HYDRA-.MATIC TRANSMISSION

Transcription

HYDRA-.MATIC TRANSMISSION
6-1
GENERAL DESCRIPTION
A controlled coupling Hydra- Matic transmission
is used as standard equipment on all 1963 Cadillac
cars. Two models of this transmission are used
to meet the requirements of the various series
cars.
The transmission used on all 1963 model 60 and
62 series cars is identified by a black name plate
attached to the lower left hand corner of the
transmission case rear face. The serial num
ber on these transmissions is preceded by the
letter C.
Transmissions used on 75
commercial chassis have an
greater capacity to meet the
quirements on these heavier
series cars and the
oil pump of slightly
greater cooling re
cars. These trans
missions are identified by an orange name plate
with the letters CA preceding the serial number.
The oil cooler for the 1963 transmission is
located in the lower tank of the radiator. Oil
from the pump passes through the cooler and then
back to the main fluid coupling.
The oil intake system of the 1963 transmission
incorporates a paper element type oil strainer on
the intake pipe. An internal by-pass is provided in
the strainer which permits increased oil flow
during cold operation when the oil is heavier. The
strainer should be replaced every 30,000 miles,
or in any case, where a major transmission fail
ure has occurred.
PRINCIPLES OF OPERATION
The 1963 Cadillac Hydra- Matic transmission
has four forward speeds and one reverse. The
gear reductions required to obtain the various
speeds are provided by planetary gearsets.
Front Unit Fig. 6-1
In the front unit, the internal gear of the plane
tary gear set is the driving member and the sun
gear is the reaction member. When power is
applied to the internal gear with the front unit
coupling empty, the sun gear is held stationary by
the front sprag and the planet carrier rotates
around the sun gear. This provides 1.55 to 1
reduction.
When the front unit coupling is filled with oil,
the sun gear and internal gear are driven at the
same speed and the planetary gearset rotates as
a unit, providing direct drive.
Rear Unit Fig. 6-1
Power from the front unit is transmitted to the
rear unit through two shafts: the intermediate
shaft and the mainshaft. Power is transmitted
from the front unit planet carrier through the
intermediate shaft to the rear unit hub. Power
from the front unit planet carrier is directed
through the main fluid coupling to the main shaft
and then to the sun gear of the rear planetary
gearset.
With the rear unit clutch released, the rear
internal gear rear unit drum is held stationary
by the rear sprag, which in turn is held stationary
by the neutral clutch. Power applied to the sun
gear causes the planet carrier to rotate around
the internal gear, providing 2.55 to 1 reduction.
When the rear unit clutch is applied, the rear
hub and drum are locked together and the internal
gear and sun gear are driven at the same speed.
The planetary gearset rotates as a unit providing
direct drive.
Reverse Unit Fig. 6-1
Reverse is obtained through a third planetary
gearset. The sun gear, connected to the rear unit
internal gear, is the driving member of the re
verse unit gearset, and the reverse internal gear
is the reaction member.
The internal gear is normally free-wheeling so
that the reverse gearset is idling. When the
transmission selector is moved to the REVERSE
position, the reverse clutch locks the internal
gear to the case and the neutral clutch is re
leased. With the reverse internal gear locked and
the rear unit idling, the reverse planet carrier is
turned in the reverse direction with 2.42 to 1
reduction.
Combined Operation
The combination of these units provides a
transmission from which four forward speeds and
one reverse speed are obtained.
1st speed is obtained by placing the front and
rear units in reduction. The 1.55 to 1 reduction
of the front unit combined with the 2.55 to 1
-n
0
1’
a
C
C
0
C
C
0
-I
0
I
zc-I
..<
a
a
a
U
C.,
C
0
-1
a
z
3
0
Intermediate
Shaft
HYDRAMATIC TRANSMISSION
6-3
reduction of the rear unit provides 3.96 to 1
reduction at the output shaft.
Selector Positions Fig. 6-2
2nd speed is obtained by placing the front unit in
direct drive and the rear unit in reduction. This
provides 2.55 to 1 reduction for second speed,
There are six selector positions which enable
the driver to control the operation of the trans
mission under various conditions.
3rd speed is obtained by placing the front unit
in reduction and the rear unit in direct drive
providing 1.55 to 1 reduction.
Parking position places transmission in neutral
and engages parking pawi with teeth in re
verse planet carrier, preventing output shaft from
turning.
4th speed is obtained by placing both units in
direct drive, causing the output shaft to rotate at
approximately engine speed.
Neutral position releases the neutral clutch,
allowing the rear unit to free-wheel so that no
power is transmitted to the output shaft.
Reverse is obtained by placing the front Unit in
reduction, the rear unit in neutral, and the re
verse unit in reduction. The combination of the
1.55 to 1 front unit reduction and the 2.42 to 1
reverse unit reduction provides a 3.74 to 1 reduction in the reverse direction,
Drive 4 position applies the neutral clutch, to
place the transmission in normal operating range.
All four forward speeds will then occur in normal
sequence.
FRONT UNIT
Selector
Position
Speed
Front Unit
Coupling
REAR UNIT
Front Sprag
Clutch
Overrun
Clutch
Neutral
Clutch
REDUCTION
PARK
On
Off
REDUCTION
---
On
Empty
Off
Off
Off
Empty
I
Off
On
Off
On
REDUCTION
Off
On
DIRECT DRIVE
Off
On
REDUCTION
I
Empty
3
Full
J
On
Empty
On
Off
On
REDUCTION
On
On
On
REDUCTION
Empty
Full
I
°
Off
On
On
On
Off
IDLING
I
On
loft
Off
Off
Off
IDLING
Off
IDLING
Off
On
Off
Off
IDLING
On
On
I
IDLING
Off
Off
Off
On
On
J
Off
On
On
I
Off
Off
Fig. 6-2
Off
IDLING
Off
On
Off
Off
IDLING
Off
On
NEUTRAL
Off
Off
IDLING
Off
f
Off
REDUCTION
----
Empty
I
Of f
REDUCTION
REDUCTION
REVERSE
Off
REDUCTION
DIRECT IRIVE
2
Off
DIRECT DRIVE
LO
1
On
REDUCTION
j
Off
Of
IDLING
REDUCTION
On
I
Off
-
DIRECT DRIVE
2
Off
DIRECT DRIVE
Off
DR3
On
On
IDLING
DIRECT DRIVE
On
Full
Off
REDUCTION
Off
Empty
Off
REDUCTION
On
Full
Oui
-
DIRECT DRIVE
1
Parking
Pawl
IDLING
___________________________
REDUCTION
DR4
4
Reverse cf
Clutch
NEUTRAL
NEUTRAL
3
Overrun
Band
_________________________________
Empty
2
Rear
Clutch
NEUTRAL
-___________
1
Rear Sprag
Clutch
REVERSE UNIT
-
Off
On
Power Flow Summarized
Off
Off
On
Off
HYDRA-MATIC TRANSMISSION
6-4
Drive 3 position prevents the transmission from
shifting above 3rd speed and applies the overrun
clutch, which allows engine braking in 3rd speed.
band and overrun clutch, which allow engine brak
ing in 2nd and 1st speeds.
Low position prevents the transmission from
shifting above 2nd speed and applies the overrun
Reverse position releases the neutral clutch and
applies the reverse clutch which places the trans
mission in reverse.
SERVICE INFORMATION
1. Hydra-Matic Diagnosis
4. When a shift is missing, do not attempt an
upshift by overspeeding the engine.
The following guide has been developed to
assist in diagnosing Hydra-Matic transmission
conditions. This procedure may be used only on
controlled
coupling type Hydra-Matic trans
missions. It does not apply to other transmissions,
5. Do not alter shift pattern by changing Selector lever position while car is in motion.
6. If operation condition is not found in table,
use digit for "normal".
The instructions must be followed in the exact
sequence as outlined below. Any deviation from
this procedure will result in incorrect diagnosis.
7. Connect a portable tachometer to engine
whenever possible. Engine RPM will identify shift
points. Dropping of needle to approximately 2/3
of its previous reading will verify that a shift has
a. Preliminary Instructions
taken place.
1. Make sure engine and transmission are at
normal operating temperatures.
all
b. Neutral Table Fig. 6-4
2. Make sure selector lever moves freely in
positions and pointer is correctly aligned.
3. Check the following,
sary:
1. Move
4. Stop car if it moved.
Drive 4 Range
1-2
850 RPM
to Neutral position.
3. Select digit in Neutral Table that describes
transmission’s action. This is the first digit of
the Condition Number.
Oil Level
b. Manual Linkage Adjustment
c. TV Linkage Adjustment
Minimum
Throttle
lever
2. Accelerate engine normally.
and correct if neces
a
Shift
selector
Drive 3 Range
Lo Range
Full
Throttle
Minimum
Throttle
Full
Throttle
Minimum
Throttle
Full
Throttle
2810 RPM
850 RPM
2810 RPM
850 RPM
2810 RPM
2-3
1380
3850
1380
3850
4590
4590
3-4
1270
4170
4170
4170
4170
4170
4-3
630
2485
2485
2485
2485
2485
3-2
540
1590
540
1590
2560
2560
2-1
470
1000
470
1000
470
1000
NOTE: These shift points are based on nominal engine speed. Variances from these figures can be
considered normal, if shift pattern is consistent.
Fig. 6-3
Transmission Shift Point Chart
6-5
Neutral Table
NORMAL
NEUTRAL
CONDITION
OR SLIPS
SKIPS 2ND
GEAR
IN 1ST
& 3RD
NO
NO
2ND, 3RD,
1ST OR
OR 4TH GEAR
Disconn.ct TV rod &
r.ch.ck in DR-3 for
possible change.
2ND
*
GEAR
I
.
DR-3
NO 4TH GEAR
2ND GEAR
Do not
*xceed
76 MPH
ONLY
NO
3RD OR
4th GEAR
DRive 3 Table
DRive 4 Table
1ST GEAR
NORMAL
NORMAL
STALL CONDITION
OCCURS ON
1-2 SHIFT
SKIPS
3RD
GEAR
NO
2ND OR
4th GEAR
/ 1ST ORNO 2ND
NORMAL
See
items
STARTS IN 3RD
& SHIFTS
TO 4TH
SLIPS
NEUTRAL
CONDITION
9 & 6
STALL
CONDITION
Car may move
STALL
IN 1ST
GEAR
.
CONDITION
but will not
roll freely
I
LO
SLIPS IN 1ST
AND
2ND GEAR
NO
ENGINE
BRAKING IN
1ST OR 2ND
.
*
NO
2ND
GEAR
NEUTRAL
CONDITION
2ND
GEAR
ONLY
NO ENGINE
BRAKING IN
REVERSE
Check above
10 MPH
SLIPS
IN
REVERSE
REVERSE
:
.
DRIVE SELECTOR
CANNOT BE MOVED
INTO REV. WITH
ENGINE
RUNNING
REQUIRES
EXCESSIVE
POWER FOR
REVERSE, BUT
ROLLS FREELY
Reverse Table
LO Tab’e
Fig. 6-4
Diagnosis Tables
6-6
c. Drive 4 Table Fig. 6-4
3. Select 4th digit of Condition Number from
LOW Table. Stop car.
1. Move selector lever to DRive 4 position.
f.
2. Accelerate car and note action.
Reverse Table Fig. 6-4
1. Move
3. Select 2nd digit of Condition Number from
DRive 4 Table. Stop car.
d. Drive 3 Table Fig. 6-4
1. Move
selector
lever to Reverse position.
3. Select 5th digit of Condition Number from
Reverse Table.
selector lever to DRive 3 position.
g. Diagnosis
3. Select 3rd digit of Condition Number from
DRive 3 Table. Stop car.
1. Refer to Condition Index, Fig. 6-5, and find
1ndex Number that corresponds to 5 digit Con
dition Number.
e. Low Table Fig. 6-4
1. Move selector lever to LOW range position.
h. Summary
Condition Number
Index Number
1- 1852
2 -0722
2- 0733
2 -0738
2 -0743
2-0748
2-0752
2 -0783
2- 1552
2- 1812
2- 18 19
2- 1852
2- 1853
2- 1854
2- 1858
2- 1859
2-2902
2-2909
2-3062
2-3072
2- 3075
2 -4 192
2-4194
2-4196
2- 5252
2 -6302
2-6602
2-7452
2-8552
2 -9602
2-9609
3- 1852
3- 1854
3- 3074
3
17
16
16
22
22
17
Fig. 6-5
2. Using Index Number, refer to Diagnosis
Index, Fig. 6-7, for cause or causes of condition.
12
18
24
23 & 24
13
15
14
23
6
6
19
19
4
5
5
5
8
7
7
9
10
11
11
20
21
2
Condition Index Chart
For additional information in diagnosing the
Hydra-Matic transmission, a summary of the
various clutches, overrun band, and front unit
coupling in the various speeds and driving ranges
is found in Fig. 6-2. A summary of the trans
mission shift points is found in Fig. 6-3. The
transmission case oil passages are shown in
Fig. 6-6.
2. Checking Oil Pressure
The oil pump pressure can be checked with
transmission in car, using Pressure Gage, J- 5907.
1. Clean dirt from bottom of reverse piston
housing and remove pipe plug from housing.
2. Screw pressure gage line fitting into hole in
piston housing and place gage in car so that it can
be seen from driver’s seat, Fig. 6-8.
3. Drive car until transmission oil has reached
normal
operating temperature approximately
200°F.
a. Drive Range Check
The following tests may be made by road test or
with car on jack stands.
1. Zero throttle pressure. Above 20 MPH in
fourth speed with zero throttle, oil line pressure
should be 60 to 70 psi.
2. Full throttle pressure road test. Full
throttle pressure in any drive range should be at
least 30 psi higher than zero throttle pressure
test reading.
b. Reverse Pressure Check
to prevent fluid leaks are as follows:
1. Place selector lever in Reverse position and
note pressure with engine running at 480 RPM.
This reading should be as high or higher than
previous pressure checks in drive range.
1. Use new gaskets and 0-ring seals whenever
there is a disassembly.
2. With selector lever in Reverse, apply foot
brake and increase engine speed to half throttle.
Pressure should increase to 175 psi minimum.
The pressure range under this condition should be
from 175 psi to 200 psi.
If pressure
readings are below specified
amounts for any of these tests a malfunctioning
oil pressure regulator or a leak in the system is
indicated.
3. Fluid Leakage Precautions
The several precautions that must be observed
Fig. 6-6
2. Use a very small amount of petrolatum to
hold gaskets and thrust washers in place during
assembly, or to seal gaskets. Never use gasket
paste or shellac.
3. Make sure that composition cork and paper
gaskets are not wrinkled or creased when in
stalled. Make sure that gaskets have not stretched
or shrunk during storage.
4. Make sure the square type 0-ring seals are
installed squarely and are not twisted during
assembly.
5. Make sure that mating surfaces of castings
are flat and smooth, free of deep scratches, chips,
and burrs.
Transmission Case Oil Passages
6-8
Index No.
Index No.
1
Condition 2-1852
Transmission operates properly in all
DRive selector positions and correct gears.
2
Condition 3-3074
Rear unit fails to provide a reduction, has
direct drive only.
a Mechanical failure of rear clutch not
permitting it to release.
gearset locked
b Reverse
planetary
together.
c Rear planetary gearset locked together.
3
Condition 1-1852
a Reverse cone clutch not fully released.
Mechanical difficulty
4
Condition 2-3075
a Gi governor valve stuck open.
b No. 3 governor ring broken.
5
Conditions 2-4192, 2-4194, 2-4196
Front unit has no reduction, Direct drive
only.
a Coupling valve stuck open.
b Fluid clutch vanes partly loose and
clutch locked together. Metallic par
ticles in the oil will indicate this con
dition.
c Front planetary gearset locked to
gether.
6
7
8
Conditions 2-2902, 2-2909
Both units have reduction and direct drive.
Oil circuit difficulty.
a Amplifier valve stuck closed.
b Transition’valve stuck open. Afterre
moving pan, check exposed amplifier
valve for freedom of movement.
Front unit fails to provide direct drive,
has reduction only.
a Coupling valve stuck closed.
b Fluid clutch vanes loose but clutch
not locked together. Metallic particles
in the oil indicates this condition.
c Coupling signal valves not closing.
d Coupling feed oil leaking internally and
not filling the fluid clutch.
Condition 2-5252
Oil circuit difficulty
a Transition valve stuck closed.
b 3-4 Shift valve stuck open.
Fig. 6-7
Check main line pressure at idle speed
with transmission in neutral. If line pres
sure of 95 lbs. is found, item a is indi
cated. If line pressure of 65 lbs. is found,
Item b is indicated.
9
Condition 2-7452
Rear unit fails to provide direct drive, has
reduction only.
a G2 governor valve stuck closed.
b 2-3 Shift valve stuck closed.
c No, 1 governor ring broken.
d G2 passage through reverse piston
cover to shift valve body obstructed.
e Less than correct number of rear
clutch plates.
f
Rear clutch apply oil leaking internally.
g Rear clutch mechanical apply failure.
With car on jack, check main line pressure
at 30 MPH with TV rod disconnected. Line
drop pressure of 65 lbs. indicates item b,
e, f, or g. Normal line pressure, 95
lbs., indicates item a, c, or d.
10
Condition 2-8552
Oil circuit difficulty.
a G2 governor valve restricted.
b No. 1 governor ring broken.
c 3-4 Shift valve stuck closed.
Disconnect TV rod, check 2-3 shift point.
If higher than minimum throttle specifica
tions, item a orb is indicated. If normal,
item c is indicated.
11
Both units fail to provide a direct drive,
have reduction only. No governor pres
sure to shift valves.
a Gl governor valve stuck closed.
b Gl governor weight missing.
c No, 4 governor ring broken.
d Gl passage from governor to shift
valve body obstructed. Item d will
apply where this condition has occur
red immediately following the replace
ment of such parts as reverse piston
housing, shift valve body, channel plate,
or transmission case.
12
Condition 2-0783
Both units fail to provide reduction or
direct drive.
a Pressure regulator valve stuck.
b Oil pump slide stuck.
c Oil pump drive tangs sheared.
d Front sprag broken and overrun clutch
burned up.
Diagnosis Index Chart
Index No.
Index No.
a. If the car has a normal reverse, item
b is indicated.
Consult oil circuit chart for possible points
where line pressure could leak into the
passage found to be causing the stall con
dition. Check these points in the trans
mission for foreign matter between valve
body surfaces and for damaged surfaces.
Also check for full travel of valves which
are connected with the oil circuit that was
indicated to be faulty.
Manual linkage to manual valve dis
connected.
Check main line oil pressure. Normal
pressure indicates item d or e. Very
low or no oil pressure will indicate item
a or b. No oil pressure will indicate
item a, b, or c.
e
13
14
15
6-9
Condition 2-1853
Reverse internal gear not being held in
reverse.
a Reverse stationary cone key not in
place.
b Linkage to manual valve loose or im
properly adjusted.
c Reverse clutch piston not applying.
If the car will move backwards under its
own power, even slightly, also see Index
No. 14.
Condition 2-1858
Reverse internal gear not being held firmly.
a Pressure regulator valve not operating
to provide reverse pressure of 160 to
200 lbs.
b Oil Pump output low.
c Internal leak in the reverse cone clutch.
d Mechanical failure of reverse cone
clutch.
Check main line pressure in neutral. If
below normal, item a or b is indicated.
If normal, check main line pressure in
reverse. If below normal when checked in
reverse, item a or c is indicated. If
main line pressure is normal when checked
in reverse, item d is indicated. If car
will move just slightly in reverse, also
see Index No. 13.
Condition 2-1854
Oil circuit difficulty causing stall condition
in reverse.
NOTE: Check manual linkage adjustment.
a Rear unit multiple disc clutch applied.
b Overrun band applied.
c Neutral clutch applied.
This condition is caused by oil pressure
leaking into the supply passages of item
a, b, or c. Remove overrun band
servo-piston, spring, and accumulato:r body
complete. Temporarily replace oil lines,
pan, and oil to test. If stall condition in
reverse is present, item c is indicated.
If stall condition has been corrected, see
next paragraph.
Replace only the accumulator body, leaving
out the band servo-piston, and spring.
Replace oil pick-up lines, screen, pan, and
oil to test. Stall condition indicates item
Fig. 6-7
16
Front unit fails to provide reduction in
DRive 4.
a Front sprag broken, overrun clutch
operating normally.
17
a Rear sprag broken or flipped over.
b Neutral clutch burned up or not apply
ing.
18
Condition 2l552
Transmission will not provide a 3-4 up
shift at full throttle or in DRive 3.
a Engine not providing sufficient power.
b G2 valve sticking or has limited travel.
c Incorrect 3-4 shift valve spring.
d Sticking 3-4 regulator plug.
Check minimum throttle shift points in
DRive 4. If normal, and not excessively
high, item a is indicated.
19
Rear unit does not provide reduction except
in reverse. Oil circuit difficulty
a Main line pressure is leaking into the
2-3 clutch apply passage. Inspect 2-3
shift valve and shift valve body.
b 2-3 Shift valve stuck open.
20
Condition 3-1852
a Overrun band servo-piston sticking
when partially applied.
b Neutral clutch not releasing completely.
21
Condition 3-1854
a Overrun band servo-piston
applied position.
stuck
22
a Front sprag installed backward.
23
a
Overrun clutch burned
applying.
24
up
in
or not
a Overrun band burned upor not applying.
Diagnosis Index Chart
6-10
check finish of torus cover neck and bearing sur
face in flywheel housing.
5. Flywheel housing - Inspect flywheel housing
for indications of oil seepage through casting.
6. Flywheel housing to case
installed or damaged. Check
seal in place. Seal must be
above machined surface before
seal - Improperly
groove depth with
at least .015 inch
installation.
7. Torus cover - Inspect weld at torus cover
neck for indications of leakage. See Note 19 for
checking procedure.
b. Extension Housing
1. Rear seal not installed properly or damaged.
2. Gasket extension housing to case improper
ly installed.
Fig. 6-8
Checking Oil Pressure
3. Gasket reverse
properly installed.
4. External Leaks
When investigating external oil leaks, first determine whether leak originates from trans
mission or engine. A red aniline dye preparation
should be added to the oil in whichever Unit 5
suspected of leaking. Red dye appearing in the
leakage oil will then give a positive identification.
piston housing to case im
4. Reverse piston housing and extension housing
attaching screws not torqued to specifications.
5. Breather pipe or speedometer gear housing
not tight.
If oil leak is found to be in transmission, check
for leaks in areas described below. It will be
necessary to remove flywheel housing front and
lower covers to determine location of leakage in
flywheel housing area.
a. Front End
6-9, numbered arrows,
NOTE: In Fig.
corresponding to the descriptions below, point
out locations of possible leaks at front of trans
mission.
1. Torus
installed.
drain
plug
loose
or
improperly
2. Torus cover to flywheel seal not installed
properly, or damaged. Check for possible ob
struction at point where flywheel seal retainer
contacts flywheel.
3. Flywheel
cations.
screws
not
torqued
to
specifi
4. Front seal leak - Check front seal to see
that it is correctly installed and is not damaged.
When installing a new front seal, maIc sure
that bore is free from staking materialid that
garter spring on seal is correctly positioned. Also
Fig. 6-9
Points of Possible Oil Leaks
6. Line pressure plug not tight.
6-li
E. Oil Seal Ring - Front unit driven torus
member to front unit driving torus member. In
spect oil seal ring to determine whether it is cor
rectly installed and not damaged.
7. Porous casting.
8. Plug in propeller shaft yoke not tight.
F. Oil Seal Ring - Front unit torus cover to oil
pump. Inspect ring to determine whether it is
correctly installed and not damaged.
c. Cooler Connections
1. Outside cooler connections
stalled or damaged.
improperly
in
G. Bushing - Front unit torus cover to driven
torus shaft. Inspect bushing to determine whether
it is loose or worn excessively.
2. Damaged sleeve 0-ring seals.
3. Cooler
pipe
to
radiator gasket damaged.
4. Flare on pipe damaged at radiator.
d. Filler Tube
1. Damaged
seal.
or improperly
installed
0-ring
2. Filler tube not fully seated in case.
H. Bushing - Oil pump to front unit driven torus
shaft. Inspect bushing to determine whether it is
loose or worn excessively.
I. Oil Seal Ring - Driven torus shaft to inter
mediate shaft. Inspect ring to determine if it is
correctly installed and not damaged.
In addition to points shown, leaks at these lo
cations will also cause torus drain back:
3. Dip stick not in all the way or not seating
properly.
1. Torus Feed Valve - Oil Pump. Inspect torus
feed valve in oil pump to make bertain it is free
in bore.
5. Internal Leaks Causing Torus
Drain Back
2. Oil Seals - Cooler sleeve oil pump. Inspect
seals to make certain they are not damaged and
are correctly positioned.
Torus drain back is a condition where torus oil
slowly drains back into transmission case when
car is parked overnight. This is indicated by car
failing to move and having excessive engine "run
away" for a few seconds after starting.
When torus drain back is indicated, the follow
ing points should be checked. See lettered arrows
in Fig. 6-9.
A. Bushing - Flywheel to driven torus hub. In
spect bushing to determine whether it is loose or
worn excessively.
bushings,
care
NOTE: When inspecting
should be exercised to determine whether a
bushing is simply "worn in" or worn to such
an extent as to be considered not serviceable.
All bushings wear to a certain degree and will
indicate this wear; however, it would be he]Lpful
to fit the mating parts into the bushing and ob
serve the amount of looseness.
B. Torus Check Valve - Inspect torus check
valve to make sure it is free in bore of driven
torus member.
C. Bushing - Driving torus hub to driven torus.
Inspect bushing to determine whether it is loose
or worn excessively.
D. Bushing - Front internal gear to intermedi
ate shaft. Inspect bushing to determine whether it
is loose or worn excessively.
6. Tests for Hydra-Matic Noises
Testing for noises requires close attention to
determine the source of trouble. An important
point to remember is that, although Hydra-Matic
transmissions are relatively quiet in operation,
there is always a certain amount of gear noise
when either the front or rear unit is in reduction,
or when in reverse. This is typical of any gear
train when it is operating. Before any test of
Hydra-Matic noise is made, the following factors
must be considered:
1. The engine must be tuned to run smoothly,
so that engine noise is not mistaken for trans
mission noise.
2. The rubber engine mounting pads, particu
larly the one under the transmission extension
housing, must be tested for proper torque tight
ness of attaching screws, and should be visually
checked to assure that no grounding occurs be
tween engine or transmission and frame.
3. Ample clearance must be present at cowl
and floor pan to be sure that body does not touch
engine, transmission, dipstick tube or linkage
rods. Normal Hydra-Matic noise levels would be
magnified to an unacceptable level if any me
chanical grounding occurs through frame or body,
and this possibility must be eliminated before
testing.
6- i2
4. The transmission to radiator lower tank
cooler pipes must be checked for any grounding
to exhaust system, frame, or sheet metal to avoid
high magnification of normal oil pump and gear
noise levels.
Use Diagnosis Chart, Fig. 6- 10, as a guide for
locating sources of noise.
a. Front Unit
The front unit planetary gears may be heard in
Dr-4, Dr-3, Lo and Reverse selector ranges. In
forward driving ranges, this gearset operates in
reduction in first and third speeds. Gear noise
from a planetary unit is usually heard as a whine,
which is somewhat muffled by the main fluid
coupling oil surrounding these gears.
NOTE: If a planetary gearset is unaccept
able due to noise, entire gearset must be re
placed as a unit to avoid worn gears causing
same characteristics in new gears.
d. Oil Pump
The oil pump may produce a whine at any time
the engine is running, especially during 1-2 and
3-4 upshifts when hot. This is distinguishable
from gear noise because it remains through all
gear ratios and noise will change with engine but
not car speed.
7. Linkage Adjustment
a. Manual Linkage
b. Rear Unit
i. Remove slush deflector.
The rear unit planetary gears may cause a
whine in Park and Neutral, first and second speeds
in any forward driving range, and in reverse dur
ing deceleration.
2. Remove clevis from manual lever on trans
mission, Fig. 6-li.
c. Reverse Unit
4. Place manual lever on transmission in Dr-4
Position.
The reverse unit planetary gears will cause a
whine during reverse acceleration only. Due to
limited use of reverse, the acceptable noise level
for these gears is higher than for the other two
gearsets.
3. Loosen lock nut on transmission manual rod.
5. Place selector lever on steering column in
Dr-4 position against stop.
6. Adjust length of manual rod until hole in
Occurs Under Following Conditions
1. Gear noise in Dr-4, Dr-3, Lo, R
and third speeds.
-
Possible Cause
reverse, first
Front Unit Planetary Gears
2. Gear noise in P, N, Dr-4, Dr-3, Lo, R - neutral,
reverse coast, first, and second speeds.
Rear Unit Planetary Gears
3. Gear noise in R
Reverse Planetary Gears
-
reverse acceleration.
4. Buzz or whine at upshifts
gear.
or low speed in any
Oil Level Low
Oil Pump
Cooler Pipes Grounded
Intake Pipe "0" Rings Leaking
5. Whine or whistle any time car is in motion.
Governor Drive Gears
6. Rattle or buzz under light load in 3rd and 4th
speeds.
Torus Cover - Dampener Spring
Reverse Gearset Rattling
7. Squawk when engaging Reverse.
Low Oil Pressure
8. Vibration at certain engine speeds.
Flywheel - Balance
Torus Cover - Balance
Flex Plate - Runout
Fig. 6-10
Noise Diagnosis Chart
-
Internal Leak
6-13
manual lever lines up with hole in clevis and then
increase rod length one turn more.
NOTE: If clevis contacts nut before slack is
taken up, nut should be backed off still further.
7. Install clevis on manual lever and tighten
lock nut.
8. Check manual selector lever in car. It should
be free to enter "Park" position and Dr-4 stop in
steering column should correspond to Dr-4 detent
position in transmission. Readjust if these con
ditions are not met.
9. Check to see that indicator pointer indexes to
Dr-4 position when selector lever is at Dr-4 stop.
Adjust if necessary.
b. Throttle Control and TV Rod Linkage
1. Remove spring clip from carburetor rod
trunnion and remove trunnion from relay bracket
lever.
Fig. 6-12
9. Turn rear adjusting nut into contact with
trunnion and use two wrenches to tighten nuts. Be
careful not to put any binding force on carburetor
plate.
10. Remove
2. Place 1/4 drill shank through gaging hole in
dash relay lever and into dash relay bracket.
3. With engine running, set carburetor throttle
lever in hot idle position. Air Conditioner
"OFF".
4. Adjust carburetor throttle rod trunnion to
allow free entry into dash relay lever.
5. Install spring clip in trunnion.
T.V. Rod Adjustment
drill
shank from relay bracket.
11. Road test car. Adjustment may be altered
as required to improve shift smoothness.
12. If 4-3 downshift cannot be obtained, check
carburetor for wide open throttle and choke un
loader operation with accelerator pedal fully de
pressed,
Perform
accelerator
pedal height
adjustment if necessary.
c. Accelerator Pedal Height Adjustment
6. Using two wrenches, back off both adjusting
nuts on TV rod at carburetor to allow free move
ment of rod in trunnion, Fig. 6-12.
1. Remove cotter key from trunnion on inner
side of accelerator pedal arm and remove trun
nion from arm.
7. Push end of TV rod toward rear of car to
position transmission throttle lever against its
stop and hold with light pressure.
2. Adjust trunnion either up or down as required
to obtain wide open throttle with pedal fully de
pressed.
8. Turn front adjusting nut against trunnion
until all slack is taken up. Then tighten nut three
full turns.
3. Assemble linkage and install slush deflector.
8. Adding and Changing Fluid
a. Hydra-Matic Oil Recommendations
In order to obtain the maximum performance
and satisfaction from the Hydra-Matic trans
mission, it is necessary that the proper trans
mission fluid be used. Whenever the transmission
is drained and refilled or fluid is added, use only
Automatic Transmission Fluid Type "A", design
ated AQ-ATF, followed by three or four digits and
the suffix letter "A".
Fig. 6-11
Manual and Throttle Levers
The original factory fill fluid in the trans
mission should be changed at 30,000 miles. Sub
sequent changes should be made at 16,000 mile
intervals. For cars in commercial use, or those
6-14
C
B
A
-i½"-
c. Changing Fluid
1. Remove lower flywheel housing cover plate.
2. Remove drain plugs, Fig. 6-14, from trans
mission oil pan and torus cover.
A. Low Operating Temperature 80°-100°F.
B. Normal Operating Temperature 160°.200°F.
C. Extreme Operating Temperature 260°.300°F.
Fig. 6-13
Transmission Oil Level
subjected to heavy city traffic during hot weather
or when the engine is idled for prolonged periods,
the original factory fill fluid should be changed at
16,000 miles. Subsequent changes should be made
at 9,000 mile intervals in this type service.
b. Checking Fluid Level
The dipstick and filler tube for the Hydra-Matic
transmission are located under the hood at the
right rear side of the engine on all 1963 Cadillac
cars.
The fluid level should be checked at every en
gine oil change. Add fluid, if necessary, until
proper level is indicated on dipstick. Proper level
is based on engine operating temperature, Fig.
6-13. Since the full and add dimple marks on the
transmission dipstick are only one pint apart, and
since normal expansion and contraction of the
fluid with temperature changes will more than
span this gap, careful attention to the degree of
engine warm-up and adherence to the fluid check
ing procedure below, will be necessary in order
to judge the actual fluid level correctly. The fluid
level should always be checked after the engine
has been running to make certain the fluid cou
pling is full. Run the engine with the selector
lever in "P" Park position at 800 RPMfor 1-1/2
minutes low operating temperature.
Reduce engine speed to slow idle, remove and
wipe dipstick, and check fluid level. With engine
still running, add fluid through dipstick tube to
bring to proper level.
3. Allow old fluid to drain completely and then
reinstall drain plugs. Replace lower flywheel
housing cover plate.
4. Pour seven quarts of Hydra-Matic fluid into
filler tube.
5. Run engine at a speed of 800 RPM for ap
proximately 1-1/2 minutes with selector lever in
"P" Park.
6. Reduce engine speed to slow idle carburetor
off fast idle cam and add 1-1/2 to 2 quarts of
fluid to bring level on dipstick to proper level as
indicated by operating temperature, Fig. 6-13.
7. Turn off ignition and replace dipstick.
NOTE: The capacity of the Hydra-Matic
transmission is approximately nine quarts for a
refill, but the correct level is determined by the
mark on the dipstick rather than by the amount
added. It is important that the proper level be
maintained. Do not overfill, as foaming might
occur when the fluid heats up. If the oil level is
too low, the pressure regulator will become
noisy, resulting in possible malfunction of the
transmission,
9. Towing Instructions
The Hydra-Matic transmission used on 1963
series cars will not allow the engine to be started
by pushing. If the car cannot be started normally
or by the use of jumper cables, it will be neces
sary to tow the car to the nearest service station.
It is possible to tow or push 1963 series cars
without disconnecting the propeller shaft or
raising the rear end of the car. The transmission,
if operating properly, will not be damaged by tow
ing. The car can be towed at speeds up to 30 MPH
for distances up to 50 miles. Always tow the car
with the transmission
shift lever in neutral
position.
10. Extension Housing Removal and
Installation Transmission in Car
a. Removal
1. Raise car on jacks or hoist.
Fig. 6-14
Transmission Drain Plugs
2. Remove propeller shaft assembly. See Sec
tion 7, Note 10.
6-15
3. Disconnect brake cables from parking brake
relay lever. Remove retracting spring and re
move relay from frame.
4. Disconnect speedometer cable at extension
housing and remove speedometer drive gear.
5. Remove screws that hold rear engine mount
to extension housing.
6. Raise transmission with transmission hoist
to take weight off rear engine support. Remove
support from frame.
7. Remove eight screws that hold extension
housing to case, and slide extension housing rear
ward and downward to remove from car. Make
sure that output shaft splines do not come in con
tact with extension housing rear seal.
8. Remove housing to case gasket.
b. Installation
Fig. 6-15
Removing Extension Housing Oil Seal
1. Install new extension housing to case gasket.
2. Carefully install extension housing over out
put shaft onto case.
CAUTION:
Use extreme care to be certain
that output shaft does not contact rear seal dur
ing installation as splines could damage seal
lip.
3. Install
screws.
eight
extension
housing
to
case
4. Install speedometer drive gear and connect
cable.
5. Install rear engine support on frame.
6. Remove transmission hoist and install sup
port to extension housing screws.
3. Check front propeller
See Section 7, Note 11.
shaft yoke for leak.
4. Use hammer to drive screwdriver under lip
of oil seal and pry seal out of housing, Fig. 6-15.
5. Install new oil seal in extension housing,
using Tool No. J-5l54, Fig. 6-16.
6. Install propeller shaft assembly. See Section
7, Note 10.
b. On Bench
1. Insert screwdriver under lip of old oil seal
and pry seal out of extension housing.
2. Install new oil seal in extension housing,
using Tool No. J-5l54.
7. Install propeller shaft assembly. See Section
7, Note 10.
8. Install parking brake relay lever and re
tracting spring in position in frame. Connect
brake cables to lever and adjust cables. See
Section 8, Note 2.
11. Extension Housing Oil Seal
Replacement
a. On Car
1. Raise car on jacks or hoist.
2. Remove propeller
Section 7, Note 10.
shaft
assembly.
See
Fig. 6-16
Installing Extension Housing Oil Seal
6-16
Oil Seal Installer
And Staker J-7026
Seal Installer over hub of flywheel housing with
seal centered in hub opening.
NOTE: Make certain that staking tool is not
in passage in side of Seal Installer while seal is
being installed.
7. Drive seal in with hammer, making certain
that seal is firmly seated on bottom of seal bore,
Fig. 6-17.
8. Insert staking tool into side of Seal Installer
and tap end of tool to stake edge of flywheel hous
ing seal, Fig. 6-18. Seal should be staked into
position at three points, approximately 120° apart,
where housing has metal added.
NOTE: Do not strike staking tool with ham
mer any harder than is necessary to stake edge
of seal lightly,
Fig. 6-17
Installing Flywheel Housing Oil Seal
12. Flywheel Housing Oil Seal
Replacement
1. Remove transmission from car as described
in Note 13.
2. Remove flywheel housing from the trans
mission as described in Note 15a.
3. Drive old seal out of bore.
4. Using a file, carefully clean staked material
out of bore,
9. Install
Note l8h.
flywheel
10. Install
Note 14.
housing
transmission
as
as
described
described
in
in
13. Removal of Transmission from Car
1. Disconnect battery.
2. Place car on hoist or on jack stands.
3. Remove starter
5. Place Flywheel Housing Support, J-7027, on
level area and position flywheel housing on
support.
4. Remove
covers.
6. Slide new seal on pilot of Flywheel Housing
Oil Seal Installer and Staker, J-7026, and position
5. Drain
cover.
front
motor and slush deflector.
and lower flywheel housing
transmission
at
oil pan and torus
6. Remove transmission filler
bolt from exhaust manifold.
pipe
bracket
7. Clean dirt away from pipe flange and slide
filler pipe out of sleeve in transmission case.
8. Disconnect brake cables from parking brake
relay lever. Remove retracting spring and remove
relay from frame.
9. Remove propeller shaft assembly.
tion 7, Note 10.
See Sec
a. Loosen and remove nuts securing the two
engine side supports to the flywheel housing and
remove side supports from frame cross member.
10. Remove intermediate frame cross member
below flywheel housing.
Fig. 6-18
Staking Flywheel Housing Oil Seal
11. Disconnect speedometer cable from exten
sion housing.
6-17
12. Disconnect TV and manual rods.
13. Remove four nuts from flywheel-to-drive
plate screws.
14. Place jack or other suitable device under
rear of engine oil pan, using a wood block to pre
vent damage to pan.
15. Place transmission hoist under transmis
sion and raise it just enough to take the load off
the rear engine support.
16. Disconnect rear motor mount at support
bracket. Remove shims between rear cushion
and cross-member.
17. Remove six screws and remove rear engine
support from frame.
18. Remove and discard oil cooler hoses from
rear oil cooler lines and sleeves at lower con
nections, Fig. 6- 19. Cap lines and sleeves to
prevent leaking.
19. Remove six screws holding flywheel housing
to engine.
20. Remove transmission and flywheel housing
as a unit by moving assembly toward rear of car,
disengaging flywheel housing from locating dowels
on engine, and then tilting front of unit downward
to lower it from car.
14. Installation of Transmission in Car
1. Raise transmission
with transmission jack.
four torus cover screws,
wheel housing with dowels
into position carefully
Align drive plate with
and dowel holes in fly
on engine.
2. Install six flywheel housing to crankcase
screws, and tighten to 4-5 foot-pounds. Be certain
flywheel is as far forward as possible.
3. Clean ends
of
cooler
lines
with solvent.
4. Place new oil cooler seals on each cooler
sleeve tip and in one motion insert sleeve into
transmission case. Avoid pulling back on the
sleeve once installation has been made in the
transmission case.
CAUTION: If it becomes necessary to pull
on the sleeve, then completely remove s]Leeve
from transmission case and reposition the seal
to
insure that
seal is not damaged or
mispos itioned.
5. Connect oil cooler lines to cooler sleeve
hoses and secure with clamps. Torque clamps to
20 inch-pounds.
Fig. 6-19
Removing Oil Cooler Pipes
6. Lift engine and transmission to about one
inch above normal height and install engine rear
support bracket on frame. Tighten three bracket
bolts on one side only. Install three bracket bolts
on other side loosely.
7. Lower transmission carefully and insert
shims between the rear cushion and the crossmember. Position plate on bottom side of crossmember and loosely install rear cushion to
cross member. Remove block from engine pan
and transmission jack.
NOTE: Install the same number of shims
removed to assure proper alignment of trans
mission and propeller shaft.
8. Install the four nuts that attach drive plate
to flywheel and tighten to 20 foot-pounds torque,
Be sure drain plugs in torus cover 7 foot-pounds
torque and oil pan 40 foot-pounds torque are
tight.
9. Install
covers.
flywheel
housing
front
and
lower
10. Install starter motor.
11. Install filler tube in transmission with
support bracket properly positioned on exhaust
manifold.
12. Connect TV and manual rods.
13. Install speedometer cable.
14. Install slush deflector.
15. Tighten three remaining bolts on engine
rear support bracket.
16. Install propeller shaft assembly.
tion 7, Note 10.
See Sec
6-18
17. Install parking brake relay lever and re
tracting spring in position in frame. Connect
brake cables to lever and adjust cables. See Sec
tion 8, Note 2.
25. Install each engine side support cushion
in frame slots, and loosely install flat washer,
lock washer, and retaining nut.
26. Slide each cushion support toward bell
housing until cushion support just touches housing.
18. Adjust manual and TV linkage as described
in Note 7.
NOTE: Be sure that underside of cushion
support bracket is flat against frame.
19. Check torque of engine front cushion-toframe nuts. These nuts should be tightened to
90 foot-pounds.
27. Scribe a reference line on frame adjacent
to each bracket.
20. With rear cushion-to-frame cross member
attaching screws loose, pry transmission exten
sion housing retainer up off cross member to
allow engine to move backward as far as possible.
28. Slide each bracket 1/16 inch inboard toward
bell housing letting rubber cushion ride up bell
housing.
21. Scribe a line on underside of cross member
ai rear edge of rectangular plate.
29. Tighten each retaining nut to 25 foot-pounds
compressing rubber cushion until bracket again
lies flat on frame member.
22. Place a bar at rear of engine rear cushion
front attaching screw and pry engine and trans
mission assembly as far forward as possible.
30. If either bracket is not 1/16 inch inboard of
reference line after retaining nuts are tightened,
repeat above procedure.
23. With engine in this position, scribe a second
line on cross member at rear edge of plate.
31. Lower
24. Allow engine to move rearward until rear
edge of plate is positioned halfway between the
two scribed lines and then tighten rear cushionto-frame attaching screws to 55 foot-pounds,
car to floor and connect battery.
32. Install filler pipe bracket to exhaust mani
fold screw.
33. Add fluid to transmission as required.
Flywheel Housing Assembly
Torus Cover Assembly
Steel Backing Washer
Steel Backing Washer
Snap Ring
Front Sun Gear
Intermediate Shaft Snap Ring
/////Mainshaft
Flywheel Housing Seal
Ring Seal Flywheel Housing to Case
Front Internal Gear’
Needle Thrust Bearing
Steel Selective Washer
Bronze Thrust Washer
Driving Torus Assembly
Retaining Pin
Driven Torus Assembly
Torus Check Valve Spring
Torus Check Valve
Ring Seal Flywheel to Torus Cover
Fl,ywheel
Fig. 6-20
Flywheel Torus Members Cover and Housing Disassembled
Inner Snap Ring
6-19
15. Transmission Disassembly to
Remove Major Components
a. Remove Flywheel, Torus Member, Torus
Cover and Flywheel Housing, Fig. 6-20
Fluid coupling cannot be removed as a unit.
Components must be taken off one at a time as
described below:
1. Remove eight attaching
flywheel from torus cover.
nuts and remove
2. Remove flywheel to torus cover rubber oil
ring seal and discard.
3. Remove snap ring that retains driven torus
member to mainshaft, using Pliers, J-4880, and
remove driven torus member, Fig. 6-21.
4. Remove inner snap ring locating driven
torus member on mainshaft, using Pliers, J* 4880,
Fig. 6-22.
5. Remove snap ring that retains driving torus
member to intermediate shaft, using Pliers,
J-6083, and remove driving torus member.
CAUTION: Do not attempt to remove torus
cover and driving torus member together.
6. Remove bronze thrust washer and steel se
lective washer from front unit sun gear.
7. Remove front unit sun gear from shaft of
front unit coupling driven torus member.
8. Remove intermediate shaft snap ring, using
Pliers, J-8059.
Fig. 6-22
Removing Driving Torus Snap Ring
9. Remove internal gear with steel thrust
washer, needle bearing and second steel black
washer.
10. Remove torus cover.
CAUTION: Do
cover by pulling
manner, as this
seal. Work hub
oil seal and pull
not attempt to remove torus
or pushing on cover in a rough
may result in a damaged oil
of torus cover back through
cover out with a quick motion.
11. Install Flywheel Housing Oil Seal Protector,
J-61l9, remove six cap screws, and remove fly
wheel housing, Fig. 6-23. Remove special tool.
Fig. 6-21
Remove Snap Ring Retaining
Driven Torus Member
Fig. 6-23
Removing Flywheel Housing
6-20
5. Install bracket and transmission into base
and install lock pin in base with oil pan facing up.
c. Remove Oil Pan, Oil Strainer and Intake Pipe
NOTE: Units may be removed with trans
mission in car.
1. Take out fifteen cap screws and lock washers
and remove oil pan and gasket. Discard gasket.
2. Loosen accumulator attaching screw that
retains intake pipe clip and rotate clip away from
intake pipe, Fig. 6-26.
3. Pull oil strainer and intake pipe assembly
straight out to disengage from retaining clip on
coupling valve body, Fig. 6-26.
Fig. 6-24
4. Separate intake pipe from oil strainer.
Oil Cooler Sleeves Disassembled
12. Remove and
case seal ring.
discard flywheel
housing to
5. Remove 0-rings from oil pump and strainer
for inspection. If replacement is necessary, dis
card 0-rings.
b. Remove Front Unit Coupling Assembly
NOTE: Transmission must be removed from
car. Remove flywheel, torus members, torus
cover and flywheel housing Note l5a.
1. Remove front unit coupling assembly
pulling toward front of transmission.
by
d. Remove Control Valve and ServoAccumulator Assemblies
mission in car. Requires removal of oil pan,
oil screen and intake pipe Note l5c.
2. Remove screw that holds oil cooler sleeve
strap and remove strap and oil cooler sleeves
from side of transmission, Fig. 6-24. Remove
0-rings from cooler sleeves and discard.
3. Remove cooler sleeve-to-case square sec
tion seals from cooler sleeve bores in trans
mission case, and discard.
4. Attach bracket for holding fixture to front
flange of transmission case, Fig. 6-25.
Oil Strainer
Retaining
Clip
Oil Strainer
/
Intake Pipe
Intake
Pipe
Clamp
Fig. 6-25
Transmission in Holding Fixture
Fig. 6-26
Accumulator
And Servo
Body Attaching
Screws
Bottom View of Transmission
6-21
f. Remove Parking Pawl and Linkage and
Detent Spring
Servo and
Accumulator
Assembly
/
1. Remove oil pan, oil strainer and intake pipe
as described in Note 15c.
2. Remove control valve and servo-accumula
tor assemblies as described in Not 5d.
3. Remove Detent and throttle lever assemblies
as described in Note 15e.
4. Remove extension housing as described in
Note lOa.
NOTE: Remove one screw securing reverse
piston housing to case, and rotate reverse pis
ton housing until parking pawl pivot pin hole is
exposed.
Fig. 6-27
5. Remove parking pawl pivot pin from trans
mission case by pushing on inside end of shaft
with a thin rod such as welding rod, Fig. 6-30.
Removing Servo and Accumulator
1. Remove two screws holding servo- accumula
tor assembly to case, Fig. 6-26. Be prepared
for some spring tension under servo.
2. Remove servo-accumulator
servo release spring, Fig. 6-27.
assembly
6. Remove parking
Fig. 6-29.
7. Unhook parking
lever.
pawl
spacer from case,
brake spring from parking
and
3. Remove five control valve assembly to case
attaching screws and remove control valve as
sembly, Fig. 6-27.
CAUTION: Io not let assembly rest o end
of channel plate to case spacer, and do riot let
manual valve drop out of its bore.
8. Remove parking
shaft.
bracket and spring from
9. Rotate parking lever and pawl and remove
from parking brake pin.
10. Remove attaching screw for detent spring
and remove detent spring assembly, Fig. 6-29.
g. Remove Oil Pump and Overrun Clutch
e. Remove Detent and Throttle
Lever Assemblies
mission in car. Requires removal of oil pan,
oil strainer, and intake pipe Note l5c, and
control valve and servo-accumulator assem
blies Note 15d.
NOTE: Transmission must be removed from
car. Requires removal of flywheel torus mem
bers, torus cover and flywheel housing Note
I
Inside Detent
Control
1. Loosen clamp screw that holds inner TV
lever to TV shaft, Fig. 6-28.
2. Withdraw outer TV lever and shaft from
case. Discard 0-ring seal.
3. Remove inner TV lever.
4. Loosen detent control set screw, Fig. 6-28.
5. Withdraw manual lever and shaft from case.
Remove steel washer and seal ring, Fig. 6-29.
6. Remove inside detent control.
Fig. 6-28
inside Control Levers
6-22
Fig. 6-29
Control Levers and Parking Brake Assemblies
l5a, front unit coupling assembly Note l5b,
oil pan, oil screen and intake pipe Note l5c,
and control valve and servoaccumulator Note
1 5d.
1. Remove pressure regulator plug assembly
from side of transmission, Fig. 6-32.
-
Disassembled
cocking in bore. If pump assembly is tight in its
bore, it may be necessary to remove two nearly
opposite pump cover screws and install Slide
Hammer, J-6125, to remove pump, Fig. 6-33.
4. Remove pump locating screw and washer
from interior of transmission, Fig. 6-31.
2. Remove pressure regulator spring and valve.
3. Remove three washer-head screws attaching
oil pump to center bearing support and remove
pump assembly, taking care to prevent pump
5. Remove special tools from pump, if used.
6. Remove overrun clutch plate, release spring,
and bronze thrust washer if they did not come
out with pump.
h. Remove Center Bearing Support, Neutral
Clutch and Rear Unit Assembly
NOTE:
Transmission must be removed from
n:JJg Brake Lever
Fig. 6-30
Removing Parking Pawl Pivot Pin
Fig. 6-31
Removing Oil Pump Locating Screw
6-23
Pressure
Regulator
Assembly
Valve Stop
Pin
Seal
Spring
Valve
Reverse Booster Plug
Len,..
Fig. 6-34
Fig. 6-32
Removing Pressure Regulator Assembly
car. Requires removal of flywheel, torus mem
bers, torus cover and flywheel housing Note
l5a, front unit coupling Note 15b, oil pan,
oil screen and intake pipe Note 15c, control
valve and servo-accumulator Note l5cL, and
oil pump and overrun clutch Note l5g.
1. Install Neutral Clutch Retainer, J-6l35, over
intermediate shaft and tighten screw, Fig 6-34.
CAUTION: Locking screw must be positioned
toward front of transmission and screw must
be withdrawn far enough so as not to score
intermediate shaft during installation.
rtto Case
Removing Center Support to Case Snap Ring
3. Remove governor assembly from reverse
piston housing assembly by pulling rearward,
Fig. 6-35.
4. Remove gear flat type governor drive gear
retaining snap ring, governor drive gear, gover
nor drive gear key and front wave type retaining
snap ring.
NOTE:
moved.
Key may fall out when gear is re
5. Remove rear bearing snap ring from output
shaft, Fig. 6-35.
2. Remove eight cap screws and remove breath
er pipe and extension housing and gasket. If hous
ing sticks, a light tapping will loosen housing.
Discard gasket.
Fig. 6-33
Removing Oil Pump Assembly
Fig. 6-35
Removing Governor Assembly
6-24
Reverse Stationary Cone
Reverse Fiber
Internal Washer
14. Remove reverse piston housing attaching
screw, Fig. 6-35, and remove reverse piston
housing from case.
15. Remove governor main line and G-2 oil
filter screens.
16. Remove and discard reverse piston housing
to case gasket.
Reverse
Planet
Carrier
17. Remove reverse internal gear thrust wash
er and reverse internal gear from case, Fig. 6-36.
Reverse
Release
Fig. 6-36
Reverse Unit Parts - Disassembled
18. CAREFULLY remove reverse stationary
cone from case by gently working it free.
6. Remove center bearing support to case snap
ring, using screwdriver, Fig. 6-34.
NOTE: Reverse stationary cone is made of
"Fometl" and is very brittle. Do not use any
tools to force cone free.
7. Tap end of output shaft with a soft face ham
mer to free shaft from rear bearing inner race.
19. Remove stationary cone stop key from case.
8. Slide rear unit, neutral clutch, and center
bearing support assembly out of front end of case.
20. Unhook overrun band from anchor in side
of case and remove band through front of case.
9. Remove reverse internal gear release spring
from output shaft, Fig. 6-36.
16. Disassembly, Cleaning, Inspection
and Assembly of Individual Units
10. Remove reverse planet carrier from output
shaft.
Inspect each part thoroughly after the trans
mission and individual units have been disassem
bled and cleaned, to determine which parts should
be replaced. It is very important to distinguish
between parts that are simply "worn-in" and
those worn to the extent that they affect operation
of the unit. Only "worn-out", broken or damaged
parts should be replaced.
11. Rest rear unit, neutral clutch and case
support assembly in Holding Fixture, J-61l6,
output shaft down, Fig. 6-37.
12. Remove neutral clutch drum locating key
from transmission case.
13. Rotate transmission to
with reverse piston housing up.
vertical
position
1. Check housing for cracks or porosity.
Center Bearing
Support Assembly
Neutral Clutch
Retainer J-6135
Slot for Stationary
Stop Key in Case
a. Inspection of Flywheel Housing
/
Neutral Clutch
Drum Assembly
1/
Rear Clutch -..
Drum Assembly
2. Check bearing surface for wear. Slight sur
face wear is a normal condition.
3. Check oil seal lip for wear or damage. If
necessary, replace seal as outlined in Note 12.
b. Inspection of Flywheel
1. Test flywheel for leaks as outlined in Note
19.
2. Inspect flywheel teeth for damage. Clean any
burred teeth, using a fine file.
3. Check bushing for excessive wear or scor
ing. See Note 20 for bushing replacement pro
cedure.
Clutch Unit Holding
Fixture J-6116
I
Fig. 6-37 Rear Unit Neutral Clutch and
Center Bearing Support Assembly
c. Inspection of Torus Cover
1. Test torus cover for leaks as outlined in
Note 19.
6-25
2. Inspect dampener springs and plate.
3. Inspect torus cover neck for nicks or burrs.
Torus Check Valve Spring
Cotter Pin
Torus Check Valve
‘
/
d. Inspection of Main Coupling Torus
Members and Front Unit Parts
1. Inspect driving and driven
for any type of damage. Check
and for score marks that would
against flywheel, torus cover,
member. Look through hubs to
splines.
torus members
for loose vanes
indicate rubbing
or other torus
check for worn
2. On driving torus, inspect front unit planet
carrier and planet pinions for damage. Driving
torus assembly must be replaced as a unit if any
part is unserviceable.
3. Remove cotter pin from hub of driven torus
member and remove torus check valve and spring,
Fig. 6-38. Inspect valve for nicks and burrs, and
spring for distortion. Replace spring and valve
and check to see that valve moves freely in its
bore. Install new cotter pin.
Fig. 6-38
Torus Check Valve
large snap ring, clutch cover, and driving torus
are marked for proper alignment. If not, mark
each part so that they may be reinstalled in exact
position.
4. Check bushing in driven torus hub for ex
cessive wear and scoring. See Note 20 for bushing
replacement procedure.
2. Remove large snap ring that holds front unit
coupling cover to front unit torus member.
5. Inspect front unit sun gear for burred and
scored teeth or splines.
3. Install Front Unit Coupling Valve Retainers,
J-6l22, to hold exhaust valves in position when
removing coupling cover, Fig. 6-40.
6. Inspect two steel backing washers, needle
bearing, steel selective washer, and bronze thrust
washer for distortion or damage, Fig. 6-20.
7. Inspect front unit internal gear for burred
and scored teeth, or damaged drive lugs.
8. Check bushing in hub of internal gear for
excessive wear. See Note 20 for bushing rep]Lace
ment procedure.
4. Attach Front Unit Coupling Cover Remover,
J-612l, Fig. 6-40, and remove coupling cover
from driving torus member. Discard two square
ring seals on cover.
5. When removing center nut on tool, hold lower
part of tool to prevent it from falling.
Driving Torus Assembly
e. Inspection of Transmission Case
1. Thoroughly
solvent.
clean transmission
case
Valve
Exhaust
Valve
with
2. Blow out all oil passages through case.
Check for restricted, leaking, or interconnected
passages. For references, See Fig. 6-7.
3. Inspect transmission case for cracks.
IL
Steel Thrust
Backing Washer
Bronze
f. Front Unit Coupling, Fig. 6-39
Oil Seal Ring
Driven Torus Hub
Thrust
Washer
Oil Seal Rings
Coupling Cover to’
Front Pump
Disassembly
1. Install front unit coupling assembly in Clutch
Unit Holding Fixture, J-6l16, and check to see if
Fig. 6-39
Front Unit Coupling Disassembled
6-26
Unit Holding Fixture.
Front Unit Coupling
Valve Retainers J-6122-01
9. Remove two oil seal rings from front unit
coupling cover hub.
Front Unit
Coupling Cover
Remover J-6121
Inspection
Coupling Cover
1. Inspect all parts in front unit, making sure
that they are free from burrs and scratches. If
coupling cover is burred by removal from driving
torus member, remove burrs with crocus cloth.
Inspect driven torus shaft for signs of galling or
nicks.
k/Mark with Dye
,,before Disassembly
Clutch Unit
bIding Fixture
2. Check bushing in front end of driven torus
shaft for excessive wear. See Note 20 for bushing
3. Check bushing in coupling cover neck for
excessive wear. See Note 20 for replacement
procedure.
/-
Oil Ring Seal
_-_---
Fig. 6-40
Part of J.6121
Assembly
Removing Coupling Cover
1. Place driving torus member in Clutch Unit
Holding Fixture, J-6l16.
6. Remove two exhaust valves and springs from
coupling cover.
2. Install bronze and steel thrust washers into
driving torus member with steel washer next to
driving torus.
7. Remove front unit driven torus member,
steel and bronze thrust washers and one oil seal
ring from torus shaft. Remove one interlocking
oil seal ring from hub of driven torus member.
3. Install one oil seal ring on driven torus
member and install driven torus member into
driving torus member, Fig. 6-41.
8. Remove driving torus member
from Rear
4. Install interlocking
driven torus member.
oil seal ring on hub of
5. Install two springs and exhaust valves in
coupling cover and hold in place, using Front Unit
Coupling Valve Retainers, J-6122, Fig. 6-42.
Install two oil seal rings on cover hub.
Fig. 6-41
Installing Coupling Driven Torus
Fig. 6-42
Installing Exhaust Valves
6-27
6. Install two square ring seals on coupling
cover, making sure seals are square in their
respective grooves, and apply petrolatum to cir
cumference of seals, Fig. 6-42.
7. Install studs from Front Unit Coupling Cover
Remover, J-6121, into coupling cover and position
cover in driving torus member, lining up marks
made during disassembly, Fig. 6-43.
8. Lubricate coupling cover and seals and in
sert into driving torus member, tapping evenly
with hammer on studs. Cover is secure when
snap ring groove in driving torus member shows
evenly.
CAUTION: Cover must be inserted evenly
to prevent cocking in driving torus member and
damaging seals.
9. Install large snap ring to hold coupling cover
in driving torus member. Remove studs from
coupling cover and remove front unit coupling
assembly from Holding Fixture. Remove Coupling
Valve Retainers, J-6122.
Fig. 6-43 Installing Coupling Cover
g. Oil Pump Assembly
2. Take pump cover from pump body.
3. Remove torus feed valve retaining pin, re
tamer, spring, and feed valve, Fig. 6-44.
Disassembly
1. Remove front sprag
pump.
inner race
if still in
NOTE: Be careful that retainer and spring
do not fly out when retaining pin is removed.
Spring Retainer
Valve Spring
Front Sprag
Inner Race
Spiral Snap Ring
Retaining Pin Torus Feed Valve
Front Sprag Assembly
Rotor
Pump Slide
Overrun Clutch Piston
Oil Seal Outer
Vanes
Oil Seal Inner
Check Valve Spring
Ball Check Valve
7
Seal Ring
Retaining Pin Ball Check Valvei
-
Priming Springs
Fig. 6-44
Oil Pump Assembly
Vane Ring
-
Disassembled
Pump Cover
6-28
10. Remove and discard neoprene seals from
pump body hub and piston.
11. Remove
pump cover.
interlocking
oil
seal
ring from
Inspection
1. Inspect all passages for dirt or restriction,
using tag wire.
2. Slide should move freely in pump body.
Make certain there is not a binding condition.
Also inspect slide for excessive wear and scoring.
Fig. 6-45
Installing Pump Slide
4. Remove check valve retaining pin, spring
and ball, Fig. 6-44.
5. Remove oil pump rotor along with top vane
ring.
6. Remove vanes and lower vane ring.
7. Remove slide by pushing slide toward prim
ing springs; then lift out of body at opposite end.
Note position. Remove inner and outer priming
springs.
8. Turn pump body over, remove spiral type
snap ring that retains front sprag to pump body,
and remove sprag assembly, Fig. 6-44. If outer
sprag race is damaged entire oil pump assembly
must be replaced.
9. Remove clutch piston from pump body. If
piston sticks, use plastic hammer and tap around
outer rear edge of pump body.
3. Pump vanes will have a tendency to show a
polished surface on side bearing against pump
slide. If not excessive, this is a normal condition.
Check freeness of vanes in rotor slots.
4. Check bushing in pump rotor for scores or
flaking. Slight surface wear is a normal condi
tion if not in excess. See Note 20 for bushing
5. Check bushing in pump housing for excessive
wear or looseness. See Note 20 for replacement
procedure.
6. Check torus feed valve for free movement
in bore.
7. Examine pump body and pump cover slide
surface contacts for smoothness.
8. Clean all pump parts thoroughly with solvent
and dry completely before assembly is attempted.
Care should be exercised in handling all pump
parts. They must not be knocked together or
dropped.
Assembly
1. Insert inner and outer priming springs in
pump body.
2. Position pump slide into pump body toward
priming springs. Compress priming springs with
slide and drop slide into cavity of pump, Fig.
6-45.
3. Insert bottom vane ring and center it in the
slide bore.
4. Install rotor with drive slots up, Fig. 6-46.
5. Install 7 vanes in rotor slots. Make certain
vanes fit between bottom vane ring aid slide.
Torus Feed Valve
Torus Feed Valve Spring
Torus Feed Valve Spring Retainer
Fig. 6-46
Installing Torus Feed Valve
NOTE: Check edges of vanes for wear pat
tern. One eage will be polished full length.
This edge should face the slide.
6. Install top vane ring on rotor, centering it
between vanes, Fig. 6-46.
6-29
7. Install torus feed valve, spring, retainer and
retaining pin. Make sure valve moves freely,
Fig. 46. Wide end of valve goes in first. Open
end of retainer faces inward.
8. Check for free rotation of rotor, and see
that all parts in pump are positioned correctly.
9. Install check ball, spring and retaining pin.
10. Install pump cover to pump body. Install
the one short screw over exhaust port of pres
sure regulator valve. A long screw used in this
location would jam regulator valve.
11. Install new neoprene seal on overrun clutch
hub in pump body. Lip of seal must face down
ward, Fig. 6-47.
Oil Seal
Neutral Clutch Outer
Fig. 6-48
Center Bearing Support
Center Bearing Assembly
-
Disassembled
h. Center Bearing Support, Neutral Clutch,
Rear and Reverse Units
Disassembly
12. Install new neoprene seal on overrun clutch
piston with lip facing downward, and install piston
into pump, aligning dowels and holes, Fig. 6-47.
Insert one side of oil seal ring and position in
cavity. At the same time, work around ring, com
pressing and seating it in pump cavity. Do not
force clutch piston into cavity. If sticking occurs,
dowels and holes are not correctly aligned.
13. Install sprag assembly into rear of body,
with rim of sprag assembly facing up, and check
rotation of sprag by inserting inner race, inner
race should turn counterclockwise but not clock
wise. Then remove inner race.
1. Place assembly in Holding Fixture, J-6116,
with output shaft down.
2. Remove neutral clutch retainer
intermediate shaft, Fig. 6-37.
3. Remove interlocking oil seal ring from in
termediate shaft.
4. Remove center bearing support and neutral
clutch piston assembly, Fig. 6-48.
5. Remove two oil seal rings and remove neu
tral clutch piston from center bearing support.
6. Remove neutral clutch drum assembly which
contains five composition drive clutch plates,
four steel driven clutch plates and five wave
type release springs, Fig. 6-49.
14. Install spiral type snap ring to hold sprag
assembly to pump body.
15. Install interlocking oil ring on pump cover.
Fig. 6-47
Installing Overrun Clutch Piston
tool from
Fig. 6-49 Neutral Clutch Drum
Assembly - Disassembled
6-30
13. Using tool, compress clutch release springs
until retaining snap ring is free and then remove
snap ring.
Rear Unit Clutch
Piston Assembly
14. Remove special
assembly.
Rear Drum
tool
from
clutch
cover
15. Remove clutch release spring retainer and
eight springs, Fig. 6-51.
16. Remove rear clutch piston from rear clutch
cover.
17. Remove seal rings from piston and hub of
cover and discard.
18. Remove intermediate shaft and rear clufch
hub, Fig. 6-53. Rear clutch hub is retained on
shaft by one snap ring located at rear end of hub.
Fig. 6-50 Removing Rear Clutch Piston
Assembly Snap Ring
7. Remove large snap ring that holds rear
clutch piston assembly to rear drum, Fig. 6-50.
8. Remove neutral clutch hub and rear clutch
piston assembly as a unit.
9. Remove spiral snap ring that holds neutral
clutch hub to rear clutch cover, Fig. 6-51.
10. Remove neutral clutch hub by
counterclockwise around inner race.
rotating
11. Remove rear sprag clutch retainer from
neutral clutch hub and remove sprag assembly.
12. Install Spring Compressor,
J-4670 and
J-6l29, on rear clutch cover assembly, Fig. 6-52.
/
0
Clutch Spring Retainer Snap Ring
/Rear Clutch Release Spring Retainer
Oil Seal
/
Rear Unit Sprag
Piston Outer
/
Outer Race
Neutral Clutch Hub
Rear Unit Sprag
Clutch Retainer
19. Remove steel backing washer and bronze
thrust washers located on front and rear of rear
clutch hub.
20. Remove mainshaft and rear unit sun gear.
Remove thrust bearing and retainer, Fig. 6-53.
NOTE: Sun gear is retained on mainshaft
with a snap ring at the front and a spiral ring
at the rear. Drill spot on sun gear must face
rear of transmission when installed on main
shaft.
21. Remove seven composition drive clutch
plates and seven steel driven clutch plates.
22. Remove rear drum assembly from Clutch
Holding Fixture.
23. Remove large snap ring that holds reverse
drive flange to rear drum and remove reverse
drive flange and output shaft, Fig. 6-54.
24. Remove reverse planet carrier inner lo
cating snap ring from output shaft.
Rear Clutch Spring
Compressor J-6129"’l
Rear Clutch
Release Spring
Retainer
Rear
Release
Springs
Rear Unit
Clutch Piston
Clutch Spring
Compressor J-4670
/
Spring
Retainer
Snap Ring
Rear Clutch
Cover
Assembly
Piston Inner
Rear Unit
Retainer
Clutch Cover
Snap Ring
Rear Unit Sprag Assembly
Fig. 6-51
Rear Clutch Piston Assembly
-
Disassembled
Fig. 6-52 Remove Snap Ring Retaining
Clutch Release Spring
6-31
Snap Ring
Reverse Drive Flange
Assembly
Clutch Backing Plate
Rear Unit Drum
Spiral Ring
Main Shaft
Snap Ring
Thrust Washer
Selective Thrust Washer
Steel Backing
Washer
Rear Internal Gear
15 Chamfer Toward
Front of Transmission
Rear Sun Gear
Snap Ring
Intermediate Shaft
Fig. 6-53
Rear Unit Assembly
25. Remove reverse drive flange from output
shaft, Fig. 6-53.
26. Remove selective bronze thrust washer.
Washer should remain with reverse drive flange.
27. Mark rear unit internal gear and rear unit
drum to indicate proper side and position for re
assembly and remove rear unit internal gear
from drum.
-
Disassembled
plates for scored surfaces and damage. Driven
plates must have six equally spaced waves. Waves
must be .008 inch to .012 inch high when measured
on a surface plate.
7. Inspect neutral clutch drum for scored and
damaged surfaces.
8. Inspect five wave type release springs for
distortion.
9. Inspect rear sprag retainer
damaged surfaces.
Inspection
1. Inspect neutral clutch piston for scores or
burrs. Be sure oil seal groove is thoroiughly
clean.
I
2. Inspect oil seal rings on center bearing
support and be sure all grooves are clean.
3. Inspect
Drive Flange
center bearing support for burrs.
4. Check bushing in center bearing support for
excessive wear. See Note 20 for bushing replace
ment procedure.
Snap Ring
5. Inspect five composition-faced neutral clutch
drive plates for damaged surfaces and worn teeth.
Plates should be flat. If flakes of facing material
can be removed by scratching surface with thumb
nail, plate should be replaced. Discoloration is
not an indication of failure.
6. Inspect
for scored or
four
steel
neutral
clutch
driven
Rear Drum
Fig. 6-54
Removing Reverse Drive Flange Snap Ring
6-32
15. Inspect rear clutch release spring retainer
for cracks or damage.
16. Inspect rear unit clutch cover-to-rear
clutch hub bronze thrust washer for wear, scores,
burrs, damage from overheating.
17. Inspect intermediate shaft for wear, twisted
splines and burrs.
18. Inspect rear clutch hub for damagedsplines.
19. Inspect rear unit sun gear-to-rear clutch
hub bronze thrust washer for wear, scores, burrs,
damage from overheating.
20. Inspect mainshaft and rear unit sun gear
for damaged splines, teeth or bearing surfaces.
Fig. 6-55
Installing Selective Thrust Washer
10. Inspect rear sprag assembly for damage,
broken spring or scored sprags. If faulty, entire
assembly must be replaced.
ii. Inspect neutral clutch hub for damaged
splines. Check sprag surface for nicks or burrs.
21. Inspect seven rear unit composition-faced
clutch drive plates for damaged surfaces. Plates
should be flat. If flakes of facing material can be
removed by scratching surface with thumb nail,
plates should be replaced. Discoloration is not an
indication of failure.
22. Inspect seven rear unit clutch steel driven
plates for scored surfaces and damaged lugs.
Driven plates must have six equally spaced waves.
The waves must be .008 inch to .012 inch high
when measured on a surface plate.
12. Inspect rear clutch cover for scoring,
burrs, or damaged lugs and oil seal grooves.
Check bushing on hub of clutch cover for exces
sive wear. See Note 20 for bushing replacement
procedure.
23. Inspect
cracks.
13. Inspect rear unit clutch piston for scoring,
burrs, or damaged oil seal grooves.
25. Inspect rear unit sun gear-to-output shaft
needle bearing surfaces.
14. Inspect eight rear clutch release springs
for distortion or collapsed boils. Slight wear
"bright spots" on side of release springs indi
cating slight contact with piston assembly are
permissible.
26. Inspect output shaft for damaged pinions,
splines or bearing surfaces.
Reverse Drive
Flange Retainer
J-6120
Snap Ring
Reverse
Sun Gear
rear
unit
drum for
scoring
or
24. Inspect rear unit internal gear for tooth
damage.
27. Inspect reverse drive flange and sun gear.
Check bushing in sun gear for excessive wear.
See Note 20 for bushing replacement procedure.
NOTE: Reverse drive flange and sun gear
are serviced as an assembly. The parts should
not be separated.
28. Inspect overrun band lining for burned,
glazed, worn, cracked or loose lining.
29. Inspect anchor end of band for broken welds
or worn socket.
Rear Unit Drum
/
I
Fig. 6-56
Installing Drive Flange Retainer
Assembly
1. Install rear unit internal gear in rear unit
drum with the 15° chamfer on drive lugs of gear
facing front of transmission, insert Fig. 6-53.
HYDRA.MATIC TRANSMISSION
2. Insert selective thrust washer in recess of
reverse drive flange with locating lugs in retainer
and hold in place with petrolatum, Fig. 6-55.
6-33
Rear Unit Drum
3. Install output shaft in reverse drive flange
until carrier bottoms on selective thrust washer,
and install snap ring in groove nearest sun gear.
4. Install Drive Flange Retainer, J-6120, be
tween snap ring and reverse sun gear, Fig. 6-56.
5. Install output shaft assembly in rear drum
assembly and install large snap ring that holds
reverse drive flange to rear unit drum, Fig. 6-54.
6. Place drum and output shaft assembly in
Holding Fixture, J-6116, with output shaft down,
removing Drive Flange Retainer as assembly is
put in Holding Fixture.
7. Install retainer and thrust bearing in count
erbore of output shaft and retain with petrolatum,
Fig. 6-57.
8. Apply Hydra-Matic oil to faces of seven
drive and seven driven clutch plates and install
them alternately in rear unit drum. Start with
drive composition and finish with driven steel
plates, Fig. 6-57. Assemble driven plates with
lugs in rear unit drum slots.
NOTE: When installing steel driven clutch
plates, slots on O.D.. of clutch plates must line
up with one another.
9. Install mainshaft and sun gear assembly into
output shaft, meshing sun gear with rear planet
pinions.
Fig. 6-57
Installing Clutch Plates
18. Install snap ring that locks release spring
retainer to rear clutch hub.
19. Remove special tools from assembly.
20. Install rear sprag assembly in recessed
side of neutral clutch hub, Fig. 6-51.
NOTE:
face up.
Rim edge of sprag assembly must
10. Place bronze thrust washer on rear end of
rear clutch hub and retain with petrolatum.
21. Install rear sprag clutch retainer in neutral
clutch hub.
11. Install intermediate shaft and rear clutch
hub assembly, rotating clutch hub to align hub
splines with drive composition clutch plates.
22. Install neutral clutch hub on hub of rear
clutch cover, rotating counterclockwise around
inner race, and install spiral snap ring to hold
neutral clutch hub to rear clutch cover.
12. Place bronze thrust washer on front of rear
clutch hub and retain with petrolaturn.
13. Position steel backing washer on top of
thrust washer and retain with petrolatum.
14. Install oil seal on clutch piston and oil seal
on clutch cover hub, Fig. 6-51.
15. Install rear clutch piston into rear clutch
cover and insert rear clutch release springs into
rear clutch piston, Fig. 6-51.
16. Position rear clutch release spring re
tainer tangs up and snap ring on release springs.
17. Using Spring Compressor,
J-4670 and
J-6129, compress springs until snap ring groove
in rear clutch hub is visible, Fig. 6-52.
CAUTION: Check for proper rotation of
sprag assembly. Neutral clutch hub should
rotate counterclockwise only.
23. Install rear clutch piston and neutral clutch
hub assembly into rear drum, with clutch hub up.
24. Install large snap ring that holds rear
clutch piston assembly to rear unit drum, Fig.
6-50.
25. Install neutral clutch drum on rear unit
with driven clutch plate lugs up, Fig. 6-58.
26. Apply Hydra-Matic oil to five drive com
position and four driven steel clutch plates and
alternately install them, starting with a composi
tion plate and ending with a composition plate.
6-34
neutral clutch drum, neutral clutch plates, case
center support or transmission case were re
placed, a new service neutral clutch piston
must be installed, except where thinnest piston
is already in transmission.
Thinnest production piston and service piston
are identified by a number 3 stamped in relief
on face of piston. Pistons numbered 4, 5, or 6
are thicker and could cause clutch plates to
burn up if used with other parts.
30. Install center bearing support into neutral
clutch drum.
31. Install interlocking oil seal ring on inter
mediate shaft.
32. Rotate center bearing support so that right
hand edge of cup plug in edge of center bearing
support is aligned with left edge of first neutral
clutch plate slot to right of neutral clutch drum
key slot, as shown in Fig. 6-59.
Fig. 6-58
Installing Neutral Clutch Drum
Also install five wave type clutch release springs,
one with each composition plate, Fig. 6-58.
27. Install inner and outer neutral clutch piston
oil seals with lips facing down, Fig. 6-48.
28. Install neutral clutch piston into center
bearing support, indexing dowel holes with pins
in piston. Compress outer piston seal into bore,
using care not to damage seals during installation.
29. Install two oil seal rings on center bearing
support, Fig. 6-48.
NOTE:
When
servicing
neutral
clutch,
33. Install Clutch Retainer, J-6135, over in
termediate shaft by compressing center bearing
support assembly into neutral clutch drum and
tightening lock screw on Clutch Retainer, Fig.
6-59.
CAUTION: Lock screw on Clutch Retainer
should be farthest away from center bearing
support assembly and screw must be withdrawn
far enough so as not to score intermediate shaft
during installation.
34. Mark near drum to indicate alignment of
neutral clutch drum key slot, Fig. 6-59. This will
help guide units into place during installation into
transmission case.
if
Checking Rear Unit Sun Gear End Play
Neutral Clutch
‘Plate Slot
It is very important at this stage in the assem
bly of the transmission to check the amount of
rear unit end play. This check is very critical
because, if there is too much clearance, integral
components may become mispositioned and noise
will result. If clearance is insufficient, there will
be too much preload on the washer resulting in
failure in the rear unit.
To check end play, proceed as follows:
Neutrc
Clutch Di
Key s;
Alignment
Marks
L
1. Place complete rear unit assembly in Hold
ing Fixture, J-6116, output shaft up.
2. Position overrun band around rear unit drum
to provide a holding fixture for Dial Indicator
Support Rod, J-6126.
Fig. 6-59 Alignment of Center Bearing
Support and Neutral Clutch Drum
3. Place Dial Indicator Support Rod between
ends of band and secure band and Rod to drum,
Fig. 6-60.
6-35
4. Install Dial Indicator, J-8001 with plunger
protruding through small hole in reverse drive
flange and resting on a rivet holding one of the
planet gears.
Output Shaft
5. Lift output shaft up and down and note sun
gear end play. This distance should be between
.004 inch - .013 inch.
Dial Indicator J-8001
If distance is more or less than specified, om
pensate by removing snap ring and reverse drive
flange, and inserting a thrust washer of correct
size to bring end play within specifications, Fig.
6-55.
Selective thrust washers are furnished in fol
lowing nine thicknesses:
Marking
.1
Thickness
1
2
3
.055
.060
.065
.070
.075
.080
.085
.090
.095
4
5
6
7
8
9
Overrun Band
.059
.064
.069
.074
.079
.084
.089
.094
.099
-
/
i. Reverse Unit Parts
Dial Indicator
Support J-6126
Drum Assembly
Disassembly, Fig. 6-61
1. Remove large snap ring that holds reverse
piston release spring and retainer.
2. Remove
spring.
retainer
3. Lift reverse
housing.
and
piston
wave
from
type
reverse
4. Remove and discard reverse
and outer oil seals.
5. Remove bearing-to-housing
tap rear bearing out of housing.
release
Fig. 6-60
Checking Rear Unit End Play
4. Inspect reverse internal gear, Fig. 6-36,
for damaged teeth and scored or damaged outside
cone surface.
piston
piston inner
snap ring and
5. Check bushing in reverse internal gear for
excessive wear or scoring. See Note 20 for bushing replacement procedure.
Spring
Retainer
Rear Bearing
Inspection, Figs. 6-61, 6-36
1. Inspect all parts to make sure they are free
from dirt.
2. Inspect reverse piston and piston housing for
burrs, scoring or other damage. Remove burrs,
if present, with fine crocus cloth and light oil.
All damaged parts should be replaced.
3. Inspect all oil seal grooves and be sure they
are clean.
N
ONc
Snap Ring
Reverse Piston
Fig. 6-61 Reverse Piston Housing
Assembly - Disassembled
Reverse
Piston
Housing
6-36
2. Install new inner and outer reverse piston
oil seals with lips facing reverse piston housing.
3, Install reverse piston over special tool,
J-7577 and rotate piston to align with dowel pins.
4. Compress outer piston seal into bore of
housing, using care not to damage seals during
installation, Fig. 6-62.
5. Remove special tool, J-7577.
6. Place release spring and retainer on piston
and install large snap ring.
Fig. 6-62
NOTE: Rear bearing will be installed after
housing is installed on transmission.
Installing Reverse Piston
6. Inspect reverse planet carrier for worn or
damaged teeth and inspect parking teeth for
damage.
j. Extension Housing
7. Inspect splines of reverse planet carrier for
damage.
1. Inspect extension housing for cracks or ex
ternal damage.
8. Inspect reverse clutch stationary cone for
burning or excessive wear.
2. Inspect gasket surface for nicks or burrs,
and clean up.
9. Inspect wave type reverse clutch piston re
lease spring, Fig. 6-61, for signs of damage or
distortion,
3. Inspect oil seal lip for wear or damage.
necessary, replace as outlined in Note 11.
10. Inspect tang type reverse internal gear
release spring, Fig. 6-36, for signs of damage
or distortion.
11. Inspect fiber thrust washer reverse
ternal gear-to-clutch housing for damage.
in
12. Inspect rear bearing for signs of damage.
If there is any question about bearing condition,
it should be replaced.
Assembly
1. Place Reverse Piston Inner Seal Pilot, J
7577, over inner hub of reverse piston housing,
Fig. 6-62.
If
4. Check both bushings in neck of housing for
excessive wear. See Note 20 for replacement
procedure.
k. Governor Assembly
1. Remove four governor oil seal rings.
2. Remove two cover plate-to-governor driven
gear attaching screws.
3. Remove governor
plate.
driven gear
and cover
4. Remove G-2 bushing retaining pin, G-2 bush
ing and valve assembly, and stop washer.
Governor
Driven
Gear
5. Remove G-2 valve from bushing.
Governor
Body
Oil Seal
Rings
Gi Weight And
,ZPlunger Assembly
4
Cover Plate
/
Stop Washer,,,,
/0
G2 Valve-st
G2 Bushing
Retaining Pin
Bushing
Fig. 6-63
Governor Disassembled
Attaching
Screws
Inspection
1. Inspect all parts to make sure they are free
from dirt.
2. Inspect valves and bushing for burrs or other
damage. Burrs, if present, must be removed by
using a fine crocus cloth with light oil.
3. Test all valves and bushings in individual
bores for free movement.
NOTE: If governor valves still stick,
place complete assembly.
re
4. Inspect governor ring lands and oil seal
rings for clearance in grooves. If lands are dam
aged or worn, replace complete assembly.
6-37
"0" Ring Seal Pressure Regulator Plug
Reverse Booster Plug
5. Inspect governor drive gears for burrs or
other damage. Gears may be replaced separately
if necessary.
Assembly
1. Install G-2 stop washer on G-2 valve.
Pressure Regulator Valve Stop Pin
Pressure Regulator Plug
2. Insert G-2 valve in bushing.
3. Install G-2 bushing and valve assembly in
governor body.
4. Rotate bushing to align recess in bushing
with retaining pin hole and install retaining pin.
5. Position governor driven gear over governor
tower.
6. Place cover plate on governor body, being
careful not to drop retaining pin or driven gear,
and install two attaching screws.
7. Install four oil seal rings in the grooves that
do not contain oil holes.
Fig. 6-64
Pressure Regulator Assembly
2. Install reverse
regulator plug.
booster
-
plug
Disassembled
in pressure
3. Install pressure regulator valve stop pin in
reverse booster plug.
m. Servo-Accumulator Assembly
1. Remove servo piston from servo body.
2. Take out five accumulator cover attaching
screws, and remove cover and gasket.
I. Pressure Regulator Assembly
1. Remove pressure regulator
from reverse booster plug.
valve stop pin
2. Remove reverse booster plug from pressure
regulator plug.
3. Remove TV accumulator plug stop pin and
trimmer valve plug retainer small sheet metal
slug.
4. Remove trimmer valve plug, trimmer valve
and spring, and TV accumulator plug.
3. Remove 0-ring seal from pressure regula
tor plug.
"
Accumulator
Cover
Gasket
Retaining Ring
Inspection
Piston Stem
.-
2. Inspect parts for burrs or other damage.
if burrs are present, remove them, using fine
crocus cloth with light oil. Replace all damaged
parts.
3. Inspect 0-ring seal. If seal shows undue
wear or damage, discard and use new seal when
assembling.
4. Check regulator spring.
sprung or set.
Oil Seal Ring
cz:
1. Inspect all passages to determine whether
any are blocked with dirt or metal chips.
.-
Accumulator
Plug Stop Pin
Trimmer Valve
Plug
‘‘
‘"‘
Accumulator
Piston
Accumulator
Spring
Retaining
Washer
Trimmer
Valve
-*.-
‘
/
Replace if twisted,
‘
gSeal
Trimmer Valve
i
Spring
Trimmer Valve
vo
Servo
Spring
Assembly
1. Install
plug.
Servo and
Accumulator
Body
hJM-*TV Accumulator
Plug
---4r’1
0-ring seal on pressure
regulator
Fig. 6-65
Servo and Accumulator
-
Disassembled
6-38
4. Install TV accumulator plug, slotted end out,
and align slot in plug with vent passage.
NOTE: Use Small screwdriver to align valve
carefully in bore.
5. Install trimmer valve spring into trimmer
valve, and install valve and spring, spring end
first, into bore.
6. Install trimmer valve plug into bore.
7. Install TV accumulator plug stop pin into
vent passage and into slot in plug.
8. Install trimmer valve plug retainer into ac
cumulator body and groove in trimmer valve plug.
Fig. 6-66
Accumulator Piston Installed
5. Remove accumulator piston and spring as
sembly.
6. Compress accumulator spring, remove re
taining washer and remove spring.
7. Remove accumulator piston stem from ac
cumulator piston. It is not necessary to remove
small retaining ring from piston stem.
8. Remove oil seal ring from accumulator
piston.
Inspection
1. Inspect accumulator piston assembly for
damaged oil seal ring, and scores or burrs in
ring land grooves.
9. Install accumulator piston assembly into
accumulator body, stem end first, being careful
not to damage accumulator piston oil ring.
NOTE: Stem must be seated in recess in
bottom of accumulator body. If stem is properly
seated, piston will be 3/64 inch above face of
accumulator body, Fig. 6-66.
10. Install accumulator cover with new gasket.
11. Install servo piston and spring.
17. Control Valve Assembly-Disassembly,
Inspection and Assembly
4. Inspect servo piston assembly for distorted
rod, damaged oil seal ring lands, or broken oil
seal ring.
The complete control valve assembly for the
1963 Cadillac Hydra-Matic transmission consists
of
three individual assemblies and two spacer
plates connected to a channel plate. In disassem
bly and assembly procedures, each individual
body should be disassembled, cleaned and in
spected, and assembled before going to the next
body. This should be done to avoid confusion of
component parts. The names of the individual
assemblies are: 1 Coupling Valve Body Assem
bly, 2 Shift Valve Body Assembly, and 3 Manual
Valve Body Assembly.
5. Inspect trimmer valves, plugs, and spring
for scores or burrs. Clean up with fine crocus
cloth and oil if necessary.
a. Inspection of Complete Control Valve
Assembly or Individual Units
After Disassembly
Assembly
1. Wash body castings, valves, and other parts
in clean solvent.
2. Inspect accumulator spring for collapsed or
distorted coils.
3. Inspect accumulator body
passages, scores or burrs.
1. Install
for restricted
oil seal ring on accumulator piston.
2. Install accumulator piston stem into piston
with small retaining ring towards flat side of
piston.
3. Place accumulator spring over stem end of
piston, compress spring, and install spring re
taining washer.
CAUTION: Do not allow valves to bump to
gether, as this might cause nicks and burrs.
2. Inspect all valves carefully to make sure
that they are free from dirt and are not damaged
in any respect. If burrs are present, they should
be removed by a fine stone or fine grade of cro
cus cloth and light oil. Be careful not to round
off shoulders of valves.
Free
Length
Name
6-39
Coil
Diameter
Wire
Diameter
Number
of Coils
1.03"
1.18"
.90"
1.70"
1.04"
.39"
.50"
.31"
.59"
.25"
.035"
.030"
.032"
.036"
.035"
9.5
12
10.5
9
17
1.72"
2.79"
2.03"
1.21"
.39"
.59"
.35"
.26"
.035"
.063"
.054"
.028"
14.5
19
23.5
16
.65"
1.68"
1.20"
.29"
.39"
.22"
.032"
.054"
.026"
8.5
17
12.7
.71"
3.22"
2.66"
.22"
1.00"
1.10"
.026"
.092"
.135"
12.5
11
10.4
Springs
Body Springs
Fig. 6-67
Comparison of Springs in Valve Bodies
3. All valves and plugs should be tested in their
individual bores to make certain that free move
ment can be obtained. All valves should fall freely
of their own weight with a slight tapping action on
the body. In checking, be careful to prevent valve
damage in any way.
4. The manual valve is the only valve that may
be serviced separately. If other valves are de
fective or damaged beyond repair, a new valve
body assembly should be installed.
5. Remove three screws retaining manual valve
body to channel plate and remove manual valve
body.
6. Remove channel plate to case spacer.
7. Remove thermostatic feed valve element
from channel plate.
Manual Valve Body
5. Before reassembly, make certain springs
can be accurately identified for correct assembly,
Fig. 6-67.
b. Control Valve Assembly-Disassembly
Plate To
Channel Plate
Fig. 6-68
CAUTION: Handle control valve assembly
very carefully after removal and after disas
sembly into component valve bodies. Avoid
bending, striking, or otherwise damaging spacer
plates. Support spacer plates to avoid bending
them.
Shift Valve
Body
Thermostatic
Feed Valve
1. Take out manual valve.
Plate To
Valve Body
Spacer
2. Remove three screws retaining shift valve
body to channel plate and remove shift valve body.
3. Remove two screws retaining coupling valve
body to channel plate and remove coupling valve
body.
4. Remove channel plate-to-valve body spacer.
Coupling Valve Body
Fig. 6-68
Control Valve Assembly
-
Disassembled
6-40
c. Coupling Valve BodyDisassembly, Fig. 6-69
1. Remove three screws retaining front end
plate and remove plate.
2. Remove transition valve and spring.
3. Install rear end plate and oil strainer re
tainer clip, using one screw through the clip. Do
not tighten screw.
4. Rotate plate over limit valve springs while
holding springs compressed. Install remaining
screw and tighten both screws.
3. Remove coupling signal valve, coupling valve,
coupling valve spring, and plug from valve body.
5. Install coupling valve plug, spring, coupling
valve, and coupling signal valve.
4. Remove two screws retaining rear end plate,
while holding plate against limit valve spring
tension, and remove end plate and oil strainer
retaining clip.
6. Place transition valve spring in transition
valve and install valve and spring, spring end
first, into coupling body.
5. Remove inner and outer limit valve springs.
7. Install front end plate with three screws.
6. Remove limit valve and washer.
e. Shift Valve Body- Disassembly, Fig. 6-70
Coupling valve body is now disassembled, and
an inspection of parts should be made see Note
17a before body is assembled.
1. Remove neutral
clutch by-pass reed valve.
2. Remove two screws retaining regulator valve
body cover and remove cover.
d. Coupling Valve Body-Assembly
3. Remove two screws retaining regulator valve
body end plate and remove plate.
1. Install limit valve, stem end out.
2. Install limit valve washer, inner spring, and
outer spring.
4. Remove 2-3 and 3-4 TV valves from regula
tor valve body.
Inner Limit Valve Spring
Oil Strainer
Retaining Clip
Coupling Valve Plug
Coupling
Valve Body
Coupling Valve
Coupling Signal Valve
O1
Rear End Plate
Coupling
Valve
War
Outer Limit
Limit
Valve Spring
Transition Valve Spring
Transition Valve
Front End Plate
Fig. 6-69
Coupling Valve Body
-
Disassembled
5. Remove one screw retaining regulator body
to shift valve body and remove regulator body.
6. Remove neutral clutch spring, 2-3 TV regu
lator valve spring, 2-3 shift valve spring, 3-4 TV
regulator valve spring, and 3-4 shift valve spring
from shift valve body.
6-41
2. Install 2-3 governor valve and amplifier
valve with largest lands facing outward, and attach
shift valve body end plate with four screws.
3. Install neutral clutch valve, and 3-4 shift
valve with largest diameter land facing outward.
7. Remove neutral clutch valve, 2-3 shift valve
with spacer, and 3-4 shift valve.
4. Place spacer on large end of 2-3 shift valve,
with rim of spacer against large land on valve,
and install valve and spacer in shift valve body.
8. Remove four screws retaining shift valve
body end plate and remove plate.
5. Install 2-3 and 3-4 shift valve springs and
neutral clutch valve spring.
9. Remove amplifier valve, 2-3 governor valve,
and 3-4 governor valve.
6. Install regulator valve body to shift valve
body with one screw in boss on regulator valve
body. Use middle length screw.
Shift valve body is completely disassembled, and
an inspection of parts should be made see Note
17a before valve body is assembled.
7. Install 2-3 and 3-4 TV
springs in regulator valve body.
f. Shift Valve Body-Assembly
8. Install 2-3 and 3-4 TV valves, with small
ends toward shift valves.
1. Install 3-4 governor valve with
facing outward.
round end
regulator
valve
9. Install regulator valve body end plate with
two remaining screws.
Regulator Valve Body Cover
Regulator Valve
Body Plate
/
2-3 TV
2-3 TV Regulator
Neutral Clutch Valve Spring
Valve Spring
Spacer
Neutral Clutch
TV
Regulator Valve
By-Pass
Reed Valve
Regulator Valve Body
Shift Valve Body
Shift. Valve Spring
Amplifier Valve
2.3 Shift Valve Spring
3-4 Shift Valve
2.3 Shift Valve
3-4 Governor Valve
2-3 Governor Valve
Fig. 6-70
Shift Valve Body
-
Disassembled
6-42
10. Install
regulator
valve body cover plate.
8. Remove reverse blocker piston and spring.
11. Install
neutral clutch by-pass reed valve.
Manual valve body is now completely disas
sembled and an inspection of parts should be made
see Note 17a before valve body is assembled.
g. Manual Valve Body- Disassembly, Fig. 6-71
h. Manual Valve Body-Assembly
1. Remove two screws retaining TV lever stop
and remove stop.
1. Install reverse blocker piston,
out.
CAUTION: Do not change setting of factory
adjusted TV stop screw.
slotted end
2. Install reverse blocker spring and hold it
compressed while installing new retaining pin.
2. Remove detent plug, detent valve, line drop
signal valve and signal valve spring.
3. Crimp end of pin to retain.
3. Remove TV plunger guide and plunger and
remove plunger from guide.
4. Install throttle
manual body.
valve, large land first, into
4. Remove TV spring and detent pin.
5. Install TV spring and detent pin into TV bore.
5. Remove throttle valve.
6. Install TV plunger guide on TV plunger and
install as unit.
6. Clip one end of reverse blocker piston re
taining pin.
7. Install line drop signal valve spring and
valve, lining up spring to be sure it is fully po
sitioned in bottom of bore.
7. Hold thumb over reverse blocker piston bore
and remove retaining pin.
TV Lever Stop
TV Plunger
Throttle Valve Spring
Manual Valve
Manual Valve Body
Detent Pin
Throttle
TV Plunger Guide
Detent Plug
Detent Valve
Line Drop Signal Valve
Line Drop Signal Valve Spring
Retaining Pin
Reverse
Blocker
Piston
Reverse
Blocker
Spring
Fig. 6-71
Manual Valve Body
-
Disassembled
8. Install
detent plug.
detent
valve, small
end first,
6-43
and
9. Attach TV lever stop bracket to manual body
with two screws.
stationary Stop Key
‘erse Stationary Cone.
i. Control Valve Assembly-Assembly, Fig. 6-68
1. Install thermostatic feed valve element into
channel plate.
2. Position channel
channel plate.
plate to case spacer
on
3. Position manual valve body on channel plate
to case spacer, and install three attaching screws
finger tight.
NOTE: Do not tighten any valve body as
sembly screws until all individual bodies have
been installed and aligned.
4. Install and align channel plate-to-valve body
spacer on channel plate.
5. Position shift valve body on channel plate-tovalve body spacer opposite manual body, and in
stall three attaching screws finger tight.
6. Install coupling valve body with two attaching
screws finger tight.
7. Install five case mounting screws in their
proper holes in control valve assembly to align
spacers, and tighten all 8 body attaching screws.
Fig. 6-73
Installing Overrun Band
key in transmission case using petrolatum to
hold in place, Fig. 6-72.
2. Install overrun band in transmission case
and attach band to stationary anchor in case,
Fig. 6-73.
3. Install reverse stationary cone stop key in
transmission case using petrolatum to hold in
place, Fig. 6-73.
8. Install manual valve in manual valve body.
18. Assembly of Transmission to
Install Major Components
a. Install Center Bearing Support
Neutral Clutch and Rear Unit Assemblies
1. Install neutral clutch drum stationary stop
4. Remove neutral clutch and rear unit assem
bly from holding fixture and install in trans
mission case by inserting output shaft through
front of transmission case. Use guide lines on
rear unit drum to align neutral clutch drum lo
cating slot with stationary stop key in trans
mission case, Fig. 6-74.
If unit does not go in far enough so that snap
ring groove in transmission case is visible ahead
of center bearing support, slight pressure may be
necessary to force unit into place.
5. Install
Fig. 6-72
Installing Stationary Stop Key
Fig. 6-74
large
snap
ring that holds center
Aligning Center Bearing Support Key Slot
6-44
10. Install reverse internal gear on reverse
planet carrier. Rotate to align internal gear with
planet gears.
11. Install fiber thrust washer on reverse in
ternal gear hub, Fig. 6-36.
12. Install screens in main line pressure pas
sage and in G-2 passage.
13. Using new gasket, install reverse piston
housing assembly and attach with one screw,
Fig. 6-77.
14. Remove Clutch Retainer, J-6135, from in
termediate shaft.
Fig. 6-75
Checking Center Bearing Support Alignment
bearing support in position. Opening in ring must
be at top of transmission case.
6. Rear clutch apply and neutral clutch apply
ports in case and in center bearing support must
be in alignment, Fig. 6-75. If not properly aligned,
center bearing support can be turned by tem
porarily installing one oil pump attaching screw
and using a pry bar to turn support slightly.
7. Position reverse planet carrier
shaft, Fig. 6-76.
15. Install rear bearing over output shaft and
into piston housing.
16. Install snap rings retaining rear bearing
to output shaft and to reverse piston housing,
Fig. 6-77.
17. Install front
gear snap ring.
wave
type governor drive
Be certain snap ring is properly seated in
groove in output shaft.
on output
8. Install reverse stationary cone into case,
exercising care to prevent binding, Fig. 6-76.
9. Install tang type reverse carrier-to-internal
gear release spring, Fig. 6-76.
18. Install governor drive gear key, Fig. 6-77.
19. Install governor drive gear, aligning slot in
gear with key, Fig. 6-77.
20. Install rear flat type governor drive gear
snap ring.
21. Install governor into reverse pistonhousing.
Be sure to compress oil seal rings as governor
assembly is installed.
22. Using new gasket, install extension housing
and breather pipe.
Drive Gear Key Slot
Fig. 6-76
Installing Reverse Internal Gear
Fig. 6-77
1
Rear Bearing Snap Rings
Installing Governor Drive Gear
HYDRA..MATIC TRANSMISSION
6-45
b. Install Overrun Clutch and Oil Pump
1. Install front sprag inner race in oil pump
with drive lugs up.
2. Install overrun clutch release spring, clutch
plate and bronze thrust washer in oil pump.
NOTE: Tangs of thrust washer face toward
front of transmission and must line up with
tangs of clutch plate.
3. Install oil pump assembly,
prevent pump cocking in bore.
taking care to
CAUTION: Position pump in bore so that
pressure regulator hole in pump body is aligned
with pressure regulator hole in transmission.
4. Install and tighten three washer-head screws
holding pump body to center bearing support,
then back off 1/4 turn on each screw, Fig. 6-78.
Fig. 6-78
Positioning Center Bearing Support
7. Install parking pawl pivot pin.
5. Apply air pressure in neutral clutch hole in
case to position center bearing support against
snap ring, Fig. 6-78.
6. With air applied, install and tighten the caseto-oil pump lock screw and torque to 27 footpounds, Fig. 6-78.
7. Tighten three pump-to-center support screws
to 30 foot-pounds.
8. Install pressure regulator valve arid spring
in hole in side of transmission case, Fig. 6-78.
9. Install
pressure
regulator
plug assembly.
d. Install Detent and Throttle Lever
Assemblies
1. Install steel washer
lever shaft.
and 0-ring on manual
2. Position inside detent control against detent
spring and roller, with dowel pin on parking brake
bracket outside detent lever, Fig. 6-28.
3. Install manual lever and shaft through case,
aligning serrations on shaft with serrations in
inside detent control. As an aid in aligning ser
rations note recess in manual shaft that mates
with set screw in inside detent control.
c. Install Parking Pawl Linkage and
Detent Spring
1. Install detent spring and roller assembly on
mounting pad in transmission case with attaching
screw finger tight.
2. Hold inside detent control in position in
transmission case to act as guide while centering
roller, Fig. 6-79.
3. Center roller in one of the detents in detent
control and tighten detent spring attaching screw.
4. Install parking pawl spacer, Fig. 6-30.
5. Install parking brake lever and pawl on park
ing brake pin with pawl in position for installation
of pawl pivot pin.
6. Install parking brake bracket Ofl brake pin
and hook parking bracket spring on parking brake
lever.
Fig. 6-79
Centering Detent Roller
6-46
6. Install inner TV lever on TV shaft, aligning
serrations on shaft with serrations in lever. Tang
on inner TV lever points toward side of trans
mission case, Fig. 6-80.
7. Press inner TV lever on TV shaft as far as
possible and then back off slightly to provide
.005 inch - .010 inch clearance between inner TV
lever and inside detent control, Fig. 6-80, and
tighten clamp screw.
8. Pull on outer TV lever to be sure inner TV
lever is secure on shaft. Recheck clearance and
adjust if necessary.
e. Install Control Valve and ServoAccumulator Assemblies
Fig. 6-80
Measuring T.V. Lever Clearance
1. Position control valve assembly on trans
mission case, aligning manual valve with pin in
inside detent control and inner TV lever with TV
plunger. Be sure dowel pin in manual body indexes
with hole in transmission case.
4. Press inside detent control on manual shaft
as far as possible and tighten set screw securely.
2. Install five control valve assembly attaching
screws and tighten, Fig. 6-27.
5. Install 0-ring seal on TV lever shaft and in
stall TV shaft through manual shaft, Fig. 6-29.
3. Install servo release spring and servoaccumulator assembly and secure with two at
taching screws. Make sure intake pipe clip is
under long bolt and leave this bolt loose until
intake pipe has been installed, Fig. 6-26.
f. Install Oil Pan, Oil Strainer and Intake Pipe
1. Install new 0-rings in oil strainer and pipe
assembly if required.
2. Install intake pipe into strainer assembly,
being careful not to cut 0-ring.
3. Install intake pipe into pump assembly, again
being careful not to cut 0-ring.
4. Align strainer with retaining clip on coupling
valve body and press down to secure, Fig. 6-26.
5. Rotate pipe retaining clip over pipe and
tighten accumulator attaching screw.
6. Using new gasket, install oil pan. Torque
screws to 13 foot-pounds.
7. Check oil pan drain plug tightness. Tighten
to 40 foot-pounds if necessary.
g. Install Front Unit Coupling Assembly
1. Install front unit coupling assembly into
case, making sure that unit engages both front
sprag and oil pump rotor.
Fig. 6-81
Checking Front Unit End Clearance
2. Perform front unit end play check as follows:
a. Position transmission
housing down.
vertically,
extension
6-47
4. Remove bracket from transmission case.
5. Install front unit coupling.
b. Install front unit internal gear, black steel
washer, needle bearing, and second steel washer,
Fig. 6-81. Do not install snap ring as units must
be removed after front end play is checked.
c. Install front unit sun gear with grooved side
down.
6. Install new square section seals and 0-rings
on oil cooler sleeves and install cooler sleeves
in transmission case. Secure cooler sleeves with
strap and strap retainer screw. Tighten screw to
18 ft. lbs.
d. Install selective washer and bronze thrust
washer over intermediate shaft.
h. Install Flywheel Housing, Torus Cover
Torus Member and Flywheel, Fig. 6-20
e. Install Front Unit End Play Checking Gage,
J-6282, and a No. 1 selective spacer, Part No.
8616703, over intermediate shaft. Push down on
tool to take up all clearances so that proper end
play can be measured.
1. Place Flywheel Housing Seal Protector,
6119, over intermediate shaft.
f. If No. 1
inner sleeve
rect. If No. 1
ing additional
selective spacer is flush with end of
of tool, front unit end play is cor
spacer is not flush, perform follow
steps.
g. Remove No. 1 spacer and remove Gage J
6282.
h. Remove bronze thrust washer and se]Lective
washer and replace selective washer with a larg
er or smaller washer, as required.
Selective washers are available in the following
11 sizes:
Identification
Stamp
1
2
3
4
5
6
7
8
9
10
11
-
-
-
2. Install new 0-ring seal on rear of flywheel
housing and attach housing to case.
3. Remove Seal Protector.
4. Install torus cover, making sure cover is
bottomed in transmission.
5. Install front unit internal gear, rotating it
to engage driving member of front unit coupling,
while also rotating torus cover to engage tangs of
internal gear.
6. Install black steel washer, needle bearing,
and second steel washer.
7. Install
snap ring
on fluid coupling shaft.
8. Place front unit sun gear on intermediate
shaft with grooved side down.
Size
.045
.058
.071
.084
.097
.110
.123
.136
.149
.162
.175
J
.047
.060
.073
.086
.099
.112
.125
.138
.151
.164
.177
i. Replace bronze thrust washer, Gage J- 6282,
and No. 1 selective spacer.
j. Check to insure that spacer and inner sleeve
of tool are flush. Repeat procedure as necessary
to achieve this result.
k. Remove No. 1 selective spacer, Gage J- 6282,
bronze thrust washer, selective washer, sun gear,
needle bearing with 2 steel washers, internal gear,
and front coupling.
3. Remove transmission with bracket from
bench base and place transmission on trans
mission hoist.
9. Install steel
thrust washer.
selective washer and bronze
10. Position driving torus member on inter
mediate shaft and install snap ring, using Pliers,
J- 6083.
11. Install driven torus-to-main shaft
locating snap ring, using Pliers, J-4880.
inner
12. Install driven torus member and install
snap ring that holds driven torus to main shaft
using Pliers, J-4880.
13. Install new ring oil seal on flywheel and
mount flywheel on torus cover with dowels aligned
with torus cover holes. Working clockwise, start
at stud next to drain plug, and install a nut on
this and the next stud. Skip one stud and put nuts
on the next two. Continue around flywheel.
19. Torus Cover and Flywheel Leak Test
The following procedure can be used to check
torus cover assembly, flywheel, and torus coverto-flywheel seal for leaks.
6-48
NOTE: Make sure parts are thoroughly dry
before assembly into transmission.
20. Bushing Replacement Procedures
The special tools referred to in the following
procedures are part of Bushing Service Tool Set,
J- 8532.
a. General Instructions
Before installing any precision bushing, be sure
that bore into which it is to be driven is clean and
free of burrs. Remove burrs with a scraper or
small file. Protruding metal in these bores can
distort the precision bushing, making it tight 011
shaft.
Fig. 6-82
Testing for Torus Cover Leaks
1. Install plug, part of Torus Cover Hub Plug
and Valve Adapter J-7073, into torus cover hub,
with hub flange on inside of torus cover, Fig.
6-82. Tighten securely in place.
CAUTION: Be sure that flange of hub plug
is on inside of torus cover, otherwise plug
might be forced out of cover when air pressure
is applied.
2. Attach flywheel to torus cover, using a new
flywheel-to-torus cover seal and eight nuts. It
is not necessary to install the four nuts that
secure engine drive plate to flywheel.
3. Remove oil drain plug from cover and install
Valve Adapter, part of J-7073, in drain hole.
4. Apply compressed air with a service air
hose until approximately 50 psi air pressure is
obtained.
When staking extension housing bushing, be sure
to force staking tips as far into metal as possible.
They should always be located in the oil groove.
Also check to see that a burr is not raised above
bearing surface after staking. Any such burrs
must be removed carefully with a bearing scraper.
Be extremely careful with reamers and reamer
guide fixtures to avoid damaging locating or cut
ting edges. These are precision tools and one
nick can render them useless.
Always store tools in their proper compartment
in tool box. This will make it easy to choose the
correct driver for each bushing. Using a driver
which is "almost" correct may damage the bush
ing during installation.
b. Flywheel-Figs. 6-83, 6-84
1. Place flywheel on bench with bushing side up.
2. Locate split in bushing and start point of
Chisel, J-8400-1, beside split with flat side of
Chisel facing in, Fig. 6-83.
5. Immerse assembly in a liquid, noting any
sign of bubbles that would indicate a leak.
If a flywheel assembly is not available, an
alternate method using a soap solution may be
used. Using a paint brush, apply solution to all
areas where leaks may occur and check for signs
of bubbles.
6. Depress valve stem in Adapter to release
air pressure, then remove Adapter.
CAUTION: Always release air pressure be
fore removing Valve Adapter, as a definite
hazard exists should Adapter blow out during
removal.
7. Remove eight nuts holding flywheel to torus
cover and remove flywheel.
8. Remove Hub Plug.
Fig. 6-83
Removing Bushing From Flywheel
6-49
J.8092
/
J-8400-6
/
Fig. 6-84
J-8400-30
large End Up
Installing Bushing in Flywheel
3. Tap Chisel with hammer until split in bush
ing opens up, then remove bushing.
4. Install new bushing using Driver Head, J
8400-2, and Handle, J-8092, Fig. 6-84.
c. Main Coupling Driven Torus-Fig. 6-85
1. Place driven torus on bench with bushing
side up.
Chisel facing in.
8400-4 and Handle, J-8092.
Fig. 6-86
Installing Bushing in Front
Unit Internal Gear
large end up, and position internal gear on Sup
port with gear teeth up.
Chisel facing in.
J-8092
d. Front Unit Internal Gear, Fig. 6-86
1. Place
Support,
J-8400-30,
/
on bench with
J-8400-3
Fig. 6-85
Installing Bushing in Driven Torus Hub
Fig. 6-87 Installing Bushing in Front
Coupling Driven Torus Shaft
6-50
8400-6, and Handle J-8092.
J.8092
1/
e. Front Coupling Driven Torus Shaft, Fig. 6-87
1. Place front coupling driven torus on bench
with vanes up.
Chisel facing in.
J.8400.8
/
Drive Recess
8400-3, and Handle, J-8092.
J.8400.30
f. Front Coupling Cover, Fig. 6-88
1. Place Support, J-8400-30, on bench with
small end up and position front coupling cover on
Support with neck of cover up.
Fig. 6-89
Installing Bushing in Oil Pump Rotor
g. Oil Pump Rotor, Fig. 6-89
Chisel facing in.
8400-8, and Handle, J-8092.
J-8092
/
1. Place Support, J-8400-30, on bench with
large end up and position pump rotor on Support
with drive recesses up.
Chisel facing in.
3. Tap Chisel with hammer until split opens
up, then remove bushing.
8400-8, and Handle, J-8092.
h. Oil Pump Body, Figs. 6-90, 6-91
J.8400-8
J-8400.30
Small End Up
A special procedure is necessary for the pump
body bushing because all tolerances are extremely
close.
1. Place pump body, sprag side up, on Support,
J- 7027
Chisel facing in.
3. Tap Chisel with hammer until split opens up,
then remove bushing.
Fig.. 6-88
Installing Bushing in Front Coupling Cover
4. Install new
Head, J-8400-9,
notch in bushing
across from oil
6-90.
bushing, 8617596, using Driver
and Handle, J-8092. Half moon
must be up and diametrically
intake hole in pump body, Fig.
6-51
pressure.
Maintain a firm downward pressure
but do not force.
As top step of reamer flutes nears bushing,
ease off pressure to avoid dropping rapidly and
scoring bushing. Continue to ream smoothly until
Reamer bottoms in Pilot Sleeve.
CAUTION: Never r e am counterclockwise,
and never ream with a power source.
9. Do not remove Reamer through bushing. Re
move Handle, J-8400-36, and lift pump body from
Reamer and Sleeve, leaving tools in vise.
10. Check location of half moon notch in bush
ing, Fig. 6-90. If it has moved in relation to oil
hole, bushing is too loose and an oversized bush
ing must be installed. If bushing is still located
properly, disregard remaining steps.
11. Perform
Fig. 6-90
Positioning Bushing in Oil Pump Body
5. Lubricate ground surfaces of Pilot Sleeve,
J-8400-32, and sprag outer race in pump body.
Carefully install Sleeve in sprag race, aligning
holes in Bracket with dowels in pump body. Do
not force or cock these precision parts.
6. Place Sleeve in vise and grip lightly on flats
provided.
7. Lubricate pilot of Reamer, J-8400-31, and
insert it through bushing into Pilot Sleeve, Fig.
6-91.
8. Using Handle, J-8400-36, turn Reamer
CLOCKWISE with a constant, smooth downward
steps
1, 2, 3, 5, and 6 above.
12. Perform steps 7, 8, and 9 using Reamer,
J-8400-65, to ream bore in pump housing.
13. Place pump body, sprag side
J-7027, and install new .030 inch
bushing, with half moon notch up
cally across from oil intake hole,
Driver Head, J-8400-9, and Handle,
up, on Support,
oversized O.D.
and diametri
Fig. 6-90. Use
J-8092.
14. Perform steps 7, 8, and 9 using Reamer,
J-8400-31, to ream bushing.
i. Center Bearing Support, Fig. 6-92
1. Remove bushing from neck of center bearing
support with Driver Head, J- 8400-11, and Handle,
J-8092
/
Line Up
Oil Holes
J-8400-1 2
/
J-8400-32
Fig. 6-91
Reaming Pump Body Bushing
Fig. 6-92
Installing Bushing in Center Bearing Support
6-52
J-8092. Note location of oil hole in bushing as it
is being removed.
2. Stand center bearing support upright
flange end up.
with
8400- 12, and Handle, J-8092. Oil hole in bushing
must line up with oil hole in center bearing sup
port, Fig. 6-92.
j.
J-8400-1 6
Rear Unit Clutch Cover, Fig. 6-93
1. Place
end up.
clutch cover on bench with bushing
Chisel facing in.
8400-14, and Handle, J-8092.
Fig. 6-94
Installing Bushing in Reverse Sun Gear
I. Reverse Internal Gear, Fig. 6-95
1. Place reverse internal gear on large end of
Support, J-8400-30, with gear teeth down.
k. Reverse Sun Gear, Fig. 6-94
1. Place reverse
sun gear down.
drive flange on bench with
Chisel facing in.
8400-16, and Handle, J-8092.
Chisel facing in.
8400-17, and Handle, J-8092.
m. Extension Housing, Figs. 6-96, 6-97
1. Remove
J-8092
oil
seal as outlined in Note 11.
2. Place extension housing on bench with output
shaft end up.
3. Locate split in upper bushing and start point
of Chisel, J-8400-1, beside split with flat side of
Chisel facing in.
J-8400-14
y
Fig. 6-93
Installing Bushing in Rear Unit Clutch Cover
Fig. 6-95
Installing Bushing in Reverse Internal Gear
Fig. 6-96
Installing Bushing in Extension Housing
5. Repeat steps 3 and 4 for lower bushing.
6. Place new bushing on long end of D:river
Head, J-8400-25, and install bushing in exte:rlsion
housing using Handle, J-8092.
Fig, 6-97
6-53
Staking Bushing in Extension Housing
7. Place new bushing on short end of Driver
Head, J-8400-25, and install bushing in extension
housing using Handle, J-8092.
8. Stake both bushings securely using Staking
Tool, J-8400-22. Be certain that staker points
enter oil groove of bushing to avoid raising burrs.
6-54
TORQUE SPECIFICATIONS
Material
N umber
Application
Size
Foot
Pounds
Special
Front end plate to coupling V.B. screw
10-24
3
Special
Rear end plate to coupling V.B. screw
10-24
3
Special
Coupling V.B. to channel plate screw
10-24
3
Special
TV lever stop to manual V.B. screw
10-24
3
Special
Manual V.B. to channel plate screw
10-24
3
Special
TV lever stop manual V.B. screw
1/4-20
8
Special
Regulator V.B. cover to regulator body screw
10-24
3
Special
Regulator V.B. plate to regulator body screw
10-24
3
Special
Regulator V.B. plate to shift V.B. screw
10-24
3
Special
Shift V.B. plate to shift V.B. screw
10-24
3
Special
Shift V.B. to channel plate screw
10-24
3
Valve body assembly to case screw
1/4-20
8
260M
Cover to accumulator body screw
1/4-20
8
280M
Servo-Accumulator assembly to case screw
3/8-16
30
260M
Inside detent lever to manual shaft screw
12-24
6
280M
Inside TV lever to TV shaft screw
1/4-28
12
280M
Detent spring to case screw
5/16-18
18
Special
Oil pan to case screw
5/16-18
13
Special
Oil pan drain screw
5/8-18
40
Special
Torus cover oil drain plug
1/8 pipe
7
1/4-28
8
5/16-18
18
3/8-16
30
280M
280M
Governor body cover to governor driven gear screw
280M
Oil pump cover to body screw
280M
Oil pump to center bearing support screw
300M
Oil pump to case screw
5/16-18
27
Special
Strap oil cooler sleeves retainer screw
5/16-18
18
Special
Pressure regulator plug
1-1/16-16
6
280M
Flywheel housing to case screw
7/16-14
50
286M
Torus cover to flywheel nut
5/16-24
20
280M
Reverse piston housing to case screw
3/8-16
30
280M
Extension housing to case screw
3/8-16
33
1/8 pipe
7
Special
NOTE:
Oil pressure take-off at reverse piston
housing plug
Refer to back of Manual, Page 17-1, for bolt and nut markings and steel classifications.
A
6-55
C
B
cC
T
S
w
Fig. 6-98
Key
Special Tools
Tool No.
Name
Key
Tool No.
Name
A
J-6115
Transmission Holding Fixture
M
J-6135
Neutral Clutch Retainer
B
J-6116
Rear Unit Holding Fixture
N
J-6282
C
J-7026
Flywheel Housing Oil Seal
Installer and Staker
Front Unit End Play Checking
Gage
0
J-7577
Reverse Piston Inner Pilot
D
J-7027
Flywheel Housing Support
P
J-8059
Snap Ring Pliers
E
J-5154
Extension 1-lousing Oil Seal
Installer
Q
J-4880
Snap Ring Pliers
R
J-6083
Snap Ring Pliers
F
J-6125
Slide Hammer Assemblies
S
J-6120
Reverse Drive Flange Retainer
G
J-6121
Front Unit Coupling Cover
Remover
T
J-5907
Pressure Checking Gage and Hose
H
J-6129
Rear Clutch Spring Compressor
U
J-8532
Transmission Bushing Service
Tool Set
I
J-4670
Clutch Spring Compressor
V
J-6122
J
J-8001
Dial Indicator Set
Front Unit Coupling Valve
Retainer
K
J-6126
Dial Indicator Support
W
J-8092
Driver Handle
L
J-6119
Flywheel Housing Oil Seal
Protector
X
J-7073
Torus Cover Hub Plug and
Schrader Valve Adapter
ri
-
FLEE’TWOOD SIXTY-SPECiAL SEDAN
6039

HYDRA-.MATIC TRANSMISSION

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