
. . . . 7A4-21
. . . . 7A442
. . . . 7A4-34
. . . . 7A4-14
GENERAL DESCRIPTION
SUBJECT
PAGE
Linkage Adjustments . . .
Oil Pump . . . . . . . .
Pinion Gears
. . . . . .
Speedometer Drive Gear
.
Tools
. . . . . . . . .
Torque Converter Diagnosis
Torque Specifications
. .
Transmission Disassembly .
Transmission Reassembly .
Transmission Removal And
Installation
. . . . . .
Valve Body . . . . . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
. . . . . . 7A4-20
. . . . . . 7A4-39
. . . . . . 7A4-55
. . . . . . 7A4-56
. . . . . .7A4-136
. . . . . . . 7A1-4
. . . . . .7A4-130
. . . . . . 7A4-22
. . . . . . 7A4-62
. . . . . . . . .
. . . . . . . . .
7A4-17
7A4 -37
ratio
Second - 1.5: 1 gear ratio
- 1.O:l
Third
Reverse - 2 .O: 1 gear ratio X 2.0 converter stall
ratio
5.0: 1
TRANSMISSION REMOVAL
1 . Remove flywheel cover.
2. Remove torque converter attaching bolts.
TRANSMISSION INSTALLATION
To install, reverse the removal procedure and include
the following:
Before installing the flex plate t o converter bolts, make
certain that the weld nuts on the converter are flush with
the flex plate and the converter rotates freely by hand in
this position. Hand start the three bolts and tighten finger
tight, then torque to specifications. This will insure proper
converter alignment. Install new oil seal on oil filler tube
before installing tube.
Connect propeller shaft to companion flange. Torque
bolts to 20 ft . lbs.
CAUTION: The propeller shaft to
companion flange fastener is an
important attaching part in that it
could affect the performance of
vital parts and systems, and/or
could result in major repair
expense. I t must be replaced with
one of the same part number or
w i t h an equivalent part if
replacement becomes necessary. DO
not use a replacement part of lesser
quality or substitute design. Torque
values must be used as specified
during reassembly to assure proper
reten tion of this part.
CHECKING AND ADDING FLUID
Refer to Section 7A3. If work has been performed on
the transmission, add the following quantity of fluid then
check fluid as outlined in Checking and Adding Fluid,
Section 7A3.
TURBO HYDRA-MATIC (400)
Pan Removal
.. ... ..
. . . . .
Converter Change
Overhaul . , . , . . . . .
. . . . . . . - 3 Quarts
. . . . . . . . 6 Quarts
. . . . . . . 10 Quarts
r
+-
SPRING
LEVER (COL.
4. CHECK OPERATION.
ASSEI\IIBk..Y
CONNECTOR
-
TRANSMISSION DISASSEMBLY
CONVERTER AND MODULATOR
Removal
1. With transmission in cradle on portable jack,
remove the converter assembly by pulling straight out.
1
Fig. 7A4-29-Removing Modulator And Valve
GOVERNOR SCREEN
GOVERNOR FEED
-7
bind.
b. Apply 25 ft . lbs. torque and select proper pin to be
used during assembly of transmission.
There are three selective pins identified as shown in the
following chart. (Fig. 7A4-44)
PINIDENT.
SIZE
TO P STEP
O P ABOVE
THREE R INGS
LONG
T H I S AREA
TWO R I N G S
MED.
LOWER
STEP OR
BELOW
ONE R I N G
SHORT
STEP LOCATION
GJ-21370-5
--
Thickness
Colors
No.
.060" to
.071" to
.082" to
.093" to
.104" to
.115" to
.126" to
Yellow
Blue
Red
Brown
Green
Black
Purple
0
1
2
3
4
.064"
.075"
.086"
.097"
.108"
.119"
.130r1
11!'
SHAFT
f.
.,,
Thickness
.074" to
.082" to
.090" to
.098" to
.106" t o
.114" to
.078"
.086"
.094"
.102"
.110"
.118"
.1
.2
.3
.4
.5
.6
HAMMER 1-6125
(NOTE: One of the races may have been removed with the
center support.)
4. Remove the reaction carrier and roller clutch
assembly. (Fig. 7A4-82)
5. Remove front internal gear ring from output
carrier assembly. (Fig. 7A4-83)
6. Remove sun gear. (Fig. 7A-84)
7. Remove reaction carrier to output carrier thrust
washer. (Fig. 7A4-85)
8. Turn assembly over.
9. Remove "0" ring from output shaft on Models
that use an "0" ring.
10. Remove output shaft to output carrier snap ring
and remove output shaft. (Fig. 7A4-86)
ORIFICE PLUG
llllllilil-
MAIN SHAF
ANGED
RACE
THRUST BEARINGS
I.D. FL.ANGED
/ RACE
ROLLER CLUTCH
PLASTIC GEAR
GOVERNOR ASSEMBLY
All parts of the governor assembly, with the except ion
of the driven gear, are a select fit and each assembly is
calibrated. The governor, including the driven gear, is
retainers.
--
---
SPRINGS ( 2 )
THRUST CAP
PRIMA?.' WEIGHT ( 2 ,
ACCUMULATOR PISTON
Inspection
(NOTE: Do not remove the teflon oil seal ring from the
front servo piston unless the oil seal ring requires
replacement. For Service, the oil seal ring will be
aluminum .)
I
Fig. 7A4-98-Removing "E" Ring
RETAINING
E RING
SERVO F'!SlON
L '
SERVO PIN
C ~ ~ ~ RVALVE
O L ASSEMBLY (Fig. 7A4-101)
VOTE: As each valve train is removed, place the
valve train in a separate location relative to its
psition in the valve body. Also, place each part of each
valve
train in the order that it is removed from the valve
bore. None of the valves or springs are interchangeable.
Keep them in the proper valve train .)
2 3 4
dewl
& e x
17
23
24
20
19
25
26 27
- - -- -
MODEL 0 6
1 MANUAL VALVE
2 RETAINING PIN
18
BORE PLUG
4 DETENT VALVE
5 . DETENT REGULATOR VALVE
6 SPACER PIN
7 DETENT REGULATOR SPRlNG
8 1-2 SHIFT VALVE
9 1-2 DETENT VALVE
10 1-2 REGULATOR SPRING
11
12
13
14
15 BORE PLUG
16 1-2 ACCUMULATOR VALVE
17 2 3 SHIFT VALVE
18 3-2 INTERMEDIATE SPRlNG
19 2-3 MODULATOR VALVE
20 2-3 VALVE SPRING
21
22
2 - 3 MODULATOR BUSHING
23
3-2 VALVE
24
25
26
27
BORE PLUG
RETAINING PIN
28
29
RETAINING PIN
SPACER PIN
(NOTE: Do not remove the teflon oil seal ring from the
CCUMULATOR SPRING
Assembly
1. Install front accumulator spring and piston into
valve body.
2. Using tools as shown in Fig. 7A4-103, install the
accumulator spring and piston and secure with retaining
ring. While installing servo, jiggle valve body while rotating
screw t o prevent piston bindmg.
3 . In lower left bore, install the 1-2 accumulator
primary spring (if required) and the 1-2 accumulator valve,
stem end out. Install the 1-2 accumulator secondary spring
(if required) and the bore plug. lnstall retaining pin from
cast surface side of valve body, with the grooves of pin
entering hole last. Tap pin with a hammer until it is flush
with the cast surface side of valve body.
4. Install the detent regulator spring and spacer in
next bore up. (Fig. 7A4- 104)
E EELER C 4 U G t
DFTFYT
OIL PUMP
L
Djsssembly
1. Place pump assembly in hole in bench or Holding
Fixture 5-6116.
2 . Compress the regulator boost valve bushing against
the pressure regulator spring and remove the snap ring,
u d g J-5403 Pliers. (Fig. 7A4-105)
3. Remove the regulator boost valve bushing and
valve
4. Remove the pressure regulator spring.
5 . Remove the regulator valve, spring retainer and
spcer(s) if present. (Fig. 7A4-106)
6. Remove pump cover to body attaching bolts and
remove pump cover from body.
7. Remove the retaining pin and bore plug from the
pressure regulator bore. (Fig. 7A4107)
8. Check condition of oil rings, then remove them
from the pump cover if necessary. (Fig. 7A4-108)
9. Remove the pump to forward clutch housing
selective washer.
10. Mzrk drive and driven gears for reassembly in same
position and remove drive gear. (Fig. 7A4-109)
PRESSURE
EGULATOR
Fk. 7A4-106-Removing
SPRING
RETAINER
WASHER
Pump Inspection
PUMP COVER
-SEAL
REG. BOSS.
MODULATOR OR
INTERMEDIATE
* *t%@rn
DRAIN
pmP1.
Install the drive and driven pump gears into the
I-
DRIVE
-- .,
r\
r P
MODULATOR OR
"-../INTERMEDIATE
PRESSURE REGULATOR
FEED HOLE
LII;EI
;
(NOTE: If teflon rings are being used, make sure slit ends
are assembled in same relation as cut, Fig. 7A4-118. Also,
make sure oil seal rings are seated in ring grooves t o prevent
damage t o rings during reassembly of mating parts over
rings.)
PUMP COVER
PRESSURE BOOST VALVE
\PRESSURE BOOSTBUSHING
SNAP RING
THRUST WASHER
PUMP OIL SEAL RINGS
3
RIGHT
WRONG
,&ers.
clutch pistons look almost the same. Make sure the forward
clutch piston is identified during disassembly so it wd be
reassembled into the forward clutch housing. The
production built forward clutch piston will be aluminum or
stamped steel.)
Inspect ion
1. Inspect the composition-faced and steel
plates for signs of burning, scoring, or wear.
2. Inspect 16 springs for collapsed coils or ig,,
,c
-0"w1
distortion.
3. Inspect the clutch hubs for worn splines,
lubrication holes, thrust faces.
4. Inspect the piston for cracks or porosity.
5. Inspect the clutch housing for wear, scoring, open
oil passages and free operation of the ball check.
Fk.
" 7A4-127-Removing: Outer Piston Seal
t
'1
I
I
FORWARD CLUTCH
FLAT STEEL
FORWARD
DIRECT
WASHERS
COMPOSITION
~isassembl~
1. Remove roller retainer snap ring and retainer. (Fig.
7 A4- 1 42)
2. Remove roller outer race (Fig. 7A4-143), and rollel
springs.)
SNAP R I N G
INTERMEDIATE
OUTER RACE
ROLLER
ASSEMBLY
INTERMEDIA1
CLUTCH
DIRECT CLUTCH
HOUSING
I N T E R M E D I A T E C L U T C H O U T E R RACE
I N T E R M E D I A T E ROLLER C L U
DIRECT CLUTCH H O U S I N G
AND RACE ASSEMBLY
IRECT CLUTCH CENTER SEAL
r\\\
DIRECT CLUTCH
HOUSING
INTERMEDIATE CLUTCH
ROLLER ASSEMBLY
Roller Assembly
~ T E Do
: not remove the three screws retaining the
IoUer clutch inner race t o the center support .)
lnspect ion
1. Inspect the roller clutch inner race for scratches or
Be sure the lubrication hole and .020"
bleed orifice is open. (Fig. 7A4-210)
2. Inspect the bushing for scoring, wear or galling.
3. Check oil ring grooves and oil rings for damage.
4. Air check the oil passages t o be sure they are open
and not interconnected.
5. Inspect the pist on sealing surfaces for scratches.
6. Inspect the piston seal grooves for nicks or other
darnage.
7. Inspect the piston for cracks or porosity.
8. Inspect the release springs for distortion.
9. Inspect support to case spacer for burrs or raised
edges.
ROLLER
ASSEMBLY
RELEASE SPRING ( 3 )
3
RIGHT
WRONG
ini ion
PINION GEARS
Removal and Instahtion
1. Support the carrier assembly on its front face.
2. Using a 112" dia. drill, remove the stake marks
from the end of the pinion pin, or pins, to be replaced. This
will reduce the probability of cracking the carrier when
pinion pins are pressed out.
BRONZE WASHER
STEEL WASHER
NEEDLE BEARINGS
BRONZE WASHER
111
Modulator and Va k e
1. Inspect the modulator assembly for any signs of
bending or distortion.
2. Inspect the "0" ring seal seat for damage.
tt
Checking Converter
1. Check converter for
7A4-196)
a. Install Tool J-21369 and tighten.
_______ RFVFRqF
II.
I"
ill
'
1 ,
[I;\' i ; :
Case Assembly
1. inspect case assembly for cracks, porosity or
interconnected passages. (Figs. 7A4-194 and 7A4-195)
*"
SPEEDOMETER
DRIVE GEAR
O-RING
O.D. FLANGE
THRUST WASHER
(METAL OR NON -METAL)
SUN GEAR
I.D. FLANGE
ASSEMBLY
ASSEMBLY
SUN GEAR
SHAFT
RACE
I.D. FLANGED
THRUST BEARINGS
I.D. FLANGED
"
&'I.
--
bolt hole is properly aligned with the hole in the case. (Fig.
7A4-223)
11. Oil and install center support to case retaining snap
ring with the bevel side up (flat side against center support)
and locating gap adjacent t o band anchor pin. Make certain
ring is properly seated in case. (Fig. 7A4-224)
12. Install case to center support bolt by placing the
center support locating Tool 5-23093 into the case direct
clutch passage, with the handle of the tool pointing to the
right as viewed from the front of the transmission and
parallel to the bell housing mounting face. (Fig. 7A4-225)
Apply pressure downward on the tool handle which
will tend to rotate the center support counter clockwise as
viewed from the front of the transmission. While holding
the center support firmly counterclockwise against the case
splines, torque case to center support bolt to 20-25 ft. lbs.
using a 3/8' 12 point thin wall deep socket.
(METAL)
I
Fig. 7A4-224-Installing Center Support To Case Snap Ring
---.I
CENTER SUPPORT
LOCATING TOOL
case snap ring, locating gap opposite band anchor pin. (Fig.
7A4-227)
(NOTE: Both sides of this snap ring are flat, and it is .093"
thick .)
16. Check Rear End Play as follows:
a. Install 5-21661 into an extension housing
attaching bolt hole. (Fig. 7A4-228)
b. Mount the Dial Indicator 5-8001, on the rod
and index with the end of the output shaft.
c. Move the output shaft in and out to read the
end play. End play should be from .007" to -019".The
selective washer controlling this end play is the steel
washer having three lugs that is located between the
thrust washer and the rear face of the transmission
case.
If a different washer thickness is required to bring the
end play within specification, it can be selected from the
following chart :
Thickness
Notches and/or N u m a l
.074" to .078"
.082" to .086"
.090" to ,094"
.098" to ,102"
.106" to -1 10"
.114" to -118"
None . . . . . . . . . . . . . 1
1 Tab Side . . . . . . . . . . 2
2 Tab Side . . . . . . . . . - 3
1 Tab O.D. . . . . . . . . . - 4
2 Tabs O D . . . . . . . . . . 5
3 Tabs O.D. . . . . . . . . - 6
17. Install front band with anchor hole placed over the
band anchor pin and apply lug facing servo hole. (Fig.
7 A4-229)
18. install manual linkage as follows:
a. If necessary, install a new manual shaft seal
into the case using a 314" diameter rod to seat the seal.
b. Insert the actuator rod into the manual detent
lever from the side opposite the pin.
c. lnstall the actuator rod ~lunger under the
parking bracket and over the $rkin;
pawl. (Fig.
7A4-230)
d. install the manual shaft through the case and
detent lever. (Fig. 7 A4-23 1)
e. Install retaining hex locknut on the manual
shaft. (Fig. 7A4-232) Tlghten detent retaining nut. (20
ft. Ibs.)
f. Install retaining pin, indexing with groove in
manual shaft. (Fig. 7A4-233)
<
1 I:!
mlflIvi
Color
No.
.060" to
,071" to
.082" to
.093" to
.104" to
.115" to
.126" to
Yellow
Blue
Red
Brown
Green
Black
Purple
0
1
2
3
4
5
6
.064"
.07S1'
.08611
.097"
.108"
.11911
.13Ot1
EXTENSION HOUSING
1. Install the extension housing to case gasket on the
extension housing.
LO CASE GASKET
\r\
SERVO PISTON
SPRING RETAlNtR
,SERVO
PISTON
P I N IDENT.
SIZE
TOP STEP
OP ABOVE
THREE R INGS
LONG
THIS AREA
TWO
LOWER
STEP OR
BELOW
ONE RING
b+
J-21370-5
R l NGS
MED.
SHORT
TURBO HYDRA-MATIC
425 TRANSMISSION
TORONADO
FOR ADDING AND CHECKING OIL, REFER TO SECTION 7 A 3
SUBJECT
PAGE
Bushing Service . . . . . .
Case Porosity Repair . . . .
. . . . . .
Center Support
Description of Operation
. .
Diagnosis . . . . . . . . .
Direct Clutch and
Intermediate Sprag . . . .
Downshift Switch Adjustments
Forward Clutch . . . . . .
Gear Units
. . . . . . . .
Information Chart . . . . .
. . . .
Linkage Adjustment
Minor Service Operation
. .
Pinion Gears
. . . . . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
. .7A4-13 1
. . . 7A4-1
. . 7A4-91
. . 7A4-73
. . . . . . . . . 7A4-1
. . . . . . . .7A4-113
. . . . . . . 7A4-2 1
. . . . . . . .7A4-110
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
. . . .7A4-100
. . . . 7A4-14
. . . . 7A480
. . . . 7A480
. . . . 7A4-99
SUBJECT
Reaction Carrier, Roller Clutch
and Output Carrier . . . . . . . . . . .
Rear Servo
. . . . . . . . . . . . . . .
Speedometer Driven Gear . . . . . . . . .
Support and Gear Unit
. . . . . . . . . .
Tools
. . . . . . . . . . . . . . . . .
Torque Converter Diagnosis . . . . . . . .
Torque Specifications
. . . . . . . . . .
Transmission Assembly . . . . . . . . . .
Transmission Disassembly . . . . . . . . .
Transmission Inspection
. . . . . . . . .
Transmission Removal and
. . . . . . . . . . . . . .
Installation
Valve Body . . . . . . . . . . . . . . .
PAGE
. 7A4-98
.7A4-104
. 7A4-8 1
. 7A4-93
.7A4-136
. .7A14
.7A4-130
.7A4-118
. 7A4-8 1
. 7A4-103
7A4-76
.7A4-106
GENERAL DESCRIPTION
--
REAR SERVO
ASSEMBLY
CENTER
SUPPORT
BOLT
3.
4.
5.
6.
7.
DETENT
SOLENOID
FRONT SERVO
ASSEMBLY
TRANSMISSION
Removal (less final drive)
1 . Disconnect battery.
2. Disconnect oil cooler lines at transmission.
3. Disconnect speedomet er cable.
4. Remove governor assembly. Cover hole to prevent
5. Install engine support tools as shown in Figs.
7A4-267,7A4-268 and 7A4-269.
FLU1 D l N D l CATOR
VACUUM MODULATOR
60 FT. LBS.
Installathn
To install transmission, reverse removal procedure. To
assist in the engagement of the final drive to transmission
splines, make sure that the final drive to transmission
mounting faces are in alignment with each other. After the
splines are engaged, loosely install two final drive to
trahsmission lower attaching bolts.
After the final drive and transmission are mated, then
align the transmission bell housing with the engine and
install the remaining attaching bolts. Torque bolts as
follows:
(NOTE: Before installing the flex plate to converter bolts,
make certain that the weld nuts on the converter are flush
with the flex plate and the converter rotates freely by hand
in this position. Then hand start all three bolts and tighten
finger tight. Torque to specifications. This will insure
proper converter alignment .)
8 INCH SUPPORT1
GAUGE PLUG
30 ft . lbs.
60 ft . lbs.
Engine Bracket to Rubber Mount
12 ft. lbs.
Oil Cooler Lines to Transmission
Oil Cooler Lines to Radiator
25 ft. lbs.
30 ft. lbs.
Final Drive to Transmission Bolts
Torque Converter to Flywheel Bolts
40 ft. lbs.
Flywheel Housing Cover
6 ft. lbs.
Starter to Engine
35 ft .lbs.
Apply sealer to bolts "E", "F" and "G" (Fig. 7A4-270)
TURBO HYDRA-MATIC(425)
Pan Removal
. . . . . . . . . . . . . . . 4 Quarts
. . . . . . . . . . . . . 6 Quarts
Converter Change
Overhaul . . . . . . . . . . . . . . . . 12 Quarts
~k)
CLAMP
SCREW
SLEEVE
COL .
LEVER
SHlFT
5. CHECK OPERATION:
A. W I T H KEY IN "RUN" POSITION AND TRANSMISS (ON I N "REVERSE",
BE SURE THAT KEY CANNOT BE REMOVED AND THAT STEERtNG
WHEEL I S NOT LOCKED.
B. W l T H KEY IN "LOCK" POS i T l O N AND SHIFT LEVER IN "PARK",
BE SURE THAT KEY CAN BE REMOVED, THAT STEE R I N G WHEEL I S
LUCKED, AND THAT THE UPPER SHIFT E V E R CANNOT BE REMOVED
FROM "PARK".
C. W ITW BRAKES FIRMLY APPLIED CHECK TO MAKE SURE THAT THE
STARTER W t LL NOT WORK IN ANY S H lFT LEVER POS I T I O N EXCEPT
NEUTRAL AND PARK.
SHIFT
/
CLAMP
SCREW
RELAY
BRACKET
SHIFT
ROD
'
FRONT
OF
CAR
LEVE R
BUSHING
N E U T R A L START
AD JuSTMENT
AND
BACK-UP
SWITCH
"
PlPE HOLES
-________7
PIN IDENTIFICATION
PIN LENGTH
Medium
Short
DRIVING ON
OIL PASSAGES
SNAP RING
(NOTE: Check the guide links. Guide links are the wide
outside links on each side of the link belt.)
DRIVEN SPROCKET AND INPUT SHAFT
Inspection
1. Inspect driven sprocket teeth for nicks, burrs,
scoring, galling, and excessive wear.
(NOTE: Wear pattern at bottom of teeth is normal.)
SPROCKET BEARINGS
Installation
1. Turn sprocket so that turbine or input shaft is
pointing upward.
2. Install new sprocket bearing as follows:
a. Install support snap ring, letter side down,
onto shaft.
c. Using 5-6133-A, drive the bearing assembly
onto the hub of the sprocket until it is resting on the
bearing seat of the sprocket. (Fig. 7A4-315)
d . Install sprocket to bearing assembly retaining
snap ring into groove in sprocket hub.
3. If necessary, install hook type cast iron oil seal ring
on turbine shaft. (Fig. 7A4-312)
.060" to
.071" to
.082" to
.093" to
.104" to
.115" to
.126" to
.064"
.07511
.086"
.097"
.108"
-119"
.1301'
Removal
I . Remove the pump cover plate to case attaching
screws. Do not remove sprocket support housing bolts at
this time.
2. Remove pump cover plate and plate to case face
gasket. Discard gasket. (Fig. 7A4-318)
3. Check condition of all seal rings and remove from
the driven support housing if necessary. (Fig. 7A4-3 19)
4. Remove the front unit end play selective thrust
washer from the hub of the driven support housing.
STATOR SHAFT
--.I.
n
HOUSING
?EVENT
VE
Removal
1. Remove forward clutch housing assembly, using
Tool 5-22241. (Fig. 7A4-325)
2. Remove forward clutch hub to direct clutch
housing thrust washer if it did not come out with the
forward clutch housing assembly.
3. Remove direct clutch housing assembly. (Fig.
7 A4-32 6)
4. Remove the front band. (Fig. 7A4-327)
5. Remove sun gear shaft from gear unit assembly.
(Fig. 7A4-328)
CHECKING TOOL
USE BOLTS F O
**-)*T@PgQ%%$"
Thickness
.m4" to
.082" to
.090" to
.098" to
.106" to
.114" to
.078"
.086"
.094"
.102"
.110"
.118"
. . . . . . . . .1
. . . . . . . . .2
. . . . . . . . .3
. . . . . . . . .4
. . . . . . . . .5
. . . . . . . . -6
INTERMEDIATE CLUTCH
DIRECT CLUTCH
THRUST WASHER
Fig. 7A4-338-Removing Rear Band
MAIN SHAFT
d!
I.D. FLANGED
T BEARINGS
ANGED
O.D.
I.D. FLANGED
>RACE
REAR
CENTER SUPPORT
Disassembly
1 . Remove the four (4) oil seal rings from the center
support. (Fig. 7A4-354)
2 . Using clutch compressor or tools J-6129 and
54670-14, compress the spring retainer and remove snap
ring. (Fig. 7A4-355)
INTERNAL G E A R
Inspection
1 . Inspect the roller clutch inner race for scratches
indentations. Be sure the lubrication hole is open
running a tag wire through this hole. See lubrication ch
for location of holes.
2. Inspect the bushing for scoring, wear, or galling.
3. Check oil ring grooves for damage or excessive
wear.
4. ~ i check
r
the oil passages to be sure they are open
and are not interconnected. See lubrication chart for
location of holes.
5. Inspect the piston sealing surfaces for scratches.
SNAP RING
INTERMEDIATE CLUTCH
RELEASE SPRING ( 6 )
L SEAL RINGS
no)
CENTER SUPPORT
ASSEMBLY
REACTION
3
RIGHT
WRONG
.wtt
PINION GEARS
Removal and Installation
1. Support the carrier assembly on its front face.
2. Using a 1/2" drill, remove the stake marks from
the end of the pinion pin, or pins, t o be replaced. This will
reduce the possibility of cracking the carrier when the
pinion pins are pressed out.
P I N O N PIN
TNZE
w-HE>E.
WASH,%
7 PLANET PINION
I
HEADED END
L-.
i, -
I
NEEDLE LARINGS
STEEL WASHER
saoNzE wAsneu A
Fig. 7A4-369-Planet Pinion Gears - Exploded
:e a- large ,
~ u n c h-_in a bench
vise to be used as an
9. Plac_
anvil while staking the opposite end of the pinion pin in
three places. (Fig. 7A4-37 1)
.
.-_
(NOTE: Both ends of the pinion pins must lie be1.ow the
face of the carrier or interference may occur.)
OUTPUT FLANGE
Inspection
Tnsnect
~ --s h- Di n-for
-1 .. -- - - - - the
-- - - h
- ~- --p- wear
--- or
-- alli in^.
2. Inspect the governor drive gear for rough or
damaged teeth.
3. Inspect the drive lugs for damage.
4. Ins~ectlubrication ~assanes.
D----U7
'
1
a
Sun Gear
1. Inspect the gear teeth for damage or wear.
2. Inspect splines for damage.
3. Be sure oil lubrication hole is owen. See Il~hrin-+:,chart for location of holes.
Sun Gear Shaft
1. Inswect shaft for cracks or splits.
2. 1nGect splines for damage. *
3. Inspect bushings for scoring or galling.
4, Inspect the bushing journals for damage.
5. Be sure the oil lubrication holes are m e -n- --lubrication chart for location of holes.
I
YY"
Mainshaft
1. Inspect the shaft for cracks or distortion.
2. 1nGect the splines for damage.
3. Inspect the bushing journals for damage.
4. Inspect the snap ring groove for damage.
5. Inspect for open lubrication passages.
THREE LOCATION
BEARING
CARRIER
GEAR RING
ASSEMBLY
SHAFT
P
I.D. FLANGE
RACE
O.D. FLANGED
RACE
THRUST
BEARlNG
/
1.0. FLANGED
'RACE
OUTPUT
FLANGE
1.D. FLANGED
THRUST BEARING
I.D. FLANGED
THRUST WASHER
! I
REAR SERVO
Disassembly
1. Remove the rear accumulator piston from rear
servo piston. (Fig. 7A4-388)
2. Remove E q h g retaining rear servo piston to band
apply pin. (Fig. 7A4-389)
3. Remove rear servo piston and seal from band apply
pin.
4.Remove washer, spring and retainer. (Fig.
7A4-390)
1/11
(NOTE: Do not remove the teflon oil seal rings from the
rear accumulator piston, unless the oil seal rings require
replacement. If the teflon inner oil seal ring, (small
diameter) requires replacement, use the aluminum oil seal
ring. The rear accumulator piston, large diameter rine
depth, is rnachmed shalfower t o tace the large tefloi
oil seal ring, if this requires replacement, use only the teflon
oil seal ring.)
I
/
E
I
i
1';
11
I
1 1
ACCUMULA?OR PISTON
Fig. 7 A4-388-Removing Accumulator Piston
SERVO PISTON
GOVERNOR ASSEMBLY
1. Inspect freeness of accumulator rings in piston
nd apply pin determined by band
d apply pin in servo piston.
ly pin and servo piston for scores
-~
RETAINING
"E" RING
SERVO PISTON
ACCUMULATOR PISTON
Governor Inspection
1. Wash in cleaning solvent, and blow out all passages.
2. Inspect governor sleeve for nicks, burrs, scoring or
galling.
3. Check governor sleeve for free operation in bore of
transmission case.
4. Check governor valve for free operation in bore of
governor sleeve.
5. Inspect governor driven gear for nicks, burrs, or
damage,
6. Check governor driven gear for looseness in
governor sleeve.
7 . Inspect speedometer drive gear for nicks, burrs, or
damage.
8. Check speedometer drive gear for looseness on
governor sleeve.
9 . Inspect governor springs for distortion or damage.
10. Check governor weights for free operation in their
retainers.
11. Check valve opening at entry and exhaust (.020"
minimum).
SERVO PIN
SERVO SP RING
SPRING RETAINER
REAR SERVO
CONTROL VALVE
FRONT ACCUMUL
Disassembly
12. Remove the retaining pin from the 1-2 valve bore
located directly below the 2-3 valve train bore.
13. Remove the 1-2 modulator valve bushing, 1-2
regulator valve, 1-2 detent valve and spring and the 1-2
valve.
14. Remove the retaining pin from the detent regulator
bore located directly below the 1-2 valve bore.
15. Remove the bore plug, detent valve, detent
regulator valve, detent regulator pin and spring.
16. Remove the 1-2 accurnuIator retaining pin and
bore plug from the hole located to the right of the manual
valve.
17. Remove 1-2 accumulator valve and the 1-2
accumulator primary spring.
RETAINING PIN
(NOTE: Do not remove the teflon oil seal ring from the
front accumulator piston unless the oil seal ring requires
replacement. For service, the oil seal ring will be cast iron.)
RIGHT
CORNER
1.
2.
3.
4.
5.
6.
7.
8.
9.
MANUAL VALVE
DETENT SOLENO ID
GASKET
FRONT ACCUMULATOR SPR ING
011 RING
ACCUMULATOR P ISTON
E-RING
3-2 VALVE P I N
3-2 VALVE SPRING
19.
20.
21.
22.
23.
24.
25.
26.
27.
*/
10.
11.
12.
13.
14.
15.
16.
17.
18.
3-2 VALVE
3-2 BORE PLUG
RETAINER PIN
2-3 VALVE
3-2 INTERMED IATE SPR l NG
2-3 MODULATOR VALVE
2-3 MODULATOR BUSHING
2-3 VALVE S PR ING
RETAINER PIN
33
34
1"
35
-- 36
28.
29.
30.
31.
32.
33.
34.
35.
1-2 VALVE
1-2 DETENT VALVE
1-2 REGULATOR S PR ING
1-2 REGULATOR VALVE
1-2 MODULATOR BUSHING
RETAINER PIN
DETENT REGULATOR PIN
DETENT REGULATOR SPR ING
DETENT REGULATOR VALVE
DETENT VALVE
VALVE BORE PLUG
RETAINER PIN
VALVE BORE PLUG
RETAINER PIN
1-2 ACCUMULATOR PRIMARY SPRING
1-2 ACCUMULATOR VALVE
1-2 ACCUMULATOR VALVE PLUG
36, RETAINER PIN
Inspection
1. Inspect gear pocket and crescent for nicks, burrs,
scoring or galling.
2. Inspect drive gear for nicks, burrs, scoring,
galling.
3. Inspect driven gear for nicks, burrs, scoring,
galling.
4. Place pump gears in pump body and check the
following gear face to pump face clearances.
a. Pump body face to gear face can be checked
11. Install 3-2 valve spring, spacer and 3-2 valve (either
end first) into 3-2 valve bore,
12. Install valve bore plug (hole end out) and retaining
pin into valve body.
13. Using Tool 5-22269, install front servo spring,
front servo piston, and retaining E-ring into front
accumulator piston pocket.
14. Install detent solenoid gasket, detent solenoid, and
attaching screws on reverse side of valve body assembly.
15. Check all valve trains t o see that they are operating
freely by compressing the valves on the springs.
16. Install manual bore plug and retaining pin.
17. Inst all manual valve into manual bore.
OIL PUMP
Assembly
1. If necessary, install a new front seal, using Tool
5.21359 to drive the seal in place. Use Sealer No. 1050026
or eauivalent on outside of seal before installing into pump.
hspection
1. Inspect the composition faced and steel clutch
plates for signs of burning, scoring, or wear.
2. Inspect the sixteen springs for collapsed coils or
signs of distortion.
3. Inspect the clutch hubs for worn splines, thrust
faces and open lubrication holes. Run a tag wire through
each lubrication hole. See lubrication chart for location of
holes.
I
Fig. 7A4-412 -Removing Forward Clutch Piston
DIRECT CLUTCH
SPRING RETAINER
FORWARD CLUTCH
Disassembly
1. ~ e m o v esprag retainer snap ring and retainer. (Fig.
7A4-425)
2. Remove sprag outer race, bushings, and sprag
assembly. (Fig. 7A4426)
3. Turn unit over and remove backing plate t o direct
clutch housing snap ring. (Fig. 7A4-427)
4. Remove direct clutch backing plate, five
composition faced and five flat steel clutch plates. (Fig.
7A4-428)
5 . Using Clutch Compressor Tools 5-6129, J-4670-14.
and 5-8765,compress springs and remove snap ring. (Fig.
7A4429)
FORWARD CLUTCH
-- -
HOUSING
- - - -
APPLY AIR
TO OEJE HOLE
BLOCK
REMAINING
I
I
10. Remove and discard the center piston seal from the
direct clutch housing. (Fig. 7A4-433)
Inspect ion
1. Inspect sprag assembly for damage.
2. Inspect sprag bushings for wear or distortion.
3. Inspect the inner and outer races for scratches or
wear that can be felt with finger nail.
4. Inspect the clutch housing for cracks, wear, proper
opening of oil passages, or wear on clutch plate lugs. Probe
oil passages with a tag wire to see that hole is open. See oil
9. Remove and discard the inner seal from the pist on.
(Fig. 7A4-133)
1
SNAP RING
HOUSING
D IRECT CLUTCH
D I RECT CLUTCH
HOUS ING
SNAP R I N G
DIRECT CLUTCH
BACK l NG PLATE
COMPOS l T l O N PLATES
DIRECT
CLUTCH
HOUSING
DIRECT 'CLUTCH
BACKING PLATE
FLTBOLTS
1"
I 12s
E-5 SOLTS ' ) a 18 \ 875
sj16
-6
BOLTS
5'1 6-
18
1 50
L*
REMOVE
1-
SPROCKETSUPPORT HOUSINGS
Color
.06OV to ,064"
.07 1" to .075"
.082" to .086"
.093" to -097"
.104" to .108"
.115" to .119"
.126" to .130"
Yellow
Blue
Red
Brown
Green
Black
Purple
DRIVE SPROCKET
RETURN SPRING
DETENT LEVER
AND PARKING
L:-O-RING SEAL
REAR SERVO
Installation
(NOTE: Before installing the rear servo assembly check
band apply pin using Tool J-21370 as follows:)
STEP LOCATION
ii_----
J -21370-7
TOP STEP
OR ABOVE
THREE R I N G S
LONG
T H l S AREA
TWO R I N G S
MED.
4
LOWER
STEP OR
5ELOW
ONE R I NG
SHORT
SPRING RETMNER
i *e?
SPACER
I,'
e
kI
GOVERNOR PIPE
PlPE HOLES
C-3 BOLTS
LTS
PIPE POSITIONS
5/1
6-1
5/16-1
8 x 1.38
8 x 1.88
GOVERNOR
Installation
1. Lay the transmission on the oil pan.
2. Position new "0" ring seal on governor assembly
then install into the case. (Fig. 7A4-490)
3. Attach the governor with the retaining clip,
*-*%a%%%@@@+
7 A 4 - 1 3 0 SPECIFICATIONS
THREAD SIZE
IDENTIFICATION
Manual Shaft
M I 0 x 1.5.6g
Groove on metric
end of shaft with
drill point in end
of shaft .
Transmission Case:
Speedometer
Attaching Bolt Hole
M 6 . 3 x 1-6H
NONE
Case Extension:
Transmission
Mount
Bolt Holes
MlO x 1.5.6H
TORQUE SPECIFICATIONS
FT . LBS.
APPLICATION
Solenoid Assembly to Pump Or Valve Body
. . . . . .
. . . . . . . . . . . . . . .
Line Pressure TakeOff
Oil Cooler Lines at T~ansrnission . . . . . . . . . . .
. . . . . . . . . . . . .
Oil Cooler Lines at Radiator
Race To Center Support . . . . . . . . . . . . . . .
. . . . . . . . . . . . .
Solenoid Assembly To Case
. . . . . . . . . . . . . . . .
Valve Body To Case
Sprocket Cover To Case . . . . . . . . . . . . . . .
Pump Assembly To Case . . . . . . . . . . . . . . .
Pump Body To Cover . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . .
Driven Support To Cover
Cover Plate To Case . . . . . . . . . . . . . . . . .
Rear Servo Cover To Case . . . . . . . . . . . . . .
Governor Cover To Case . . . . . . . . . . . . . . .
. . . . . . . . .
Vacuum Modulator Retainer To Case
. . . . . . . . . . . . . . . . . .
Oil Pan To Case
Case Extension To Case . . . . . . . . . . . . . . .
Case To Center Support . . . . . . . . . . . . . . .
Manual Shaft To Inside Detent . . . . . . . . . . . .
. . . . . . . . . . . . . . . .
Filter To Valve Body
Transmission Case To Cylinder Block Bolts (Toronado) . .
Transmission Case To Cylinder Block Bolts (Exc . Toronado)
. . . . . . . .
Flywheel To Converter Attaching Bolts
. . . . . . . . .
Transmission Mount To Transmission
. . . . . . . .
Prop Shaft To Rear Companion Flange
Speedometer Driven Gear To Case Attaching Bolt . . . .
Crossmember To Frame .98 . . . . . . . . . . . . .
. . . . . . . . . . . .
Transmission To Crossmember
Crossmember To Rear Engine Mounts (Toronado) . . . .
L
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3
15
12
25
10
10
10
10
20
20
20
20
20
20
20
13
25
25
20
10
30
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. . . . . . . . . . . . . . . . . . . . . . . . 40
. . . . . . . . . . . . . . . . . . . . . . . . 45
. . . . . . . . . . . . . . . . . . . . . . . . 20
. . . . . . . . . . . . . . . . . . . . . . . . 15
. . . . . . . . . . . . . . . . . . . . . . . . 40
. . . . . . . . . . . . . . . . . . . . . . . . 60
. . . . . . . . . . . . . . . . . . . . . . . . 60
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--
TURBO HYDRA-MATIC
BUSHING SERVICE
400 AND 425
(NOTE: When inspecting bushings, fit the mating part into
the bushing and observe the amount of looseness. Bushing
clearance is excessive if more than -008" exists when
checked with a wire feeler gauge.)
Bushings are available and can be replaced in the
following units. Service bushings do not require reaming.
1. Pump Body
2. Sun Gear Shaft
3. Center Support
4. Output Shaft or Output Flange
5. Case
6. Extension Housing
7. Stator Shaft
a.. Front Bushing
b . Rear Bushing
'
11; !I
9
1
Fig. 7 A4498 -Sun Gear Shaft Bushing Removal
\n
CASE CENTER
SUPPORT
PUMP
COVER
SUPPORT H U B ON
SOFT MATERIAL ru
PROTECT R I N G LANDS
'
7A4-136 TOOLS
J-8763
J-8765
"C" Washer
J-21369
J-21371-3-8
J-21654
J-21664
J-21795
J -22269
Holding Fixture
Slide Hammer Assembly
5116" to 318" Adapters
Spring Compressor
TOOLS 7A4-137
BT- 6603
J-21661
t'L
J-8619-11
BT-7412-L
BT-30-16
J - 5907
J - 6133
BT- 6424- 1
BT- 6603
BT-6733
BT-7412-R-L
J - 8001
J-8619-11
J-21362
J-21363
1-21368
J-21370
J-21409
J-21661
J - 22241
1-23093
J-23456
E-Z OUT
Fig. 7A4-515-Tools
-15
-16
*
jC
J - 95'34
J-2619
J -2619-4
J - 6125
J-6125-2
J -8092
J -21424-9
J -21465-1
J-21465-2
J-21465-3
5-21465-5
J-21465-6
5-21465-8
J-21465-9
J-21465-10
J-21465-13
J-21465-15
J-21465-16
5-21465-17
j- 8092
x--~%t**va*4q@@~f@%vFme~
CORRECTION
POSSIBLE CAUSE
Slips Out of High Gear
a.
b,
C,
d.
e.
f.
g.
h.
i.
Transrnissionlooseonclutchhousing.
Shift rods interfere with engine mounts or clutch
throwaut lever.
Shift linkage does not work freely, binds.
Damaged mainshaft pilot bearing.
Main drive gear bearing retainer broken or loose.
Dirt between transmission case and clutch housing.
Stiff shift lever seal
Pilot bearing loose or damaged.
Misalignment of transmission
a.
b.
c.
d.
e.
f.
g.
h.
i.
a.
b.
c.
d.
e.
Insufficient lubricant.
Worn countergear bearings.
Worn or damaged main drive gear and countergear.
Damaged main drive gear or mainshaft bearings.
Worn or damaged countergear anti-lash plate.
a.
b.
c.
d.
e.
b.
a.
b.
a.
b.
c.
d.
a.
b.
c.
d.
DIAGNOSIS
THREE SPEED AND FOUR SPEED
POSSIBLE CAUSE
CORRECTION
Noisy In All Reduction Gears
a.
b.
Insufficientlubricant.
Worn or damaged main drive gear or countergear.
a.
b.
a.
b.
a.
b.
Replace gears.
Replace side cover.
a.
b.
a.
b.
c.
a.
b.
Replace bearings.
Replace countergear thrust washers.
a.
b.
Replace bearing.
Align transmission.
h k s Lubricant
a.
b.
c.
d.
e.
f.
g.
a.
b.
c.
d.
e.
f.
g.
a.
Replace as necessary.
a.
a.
Replace as necessary.
a.
b.
Replace as necessary.
Replace gear.
a.
a.
Shift forks.
a.
Hard Shifting
a.
b.
c.
d.
a.
b.
c.
d.
PAGE
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. . . 7B-5
. . . 7 B-5
. . . 7B-1
. . . 7B-7
. . . 7B-8
. . . 7B44
THREESPEED MANUAL
TRANSMISSION
SUBJECT
PAGE
-7
3. ~ h l holding
e
relay in position in the 1st-Rev. lever
push up on reverse shift rod until detent in column is felt and
tighten swivel bolt for first and reverse rod t o recommended
torque
4. Position the transmission in neutral and insert a
3/16" rod through the 2-3 shift lever and into the alignment
hole. (Fig. 7B-4) Tighten the swivel bolt for the 2-3 shift
lever to recommended torque.
5 , Lower hoist and check shift operation with the
wgine off. Start engine and recheck.
6. Place transmission in reverse and ignition in lock
position. Check to make sure the ignition key can be
removed, the steering wheel will not turn, and the
transmission will not shift out of reverse.
TOOL J-4830-02
EXTENSION HOUSING
)j
TOOL .I-6403-6
SPEED0
DR IVEN
GEAR
SLEEVE
Fig. 7B-9-Speedometer Driven Gear
Installation
1, Inspect clutch pilot bearing and replace if neces
2. Reverse removal procedure, using the folio
specified torque ratings for the attaching pdts:
a. Transmission to engine
b. Transmission support bar to
frame bolts
c. Transmission support bar to
transmission mount bolts
d. Transmission support bar to
transmission mount nut
e. Propeller shaft strap bolts
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Gear T h r u s t Washer
B e a r i n g T h r u s t Washer
B e a r i n g Rollers (27)
Countergear
B e a r i n g Rollers (27)
Spacer
Tanged Washer
Countershaft
Key
Bearing Retainer
Gasket
Seal
Bearing Snap R i n g
Bearing Retaining Snap R i n g
M a i n D r i v e Gear B e a r i n g
Transmission Case
M a i n D r i v e Gear
M a i n s h a f t Pilot Bearings (14)
3rd Speed Blocker R i n g
Snap R i n g
2-3 S y n c h r o n i z e r Sleeve
S y n c h r o n i z e r C i u t c h Key S p r i n g
S y n c h r o n i z e r C l u t c h Hub
2nd Speed Blocker R i n g
2nd Speed Gear
Mainshaft
Gasket
Snap R i n g
Reverse I d l e r Gear
Tanged T h r u s t Washer
Reverse I d l e r Shaft
Key
1 s t Speed Gear
1st Speed Blocker R i n g
Synchronizer Clutch Hub
1st Speed S y n c h r o n i z e r Sleeve
Snap R i n g
Reverse Gear
Reverse Gear T h r u s t Washer
S p r i n g Washer
41. Rear B e a r i n g
42. Snap R i n g
43. Speedometer D r i v e Gear
43A. Drive Gear Clip
44. Gasket
45. Rear B e a r i n g Snap R i n g
46. Case Extension
47. Rear O i l Seal
48. 2nd and 3 r d S h i f t Fork
49. 1st a n d Reverse S h i f t Fork
50. 2nd and 3 r d S h i f t e r Lever
51. 1st a n d Reverse S h i f t e r Lever
52. Seal
53. Seal
54. Snap R i n g
55. Detent Cam S p r i n g
56. Detent Cam
57. Detent Cam
58. Transmission Side Cover
58A. P l u g
59. S y n c h r o n i z e r C l u t c h Key
60. B u s h i n g
,,.,a"
IT
+ n r n */ n
---a.
\-
INSTALL SEAL I N
RETAINER, S P R I N G
S I DE OUT.
-7
REAR BEARING
REVERSE l DLER
SHAFT
'
i
1
Fig. 7B-16-Removing Speedometer Drive Gear
~ O T E When
:
pressing rear bearing, be careful to center
Bearing Rollers
All main drive gear and countergear bearing rollers
should be inspected closely and replaced if they show wear.
Inspect countershaft and reverse idler shaft at the same time,
replace if necessary. Replace all worn washers.
Gears
Tmnsmission Case
1. Wash the transmission thoroughly inside and outside
with cleaning solvent, then inspect the case for cracks.
SP" g, slide the sleeve onto the hub aligning the marks made
side
before disassembly.
ASSEMBLY
9. Install
t$~ard;
:.
Procedure
1. Remove the transmission from the car md
completely disassemble as outlined.
(NOTE: In any case where the main drive gear pilot or pilot
bearing is excessively loose or worn, the pilot bearing
bushing should be replaced before checking the transmission
rear bearing bore alignment by the dial indicator method.)
SUBJECT
PAGE
~dj~stments .
.
Description
. .
1)iaPosis
Rear Oil Seal .
Side C o ~ r . .
spedficati0ns
.
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PAGE
SUBJECT
. . .
Speedometer Driven Gear
Transmission Alignment
. . . .
Transmission Disassembly
. . .
Transmission Reassembly . . . .
Transmission Removal & Installation
TOOIS . . . . . . . . . . . .
. 7B-16
. 78-15
. 78-1
. 7B-18
. 7B-18
.7B44
.
.
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. .
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.
. . . 7B-18
. . .7~-14
. . .7 ~ - 2 0
. . . 7 B-24
. . .7~-18
. . .7B45
case.
'28 \29\30
I
1
1.
2.
3.
4.
5.
i~
6.
7.
8.
9.
10.
11.
12
Clutch Gear
Bearinq Retainer
Pilot skarings
Case
4th Speed Blocker
Ring
4-3 Synch. Snap Ring
4-3 Synch. Hub
3rd speed B locker
Ring
3rd Speed Gear
2nd Speed Gear
2nd Speed B locker
Ring
1-2 Speed Sync h.
Hub
31
32
33
34
35
f x / -
Q~
I----
I-
n - _ _
NOTCH
@:&!zf5
SHIFTER ASSEMBLY
'
1
REVERSE
CONTROL LEVER
BRACKET
&-PIVOT
SHIFT LEVER
PIN
SHIFT LEVER
BRACKET
LEVER
INTERLOCK
PLATE
3RD 8 4TH
LEVER
I ST 8 2 N D
LEVER
5.
6.
7.
remove
slide transmission
1. Clutch Gear
20SpeedometerDrive
Gear and Clip
. .
.
. .
.
.
.
.
. 53 ft . lbs.
. 25 ft .lbs.
. 43 ft. lbs.
. . 35 ft. lbs.
. . 16 ft. lbs.
. . 13 ft. lbs.
. . 30 ft. lbs.
. . 113 ft. lbs.
C A U T I O N : Propeller shaft
attaching fasteners are an important
attaching part in that i t could affect
the performance of vital parts and
systems, and/or could result in
major repair expense. I t must be
replaced with one of the same part
number or with an equivalent part
i f replacement becomes necessary.
Do not use a replacement part of
lesser quality or substitute design.
Torque values must be used as
specified during reassembly to
assure proper retention of this part.
I
I
DISASSEMBLY OF MAINSHAFT
1. Using snap ring pliers, remove the 3rd and 4th speed
sliding clutch hub snap ring from mainshaft and remove
clutch assembly, third gear blocker ring and third speed gear
from front of mainshaft. (Fig. 7B-38)
Bearing Rollers
All clutch gear and countergear bearing rollers should be
inspected closely and replaced if they show wear. Inspect
counter shaft and reverse idler shaft at the same time, replace
if necessary. Replace all worn washers.
Gears
2 . Drive Gear
3. Mainshaft Pilot
Bearings
4 . 3-4 Synchronizer
Assembly
5. Third Speed Gear
6. Second Speed Gear
7. 1-2 Synchronizer and
Reverse Gear Assembly
Rear Bearing
Speedo Drive Gear
Mainshaft
Snap Ring
Synchronizing
"Blocker" Ring
,I 1
I"'
<
I
I
I ?
Fio 7R-Cn-Tnctallina R e a r R ~ a r i n o
ii
I/
M A I N DRIVE GEAR
7B-54)
5. Load the mainshaft pilot bearings (14) into the
clutch gear cavity and assemble the 4th speed blocker ring
onto the clutch gear clutching surface with its clutching teeth
toward the gear. (Fig. 7B-55)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
13.
36.
37.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
Countergear Shaft
Countergear Shaft Key
Reverse Idler Shaft
Idler Shaft Key
Reverse Idler Gear
Side Cover Gasket
3-4 Shift Fork
1-2 Shift Fork
3-4 Shifter Shaft
Retaining "E" Ring
1-2 Shifter Shaft With
"0" Rings
Reverse Shifter Shaft
3-4 Detent Cam
Detent Cam Spring
Reverse Detent Ball and
Spring
1-2 Detent Cam
Shift Cover
Plug and Gasket
Shifter Shaft Seal
Shifter Shaft Seal
Shift Cover Bolts and
Washers
Shift Cover Attaching Bolts
and Lock Washers
--
PAGE
. . . . . . . . . . . . . . . . . . 7B-3
. . . . . . . . . . 7B -27
. . . . . . . . . . . 7B-27
GENERAL DESCRIPTION
The five-speed manual transmission is a floor shift and
fully synchronized in all forward speeds. Fifth gear is an
overdrive which means that the transmission output shaft
turns faster than the input shaft when in fifth gear.
The transmission has a single shift rail with the shifting
mechanism totally enclosed inside the transmission. With this
design, the shift mechanism is unaffected by dirt, water and
corrosion.
All gears are in constant mesh with the countergear
(gears on counter shaft) including reverse (through the
reverse idler gear). When shifting gears, the selected gear is
locked to the output shaft through the synchronizer clutch
hub.
-
m E ~ TRANSMISSION
m ~ ~
MOUNTS
SUBJECT
PAGE
Tools . . . . . . . . .
Transmission
. . . . . .
Assembly
. . . . .
Disassembly
Removal and Installations
Specifications . . . . .
. . . . . . . . . .
.7~45
.
.
.
.
. 7B-38
. 7B-31
.7~.27
. 713-44
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' i
C A U T I 0 N : Propeller shaft
attaching fasteners are an important
attachin partFin that i t could affect
the per ormance of vital parts and
systems, and/or could result in
major repair expense. It must be
replaced with one of the same part
number or with an equivalent part
if replacement becomes necessary.
Do not use a replacement part of
lesser quality or substitute design.
Torque values must be used as
specified during reassembly to
assure proper retention of this part.
11
I
i
1
I
1
1
/1
,I
'1
I8
O I L SEAL
BUSHING
PIN
S H I F T E R HEAD
THREADED PLUG
POPPET SPRING
MESH LOCK PLUNGER
BREATHER A S S ' Y
SELECTOR LEVER P I V O T
W I R I N G HARNESS C L I P
NAME PLATE
BACK-UP L I G H T BRACKET
CUP PLUG
EXTENSION HOUSING MITH BUSHING
3/8-16 X 3 1/4 HEX HD. BOLT
SWITCH
NEEDLE BEARING
S H I F T RAIL
SPRING PIN
R A I L SELECTOR END
F I R S T & REVERSE S H I F T FORK
S H I F T FORK PAD
F I R S T & REVERSE S H I F T L I N K
GASKET
9/16-18 PLUG
SPEEDOMETER GEAR
SPEEDOMETER GEAR R E T A I N I N G C L I P
OR BALL & SNAP RING
SNAP R I N G
THRUST WASHER
1 S T S P E E D GEAR
SNAP R I N G
BLOCKING R I N G
SYNCHRONIZER S P R I N G
S H I F T PLATE
CLUTCH HUB
CLUTCH S L E E V E
REVERSE GEAR & BUSHING A S S ' Y
BUSHING
SELECTOR ARM - OPTIONAL
SPRING PIN
INTERLOCK PAWL
S E L E C T O R ARM R E T A I N I N G PLATE
1 / 4 - 2 0 X 3/4 HEX. HD. S E L F T A P P I N G SCREW
REVERSE I D L E R GEAR & BUSHING
BUSHING
SPRING PIN
REVERSE I D L E R S H A F T
"0" R I N G
REVERSE I D L E R GEAR
REVERSE I D L E R SHAFT
BEARI NG SPACER
ROLLER BEARING
REVERSE I D L E R GEAR
DOWEL P I N
"
*
S T A R F I R E ONLY
MIXED PRODUCTION
CENTER SUPPORT
MAGNET
NEEDLE BEARING
S H I F T RAIL
PIN
RETAINING C L I P
SELECTOR LEVER
NEEDLE BEARING
THRUST WASHER
NEEDLE THRUST BEARING
NEEDLE THRUST RACE
OUTPUT SHAFT
3 R D S P E E D GEAR
BLOCKING R I N G
SYNCHRONIZER S P R I N G
SYNCHRONIZER S H I F T PLATE
CLUTCH HUB
CLUTCH SLEEVE
SNAP R I N G
SYNCHRONIZER BLOCKING R I N G
2ND S P E E D GEAR
THRUST WASHER
SNAP R I N G
SPACER
5 T H S P E E D GEAR
2ND & 3 R D S H I F T L I N K
2ND & 3 R D S H I F T FORK
4 T H & 5TH S H I F T L I N K
4 T H & 5 T H S H I F T FORK
NEEDLE ROLLERS
SPACER
SYNCHRONIZER BLOCKING RING
SYNCHRONIZER S P R I N G
S H I F T PLATE
CLUTCH HUB
CLUTCH SLEEVE
SYNCHRONIZER BLOCKING R I N G
NEEDLE THRUST BEARING
BEARING ROLLERS
I N P U T DRIVE GEAR
NEEDLE THRUST BEARING
THRUST WASHER
NEEDLE BEARI NG
O I L SEAL
CLUSTER GEAR
SPRING
SPRING PIN
GEAR DAMPER
SNAP R I N G
THRUST WASHER
NEEDLE BEARING
CLUSTER GEAR - V 8 ONLY
CLUSTER GEAR - V6 ONLY
1/2 INCH P I P E PLUG
TRANS CASE SLEEVE
TRANS CASE
"
'
1
installation of transmission
1. Position transmission to clutch housing and slide
forward,piloting clutch gear into pilot bearing.
@oTE: Make certain main drive gear splines are clean and
&Y -1
2. Reverse removal procedure, using the following
torque ratings for the attaching parts:
~~ansmission
to clutch housing bolts . .
Crossmember t o frame nuts . . . . . .
Crossmember to transmission mount bolts
propeller shaft bolts (exc. Starfire) . . .
propeller shaft bolts (Starfire) . . . . .
. . . 53 ft. lbs.
...
. .
. . .
. ..
35 ft. lbs.
35 ft. lbs.
16 ft. lbs.
13 ft. lbs.
C A U T I O N : Propeller shaft
attaching fasteners are an important
attaching part i n that it could affect
the performance of vital parts and
systems, and/or could result in
major repair expense. It must be
replaced with one o f the same part
number or with an equivalent part
i f replacement becomes necessary.
Do not use a replacement part o f
lesser quality or substitute design.
Torque values must be used as
specified during reassembly t o
assure proper retention o f this part.
TRANSMISSION DISASSEMBLY
7
5-SPEED MANUAL TRANSMISSION 7B-33
Center Support
18. Remove center support from output shaft and
countergear. (Fig. 7B-69)
!f
OUTPUT SHAFT
SECOND AND THIRD GEAR
SYNCHRONIZER ASSEMBLY
OUTPUT SHAFT
Fig. 7 ~ - 7 6 - ~ e r n o v iThird
n ~ Speed Gear
Roller Bearings
All roller bearings in center support, case and extension
housing should be inspected and replaced if they are worn or
damaged .
Gears
1. Inspect all gears for excessive wear, chips or cracks
.
and replace any that are worn or damaged.
2. Check all three synchronizer clutch sleeves to see
that they slide freely on their hubs.
I
r Synchronizer Assembly
ring; then remove second and rhjrd
Transmission Case
1. Wash the transmission case thoroughly inside and
outside with cleaning solvent; then inspect for cracks.
2. Check the front and rear faces for burrs and if
'
case.
-- -
- --0-----0
----
--
I
Fig. 7B-79-Installing Input Shaft Bearing In Case
- - -
0 I L SEAL
EXTENSION HOUSING
SNAP, G
N
. IR
TRANSMISSION ASSEMBLY
correct
THRUST WASHE
OUTPUT SHAFT
-7
BLOCKER R l NGS
I
Fig. 7B-100-Installing Input Shaft
21. Install fourth and fifth shift link through slot and
engage in shift fork.
-s*r%~%lq$t
~ i g7~-109-1nstalling
.
Speedometer Gear and Rail Selector
Y
.*
LNPIIT SHAFT
SHlFTER HEAD
I
i
1
Fig. 7B-112-Installing Input Shaft Thrust Bearing and Case
%
!
7 B-44 SPECIFICATIONS
TRANSMISSION SPECIFICATIONS
CAPACITY
3Speed .
4-Speed .
5Speed .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- 3 112 Pints
- 2 112 Rnts
- 3 112 Pints
GEAR RATIO
*S9,RZ
First .
Second
Third
Fourth
Fifth .
Reverse
.
.
.
.
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.
*ZR,ZM,S4,RH
. .
. .
. .
. .
. .
. .
APPLICATION
Side Cover Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Transmission to Clutch Housing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Cross Support Bar to Frame Bolts - Omega & Cutlass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Cross Support Bar to Body Bolts - Starfire
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Transmission Mount to Transmission Bolts - Exc. Starfire . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Starfire . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Transinission Mount to Cross Support Bar - Omega & Cutlass Only . . . . . . . . . . . . . . . . . . . . . . . . 35
Propeller Shaft Strap Bolts - Omega & Cutlass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Propeller Shaft U-Bolt Nuts .Starfire
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Bearing Retainer to Transmission Case Bolts - Exc. Starfire . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Starfire . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Rear Bearing Retainer to Transmission Bolts - Exc. Starfire . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Starfire . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
T.C.S.Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Transmission Filler Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
_
1
1
TOOLS 7 B 4 5
SLIDE HAMMER
EXTENS ION HOUS ING BUSHING REMOVER
REAR EXTENS ION SEAL INSTALLER
(ALTERNATE)
EXTENS ION HOUSING O I L SEAL INSTALLER
S N A P RING PLIERS
EXTENS ION HOUSING O I L SEAL INSTALLER
MTENS ION HOUSING BUSHING INSTALLER
ENGINE SUPPORT BAR
SEAL REMOVER
SEAL REMOVER
D I A L INDICATOR
DRIVE HANDLE
FRONT O I L SEAL61NSTALLER
EXTENS ION
Fig. 7B-117-Tools
CLUTCH 7C-1
CLUTCH
STARFIRE-OMEGA-CUTLASS
STARFIRE CLUTCH.
. . . . . . . . . . . . . . . . . . . 7C-3
. .
7C-7
CLUTCH DIAGNOSIS
NOTE: Reset lash after any parts changes in the clutch area.
POSSIBLE CAUSE
CORRECTION
Fails to Release (Pedal Pressed to FloorShift Lever Does Not Move Freely In and Out of Reverse Gear)
a.
b.
c.
d.
e.
f.
a.
b.
c.
d.
e.
f.
g.
h.
g.
h.
Slipping
a.
b.
c.
d.
e.
f.
g.
a.
b.
c.
d.
e.
f.
g.
Grabbing (Chattering)
a.
b.
c.
d.
e.
Oil on facing.
Worn splines on clutch gear,
Loose engine mountings.
Warped pressure plate or flywheel.
Burned or smeared resin on flywheel or pressure plate.
a.
b.
c.
d.
e.
CLUTCH DIAGNOSIS
STARFIRE C L U T C H
INDEX
PAGE
SUBJECT
.
Description
Dja~0sis . .
clutch Assembly
Removal . .
stallat at ion
. . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . .
7C-3
7C-1
. . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . .
7C-5
7C-6
SUBJECT
Maintenance and Adjustments
Clutch Linkage
. . . . . .
Maintenance Recommendations
. .
Specifications and Torque
Tools . . . . . . . . . . .
PAGE
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
. . . . 7C4
. . . . 7C -3
. . . . 7C-10
. . . . 7~-10
MAINTENANCE RECOMMENDATIONS
GENERAL DESCRIPTION
The clutch is a cable operated design (Fig. 7C-1). The
pedal lever pivots on a shaft common with the brake pedal
assembly and operates the release yoke through a sheathed
cable attached to the upper section of the pedal lever. The
lower end of the cable is threaded and is provided with a ball
stud that fits into a hole in the release lever.
The clutch pressure plate, driven disc and release bearing
are of a conventional design (Fig. 7C-2), with the fork
pivoting on a ball stud located opposite the control cable
attaching point. A single plate, dry friction disc,bent finger,
b p h r a f l s ~ r i n gtype clutch is used on the Starfire. The
m m b l ~consists of the clutch driven plate, Cover-Pressure
plate and clutch release mechanism,
M A I N DRIVE GEAR
IAPHRAGM SPRING
BALL
CLUTCH
HOUSING
1 . P R I O R T O A T T A C H M E N T OF C A B L E ,
P L A C E G A U G E J-23644 SO F L A T E N D
IS A G A I N S T F R O N T F A C E O F T H E
CLUTCH HOUSING A N D THE H O O K E D
E N D IS L O C A T E D A T P O I N T OF C A B L E
ATTACHMENT ON FORK.
2. T U R N B A L L S T U D I N W A R D BY H A N D
U N T I L CLUTCH RELEASE BEARING
MAKES CONTACT WITH CLUTCH
SPRING F I N G E R S .
3. I N S T A L L L O C K N U T A N D T I G H T E N
(25 F T . LBS.) B E I N G C A R E F U L N O T
T O CHANGE B A L L STUD ADJUSTMENT.
4. I N S T A L L B A L L S T U D CAP.
5. R E M O V E G A U G E B Y P U L L I N G O U T W A R D A T HOUSING END.
HOUSING
GAUGE
J-23644
SERVICE OPERATIONS
CLUTCHCABLE REPLACEMENT
1. Remove clutch fork cover at side of housing.
2. Disconnect return spring and clutch cable at clutch
shift fork.
3. Remove clip and pin retaining cable to pedal arm.
4. Pull cable assembly through reinforcement and
disengage from fender skirt reinforcement.
5 . Push new cable through body reinforcement. Secure
cable end to pedal arm with pin, washer and clip.
(NOTE: Lubricate retaining pin with graphite type grease .)
Inspection
1. Examine friction surfaces of flywheel and pressure
plate for scoring, roughness, or severe overheating. Slight
roughness may be smoothed with fine emery cloth, but if
surface is deeply scored or grooved, part should be replaced.
2. Inspect clutch driven plate for condition of facings,
or facing wear to rivets, loose rivets, broken or very loose
torsional springs. If oil is found on the driven plate facings,
examine the transmission drain back hole, pilot bushing,
engine rear main bearing, transmission input shaft seal, and
other local points for oil leakage.
3. Check fit of driven plate hub on transmission input
shaft gear for an easy sliding fit.
4. Inspect clutch release bearing for scoring or
excessive wear on front contact face. Check for roughness
and free fit on clutch drive gear bearing retainer.
CLUTCH DRIVEN
BOLT
. . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . .
e
7C-7
7C-1
7C-9
7C-9
CLUTCH PILOT
SUBJECT
PAGE
. . . . . . . . . . 7C-7
. . . . . . . . .
7C-7
. . . . . . . . . . 7C-10
. . . . . . . . .
.7C-10
LEVER AND
RETURN
SHAFT ASSEMBLY
RETA l NER
PUSH ROD
ADJUSTING
ROD
b
BRACKET ASSEMBLY
SHAFT ASSEMBLY
UTCH RETURN SPRING
LOWER PUSH ROD
b
FILL RECESS
WITH WHEEL
BEAR ING LUBE
BEARING LUBE
Removal
1 . Remove transmission.
2. Disconnect the clutch return spring and clutch rod
assembly.
3 . Remave the clutch release bearing.
4. Remove flywheel housing leaving starter attached t o
engine. Release fork and ball stud will remain with housing.
The clutch release fork, boot and ball stud are accessible for
service. (Fig. 7C -12)
5. Scribe an "X" mark on the flywheel opposite the
"X" on the cover. The cover is marked "X" for balance
purposes. (Fig. 7C-13)
(NOTE: Loosen pressure plate attaching bolts evenly
approximately one turn at a time.)
(NOTE: DO NOT LUBRICATE splines as the lubricant will
be forced into the dampener friction surfaces by centrifugal
force and clutch rattle can occur.)
CLUTCH SPECIFICATIONS
DISC FACINGS
.
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.
THICKNESS
All
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
TORQUE SPECIFICATIONS
CLUTCH
Specified torque is for installation of parts only. Checking of torque during inspection may be 10% below that specified.
APPLICATION
. . . .
Clutch Cover .Exc. Starfire
Clutch Cover & Pressure Plate - Starfire
. .
Clutch Housing To Engine Block
Ball Stud to Engine - Omega &
Clutch Lever and Shaft Assy. t
Clutch Lever and Shaft Assy . t
Clutch Release Fork Ball Stud -
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
J-1448
J-1448
Fig. 7C-15-Tools
14
r~mmt"a6ett~t~jtr
3v
CHASSIS ELECTRICAL
AND
INSTRUMENT PANELS
. . . . . . . . . 8 A 1.1
J N S T R U M E N T P A N E L .STARFJRE . . . . . . . . . . 8 A 2.1
I N S T R U M E N T P A N E L .O M E G A . . . . . . . . . . . 8 A 3.1
I N S T R U M E N T P A N E L . C U T L A S S . . . . . . . . . . . 8 A 4.1
I N S T R U M E N T P A N E L . 88.98 . . . . . . . . . . . . - 8 A 5 - 1
C H A S S I S ELECTRICAL .ALL SERIES
I N S T R U M E N T P A N E L .T O R O N A D O
C H A S S I S ELECTRICAL
. . . . . . . . 8 A 6.1
.ALL SERIES
INDEX
PAGE
Back-up Lamp Switch Adjustment
bttery
. . . . . . . . . . .
Buzzer. Horn Relay -Key Warning
. . . . . . . 8A144
. . . . . (Section 6D)
. . . . . . . 8A143
. . . . . . . . . . . . . . . 8A1-17
. . . . . . . . . . . . . . . (Section 6D)
. . . . . . . . . . . . . . . . . 8 A1.1
ring
SUBJECT
PAGE
"
I
I
DIAGNOSIS
The following information and illustrations on wiring
wiring harness location. fuse panel and fusible link
aid id electrical diagnosis . Refer to ELECTRICAL
C I R c u l ~DIAGNOSIS for procedures .
combination junction and fuse panel is mounted on
the
under the instrument panel . Each wire from the
fUepanel is color coded t o simplify servicing .