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ilONNg
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TECHTRANil MANUAL
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Updated
August,2003
INTRODUCTION
THM 4L6O-F,
Thisbookletcontainsgeneraldescriptionandtheprocedures
necessary
to repair,overhaul,or servicethenew
THM 4L60-Eelectronicautomaticoverdrivetransmission.The4L60-Eis a fully automaticrearwheeldrive
transmission.Thisunit is basicallya THM 700-R4with electroniccontrclsaddedto thevalvebody. Theshift
pattemis controlledelectronicallywith 2 shift solenoidsthat recievea groundsignalfrom the Powertrain
ControlModule(PCM). ThePCM will vary shiftpoints,asit is constantlyinterpretingnumerouselectronic
signalsfromvariousoperational
locatedonthevehicle.
sensors
ThePCM alsocontrolstheapplyandreleaseofthe TorqueConverterClutch(TCC). This transmission
also
recievedanotherPWM solenoidin 1995to controlTCC applyfeel.Line pressureandshiftfeel arecontrolled
electronically
with a Pressure
ControlSolenoid(PCS),locatedon the valvebody anddependent
on TPSand
\rSSsignals.
Note: Therehavebeenmany engineeringchangesin this transsxlesince itsintroduction in 1993. ATSG
alsohusuvailablean "UpdateHandbook" which includesthe manychangesand is requiredalong with this
nnnualfor aproperoverhaulor repain
No partofanyATSGpublicationmaybereproduced,
storedin anyretrievalsystemortransmitted
in anyformor
by any means,includingbut not limited to electronic,mechanical,photocopying,recordingor otherwise,
.rithout written permissionof AutomaticTransmission
ServiceGroup. This includesall text illustrations,
tablesandcharts.
"Portions of muteriuls contained herein have been reprinted under
Iicensefrom General Motors Corp, Service & Purts Operations
LicenseAgreementNumber 05I 0718. "
The informution and purt numbers contained in this booklet have
been curefully compiledfrom industry sourcesknown for their
reliability, but ATSG doesnot guarantee its accuracy.
DALE ENGLAND
JIM DIAL
FIELD SERVICE CONSULTANT
TECHNICAL CONSULTANT
WAYNE COLONNA
ED KRUSE
TECHNICAL SUPERVISOR
PETER LUBAN
GREGORYLIPNICK
JON GLATSTEIN
DAVID CHALKER
GERALD CAMPBELL
GREGCATANZARO
ROLANDALVAREZ
GABE DE LOS REYES
AUTOMATIC TRA]YSMISSrc]Y^SER
VICE GROUP
1O7THAVENUE
18635S.'\ry.
MIAMI, FLORIDA 33157
(30s) 670-416r
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INDEX
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T RO UB LE S H O OT IN G C H A R T S ........
DI A G NO S T IC T R OU BL E C OD ES
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TRANSMISSION DIS-ASSEMBLY.....
TRANSMISSION RE.ASSEMBLY.....
UPDATED LOW REVERSE PISTON
UP DA T E D P R E SS U R ER E G U L AT OR VA LV E .............
S P A CE RP L AT E S C R EE NL OC AT ION S...........
32
42
....,.,.44
. . . . . . . . . .77
.
. . . . . . .82
CHE CK I NG P R E SS U R ESW IT C H A SS EMB LY ...........
. . . . . . . . . .85
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S O LE NO I D R E SIS T AN C EC H AR T ..
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a
K
T e c h n i c a lS e r v i c el n f o r m a t i o n
fj|RrsE
4L60-E
APPI-ICATION
COMPONENT
SOI-ENOID
CHART
ANI)
}--\-=-I
-t'l:*-'',H
,l ,rt-q :\
L-
r\ ---
--
SHIFTSOLENOID
LO/ROLLER
CLUTCH
x9iprN0
AP9i-!ED
APPLIID
APPLIID
APPLIED
APPLITD
?ndt
t'
HOLDING
* sHrFTsoLENotD
rFvEHrcLEspEEorNcFEAsEs
suFFrcrENTLy
oF vEHrcLEspEEDANDN,4Ay
CHANGE
srATEts A FUNCTToN
HOWEVER,
THIS
TRANSMISSION
INPARK,
REVERSE
DOES
NOTAFFECT
OPERAIION
O8 NEUTRAL,
*' MANUAL
pREVENTED
- FrRsrGEAR
NoaMAL
rs EtEcrRoNlcALLy
UNDER
opERATTNG
coNDrTroNS
sEcoND
t t * MANUAL
ABovE
AppFoxrMATELy
48To 56KM/H
ts
AVATLABL€
FTRSTsEcoNDGEAR oNLy
t3oro 3sMpH)
Figure
I
GROUP
SERVICE
AUIOMATICTRANSMISSION
T e c h n i c a fS e r v i c eI n fo r m a t i o n
7-RrsE
EI-ECTR.ONTL
TIVTER.NAI-
CONTR.OI-S
P R E S S U RCEO N T R O S
L OTENOIO
TRANSMISSION
AUTOMATIC
O U T P U TS P E E DS E N S O R
w
C O N V E R T EC
RL U T C HS O L E N O I O
\\
fi,
,\
WP
1.2A N D2-3
SHlFTSOLENOID
3 . 2 C O N T R O LS O L E N O I O
P R E S S U RSEW I T C H
ASSEMBLY
F : -g u r e 2
t
- ^ f
r t t
-
:
-I:..SI,,!;SSION
GE
ROUP
SERVIC
Z-RrsG
T e c h n i c a lS e r v i c eI n f o r m a t i o n
TorqueConverterClutchSolenoid
The torquc converterclutch solenoidis a normally opcn exhausr
v a l v e t h a t i s u s c d t o c o n t r o l t o r q u ec o n ! ' e n e rc l u t c h a p p l y a n d
release
\ l ' h c n g r o u n d e dl e n e r g r z e db)y t h c P C N { .t h c T C C s o l c n o i dr r o p s
c o n \ c n e rs r g n aol r l l r o m e x h a u s t r n gT.h r si : i t u s ccso n v c t t csr r g r t a l
o i l p r e s s u r ct o i n c r e a s ea n d s h i f t t h e T C C v a l v e t o s h i f r r n t o t h c
apply posrtion
TCC solenoldreslstrnceshouldbe 20.4(}ohmsmlnlmum
w hen meesuredrt 20oC (6toF). Maxl mum solenold
currenlflow shouldnot exceed1.5rmps.
T h e b r a k es w i t c h i s a n i n p u r r o r h e P C M . a n d t h c P C M d i r e c r l y
c o n t r o l sT C C a p p l yb a s e do n t h c h r u k cs w i r c hs t a t u s ,
l l u l ' a u l tr sd c t c c t c dr n t h c T C C c r r c u i t c. o d c( X r 7o r 0 6 c )w i l l s c t .
TransmissionPressureControlSolenoid
pressurecontrol solenoid(or force motor) is an
The transmission
electronip
c r c s \ u r er e g u l a t otrh a tc o n t r o l sp r e s s u rheu s e do n c u r y e n t
f l o * t h r o u g hi t s c o i l w i n d r n g .T h e m a g n c t r cl l e l d p r o d u c c db y t h e
c u r l r t r o r ' c rt h c s o l e n o i d ' si n t e r n a lv a l v c w h r c hv a r i e sp r e \ \ u r et o
t h c p r e s s u r ree g u l a t ovr a l v e .
If there is a differencebetweenthe amperagecommandedby the
I'CM and thc actualamperage,
code073 will sct.
diagnostictr<luble
o n t h e H Y D R A - M A T I C4 L 8 0 U n l i k et h e p r e s s u rceo n t r o ls o l e n o i d
control solenoiddoes not pulse every l0
E, the 4L60-E pres.sure
s e c o n d fso r a c l e a n i n gc y c l e .
The PCM controlsthe pressurecontrol solenoidby commanding
c u r r e n tb e t w e e n0 a n d l . l a m p s . T h i s c h a n g c st h e d u t y c y c l e o f
['orce High
the solenord.which can rangehetween0 4o and 6O 7a. l.l amps
c o r r c s p o n dtso m i n i m u m l i n e p r c \ s u r e a. n d 0 a m p s i s t t t a x i m u m +
04c Dury Cl,cle
( i I s o l e n o i dl o s e sp o w c r .t r a n s m i s s i owni l l s t i l l h t t v e
lincprcrsure
+ 609aDuty Cycle
r l l a \n n u n ll r n ep r e s s u r e ) .
L i n e p r e s s u r vea l u e sa r c c a l c u l a t e b
d y t h e P C M u s i n gi n p u t ss u c h
as the throttlepositionsensor.
Force I o.w
Lln? Prcssure
0 Amps
L l A m p s@ 4 - 5 V
Maximum
Minimum
should
TtansmlsslonPressureContrcl Solenoldreslstance
measune
3.5- 4.6ohm whenmeasurcdet 20oC{68"F}.
The pressurecontrol solenoidtakesthe placeof the throttlevalve
thal was usedon pastmodeltransmissions.
1-2 and 2-3 Shift Solenoids
Thc l-2 and2-3 shift rolcnoids(alsocallcdA andB solcnoids)
0rc
idcnlicalsol€noid
dcviccs
thatcontrolthcmr)vcmcnt
o[ the 1.2and
by
2'1 rhri ralvcs(thc3-J (hrft\',rl\crs notdr.eclly
'n-# controll('(l
\hrfr solcnoid).Thc solcnoid\ur" nnrurull,
.*tur.t ,,,ti",,
thrl \rorkIn li)urconlhin{lrcn\
rntrr,lrllcrcnl
to \hrlithctn!ir.nirr.ron
gearsI scechiln)
solcnoidsratcs'catchup' whenthro lc positionandvchiclcspced
fsll inlorhcconcctr|nScs.
Dlagn(,stic
trouhlccodcs081and082indicalcshiftsol.noidcircuit
!oltagefJolls'
T h e P C M g n e r g i z e se a c h s o l e r r o r db y g r o u r t d r n gr t t h r o u g ha n
i n t e r n aql u a dd n v c r . T h i s s e n d sc u r r e n t h r o u g ht h ec o i l w i n c l i n gi n
the solenoidand movc.sthe internalplunger out of the exhaust
p o s i t i o n W h c n ' O N ' . t h e s o l e n o i dr c c t r r c c tfsl u i d t o m o r ' ca s h r l ' t
vllve
P C M c o n t r < l l [ csdh r l t s o l c n o r d cs l r n l r t l t c t h c n c c c ll i r r ' [ ! ' l n d
S , o v e r n oprr e s s u r et so c o n t r o ls h i l ' tv u l v co p c r a t r o n .
N o t e : T h c m a n u a l v a l v e c a n h y d r a u l i c a l l yo v e r r i d et h e s h i f t
. s o l e n o i d s .O n l y i n D 4 a r c t h e s h i f t s o l e n o i ds t a l e st o t a l l y
w h a tg e a rt h e t r a n s m i s s i oins i n . l n t h e o t h e rm a n u a l
determining
v a l v ep o s i t i o n st h
. e t n r n s m i s r i ornh r l ' t rh y d r l u l i c l l l yi t n r lt h c s h r l ' t
.Shlft solenoid reslstrnce should measure 20-40 ohms
mlnlmum when measurcd et 20oC (68oF).Shlft solenold
current flow should not cxceed 0,75 amps. The shlft
solenoidshould energlzeal a voltageof 7.5 volls or mone
(measuredscrossthc terminals).'[heshlft solenoldshould
de-cnergizer+henvoltagels one volt or less.
If both solenoldslose power, thlrd gerr only wlll resulL
Figure 3
GROUP
SERVICE
TRANSMISSION
AUTOMATIC
)
fl-RrsE
Transmission
FIuidpressure
Switch Assembly
T h e t r a n s m i s s r of n
l u r d p r e s s u r se w i t c ha s s c r n b l (yp . S A )i s a s e t o l
five pressure
s w i r c h e so n r h e v a l v e b o d y t h a r s e n . sw
e h e t h e rf l u i d
pre.ssure
is presentin five dif'ferenrvalve hrodypassage.s.The
combination
o f w h i c h s w i t c h e sa r eo p e na n d c l o s e di s u i e d b y r h e
P C M t o d e r e r m i naec t u a m
l a n u a vl a l v i p o s i r r o n-.f h c p S A a s s e m h r y
h o w e v e rc a n n o td i s t i n g u i s h
b e t w e e np a r k ; r n r lN e u t r a lf r e c a u stch c
m o n i t o r c dv a l v cb o d y p r e s : i u r easr e r c l e n r r c ranl h o t hc a s c \
seven valid combination and two invalid combinations
a r e s v a l l a b l e f r o m t h e T p S : V a l i d c o m b l n s t l o n . sf o r
Circuits A, B and C sre shown below. Invalid
comblnalions are A=0V, B=OV AND C=0V; On A=0V
B=l2V AND C=0!'.
OII PRESSURT
T h e s w r t c h e sa r e w r r e d t o p r o v i d et h r e c r r g n a l r i n e s r h r t
drc
m o n i t o r e db y r h e P C M . T h e s ei n p u t .ar r e u s c dr o h e l pc ' n r r o l l i n c
p r e s s u r et o' r q u ec o n v e r l ecr l u t c ha p p l ya n ds h i r is o l e n o i d
opcrrrirn.
V o l t a g ea t e a c ho f t h e s i g n a ll i n e s w i l l b c e r t h e rz e r o
or rwerve
volts.
T o m o n i t o rP S A a s s e m h rovp c r i r t , n .t h c r ) c \ i c ' n r r r : r rset h c i r i l r r i r l
v o l t l r g c r l n r h i n ; r t r o lr rr l r cs w i t c l tse t o ; t l ) S A c o r r r h l ) i i t t ( ) n
r.l,tirl.l
s t r l r c ci n
l t h c r t s n l c , l o r y . l l ' t h c p C M r c c s ( ) n L , ( )llr r , o, i l l c u . r l
v o l t a g ec o m b i n a t i o n(ss c ec h a r t )a c o t J c0 2 t i r v r l lr c s u l r .
PSA asscmblysignal voltagecan bc rneasurctlr'romeitehp*
ro
ground,andcomparedto thecombination
chart. on thelransmr.\sron
w i r i n gh a r n e s sp,i n N i s ' r a n g es i g n aA
r ' . p r n R i s ' r a n g es i g n u B
r ',
a n d p i n P i s ' r a n g es i g n a C
r ' , w i r h r h e w i r i n gh a r n c i sc o n n c . c r c d
a n de n g r n er u n n i n ga. v . l t a g cr n c r s u r c n r c,nr 'ti h c r et h r c cl .i n c sw r r l
indicata
c ' h i g h ' r c n d r n g( n e a rt 2 v o l r s .wt h c r r ; gr r t , t r i it s o p c 6 .
11n(l
t r l o w ( z c r ov o l t s )u , h c nt h c c i r c u r tr s s w i r c h c rtjo g r o u n d .
@
pREstNT
ot pREssuRE
VALIOTPSCOMEINANON
CHART
' A ' ' B ' 'c'
PARX
i ta
R€vrRsr | 0
r,|:uTRAt I 12
Dl
|tz
03
lt2
a2
ll2
0 1
i o
0
0
0
0
12
l2
t2
12
12
l2
0
0
r2
12
[lfcAL
i O
ILLEGAT I O
\2
0
0
0
EXPECTEO
VOIIAGEREAOINGS
T h e t r a n s m i s . s i ot enm p c r a t u r see n s ( ) r s p . f l . r ' t h e r r a n s r l r \ s r o r )
f l u i d p r e s s u rsew i t c ha s s e m b l y ,
S W I T C HL O G I C
(N/O).NORMALLY
OPEN
VehicleSpeedSensor
The v e h i c l es p e e ds e n s o r{ o r t r a n s m i s s i o(n) u t p u sr p e e d
. s e n s o rl s)
'
usedt o c o n r r o sl h i f tp o i n t sa n dc a l c u l a r T
eCC slip.
The speedsensorcontainsa coil thatgivesofi a continu.us
mugnetrc
field, A rotor rotatcspastthe renrni. *nd rhc rot{)rreerh
brc.k (hc
m a g n e t i fci c l d . E a c hb r e a ki n r h c f i e r ds c n r r s ' p u r s cr o
r h ev s s t l
( V _ e h i cS
l ep e e dS e n s u B
r u f t e r ) ,T h e V S S B s e n d . , * n * , g n o l ,r o r h r . Four wheel drive (4wD) apprications
use a vehicrespeedsensor
PCM, the firsr is a 2fi)2 pulseper mile (pplvl) signat
u.sccl
oy rne locatedon the lransfercase
engine. The secondis the transmissron/transfer
cise 40 pursepcr
In 2WD or 4WD Hi. transoutputspeed= rransl.er
r e v o l u t i o n( P P R )s t g n a u
l s e dt o c o n t r o lt h e r r a n s m i s s i o n .
casespeed
In 4wD Lo, transourpurspeed= transfercasespeed
I n t w o w h e e ld n v e ( 2 w D ) a p p r i c a r i o ntsh.e v e h i c r e
x constant
s p e e ds e n s o r s
I o c a t e do n t h e t r a n s m i s s i oenx t e n . s i ohno u s l 1 1 g
crrdes 024 or 072 wiil scr if a faurr exisrsin the vehicre
speed
\ c n \ 0 rc r r c r r i4t 0 p p R l i n e
3-2 ControfSolenoid
T h e 3 ' 2 c o n r r o ls o l e n o i di s a p u l s ew i d t h m o d u l a t e d
s o l e n o r du s e d
to rmprovethe 3-2 downshift.The solenoidregulares
rherere.asc
or
the 3-4 clurch and 2-4 bandapply,
T h c s o l c n o i du s c sc J u t yc y c r c t o ' c g u l a t c
l ) r c \ \ r r r c \t h i r ts r n . . r h r '
r e l c a s teh ec l u t c ha n cal p p l yt h eb a n d .D u t ; , c v c l c
is n'rr'.llv uhrul
f i r s tg e a r ,9 0 c / o
r n a i r o r h c rd r i v eg g ; 1 1a' n dd r o p sd u r r n gr n c l l ' a v o l t a g e [ a u l t i s d e t e c r e < rJn t h e
9Vin
3 - 2 c o n t r o ls r : l e n o i dc i r c u i t .
3 - 2 d o w n . s h i f tT. h r o t t l ep o s i t i o nv. e h i c l es p c e <aJn dr h e
c o n r r r r ; r n c l c cdtu r g r r o r t r ct r o u b i e c o c J e0 6 6 w i l l s e t .
g e a ra r eu s e dt o d e t c r n r i ndc u l y c y c l c .
Figure
4
AUIOMAIICTRANSMISSION
SERVICE
GROUP
T e c h n i c a lS e r v i c eI n fo r m a t i o n
7|RrsE
T R A N S M I S S I OSNE N S O R- T E M P E R A T U RTEO
TO VOLTAGE(approxirnate)
RESISTANCE
Transmission
FluidTemperature
Sensor
fluid temperature
sensoris partof the transmlssron
The transmissron
fluid pressureswitch assemblyand is used to help control torque
c o n v e n e rc l u t c ha p p l ya n ds h i f tq u a l i t y ,
T h e t e m p e r a t u r sc e n s o rt s u r c r t s l o r( l h e r n l t s t e rw) h i c h c h a n g e s
v a l u eb a r c do n t c m p f r a l u r e .A t l o w t e m p e r a l u r et h
s e r e s i s t a n cies
h r g h .a r r du t l o w t e m p e r a t u r et hse r e s i s t a n ci es l o w .
oc
oF
-40
-28
-16
-4
-40
-21
0
7
19
31
43
55
67
79
91
103
115
127
139
151
The PCM sends a 5 volt srgnal to the temperaturesensorand
measuresthe voltage drop in the circuit. This mean.syou will
m e a s u r ea h i g h v o l t a g ew h e n l h e t r a n s m i s s i oins c o l d , a n d a l c l w
v o l t a g cw h c nt h c t r a n . s m i s s i iosnh o t .
l l ' t h c t c m p c r i t u r c\ c n \ o r c i r c u t th a s a l ' a t r l tc. t d e 0 5 1 {o r 0 . 5 9u ' i l l
gl a high
\ c t . C o d c 0 7 9 w i t l r c t i f t h c t r a n u l l i s s t citsno p e r a t i n u
t c n l f ^ - r a t u rl o
c r a p c r t r do f t i n t e .
RESISTANCE
100544
52426
18580
12300
9379
7270
3520
2232
1200
858
675
333
241
154
115
79
60
47
10
23
3 2
4 0
68
86
110
131
145
176
194
213
239
260
284
302
ES . T E M P E R A T U R E
T R A N S M I S S I OSNE N S O RR E S I S T A N CV
a
E
s
o
g
o
s
g
o
o
o
c
t
c
E
110
100
90
80
70
60
50
40
30
?a
-50
110
Figure
130
150
5
GROUP
SERVICE
TRANSMISSION
AUTOMATIC
7
VOLTS
5
4.78
4.18
3,84
3,45
3.20
2.56
1.80
1. 1 0
3.25
2.88
2.24
1,74
1.28
.96
.64
.32
,00
[7|RrsE
1993HYDRA.MATIC
4L6O.ESHIFTSPEEDCHART
ENGINE BOOY
AXLE
RATIO
1.2SHIF|+l- 250RPM
TPS 10 2A 30 10 50
5,iL
{105}
CIOiG
c20/K
c 10i6
c?otK
c1otc
crK
ENGINE BODY
3.08
312
3,42
3 .7 3
373
{.10
3.08
3.12
clorc
3.4?
c20/K
3 .7 3
373
u
c/K
ENGINE BODY
10 20 30 10 50 10 2A 30
51d
621
OIESEL c?0/K
(LH6} c 1 0
c20/K
c10
ciK
ENGINE 800Y
1.2SHIFI+/- 250RPM
50
2-3 SHIFT+/- 200RPM
M/L
4.31
{L81}
0.10
t
1127
699
369
a
1122
762
381
r1?1
8{ 1
373
r0 20 30
f0
50 10 20 30
$
nlR
I 146 1360I6321i68 1213153519{323r
1
R 1 n 744
d3 l
1? ? 1
893 978 a q l
l-3 +/lOORPM
50
I
r116 68018081276 r571'19'142297
560 793 9 1 0 1001 980 931 12371517 704 18 4 { r30716r1 1 9 1 123tt
4.10
AXLE
RATIO
1.2SHIFT+/- 250RPM
308
3.42
3 .{ ?
3 .7 3
3 .7 3
{10
369 369 505
2.3 SHIFT+/- 200RPM
16l
IJI
I'I
3-1SHIFI+/- 150RPM
893 1 r 8 41437 1359 1359 I 359
t)l
373 373 {67 607
a
I
1 t 7 7t7 1 t 7 887 1190 4 U 1351 135{ 1351
5 1 9 556 123 ? , ?
'L1
8 7 11057
a
2'1+l3-2+lRPM lOORPM
1OO
0-10
0.10
0. 10
1r?6
699
369
1127
765
383
1120
840
???
$3 +llOORPM
20 30 40 50 1 0 20 30 10 50
3$l 382 489 595 7 1 4 144 7 4 1 872 I 170t r t ( 1310 131013.0
3-2+l- 2.1+l1OO
RPM IOORPM
0.10
0.10
0-10
1223
679
?2n
1?12
06u
319
121{
677
3?6
JU6
35t
1298 rt9d r298
1168
6{9
3t5
3.42
349 369 172 513 7 1 9 719 719 863 1068 13151291 r2911291
1171
657
308
373
359 381 516 561 7 1 8 7 1 9 7 1 8 RC?
1167
05 1
311
AXLE
RATIO
Jd5
t-2 SHIFT+/- 250RPM
t a J
566 78{ 828 893
5{5 78{ 828 893 9 1 5 981 r4601656
M/L
3.nn,42
J5r
u
3.73
3.42t3.73
3.088,12
3.73/1.10
r077 32t
IJUI
I JU/ t ? n ,
3-. SHIFI+/- 150RPM
&3 +/2-1+l3-2+llOORPM lOORPM 1OOBPM
10 20 30 10 50 't0 20 30 10 50
3 08/3.42
Qlq
5tl
+/- 200RPM
2.3SHIFT
3 42873
c 1 0 3 08/3.{2
.
1.
2,
3.
4,
0.10
3-{ SHIFI+/- 150BPM
.86 660 758 855 893
TPS 10 2A 30 40 50
4.31
{135}
a
0.10
700 8 1 7 911 981 931 1?811 5 1 1
8 705r8(5 13071635210
1
TPS 1 0 20 30 40 50 10
I
1.3+l3.2+l2-1+l100RPttl IOORPM lOORPM
r0 50
t66 6?8 7 A ? 889 953 8 1 7 12281440 1652r800r270r5672051 ,
AXLE
RATIO
c1olc
c20K
3-{ SHIFI+/- 150RPM
166 622 738 n l A 894 835 I 126128? {95 1670 1?{31551 1qR1
TPS 't0 20 30 {0
5.01
{103}
2.3SHIFI+/- 200RPM
5 6 7 8 71?qr 19183{88
9 8 1 1 4 8 ? i 1 617651
1787 1{38 ?005J4UU
545 s88 a t ( 781 781 r 1 l ' l1242r1r716131395r7001 9 1 8 t
179 7 1 9 937 100210{6 850 1308152617871940 1395r765r983
679 711 937 t0021016 850I 32915691787 19{0 139517872005 t
I
588 6i5 784 781 1non
136 5{5
I t t v 1417 r613139516781 9 1 8
179 588 65{ 71',|784 850 1177 1308 460 613 1395 r 0/ 6 1Q1n
501 654 i t 5 763 781 9 1 5 12421373J I D 613 1395 I 678 r9r8
S HI F TNO TA VA IL AB LAT
E T H IST P S
A L LS P E E D A
S R EG I V E NI N T R A N S M I S S I OONU T P U T
S H A F TR P M
( T P SD
} ATA
S P E E DA
S R EB A S E DO N P E R C E NTTH R O T T TPEO S I T I OS
NE N S O R
U S EA T E C H1 O RO T H E RS C A NT O O LT O M O N I T O R
T H I SD A T A
A L L S H I F TS P E E D A
S R EA P P R O X I M A T E
Figure
6
GROUP
SERVICE
TRANSMISSION
AUIOMATIC
8
0.r0
0.10
0.10
12a2
588
318
1?42
588
3{8
12t2
\2.2
1212
632
65{
65{
318
318
12{?
1242
65t
318
65.
318
1212
654
3{E
318
Z-RrsE
T e c h n i c aS
l e r v i c eI n fo r m a t i o n
CHECKPROCEDURE
LINEPRESSURE
4L6O.E
HYDRA.MATIC
L i n e o r e s s u r s so r e c a l i b r a t s df o r t w o s e t s o f g e a r r s n g e s- D r i v e - P a r k - N e u t raanl d R e v e r s eT. h i s a l l o w s t h e t r a n s m i s s i o n
l i n e p r e s s u r at o b e a p p r o p r i a t ef o r d i f f e r e n tp r e s s u r en e e d s i n d i f f e r e n tg e a r r a n g e s :
Gaet Rrngc
Lins--Prtguri-8angg
Dr iv e,P a rko r N e u tra l
Rev gr s o
5 5 - 1 8 9P S I
64 - 324PSI
B e f o r s p e r i o r m i n ga l i n e p r e s s u r ec h e c k ,v e r i f y t h a t t h e p r e s s u r ec o n t r o l s o l e n o i di s r e c e i v i n gt h e c o r r e c te l e c t r i c asl i g n a l
from the PCM:
l s c a nt o o l .
1 . l n s t a ta
2 . S t a r t t h e e n g i n e a n d s e t p a r k i n gb r a k e .
3 , C h e c kf o r o s t o r e d p r e s s u r ec o n t r o l s o l e n o i dd i a g n o s t i c
t r o u b l e c o d o , a n d o t h e r d i a g n o s t i ct r o u b l s c o d e s .
4 . R e p a i rv e h i c l e i f n e c e s s a r y ,
In s p e c t
. F l u i d l o v e l ( s e e S e c t i o n7 A )
. M a n u a ll i n k a g e
I n s t a l lo r C o n n e c t
. TECH1 Scan tool
. O i l p r o s s u r og E g s a t l i n e p r e s s u r et a p
P u t g 6 a r s e l e c t o ri n P a r k a n d s e t t h e p a r k i n g b r a k e .
S t a r t e n g i n ea n d a l l o w i t t o w a r m u p a t i d l e .
A c c e s st h e " P C S C o n t r o l " t e s t o n t h e T E C H 1 s c a n t o o l '
I n c r e a s eD E S I R E DP C S i n 0 . ' ! A m p i n c r e m e n t sa n d r e a d t h e c o r r e s p o n d i n gl i n e p r e s s u r €o n t h e p r e s s u r eg a g e .
( A l l o w p r e s s u r et o S t a b i l i z ef o r 5 s e c o n d sa f t e r e a c h c u r r e n tc ha n g e . )
9 . C o m p a r ed a t a t o t h e D r i v e - P a r k - N e u t rlai nl e p r e s s u r sc h a r t b e l o w .
5.
6.
7,
8.
*
NO T I CE
CAUTION
damagacoul doccur.
or transmi ssi on
T o tate
l s tru n n i n gri meshoul dnotexceed2 mi nutes,
ve
e otion'
dh i c lm
d t a l lt i m 6 st o p r e v e nut n e x p e c t e
B r a k em
s u s rb e a p p l i e a
l l p r e s s u r er e a d i n g sd i f f e r g r e a t t yf r o m t h e l i n e p r e s s u r ec h a r t , r e f e r t o t h e D i s g n o s i sC h a r t sc o n t a i n e di n t h i s s e c t i o n .
T h e T E C H 1 s c a n t o o l i s o n l y a b l e t o c o n t r o l t h e p r e s s u r ec o n t r o l s o l e n o i d i n P a r k a n d N e u t r a l w i t h t h e v e h i c l e s t o p p e d .
T h i s p r o t e c t st h e c l u t c h e sf r o m e x t r e m e t y h i g h o r l o w p r e s s u r e si n D r i v e o r R e v e r s er a n g e s .
Pre s s u reC o n tro l Sol enoi dC urrent(A mp)
0.02
Li nEP ressure{ P S l }
1 7 0 -1 9 0
0.10
165 185
1 6 0- 1 8 0
0.20
030
155 175
0.40
0.50
1 4 8 168
0,60
130 145
1 1 0 130
9 0- 1 1 5
140 160
0,70
0 .80
0,90
65-90
55 6 5
0.98
P r e s s u r east 1 5R P Ma n d6 6 " C( 1 5 0 ' F )
Figure
7
GROUP
SERVICE
TRANSMISSION
AUTOMATIC
l?|RrsE
CONDMON
INSPECT
COMPONENT
. O i l P u m pA s s e n r b l(y4 )
OIL PRESSURE
HICHOR
LOW
(VcnfyWithGage- RcferTo Line
Pressure
Checkhoccdure)
FORCAUSE
-
-
Pre.ssure
regulatorvalve{216} stuck.
Pressure
regulatorvatvespring(Zl7),
R otorgui de(21l ) omi nedor mi s assem bled.
Rotor (212) crackedor broken,
Reverseboosrvalve (219) or sleeve(ZZ0)
stuck, damagedor incorrcctly assembled.
Orifice hole in pressur€regulatorvalve
(217)pl ugged.
Stickingslide(203)or excessive
rotor
clearance.
Pressurerelief ball (228) not searedor
damaged.
Porosity in pump cover or body.
Wrong pump cover.
Purnpfacesnot flat.
Excessiverotorclearance.
. O i l F i l t e r( 7 2 )
-
htake pipe resrricted
by castingflash.
Cracksin filter body or inrakepipe.
O-ring seal(71) missing,cur or damaged.
Wrong greaseusedon rebuild.
. ValveBodyt6Ol
- Manual valve (340) scoredor damaged.
- Spacerplate(48) or gaskets{47 and 52)
inconect.misassembled
or damaged.
- Facenot flar.
- 2-3 S hi l r val ve(369)sruck.
- Checkballsomittedor misassembled.
-
. PrcssureControl Solenoid(317)
. SystemVoltage
. P re s s u re
S w i tchA ssembl y(69)
. C a s e( 8 )
- Caseto valvebody facc not flat,
. PossibleCodes:
- 24 VehicleSpeedSensor
SignalLow
- 52 Long SystemVoltageHigh
- 5 3 S y s t emV ol rageH i gh
- 7 2 V e h icl eS pccdS cnsorLoss
- 7 3 P re ssure
C ontrol
Solenoid
Currcnr
- 7 5 Sy s temV ol tageLow
- 8 l 2 -3 Shi ft S ol enoi d
Circuit Fault
- 8 2 l -2 Shi ft S ol enoi d
Circuit Fault
H A R S HS H I F T S
. PossibleCode.s:
- 2 l T h ro t tl eP osi ti onS ensor
C i r c u i t( H i g h )
- 22 ThrottlePositionSensor
Circuit (Low)
- 28 Fluid Pressure
Switch
As s embl yFaul t
- 7 3 Pre s surc
C ontrol
So l c noi dC rrrrr.' rrt
ALL 'LLUSTRATION
NUMBERSREFERENCE
HYDRA.MATIC
4L6O.EUNITHEPAIR
SECTION
Figure 8
AUTOMATIC
TRANSMISSION
SERVICE
GROUP
t0
ARrsG
INSPECT
COMPONENT
CONDITION
FORCAUSE
. T h r o t t l eP o s i t i o nS e n s o r
. V e h i c l eSpeedS ensor(36)
C o n t i n u e)d
. P r e s s u rSew i l c hA s s e n r b l(y6 9 )
. T ra n sF l u i dTemperature
Se n s o (6
r 9)
. E n g i n eC ool antTemperature
Sensor
. P r e s s u rCeo n t r o S
l o l e n o r (d3 ' 7 7 \
I NACCUIT^1'E.SH I F'I' POINTS
Oil PurttA
p s s c t t t h l(y4 )
S t u c kp r e s s u rrec g u l l t o rv i r l v c( l l ( r l .
p u r n ps l i d e{ 2 0 3 i
Sticking
V a l v eB o d yA s s e m b l y( 6 0 )
S p a c epr l a t e( 4 8 )o r g a s k c l s1 4 7a n t l5 2 )
mi sassernbl ed,
or i ncorr ecl.
darnaged
C a s e( 8 )
Porousor damagedvalvehrily pud
2 - 4 S e r v oA s s e m b l (yl 2 - 2 9 )
a , 2 - 4 a c c u m u l a t op ro r o s r t y .
servopi sl onseal s,
b, D arrraged
rl r i rl propcrlcngt h
c. A ppl y pi n danraged
2 - 4 B a r r dA s s e r n b l(y6 { ) 2 ) ,
a, Burned.
b . A n c h o rp r nn o te n g a g e d
T h r o tlte P o s iito n , 5 e ' n s o r
D i sconnected.
D amage.
V c h i c l cS p c c dS c n s o(r3 6 )
D i sconnected.
D amaged.
B ol t not ti ghtened,
4WD Low Switch
D i sconnected.
D amaged.
E A R I - YS H T F T S
. Possible
Codes:
- 6 9 T C C S t u c k" O N "
FIXEDSHIF| POINTS
. Possible
Codes:
- 2 l T h r o t t l eP o s i t i o nS e n s o r
C i r c u i t( H i g h t
- 2 2 T h rottl eP osi ti onS ensor
C i r c u i t( L o w ;
I S T C E A R R A N C EO N L Y
- NO UPSHIFT
ValveBody (60)
- l - 2 S h i f tv a l v e( 3 6 6 )s t i c h i r r g
- S p a c epr l a t e( 4 8 )o r g a s k c l (s4 7 a n r J5 2 )
or dartt:rgetl.
mispositioned
C a s c( 8 )
- Caseto valvebodv l'acenot tlat or
damaged,
- .Stuckor damaged.
- E l ectri cal
connecti on.
- Restricted
or blockedilpply
passaSes
ca.\e,
- N i c k so r b u n so n s e r v op r n ( l 3 ) o r
pin bore in case
- 4th S ervopi ston(25) i n backw ar t ls.
S h i f t . S o l e n o i d st 3 7 c ) )
. 2 -4 Se rv oA ssernbl y(l r2-29)
4L6O.E
SECTION
HYDRA.MATIC
UNITREPAIR
ALL ILLUSTRATION
NUMBERSREFERENCE
Figure
9
GROUP
SERVICE
TRANSMISSION
AUTOMATIC
ll
Z-Rrsc
CONDITION
INSPECT
COMPONENT
FORCAUSE
IST GEAR RANGEONLY
- NO UPSHIFTS
(Continued)
, 2-4BandAssembly
(602)
S L I P SI N I S TC E A R
. F o r w a r dC l u t c hA s s e r n h l v
- C l utchpl ates(649;w orn.
- Porosityor damagein forward
cl utchpi ston(630).
- Forwardclutchpistoninnerand
outerseal s(629)mi ssi ng,cul or
darnaged.
* l nputhousi ngto forw ardcl utch
h o u s i n gO - r i n gs e a l( 6 2 2 )m i s s i n g ,
c u to r d a m a g e d
- D amagcdforw ardcl urchhousi ng( 6281.
- F<lrward
clutchhousingretainerand
ball assembly(627)not sealing
or damaged.
. F o rw a rdC l utchA ccunrul at< l r
- P i s t o ns e a l( 3 5 3 )m i s s i n gc, u t o r
rl i trnl gcd
- P i s t o r(r3 5 . 1o1u t o f i r sb o r e ,
- Poro.srty
in the pistonor valve
body(350).
- Stuckabusevalve(3511.
2-4 Band (602) worn or damaged.
Bandanchorpin not engaged.
In p u tH o usi ngand S haft
A s s e m b l(y6 2 1 )
- Turbineshaftseals(619)missing,
cut or damaged.
V a l v eB o dy t60i
l - 2 A c c u n r u l a tvoar l v e( 3 7 1 ts t u c k .
- Facenot t'lat.damagedlandsor
passages.
i nterconnected
- Spacerplate(48) or gaskets(47 and 52)
incorrect,mispositioned
or damaged.
. L o w R o l l erC l utch(678)
-
Damageto lugs or innerramps.
R ol l ersnot freemovi ng.
I n a d e q u a st ep r i n gt e n s i o n .
D amageto i nncrspl i nes.
plugged.
Lube pas.sage
T o rq u eConvener(l )
- Statorroller clutchnot holding.
I -2 Ac c umul ator
A ssenrbl v
- Porosityin piston(56) or l-2 Accumulator
coverand pi n assembl (57),
y
- l )amagedri ng grooveson pi ston.
- P r : r o ns e a l( 5 5 )m i s s i n gc, u t o r d a m a g e d .
- V al vebody to spacerpl arcgaske (t 52) at
l -2 A ccumul ator
cover.mi ssi ngor
damaged,
- Leak betweenpistonand pin.
- Broken l-2 Accumulatorspring(54).
L i n e Pressure
- (.S ee
C ausesof H i gh or Low Oi l Pr essur e. )
2 - 4 S e r v oA s r e r n h l y( t, 2 . 2 9 )
- { t h . S c n ' op i s t o n( 2 5 ) i r t b l c k * ' a r d s .
(s4-59)
ALL ILLUSTRATION
NUMBERSREFERENCE
HYDRA.MATIC
4L6O-E
UNITREPAIR
SECTION
Figure 10
SERVICE
GROUP
TRANSMISSION
AUTOMATIC
l2
ARrsG
CONDITION
INSPECT
COMPONENT
s t - l l , t , l \ (o; R R O U C Ht - l
.st{ rt.-t
N O t . 3 S H t F -O
r R2 . . 1
S I I I F -.I\-I I P P I N CR. O U G H
O RH U N I ' I N C
FORCAUSE
. \ ' i r l v e B o r l v A s s c l 1 1 h l(!6 0 )
l - 2 S h i t iv a l v et r a i n( 3 6 5 - 3 6 6s) r u c k .
Gaskets(47 and52) or spi l cerpl are(48)
i ncorrect.
mi sposi ti oned
or damaged.
l - 2 A c c u m u l a t ovra l v et 3 7 l ) s t t r c k .
Facenot flat.
. 2 -4 Se rv oAssernbl (l
y r2.29)
A ppl y pi n ( l 3) too l ongor roo shor r .
2nd servoappl ypi stonsealmi ssi ngcut
. or
darnaged.
Rcstt'rcto
cd
r ntirsittg
oil ;l:rrrlgt'r
S ervoburc rn crrsedl rnugcd,
. 2 n dA c c u m u l a t o(r5 4 - 5 9 )
P orosi tyi n l -2 accumul ator
housi ng( 57)
or pi ston(56).
Pistonsealor groovedanraged.
N i cksor burrsi n l ' 2 accurnul ator
housing.
M i s s i n gu r r e s t r i c t eodi l p a s s l g e
. l - . 1B a n d( 6 0 2 )
W o r no r r n i r p o s r t i o n e d
. O r l P u m pA s s c n r b r(l4y ) o r
C a s e(8 )
Facesnot llat.
C o n v e r t e r( l )
Irrternal
darnage.
Ort Pump(4)
S t a t o sr h u f t( 2 1 4 ts l e e v es c o r e tol r o f f
l ocatron.
. Va l v eBo d y ( 60)
2-3 Valr,etrain (268-269)stuck.
val ve(3?t1stuck,
A ccumul ator
Spacerplate(48) or gaskets(47 and 52)
or damaged.
l n p u tH o u s i r rAgs r e n r b lty6 2 l )
C l u t c hp l a t c .ws o r n l 3 - + t 6 S a l
or l orw arclt649l l .
E xcessi ve
cl utchpl atetravel .
Cut or damagedpistonseals
[3-4 (624] or forward (629)1.
P orosi tyi n i nputcl utchhousi ng(621)or
pi ston(623).
stuck.dam aged
.1-4P i stoncheckhal(620)
l
o r n o ts e a l i n g .
R estri ctcd
l ppl y passuges.
Forwardclutchpistonretainerand ball
assenrblyt62'7\not seating.
S eal i ngbal l sl ooseor mi ssi ng.
C a s e( U )
retai nerand bal l assem bly
3rd A ccumul ator
n o ts e i t t i n S .
2 - 4 S e n ' <Al s s e r n b lt yl l - 1 9 l
2 n dA p p l vp r s t ( ) rne a l s( l l l a r r t ll 9 ) m r r s r n g .
cut or durn;rgcd
Po .s s i bC
l eo d es:
- 2 4 V e h i c l eS peedS ensor
S i g n a l[ - o w
- 7 2 V c h i c l c.S necd
.Scnsor
l-oss
4L6O.E
ALL ILLUSTRATION
HYDRA.MATIC
UNITREPAIR
SECTION
NUMBERSREFERENCE
Figure
I I
GROUP
SERVICE
TRANSMISSION
AUTOMATIC
l3
Asrsc
INSPECT
COMPONENT
CONDITION
2 N DA N D 3 R DC E A R SO N L Y
OR
I S TA N D 4 T I {C E A R SO N L , Y
r l ) o s r h l cC 0 d es .
- t i 2 l - 2 S h i l tS o l e
rroid
C i l c u i tl j r r r r l t
. S h i f tS o l c ' n o i d( 3
s 79)
THIRD CEAR ONLY
FORCAUSE
Sedintcnt
E l ectri calC onnccti on
r P o s r i b l c( l o d c s .
- 5 2 L o r r g . S y r t c rVr rt l l t i r g cH i g h
- 5 . 1 . S y s t c rV
r ro l t . r g el l r g h
- 6 6 l - 2 C o r t t r < tSl o l er r o i d
(lrrcuit[;ault
- 7 5 S ; , s t c n rV l l t u g c [ . o w
- 8l 2-3 Shift Strlenoid
C i r c u r t[ " u u l t
. S ) . . t c r nV r t l l i t F c
. 3 - 2 C o r t t r u lS o l r : n o r ttl. l 9 - l t
3.2FLAREORTIE.UP
N O 3- 4 S HIF T I S LIPP Ii ' l C
O R R O U C H1 . 4 S H I F T
, 3 -2 C o n trolS ol enoi d(394)
- Shorted or damagcd,
( ) r l P r r n r pA s s c n t b l v( - l)
Faces n(rltl at,
- P urnpcovcrretai nerl nd bal l asscm bly
onri ttcdor damaged.
Valvc Eody Asicntbly (60)
- Valvesstuck.
. 2-3 S hi ft val ve(368-369)trai n.
. A c c u n u l a t ovr a l v e( 3 7 1) ,
. l - 2 S h i f tv a l v et r a i n( 3 6 5 - 3 6 6 ) .
. 3 . 2 C o n r r ovl a l v e( 3 9 1 ) .
- S p i r c cJr r l l t c( 4 f l )o r g l s k c t s( 4 7 i r n d5 2 )
. r i s p o s i t i r l nocrdd a m a g c d ,
i n eo r r c c t n
2 - - lS c l r o r \ r : c r t t b l y( 1 2 - 2 9 )
- l n c o r r e cbt a n da p p l yp i n ( l 3 ) .
- Missingor damagedsen'o seals
( 2 6 a n d2 7 ) .
- P orosi tyi n pi stons,
covcror case.
- D a r n i r g cpdi s t o ns e u lg r o o v e s ,
- P l r i g g co
d r n r i s s i n og r i f i c ec u p p l u g( I l ) .
( l l s c ( t ()
- 3rd A ccuntul ator
retai nerand bal l a ssem bly
l e a ki n g .
- Porosrtyin 3-4 accunrulator
piston(44)
ot'bore.
- 3-4 A ccunrul attlpir stonsel l (45) or scal
groovc\duntaged.
- P l u g g c do r r r t i s s i nogr i l i c ec u p p l u g .
- R crtri el ed oi l passugr.' .
l r r p u tl l o u s r r t gA s s c t t t b l v( 6 2 I ;
- R e t ' etro S l i p p i n g2 - 3 S h i f t .
2 - 4 B a n d A s s e r n b l y( 6 0 2 )
* Worn or rnisassernbled.
HYDRA.MATIC
SECTION
4L6O.EUNITREPAIR
ALL ILLUSTRATION
NUMBERSREFEBENCE
Figure 12
GROUP
SERVICE
TRANSMISSION
AUTOMATIC
l4
ARrsE
CONDITION
I N S P E CC
TOMPONENT
FORCAUSE
. Po s s i b l e
C o des:
- 2 1 T h r o t t l eP o s i t i o nS e n s o r
C i r c u i (t H i g h )
- 2 2 T h r o t t l rPr o s i l i o nS c r r s o r '
C i r c r r (r lt . r r w
)
N O 3 . 4 S HI F T I S LIPP IN C
OR ROUCH 3.4SHIFT
(Co n t inr r c c J )
- 2 8 F j l 1 1 1P. ll g s s r r l t :. \ w i t c h
A s . s c r n bF
l ya u l t
- 3 7 B r a k eS w i t c hS t u c k" O N "
- 3 8 Bra k eS w i tch.S tuck" OFF'
- 67 'fCC Solenoid
C i r c u i tF a u l t
ll ct t l l
rir nev[,RSI:
or{sL.tPS
rN
I n p u t l ' l o u s r r t g, \ s s c r r r f r l tv6 l I t
3 - aA p p l y r i n g( 6 2 5 1s t u c ki n u p p l i e d
position.
Forwardclutchnot releasing.
Turbi neshaftseal s(619)nri ssi ng,
cu t or
damaged.
M a n u a lV a l v cl . i n k ( 7 0 5 )
Disconnected.
O i l P u r n pA s s e r n b l(y. 1 )
l {etai nerandbal l assenrhlmi
y ssi ngor
drrnr;tged.
S t a l u rs l r l f ts c a lr r r r g (s2 3 0 )o r n n g B r o o v e s
dl rnaged.
Statorshaftsleevescoredor damaged.
Reverseboostvalve(219)stuck.damaged
or mi sassembl ed.
C u p p l u gm i s s r n g .
l l estri ctcdoi l pas.sage.
i :acesnot fl at.
( . o n v e r t ec rl u t c hv l l v e ( 2 2 f1 r t u ek .
REVERSE
. Va l v eBo d y A ssembl y(60)
2-3 S hi ft val ve(369)stuck.
Manuallinkage(?05) not adjusted.
Spacerplate(48) and gaskets(4? and 52)
or damaged.
l -o ovr' rrunval ve(361)stuck.
n .t i s s i n g
or
O r i l ' i c e cdu p p l u gr e s t r i c t e d
rl ;.rntagcd.
I t c v e r s cl n p u t C l t r t c l r
Assembly'(605)
. [.oAnd RcversC
c lutch
C l u t c hp l a t c1 6 1 2 w
) orrt,
R everse
i nputhousi nganddrum assem bly
(605)crackedat weld.
Clutchplateretainingring out of groove.
ni ngri ng ( 610)
R eturnspri ngassembl retai
y
ottttl l gr()ovc.
S cl l s (60t{)cut (}rdl rtri tged.
R cstri ctcd
i tppl ypi l ssi .rge,
P orosrtyi n pi ston(6071.
B el l evi l l epl ate(6l l ) i nstal l edi ncorr ect ly.
clutchplatetravel,
Excessive
housi ng.
Oversi zed
-
C l utchpl ates(682)w orn.
P orosi tyi n pi ston(695).
S cal s(696)darnl ged.
ri rr g
rtg
R eturnspri ngassenrblrctarni
y
(693)mi sposi ti oned.
- Restrictcdapplyptssage.
SECTION
HYDRA.MATIC
4L6O.EUNITREPAIR
ALL ILLUSTRATION
NUMBERSREFERENCE
Figure 13
GROUP
SERVICE
TRANSMISSION
AUTOMATIC
I5
ARrsE
CONDITION
INSPECT
COMPONENT
' T HR O' T T L E
NO P A R]
OR
DELAYEDDOWNSHIFfS
FORCAUSE
. 2 - 4S c r v oA s s c n r b (l v1 2 - 2 9 )
- S ervocoverretai ni ngri ng (29)onr incd
or rlisassembled.
* 4 t h A p p l y p i s r o n( 2 5 )d a r n a g eodr
rrtisassernblcd.
- S e r v oi n n e rh o u s i n g( 2 0 )d a n r l g e do r
misassembled.
' V a l v eB o d yA s s c r r r b l(y6 0 )
- 3 - 2D o w n s h i fvt a l v e( 3 8 9 is r u c k .
- 4-3 ,S equence
val vcbodychl rrrncl
blocked.
H A R S HC A R A C E S H I F f
. V a l v eB o d yA s s e r r r b (l y6 0 )
N O O V E R R U NB R A K T N C
M A N U A L 3 . 2 -I
. E r t e r n a Ll . i n k a g e
- Not adlustedproperly.
. V u l v eB o t l yA s s c n r b l(y6 0 )
- 1 - 3 S e q u e n cvea l v e( 3 8 2 t\ r u c k
- Checkbam
ll isposirioned.
- S p l c e rp l l t e ( 4 8 )a n dg a s k c t (s4 7 a r r t 5t 2 )
i ncorrcct,
damaged
or mi sposi t onecJ.
' l n p u rC l u r c hA s s e n r b tl 6
y2l)
- Turhi neshaftoi l passages
pl ugg edor nor
drilled,
- Turbi neshaf'seal
t
ri ngs(619)da m lged.
- Turbi neshaftseal i ngbal l sl oos eor
missing.
- P orcl si ty
i n forw ard(630)or ovcn. unclut ch
p i s t o n( 6 3 2 ) .
- O v e r u n p i s r o ns e a l s( 6 3| ) c u t o r d a m a g e d .
- O v e r r u np i s r o nc h c c k b a l(l6 3 3 )n o rs e a l i n g .
. Elcctrical
l 2 V o l t sn o t s u p p l i e tdo t r a n s n r i s s i o n .
- Outsi deel ecrl i calconnector
damaged.
- Insi deel ectri cal
connecl or,
w i ri n g har . lr es. s
or sol cnoi ddamaged.
- E l ectri calshon(pi nchedsol eno idwir e) .
- S ol enoi dnor grounded.
N O T O R Q U EC O N V E R T E R
C LUT CH A P P L Y
O r i fi c ec u p p l u gr n i s s i n g .
C h e c k b a lm
l issing.
. T (l C So l cnoi tj
. Engirre
S p e e dS e n s u r
. Converter(l)
- Interrral
damage.
. En g i n eCool antTentperature
S e n s rl r
. O i l P u m pA s s e m b l(y4 )
* C onvcrtercl utchval veQ21l strrckor
assenrbl ed
backw ards.
- C o n v e r t ecrl u r c hv a l v er e t a i n i n rgi r r g( 2 2 2 )
misposirioned.
- P u m pl o c a \ eg a s k e(t6 ) m i s p o s i t i o n e c l .
- Orit'ice
c u p p l u gr c s r r i c r eodr d l l n u g c d .
- Solenoid
O - r i n gs c a l( 6 7 )c u t o r r l a n r a g e d ,
- H i gh ()r unevenbol t torquc(purn plr odyt o
covct )
ALL ILLUSTRATION
NUMBERSREFERENCE
HYDRA.MATIC
4L6O.E
UNITREPAIR
SECTION
Figure L4
TRANSMISSION
AUTOMATIC
SERVICE
GROUP
l6
ARrsE
T e c h n i c a lS e r v i c e I n f o r m a t i o n
CONDITION
INSPECT
COMPONENT
N OT O R Q U E
CONVERTER
C L U T C HA P P L Y
( C o n t i n u)e d
FORCAUSE
T ra n sFIi ri dTempcrature
.S c rrs o( 69
r )
I n p u tH o u s i n ga n dS h a f t( 6 2 1 )
- TurbrneshaftO-ri ngseal(618)cur or
damaged.
- Turbineshaftretainerand ball assembly
(617)restrictedor damaged.
B r a k eS w i l c h
P r c s r u rS
c r rr t ct r A s r c n t b l (y6 9 )
V a l v eB ody A ssenrbl y(60)
- TC C si gnalval ve(380)sruck.
- SolenoidO-ring leaking,
S o l e n o i dS c r e e n
- B l ocked.
P o s s i b lC
e odcs:
- 2l ThrottlP
e o r i t r oS
ne n s o r
C u ' c u r(tt ' l i g h )
- 2 2 T h r o t t l eP o s i t i o nS e n s o r
C i r cui t(Low )
- 2 8 F l ui d P ressure
S w i tch
Assembl yFaul t
- 3 7 B r a k eS w i t c hS t u c k" O N "
- 3 8 B r a k eS w i t c h. S t u c "kO F F '
- . 5 2L o n g S y s t e r n
V r l t a g eH r g h
- 5 . 3S y s t e nVr o l t , r g H
c igh
- 67 TCC Solenoid
- 75 SystemVolmgeLow
- 8 l 2 -3 S hi ft S ol enoi d
C i r cui tFaul t
T O R Q U EC O N V E R T E R
C L U ' T C HS H U D D E R
T o rq u eC onvertcrA rscnrl ' rl(yI )
- Internaldamage.
O i l P u n r pA s s c r r r f r(l4y)
- C onverter
cl utchval veQ24) stuck.
- Restrictedoil passage.
O i l F i l t e r( 7 2 )
- Crack in filter body.
- Flashrestrictingfilter neck.
- O-ri ngseal(7l ) cut or damaged.
. \lrrccllirrtcorrs
- Low orl pressure.
- Enginenot tunedproperly,
. I n p u tH o u s i n ga n dS h a f tA s s e m b l y - TurbineshaftO-ring(618)cut or
(62t)
damaged.
- Turbine shaft retainerand ball assembly
(617) resrictedor damaged.
T C CA P P L YW I T HA
C O L DE N C I N E
P o s s i b lC
c otlcs:
- l 4 E n g i n eC o o l a nT
t e m pS e n s o r
C i r c u i tl H i g h )
- l 5 E n g i neC ool antTempS ensor
C i r c u i t( L o w ;
ALL ILLUSTRATION
NUMBERSREFERENCE
HYDRA.MATIC
4L6O.E
UNITREPAIR
SECTION
Figure 15
TRANSMISSION
SERVICE
GROUP
AUTOMATIC
t7
[Z|RrsE
CONDITION
N O ' T O R Q U EC O N V E R T E R
C L U I ' C HR E L E A S E
INSPECT
COMPONENT
FORCAUSE
. TCC Solenord
- E xternalground.
- Cfoggedexhaustorifice.
. C o n t ' c n e r( l )
- Internaldamagc,
. V a l v e B o d y A s s e r t r h l y( 6 0 )
- C o n r ' rer e rc l u t c ha p p l yv a l v es t u c ki n a p p l y
posrti tl rr.
O i l P u m pA s s e r n b(l .yt )
- C o n v e r r ecrl u r c hv a l v ee 2 A l s r u c k ,
P(]M
- E x t c r n agl r o u n d .
. P o s s i b lC
c odcs:
- 6 9 TC C S ruck" Orr"
D R I V E SI N N E U T R A I -
2ND CEAR START
( D R I V ER A N C E I
F o rw ardC l rrrch
N ot rel ea.si ng.
M i r n r r lV
l llvc Link(70.5t
D i scrl rr
nected.
Clrc (ll)
Faccrrotfl ar,
I n t c r n t rl le : r k a g e .
. F o rwardC l utchS pragA ssembl y
{642\
- S praga.ssembli nsral
y
l ed
bac kwar ds,
NO PARK
P a r k i n gL i n k a g e( 6 3 ,7 9 - 9 0 t
- A ctuarorrod assembl (85)
y
bentor
damaged,
- A ctuato.r
rod spri ngbi ndi ngo r im pr oper ly
cri mped.
- Actuatorrod not attachedto insidedetent
l e v e r( 7 8 8 ) .
- P arki ngl ock bracket(86) cl am aged
or not
torquedproperly.
- Insi dedetenrl ever (8l tt nor to r qued
properl y.
- D e t e n r o l l e ra n ds p r r n ga s s e n r b lt y6 3 )
mi sposi ti oned
or nor rorquecl
pr oper ly.
- P a r k i n gp a w l( 8 l ) b i n d i n go r d a r n a g e d .
r { A I ' C t l El'N
t (;NotsE
P a r k r n gP u * , Il t f l )
- P arki ngpl w l rerurnspnngft10)wclk.
d l r n a g de u r r n i s a s s e n rdb.l e
OIL OUTTHE VENT
O i l P u m p( 4 )
- Chanrt'er
in pump body rotor pocketroo
l arge.
Mrscellancous
- F l u i dl e v e l- o v e r f i l l e d .
ALL ILLUSTRATION
NUMBERSREFERENCE
HYDRA.MATIC
4L6O.E
UNITREPAIR
SECTION
Figure 16
A U T O M A T IRCA N S M I S SSI E
OqNV
] iI G R C U P
l8
ARrsE
T e c h n i c a fS e r v i c e l n f o r m a t i o n
I N S P E CC
TOMPONENT
CONDITION
FORCAUSE
VIBRATIONIN REVERSE
AND
WHININGNOISEIN PARK
. Oil Pump(4)
- Brokenvanerings(210).
N O D R I V EI N A L L R A N C E S
. T o r q u eC o n v e r t e(rl )
- Converterto flex plateboltsmissing.
NO DRIVEIN DRIVERANGE
. TorqueConverter
(I)
- Statorroller clutch not holding,
- Converternot bolted to flex plate.
F R O N TO I L L E A K
. T o rq u eC o nverter(l )
- Weldedseamleaking.
- Damagedconverterhub.
. T o rc F re
S cl l (2.13)
C < l ttvcrl cr
- Dunragedsealassembly.
- Missinggarterspring.
D E L A YI N D R I V EA N D
REVERSE
- Converterdrainback,
TorqueConverter( l)
4160-EUNIT nEP4lRSECTION
HYDRA-MATIC
NUMBERSREFERENCE
ALL TLLUSTRATTON
Figure L7
GROUP
ISSIONSERVICE
TRANSM
AUTOMATIC
I9
U|RrsE
T e c hn i c a l S e r v i c eI n fo r m a t i o n
DIAGNOSTIC
TROUBLE
CODESAND DEFAULT
ACTIONS
TROUBLE
CODE
l4
F . n g r nCe o o l a n1t c r n p
S c n s oC
r i r c u i t( H i g h )
t5
EngineCoolantTemp
S e n s oC
r i rc u i r(L o w )
2l
T hr ot t lePo s i ti o nS e n s o C
r i rc r.ri t
(High)
ll
T h r o t t l cP o s i t i o n
S c n s oC
l' irctrr
(Low)
24
Vehicle
Speed
Sensor
SignalLow
CODEPARAMETERS
DEFAULTACTION
E n g i n ec 0 o l a r rttc n r p( ) v e r1 4 5 . C
(2 t)J" [;)fi rr l /] \ec()11d.
.
E ngi nccool antrenrpl e.ss
than-33oC
('27' l :) for l 12second.
. TCCapplycold.
T P v o l t r g e g r c ; r l e lr h i r n
4 . i i l i v o l L sf o r t i r r r p5 . a , , n d r .
. No TCC.
. Fi xedshi frpoi nts,
. Harshshifis.
' Maximurnline pressure.
. No fourth gear in hot rnode.
W i t h c n g i n cn r r r n i r r g
T .P v o l r a g e
l essl l urrr.06 v' ol l rl i rr l ' orrrseconds.
( [ ) i e s cils l c s rt h i r r.tl ( l v o l t s . )
. No TCC.
. Fi xedshi frpoi nrs.
. H arshshi fts.
' Maxi muml i ne prcssur e.
. No founh gearilt hot rnode.
ln Drivc or Revcrsewith enginespeed
grcaterthan 3000 r?nt.outputspeed
i s l essthan250 rpm for threeseconds,
t M A P i s l 0 f ) - 2 . s1. sP a ,T P i s l 0 - l 0 ( ) 7 c )
a
a
P C M t l c t e c tos r r co l ' l * ' o " i n v a l i d "
28
FluidPressure
SwitchAsscmblv
l;aulr c o m b i r r u t i o on fs' P S Ms i g n a l sf o r
TC C appl ycol d.
Maximum line pressure.
Secondgearonly.
.
.
.
No TCC.
Harshshifts.
No fourth gear in hot mode.
77
B r a k cS r v i r cS
h t u c k" O N "
Wi th hrakeon, r' cl ri cl espeedi .s
.
.
5 - 2 0r n p hl i l r s i x s e c o n d st hl e n
v e h i c l es p c c di . > 1 0 r n p hl b r s i x
\ ( . c o n d sT.h r sr r r u sht a p p e ns c v e nt i n r c s .
No TCC.
No lbunh gear in hot modc,
38
BrakeSwitchSruck"OFl:"
W i th brakeofl ' .vehi cl espeedi s
> 20 mph for si x seconds,
thenvehi cl e
speedis .5-20nrph I'orsix seconds.
T h i sr n u sh
t a p p c ns c v e nt i m e s .
No TCC.
No founh gear in hot mode.
.52
LorrgS1'ste
rl Volrage
Hrgh
O c r r c l r t r rvro l t ; r p ri s: r t r e i t t ct rh a n
l 6 l o l l r l i r r 'l 0 t ) r r l t ) ut c s .
53
Volrage
System
High
Generatorvoltageis greaterthan
1 9.5vol tsfor tw o seconds.
f'ivescconds.
.
.
No TCC.
Maxi muml i nr-'prcssur e.
Third gcarorrly.
o
a
I
No TCC.
Maximumlinepressure.
Thirdgearonly.
58
Transmission
[:ltrid
Temp.Sensor
Circuit(Highl
T r o n s r n i s s i ol lnr r i ctle m p e r a t u irse
r : r c i l t ctrh l l r l 5 , l ' C ( J O t ) . Ff)o r
o rt csecontl .
.
N o defaul tacti on.
59
Transmi.ssion
Fluid
TempSensor
Circuit(Low)
Transmission
f'luidtemperature
is
below-3loC(-54oF)
for
onesecond.
'
No defaultaction.
Figure
18
TRANSMISSION
AUTOMATIC
SERVICE
GROUP
20
|!RrsE
DIAGNOSTIC
TROUBLE
CODESAND DEFAULT
ACTIONS
TBOUBLE
CODE
66
3- 2 Co n tro lS o l e n o i d
Cir c u i rF a u l r
67
TCC.Solcnoid
(-'rrcuiF
t lrrlt
C O D EP A R A M E T E R S
A t h i g hd u l y c y c l c .r h ec i r c u i rv o l r a g e
h i g h - O R . a t l o w d u l y c y c l er h ec i r c u i r
v o l ta gei s l ow for four seconds.
DEFAULT
ACTION
.
.
T C C i s c o m m a n d eodn . b u t c i r c u i ri s
.
h i g h- O R -T C C i s c o m m a n d eodf f h u l
c r r c u i tv o l t i r g ci s l r r wf r l rt w o s e c o n d s .
Thi rd gearonl y
No TCC.
No fourthgearin hot nlo(le.
69
T C C S t u c k" O N "
W i t h g c a rs c l e c l oirn a d r i v er a n g c .
t r a n s m i s s i oi nn 2 n d .3 r d o r 4 t h .
TP Sensorgreatcrthan25% and TCC
u n l o c ked- sl i p i s berw een-20 and
20RPM.
.
.
TC C " ON " i n al l gears.
E arl yshi fts.
T w o s ucccssi vc
specdreadi ngs
havea
d i ffc renceof morel hen l 0O0R P M.
(Differencemustbe morethan
1 5 0 0R P M i n P a n dN . )
o
72
Vehicle
Speed
Sensor
Loss
Maxi muml i ne pressure.
Secondgearonly.
Pressure
controlsolenoidre(urn
a m p e r a gvea r i e sm o r et h a n. 1 6a m p
fro m comntanded
amperage
for
o n e s ccond.
.
.
Harshshifts.
Maxi muml i ne pressure.
S y s t e mv o l t a g ei s l e s st h a n7 . 3V a r
h i g ht e m p sa n d l e s st h a n I 1 . 7V a r h i g h
tempsfor four ,seconds.
.
.
.
No TCC.
Maxi muml i ne pressure .
Third gearonly.
2 - l S h i f tS o l e n o i di s c o r n m a n d e"dO N " .
.
b y PC M but ci rcui rvol tagei s hi gh for
.
tw o s e conds
OR
2 . 3 S h i f tS o l en o i di s c o m m a n d e"dO F F '
b y P C M b u l c r r c u i vt o l t a g ei s l o w f o r
l w o s ec()nds
No TCC
Second
or thirdgearonly.
1 " 2S h i f tS o l e n o i di s c o m m a n d e"dO N "
b y PC M but ci rcui tvol ragei s hi gh for
tw o s econds
OR
l - 2 S h i f tS o l e n o i di s c o m m a n d e"dO F F '
b y P C M h u l c r r c u i vt o l t l g ei s l o w l o r
l w O s r' C onds.
Second
or thirdgearonly
OR
Firstandfourthgearsonly.
73
Prcssure
ControlSolenoid
Currenl
75
Voltage
System
Low
19
T r u n s n r i r s i oFnl u i dO v c r t c r r r p
8t
2 - 3 S h i f tS o l e n o i d
82
l - 2 S h i f tS o l e n o i d
C i r c u i tF a u l r
a
T r : r n s n r i r s i ot rcrr n pi s h i g h c rt h a n
1 . 5 0 " C( 1 0 2 " F) l o r r r x s < l c o n d s .
Figure
19
SERVICE
GROUP
TRANSMISSION
AUTOMATIC
2l
ARrsG
TORQUE
CONVERTER
CT UT CH
(TCCI
SOLENOID
3-2
CONTROL
SOLENOID
VEHICLE HARNESS
CONNBCTOR
1 - 2S H I F T
SOLENOIO
2 . 3S H I F T
SOLENOID
o
PRESSURE
CONTROT
SOLENOID
CAVITY
c
FUNCTION
A
(LOW}
1 , 2S H I F TS O L E N O I D
I
2 . 3S H I F TS O L E N O I {DL O W }
T R A N S M I S S I OFNL U I D
P R E S S U RS
EW I T C HA S S E M B L Y
P R E S S U RCEO N T R O S
LOLENOID
IHIGH)
(LOW}
P R E S S U RC
EO N T R O LS O L E N O I D
I
E
B O T HS H I F TS O L E N O I D ST,C CS O L E N O I D ,
A N O 3 - 2C O N T R O S
LOLENOID
{HIGH}
L
T R A N S M I S S I OFNL U I DT E M P E R A T U R E
(HIGH}
M
T R A N S M I S S I OFNL U l OT E M P E R A T U R E
(LOW}
N
R A N G ES I G N A L- A '
P
R A N G ES I G N A L" C "
R
R A N G ES I G N A L" B '
S
3 - 2C O N T R OSL O L E N O I(DL O W }
T
(LOW)
T C CS O L E N O I D
tf-n-l
t-
,**ar,ra,o*
FLUID
TEMPERATURE
SENSOR
(INTERNAL}
WIR.ING
SCFTEMATTC
Figure 20
TRANSMISSION
SERVICE
GROUP
AUTOMATIC
22
AsrsE
:TR.ANSMISS
ION
CASE
CONNECTOR
NoTE: THE TRANSMISSION
CASECONNECTOR
AND THE LOCK-UPSOLENOIDARE
INTREGALPARTSOF THE TRANSMISSION
WIRING MRNESS AND I,IUSTBE
REPLACED
AS AN ASSEI4BLY,
-----aar-r--3
V I E W L O O K I N GI N T O
TRA}-ISMISSION
CASECONNECTOR
Prrlrn
CoaFol
Solrtfol4Hhh
Prolgn Conrrol
3obno|d-Lor
Shli toLno{d8
shn so|.nold-A
A\B \C D
+tlV litrrl
L/M N\P R\S
!2 Dovnrhllt
Solonold
tnFeiln
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P S UR r n g r . S
?;frrurr
l-F
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PSlt Frnge .A
TCGSo11notO
Figure 2L
GROUP
SERVICE
AUTOMATIC
TRANSMISSION
2j
f|RrsE
T e c h n i c a lS e r v i c ef n fo r m a t i o n
l-fi"-lI
LJLJ\(
IITI
FII
I l p Il
n.)
|
|
VAI-VE
BODY
PASSAGES
n.ND cFrl
AND
CFIECKBAI-II-ocAl
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lll[L
LN I_Y
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14
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6
!t-;-l
ILL.
NO.
1
2
3
4
5
6
7
8
9
1O
11
12
13
,I4
ILL,
NO.
DESCRIPTION
SUCTION(INTAKE}
DECREASE
LIN€
C O N V E N T EFRE E D
RELEASE
APPLY(REGAPPLY}
TO COOLEB
LUEEFROMCOOLER
ACTUATORFEEDLIMIT
F I L T E R EA
DC T U A T O RF E E D
T O R O U ES I G N A L
PR
D1.3.2
LO/REVERSE
15 REVERSE
18 REVERSE
. L.'
I N P U T( R E VC
OESCRIPTION
17 D4
18 FORWARD
C L U T C HF E E D
1 9 R E A RL U B E
zo Accuuul-,AToR
21
22
23
24
25
26
?7
28
29
30
31
32
S I G N A LA
2NO
2 N DC L U T C H
C . C ,S t c N A L
3 . 4S T G N A L
3 R DA C C U M
3 . 1C L U T C H
qtH SrGrual
SERVO
FEED
4TH
3 . 4A C C U M
D3
rLt.
NO,
33
34
35
36
37
38
39
40
4I
{2
43
44
45
16
DESCRIPTION
OVERRUN
O V E R R U NC L U T C HF E E D
OVERRUN
CLUTCH
D2
O R | F | C E0D2
3.2SIGNAL
LO
LO/lST
EXHAUST
ORIFIC€D
EXHAUST
VENT
S E A LD R A I N
VOIO
L I N EP R E S S U RTEA P
Figure 22
AUIOMATIC
TRANSMISSION
SERVICE
GROUP
24
ARrsG
375
\
395
'3 7 6
378
364
/
I
t
,
I
PRESSURE
CONTROL
SoLENOIO
395.---\-
371
_. - 372
., 373
381384
:'LT..O
381
395
385
386
367
379
381--- _
389-----
367
390
381
362
395
363
391__
F
3s7
-\-/
364
3s8C 3se 360 361
\-'l
A-
381
393
392
3gl --'-
3s3 354
340
340
353
354
355
356
357
358
359
360
361
352
363
361
365
366
367.A
367.8
368
369
370
371
31?
373
V A L V EM
, ANUAL
D C C U M U L A T OORI L
S E A L ,F O R W A R A
DC C U M U L A T O R
P I S T O NF, O R W A R A
ACCUMULATOR
P I N ,F O R W A R D
ACCUMULATOR
S P R I N GF, O R W A R D
ABUSE
V A I V E ,F O R W A R D
A B U S EV A L V E
S P R I N GF, O R W A R D
PIUG,SORE
P I N ,C O I L E DS P R I N G
V A L V EL, O W O V E R R U N
VALVE
S P R I N 6 L, O W O V E R R U N
ACCUMULATOR
C O V E RF, O R W A R D
A C C U M U L A T OCRO V E R
B O L TF, O R W A R D
S P R I N G1, . 2S H I F TV A L V E
V A L V E 1, . 2S H I F T
(A)
1 . 2S H I F TS O L E N O I D
2 . 3 S H I F TS O L E N O I (DB )
V A L V E2, . 3 S H I F T
V A L V E2, . 3 S H U T T L E
VALVE
S P R I N G1, . 2A C C U M U L A I O F
V A L V E1, . 2A C C U M U L A T O R
S L E E V E1, - 2A C C U M U L A T OVRA L V E
P L U G ,B O R E
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
F E E DL I M I T
V A L V EA, C T U A T O R
F E E DL I M I TV A L V E
S P R 1 N GA,C T U A T O R
P L U GB
, ORE
P R E S S U RC
E O N T R O LS O L E N O I O
P ,R E S S U RCEO N T R O S
LOLENOID
RETAINER
RETAINER
S ,O L E N O I D
V A L V EC
, O N V E R T ECRL U T C HS I G N A L
P L U 6 ,B O R E
S P R I N G4, ' 3 S E Q U E N CVEA L V E
V A L V E4, . 3 S E O U E N C E
V A L V E3, . 4 R E L A Y
V A L V E3, . 4 S H I F T
S P R I N G3, . 4 S H I F TV A L V E
EB U S E
V A L V ER
, E V E R SA
EB U S EV A L V E
S P R I N GR
, E V E R SA
V A L V E3, . 2 D O W N S H I F T
S P R I N G3, . 2 D O W N S H I FVTA L V E
V A L V E3, . 2 C O N T R O L
LALVE
S P R I N G3, . 2 C O N T R O V
S P R I N GB, O R EP L U G
3 . 2 C O N T R OS
LOLENOID
B ,O R EP L U G
RETAINER
Figure 23
GROUP
SERVICE
TRANSMISSION
AUTOMATIC
25
355 356
fi|RrsE
SPACER.
PI..A:TE,
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tu!-,
3
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IDENTIFICATIONCODE
ILL,
NO,
1
2
3
1
6
6
7
E
9
10
11
12
13
14
15
16
DESCII?TION
SUCTTON
ilNTAXt)
DECEEAST
LINE
C O N V E i T E TI I E O
RELEASE
APPLY(REGAP?LY)
TO COOLET
L U B EF R O MC O O L E R
A C T U A T OTRE E DL I M I T
F I L T E R EADC T U A T O R
FEED
TOROUE
SIGNAL
PR
D4-3.2
L O / R E VRES E
REVERSE
R E V E R SI E
N P U T( R E VC, L )
ILL.
NO.
DESCRIPTION
17
1I
19
20
21
22
2?
21
25
26
27
28
29
30
31
32
D4
FORWARC
D L U T C HF E E D
R E A EL U B E
ACCUMULATOR
S I G N A LA
2ND
z N DC T U T C H
C.CSTGNAL
3 - 4S I G N A L
3 F DA C C U M
3 - 4C L U T C H
4 T HS I G N A L
S E R V OF E E D
4TH
3 . 4A C C U M
D3
ILL.
NO.
OESCRIPTION
33
31
35
36
37
38
39
10
41
42
13
11
45
16
OVERRUN
OVERRUN
C L U T C HF E E O
OVERRUN
CLUTCH
D2
O R I F I C ED 2
3.2SIGNAL
LO
Lo/1sT
EXHAUST
O R I F I C EEDX H A U S T
VENT
S E A LD R A I N
VOto
L I N EP R E S S U RTEA P
Figure 24
AUTOMAIIC
TRANSMISSION
SERVICE
GROUP
26
AHrsE
VAI-VE
T()
BODY
SPACER.
PI-ATE
GASKET
4;.Aft?:,:d#
o oo* I d'Eo"[,l
nn
o
I
1 / oo
2
do
, Uoo
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r[JU
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ltta
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ploo,?D'
o oo
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n
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24
"ilI
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9,Q.ioo
,{o
;
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ILL.
NO.
1
2
3
1
5
O
7
8
9
1O
11
12
13
11
15
16
3f o'uo Jl
o
o
c5t-
il
ILL.
N O.
OESCRIPTION
S U C T I O N{ I N T A K E }
DECREASE
LINE
C O N V E R T EFRE E O
RELEASE
APPLY{REGAPPLY}
TO COOLER
L U S EF R O MC O O L E R
F E E OL I M I T
ACTUATOR
F I L T E R EA
DC T U A T O RF E E D
PR
Drt-3-2
LO/SEVERSE
REVERSE
I N P U TI R E V C
REV€RSE
. L.}
17
18
19
20
21
22
23
24
25
?6
27
28
29
30
31
32
DESCRIPTION
04
FORWARD
C L U T C HF E E D
R E A RL U B E
ACCUMULATOR
S I G N A LA
zND
z N OC T U T C H
C . C .S I G N A L
3 . 4S I G N A L
3 R DA C C U M
3 - 4C L U T C H
4 T HS I G N A L
S E R V OF E E O
4TH
3 - 4A C C U M
D3
/
\;0,,(\
-,
\
ILL.
NO.
33
34
35
36
37
38
39
r0
{1
12
43
14
a5
.6
D€SCRIPTION
OV E R R U N
FEED
OV E R R UCNLU TCH
OV E R R UCNLU TCH
02
D2
ORIFICED
3-2SIGNAL
LO
LOI1ST
EXHAUST
OR IFIC EEDX H A UST
VENT
SEALDRAIN
volD
TAP
LINEPRESSURE
Figure ?5
GROUP
SERVICE
AUIOMATICTRANSMISSION
27
fi|RrsG
SPACER
PI-,ATE
-r.
(
)
i^^
c
GASKET
o
T136
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q
|
rg: %',?%$l
ILL.
NO.
I
2
3
1
5
E
7
8
9
1O
11
12
13
14
I5
I6
DESCRIPTION
SUCTION
{INTAKE}
OECREASE
LI NE
CO NV E R T ER
F E ED
RE T E A S E
(REGAPPLY}
APPLY
TO COOLER
LUE EF RO MC O OL E R
ACTUATOR
FEEDLIMIT
FILTERED
ACTUATOR
FEED
T O R O USEI G N A L
PR
04. 3- 2
LO I RE V € R S E
REVERSE
R E V E R SI N
EP U T
{ R E VC. L . )
ILL.
NO,
OESCRIPTION
17
18
19
?O
21
22
23
24
25
26
27
28
29
30
31
32
04
FORWARD
C L U T C HF E E O
R E A RL U B E
ACCUMUTATOR
A
SIGNAL
zND
2 N DC L U T C H
C.CS
. IGNAL
3 . 4S I G N A L
3 R DA C C U M
3 . 4C T U T C H
4 T HS I G N A L
FEED
SERVO
4TH
3 . 4A C C U M
D3
ILL.
NO.
DESCRIPTION
33
34
35
36
37
38
39
40
41
12
43
44
45
16
OVERRUN
OV E R R UCNLU TCH
FEED
OVERRUN
CLUTCH
A2
OR IFIC EDD2
3-2S TGN A L
LO
LO/lST
EXHAUST
ORIFICED
EXHAUST
VENT
S€ALDRAIN
VO|D
LIN EP R E S S U RE
TAP
Figure 26
AUTOMATIC
TRANSMISSION
SERVICE
GROUP
28
T e c h n i c a lS e r v i c e I n f o r m a t i o n
ARrsE
PASSAGES
3 LINE
6 A P P L Y( R E GA P P L Y }
F E E DL I M I T
9 ACTUATOR
11 TOROUE
SIGNAL
12 PR
1 3 0 4 . 32
14 LO/REVERSE
15 REVERSE
1 6 R E V E R SIEN P U T{ R E VC. L , )
17 D1
18 FORWARD
C L U T C HF E E D
20 ACCUMULATOR
A
21 SIGNAT
22 2ND
2 3 2 N DC L U T C H
2 4 C C .S T C N A L
2 6 3 R OA C C U M
2 7 3 . 1C L U T C H
28 lTH SIGNAL
2 9 S E R V OF E E O
30 lTH
31 3.{ ACCUM
32 03
33 OVERRUN
FEED
34 OVERRUC
NLUTCH
3 5 O V E R R UC
NL U T C H
36 02
3 8 3 . 2S I G N A L
39 LO
10 Lo/1sT
41 EXHAUST
15 VO|D
rS W-f w
affiFtr
gtl
lJw-r-:1
rEffiG5-t
\ a--{rrt-/..-l_g}l
r__J
r_45
'
(_/
r\-
t
27
A
LINE
TO COOLER
REVERSE
C . C .S I G N A L
|
CASE PASSAGESAND CHECKBALLLOCATIONS
Figure
3
7
8
11
15
24
lF:
27
35
36
43
45
46
A
B
3 - 4C L U T C H
OVERRUC
NLUTCH
02
VENT
VO|D
L I N €P R E S S U RTEA P
c
D
11
40
B
2 . 4 S E R V OB O R E
S E R V OE X H A U S TH O L E
2ND 7 1TH BAND APPLYPASSAGE
3 R DA C C U M .P R E S S U RTEA PP A S S A G E
P L U G ,C A S ES E R V O
R E T A I N EA
RN O B A L LA S S E M E t Y3 R DA C C U M .
2-4 SERVOPASSAGES
CASE PUMPPASSAGES
Figure 28
Figure 29
CR
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A U T O M AT R
I CA N S M I S SSIEORNV ] G
29
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18
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c VALVEBOOYFACE
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E
EXHAUST
F
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't5
RETAINER
S ,E R V OC U S H I O NS P R I N G
1 6 S P R I N GS
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1 7 P I S T O N 2, N D A P P L Y
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2-4
16
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13
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I
19 RINGO
, I LS E A L{ 2 N OA P P L YP I S T O N. I N N E R )
2 0 H O U S I N GS, E R V OP I S T O N{ I N N E R }
21 SEALO
, .RING
2 2 S P R I N GS, E R V OA P P L YP I N
2 3 W A S H E RS, E R V OA P P L YP I N
2 4 R I N C ,N E T A I N E(RA P P L Y
PIN)
2 5 P I S T O N4, T HA P P L Y
2 6 R I N GO
, i LS E A t { 4 r H A P P L Y
.OUTER}
PISTON
27 SEALO
, " R I N G{ 2 . 4S E R V OC O V E R )
2 8 C O V € R2, . 4 S E R V O
29 RINGS
, E R V OC O V E RR E T A I N I N G
4 0 R E T A I N EA
RN O B A L LA S S E M E L Y3 R DA C C U M ,
SERVO
PASSAGES
Figure 30
TRANSMISSION
AUTOMATIC
SERVICE
GROUP
l0
ARrsE
'9re,
c3l
I r-:-:(at
,-..,\_1_J J / ,
( lr-r/l
1\--//
1
3
3
4
A
I
11
16
24
35
41
d3
44
45
S U C T I O N{ I N T A K E )
DECREASE
LINE
R ET E A S E
A P P L Y{ R E GA P P L Y }
TO COOLER
L U E EF R O MC O O L E R
REVERSE
I N P U T{ R E V C
. L.)
C . C .S I G N A L
OVERRUN
CLUTCH
€XHAUST
V €N I
S E A LD R A I N
VOID
t . ? _ rl l i
[f
PTIMP
COVER.
PASSAGES
Figure 31
2 DECREASE
3 LINE
4
5
7
I
1t
16
24
21
3s
41
43
41
45
RELEASE
TO COOLER
. L.}
REVERSE
I N P U T( R E VC
c.c. slcNAt
3 . , 1C L U T C H
OVERRUN
CLUTCH
EXHAUST
VENT
S E A LD R A I N
VOID
PI-'MP
PASSAGTES
BOI)Y
Figure 32
GROUP
SERVICE
TRANSMISSION
AUTOMATIC
3l
o
ARrsE
T e c h ni c a l S e r v i c eI n fo r m a t i o n
T R A N S M I S SDI O
I SNA S S E M B L Y
1. Thoroughly clean the exterior
of the
transmiss i.on case.
2. fnstall
holding fixture
J-8763-02
onto the transmission
case as shown
in Figure 33.
3. fnstall
holding f ixture i.nto the base
as shown in Figure 33.
4. Drain the transmission fluid
out the
extension housing by rotating
so the
be1l housing is facing up.
5. Rotate transmission so that bottom
pan is facing up (See Figure 34).
6. fnstall
servo cover compressor shown
in Figure 3l+ if necessary.
7, Remove servo cover snap ring and the
2-4 servo cover (See Figure 34).
8. If the servo cover seems to be hung
on the f'O" ring,
cut and remove the
rrorr
ring seal before removing cover.
9. Remove the 2-4 servo assembly (See
Figure 34).
10. As a diagnostic aid, the servo pin
length should be checked at this time
to determine if it is too short or
too long.
11. Install
band apply pin tool J-33037
with the apply pin (See Figure 35).
12, Install
servo cover retaining
ring
to secure tool (See Figure 35).
13. Apply 98 in.lb.
of torque, and if the
white line 'fA' appears in gage slot ilBf'
the pin length is correct (Figure 35).
14. Use pin selection chart in Figure 35
to determine correct pin length if new
pin is required.
15. fnstall
piston compressor J-22269-01
and remove retaining
ring as shown in
Figure 36.
/J 29714
12
28
2 0 H O U S I N GS, E R V OP I S T O N
29
(iNNER)
S P R I N GS,E R V O
R E T U R N 2 1 S E A L ,O . R I N G
r 3 P I N ,2 N OA P P L YP I S T O N 2 2 S P R I N G .
S € R V OA P P L YP I N
zND
1 4 R I N GR
, E T A I N E(R
23 WASHER,SERVOAPPLY
A P P L YP I S T O N }
PIN
1 5 R E T A I N E RS,E R V O
24 RING,RETAINER
{APPLY
CUSHION
SPRING
PIN}
'16
S P R I N GS, E R V OC U S H I O N2 5 PISTON,1TH APPLY
1 7 P I S T O N2, N DA P P L Y
2 8 C O V E R2. . 4 S E R V O
1 8 R I N GO
, I LS E A L( 2 N D
, E R V OC O V E R
29 RINGS
A P P L YP 1 S T O NO U T E R }
RETAINING
1 Q R I N GO
, I LS E A L( 2 N D
A P P L YP I S T O N. I N N E R }
t t
Figure
34
i6.
Remove cushion spring retainer,
cushion
spring from Znd apply piston.
L7. Use Figure 37 for parts identification
and disassembly procedures.
- J 8763"02
(Continued on Page 34)
Figure 33
AUTOMATIC
TRANSMISSION
SERVICE
GROUP
32
Z-RrsG
J 33037
A W H I T EL I N E
B G A G ES L O T
;;----.-)
--.-]-=23.---\
__@
P I NI S P R E S EA
T T F A C T O RA
YN D M U S TN O T B E
R E A D J U S TDE
\@
---6
22\_._r
2.4 S ER VOPIN S EL E C T ION
t - _ -
PIN LENGTH
65.82-66.12
6723-67,53
68 61-6894
2 .5 9 -2 .6 0
2 .6 5 .2 .6 6
2 . 1 4 -721
1 GR O OV E
2 G R O OV E S
N OG R OOV E
Figure 35
ILL.
NO.
DESCRIPTION
1 2 S P R I N GS, E R V OR E T U R N
1 3 P I N ,2 N DA P P L YP I S T O N
, E T A I N E (R2 N DA P P L YP I S T O N }
14 RINGS
15 RETAINER
S ,E N V OC U S H I O NS P R ] N G
1 6 S P R I N GS, E R V O
CUSHION
1 7 P I S T O N2, N D A P P L Y
18 RINGO
, I L S E A L{ 2 N DA P P L YP I S T O N. O U T E R }
19 RINGO
, I I S E A L{ 2 N DA P P L YP I S T O N. I N N E R }
2 0 H O U S I N GS, E R V OP I S T O N{ I N N E R }
21 SEALO
, .RING
2 2 S P R I N GS
, € R V OA P P L YP I N
, E F V OA P P L YP I N
2 3 W A S H E RS
PIN}
2 4 R I N G ,R E T A I N E(RA P P L Y
2 5 P I S T O N4, T HA P P L Y
, I L S E A L( 4 T HA P P L YP I S T O N" O U T E R )
26 RINGO
2 7 S E A L ,O . R I N G( 2 . 4S E R V OC O V E R }
2 8 C O V E R2, . 4 S E R V O
2 9 R I N G ,S E R V OC O V E RB E T A 1 N I N G
J 22269-01
1 7S E C O N D
A P P L YP I S T O N
Figure 36
Figure
37
CR
E OUP
A U T O M AT R
I CA N S M I S SSIEORNV I G
)3
Ij|RrsG
<
r35
J 38417
3 5 B O L I S P E E DS E N S O RR E T A I N I N G
3 6 S P E E DS E N S O RI,N T E R N A L
TRANSMISSION
Figure
Continued
38
from Page 32.
18. Remove speed sensor retaining
bolt if
so equipped. Four wheel drive speed
sensor is located in Transfer Case.
19. Rem ov e sp e e d s e n s o r a s s e rn b l y and the
!f0"
ring seal using J-384I7 tool as
shown i.n Figure 38.
20. Remove 4 extension housing bolts,
extension housing and ,ttott ring seal
2 L . Rem ov e ou tp u t s h a ft s l e e v e a n d the
trgtt ring,
if so equipped. Not al1
m odels use a n o u tp u t s h a ft s l e e ve
and seal.
22. Remove the bottom pan bolts,
oil paor
and t he b o tto m p a n g a s k e t a s s how n
in Figure 40.
23. Remove the oi1 filter
and filter
seal.
F ilt er
s e a l rn a y b e s tu c k i n p u mp bore.
ILL.
NO.
8
30
31
32
33
34
35
36
37
687
on next
C A S E ,T R A N S M I S S I O N
S E A L ,C A S EE X T E N S I O N
TO CASE
EXTENSION
C ,A S E
B O L TC
, A S EE X 1 E N S I O N
TO CASE
E U S H I N GC, A S EE X T E N S I O N
S E A LA S S E M B L YC A S EE X T E N S I O N
OIL
B O L TS
, P E E DS E N S O RR E T A I N T N G
S P E E DS E N S O RI,N T E R N A L
TRANSMISSION
SEAL,O.RING{ITSSTO CASEEXTENSION}
SHAFT,OUTPUT
Figure 39
76
x
7:\1
75
73
NO T E :
Open the bottom pan filter
by prying
t he m et al c ri rn p i n g a w a y fro m the top
(Black Section) and
of the filter
seperate. The filter
may contain some
evidence for root cause diagnosis,
such as clutch material,
bronze chips
indicating
bushing wear, or steel
particles.
(Continued
DESCRIPTION
h
.//
\
---/L
72
71
page).
8
71
72
73
75
76
SEALF
, ILT€R
FILTER
A S S E M B L YT,R A N S M I S S I O O
NIL
GASKEI TRANSMISSIOO
N I LP A N
P A N ,T R A N S M I S S I O O
NIL
S C R E WT, R A N S M I S S I O O
N I LP A N
Figure
40
AU I O M A I ITCR A N SI SMS I OSNE R V I G
CE
ROUP
34
T e c h n i c a fS e r v i c eI n f o r m a t i o n
lZ|RrsG
C o n t inued
f r om P a g e 3 4
connectors from
24, Disconnect electrical
3-2
motor ,
f
o
r
c
e
shif t solenoi-ds,
s
w
itch
p
r
e
s
s
u
r
e
s
o
l
e
n
o
i
d
,
downshift
assembly.
NO T E : Us e e x tre m e c a re w h e n re movi ng
these connectors so as not to break
them,
25, Remove the 3 wiring harness retaining
and gentlY remove the case
bolts,
connector from the case bore.
26, Remove the lock-up solenoid retaining
and remove the solenoid from
bolts,
t he punp.
27. Remove the wiring harness and lock-up
solenoid assenblY from the case.
28. Remove the pressure switch assembly
bo1ts, and the Pressure
retaining
switch assemblY.
2 9 . Rem ov e t he ma n u a l l e v e r d e te n t spri ng
retai-ning bolt and the detent spring'
3 0 . Rem ov e t he re m a i n i n g v a l v e b o d y bol ts
the valve body from the case
and lift
while m an u v e ri n g th e v a l v e b o d Y to
disconnect the manual link from the
manual valve.
31. Refer to Fi-gures 4l and 42,
(Continued
58
59
62
64
68
70
364
COVEB
BOLT,ACCUMULATOR
RO V E R
BOLT,A C C U M U L A T O C
BOLT,VALVEBODY
BOLT,M A N U A L D E T E N TS P R I N G
BOLT,HEX WASHERHEAD(SOLENOID}
SWITCHASSEMBLY
BOLT,PRESSURE
COVER
BOLT,FORWARDACCUMULATOR
Fi.gure 4L
on Page 36).
8
60
63
64
66
69
70
C A S E .T R A N S M I S S I O N
VALVEASSEMBLYCONTROLBODY
S P R I N GA S S E M B L YM, A N U A LD E T E N T
BOLT,MANUAL DETENTSPRING
A S S E M S L YW I R I N GH A R N E S SA N D
SOLENOID
SWITCHASSEMBLYTRANSMISSIONPRESSURE
SWITCHASSEMgLY
8OLT,PRESSURE
Figure 42
ROUP
CE
OR
NV I G
AUTOMAT
I IR
C A N S M I S SSIE
35
Ii|RrsE
T e c h n i c a lS e r v i c e I n fo r m a t i o n
Continued
---TI
I
rr
-riV
iii ll
I
I
89
63
88
89
340
from Page 35.
32, R emove 3 bol ts from spacer plat e suppor t
plate,
and remove support plate.
and
33. R emove the I' 2 accumul ator bolt s,
remove the accumul ator assemb ly.
34. R emove the 3-4 accumul ator spr ing and
3-4 accumulator piston from the case.
35. Refer to Figure 44.
in
l ocat ed
36. There are seven checkbal l s
the valve body, all of whi.ch are .250"
are
locations
in diameter, and their
shown in Figure 45.
37. There is only one checkball located in
the case, which is also .250" diameter,
is shown in Figure 46.
and its location
S P R I N GA S S E M B L YM, A N U A LD E T E N T
I E V E R I, N S I D EO E T E N T
L I N K ,M A N U A LV A L V E
V A L V EM
, ANUAL
Figure 43
(Continued on Page 38).
71
53
13 PIN.ACCUMULATOR
PISTON
11 PISTON,
3.' ACCUMUTATOR
16 SPRING,
3-4ACCUMUI.ATOR
.7 GASKET,
PLATETO CAS€
SPACER
.8 PIATE,VAIV€EODYSPACEF
52 GASKET,
PLATE
TO VALVESODY
SPACER
PLATESUPPORT
53 PLATE,
SPACER
51 S P RI NG1., 2A C C U M U L A T O R
1. 2A C C U M U L A T O R
5 6 P I S T O N,
A NDP INA SS EME L1Y,.2AC C U M U L A TOF
5 7 CO V E R
58 8OLT,ACCUMUIATOR
COVER
59 BOLT,ACCUMULATOR
COVER
77 BOLT,SPACER
PLATESUPPORT
Figure 44
GROUP
SERVICE
TRANSMISSION
AUTOMATIC
)6
7|RrsG
t
ez
,3
2
3
1
5
6
8
12
a;\
f il )oo,rl
9 1( r 1 )
w,/
I2
3 R OA C C U M U L A T O R
R E V E R SIE
NPUT
3 . I C L U T C HE X H A U S T
FEED
OVERRUC
NLUTCH
OVERRUN
C L U T C HC O N T R O L
1 . 2U P S H I F T
FORWARD
C L U T C HA C C U M ,
38
40
91
92
. LEED)
P L U G ,T R A N S M I S S I O C
N A S E( A C C U M B
R E T A I N EA
RN D B A L LA S S E M E L Y3 R DA C C U M .
N O . 1 OC H E C K E A L L
S C R E E NT,C C
Figure 46
Figure 45
GROUP
SERVICE
TRANSMISSION
AUIOMATIC
37
[!|RrsE
T e c hn i c a f S e r v i c el n fo r m a t i o n
D I A LI N D I C A T O R
2 7 8 m m{ 11 " }B O L T
L O C KN U T
J 25022
J 24773.A
Figure
47
Continued from page 36.
38. Rotate transmission ro an upright
(Pump Faeing Up) as shown in Figure
47.
39. As a diagnostic aid, trhnsmission end
play should be checked. before removing
the oi1 pump. If the end play is not
within specificationsr
)ou should
watch for possible worn or misassernbly
of parts during disassembly.
4 4 . fnstall
dial indicator
using adapter
as needed (Figure 48) and lifting
tool J-24773-A as shown in Figure 47.
4 I . Set dial indicator
to zero.
4 2 . Pull up on lifring
tool J-24773-A,
and observe reading.
43. End play should be .015" to .036".
NOTE: NEVERset end play any closer
than .015", because aluminum
pu rn p w i l l
e x p a n d o r ttG row "
and you could end up with a
negative end play.
4 4 . Record end play reading.
4 5 . R e m o v e r t O r ?r i n g s e a l f r o m t h e t u r b i n e
shaft if you have not already done so.
4 6 . fnstall
oil purnp remover and adapter
as shown in Fi_gure 49.
4 7 . Remove all oil pump retaining bolts
and trort rings.
48.
o j .1 p u m p a s s e m b l y u s i n g t h e
l" T ?y :
J'37789 remover (Figure 49).
(Continued
on next
A 2 9 8 m mT U R E I N ES H A F T
B 2 4 5 m mT U R B T NS
EH A F T
Figure
J 37789
IHE SOLENOID
A S M . A N O O I L F T L T EM
RU S T B E R E M O V E D
BEFORE
O I L P U M PR E M O V A L
Figure 49
page).
AUIOMATIC
TRANSMISSION
SERVICE
GROUP
l8
48
FZRrsE
2
8 C A S E ,T R A N S M I S S I O N
687 SHAFT,OUTPUT
Figure
51
49. R emove band anchor pi n from va lve body
side of case (See Figure 50).
50. Remove the input housing and reverse
input housing together by grasping the
turbine shaft and liftlng
(Figure 50).
51. Remove the 2-4 band assembly.
52. R emove the i nput sun gear from t he
input carrier.
53. Set the oil pump, input housirg,
and
reverse input housing aside for the
component disassembly.
54. Install
J-29837 on case as shown in
Figure 51, to protect output shaft
from falling
out during disassembly
w hen the next snap ri ng i s removed.
2 BOLT,PUMP TO CASE
3 O.RINGP
, U M PT O C A S EE O L T
1 P U M PA S S E M E L YO ' L
5 S E A L ,O I L { P U M PT O C A S E }
6 G A S K E TP, U M PC O V E NT O C A S E
8 C A S ET
, RANSMISSION
' l l P l N , B A N OA N C H O R
6 0 1 W A S H E RT, H R U S T( P U M PT O D R U M }
602 EAND ASSEMELY,
2.1
605 FIOUSING
A N D D B U M A S S E M E L YR, E V E R S IEN P U T
CLUTCH
6 2 1 H O U S I N GA N D S H A F TA S S E M B L YI N P U T
6 5 8 G E A R I, N P U TS U N
F i .g u re 5 0
GROUP
TRANSMISSION
SERVICE
AUIOMATIC
)9
f|RrsE
'
Y
---
661
662
670
6820
D
6828
673
682A
674
683
675
685
676
684
692
678
693
679
694
681
8
661
662
663
R E T ,O U T P U TS H A F TT O I N P U TC A R R I E R
C A R R I EA
R S S E M B L YI N P U T( C O M P L E T E )
B E A R I N GA S S E M B L YT H R U S T( I N P U TC A R R I E R
TO
REACTIONSHAFT}
695
697
Figure 52
Continued from Page 39.
55. Remove the snap ri.ng f rom the output
shaft that i.s retaining
the input
(See Figure 52).
carrier
56. Remove the output shaft at this time.
NOTE: The manufacturer assembles the
output shaft and reaction ring gear
with adhesive, or a staking process
for ease of assembly. If these parts
have not become seperated during use,
the output shaft will
come out later
along with the reaetion ring gear.
57. Remove the input carrier
and thrust
bearing as shown in Figure 52,
58. Remove input ring gear and the thrust
washer as shown in Figure 53.
59. Remove the reaction
sun shell and the
reaction sun gear (See Figure 53).
60. Remove thrust washer from the top of
Iow roller
clutch inner race as shown
in Figure 53.
61. Remove snap ring from case that is
retaining
the low ro11er clutch support
62, Remove the low roller
clutch assernbly
from the case.
8
664
666
669
670
673
674
675
676
678
679
680
CASET
, RANSMISSION
G E A R ,I N P U TI N T E R N A L
SHAFT,REACTION
CARRIER
NH A F T / S H E L L }
W A S H E RT, H R U S T( R E A C T I O S
NU N
S H E L LR
, E A C T I OS
NU N
G E A RR
. E A C T I OS
W A S H E RT, H B U S T{ R A C E I R E A C T IS
OHNE L L }
R A C E L, O A N D R E V E R SR
EO L L E R
CLUTCH
B I N G ,L O A N D R E V E R SSEU P P O RT
TO C A S ER E T A I N E R
ASSEMBLY
CLUTCH
L O A N D R E V E R SR
EO L L E R
S U P P O RA
T S M , ,L O A N D R E V E R S C
ELUTCH
S P R I N GT, R A N S M I S S ] O(NL OA N D R E V E R S C
ELUTCH
RETAINER}
SUPPORT
681 CARRIER
A S S E M E I YR E A C T I O N
6 8 2 A P L A T EL, O A N D R E V E R SC
E L U T C H{ W A V E D )
6 8 2 8 P L A T ES, P A C E R
L O A N D R E V E R SC
EL U T C H( S E t E C T I V E )
6 8 2 C P L A T EA S S E M E L Y
€ L U T C H( F I B € R }
6 8 2 0 P L A T EL, O A N D R E V E R SC
EL U T C H( S I E E L )
NA R R { E R /
6 8 3 B E A R I N GA S S E M B L YT,H R U S T( R E A C T I O C
SUPPORT}
6 8 4 G E A R I, N T E R N AR
L EACTION
6 8 5 S U P P O R TI N
, TERNAL
REACTION
GEAR
N E A RS U P P O RTTO C A S E
6 9 2 B R G, R E A C T I OG
693 RINGL
, O A N D R E V E R SCEL U T C HR E T A I N E R
694 SPRING
ASSEMBLL
YO A N D R E V E R SCEL U T C H
6 9 5 P I S T O NL.O A N D R E V E R SCEL U T C H
6 9 7 O E F T E C T OORI L
, ( H I G HO U T P U TM O D E L S
ONtY)
Fi.gure 53
SERVICE
GROUP
TRANSMISSION
AUTOMATIC
40
fi|HrsE
693
691
695
J 23327
8 C A S E .T R A N S M I S S I O N
6 9 3 R I N G .L O A N D R E V E R SC
EL U T C HR E T A I N E R
694 SPRING
A S S E M E L YL ,O A N D R E V E R SC
EL U T C H
6 9 5 P I S T O NL, O A N D R E V E R SC
ET U T C H
Fi.gure 54
63. Remove the anti-clunk
spring from the
case (See Figure 53).
64. Remove the Lowlreverse clutch plates
from the case (See Figure 53).
65. Remove the reaction carrier,
output
shaft (ff StiII Atrached), and the
reaction ring gear at one time by
lifti.ng up on shaft.
66, Remove reaction ring gear bearing from
case, or it may be stuck to the back
of reaction ring gear.
67. Remove bolts from parking bracket and
remove the parking lock bracket.
68. Install
clutch spring compressor tool
J-23327 as shown in Figure 54.
69. Compress the return spring and remove
the snap ring from case boss.
70, Remove the spring compressor and the
1ow/reverse return spring assernbly.
7L, Remove the low/reverse clutch piston
by applying regulated
air pressure
to the case apply passages marked frAf'
in Fi.gure 55.
A P P L YA I R P R E S S U R H
E E R ET O R E M O V EL O A N D
REVERSE
P I S T O NF R O MT H EC A S E
693 R I N G ,L O A N D R E V E R S C
E L U T C HR E T A I N E R
6 9 4 S P R I N GA S S E M B L YL O A N D R E V E R S C
ELUTCH
69s PISTON,LO AND REVERSE
CLUTCH
Figure
IT NECESSARY:
72, Remove the manual shaft inside nur.
73. Remove the manual shaft retainer
and the rnanual shaf t.
74, Remove the inside detent lever that
we call the rooster cornb, and the
parking lock actuator assembly.
75. Remove the manual shaft seal from
the case with smal1 screwdriver.
GROUP
SERVICE
TRANSMISSION
AUTOMATIC
4l
55
lZ|RrsE
CLEAN
I NGPROCEDURE
1. Completely disassemble all components
and clean all parts thoroughly with
solvent or the equivalent.
2, Dry al1 parts with compressed air,
DO NOT wipe clean with cloth.
IRANSM
I SSI ONRTASSEMBLY
AND
COMPONENI
REBU
I LD PROCTDURE
1. The assembly of some components will
require use of an assembly lube, It is
reconmended that ttTransJel t' or t he
equivalent
be used during assembly.
N OTE : D o not use any type of gre ase t o
retain any parts during assembly
of this unit.
Greases other than
the reconmended assernbl y lube will
change fluid
characteristics
and
cause undesi.rable shift
conditions
and/or filter
clogging.
2. Thoroughly inspect the case assembly
for any damage, ineluding
all case
passages and bores.
3. R epai r any damaged threaded h oles wit h
heli-coi1s.
4. fnsure that the orifice
cup plugs are
still
in the servo bore, and the 3-4
accumulator bore (See Figures 57 & 59).
5. Replace case bushing as necessary.
6. Inst.all
both cooler line fittings
and
t.orque to 28 f t. lb.
7 . INSPECT 3RD ACCTIMCAPSULE FOR LEAKAGE.
1. Install
the servo assembly into the
servo bore and install
snap ring.
2. Pour a sui.table solvent into the
accumul ator
bore from the valve body
side.
3. Watch for leakage inside the barrel
of the case.
4. If leakage is observed, replace the
3rd accumulator capsule assembly.
8 . IF REPLACEHENTIS NECESSARY.
1. Remove the old capsule assembly with
a number 4 screw extractor.
2. fnstall
the new capsule assembly using a 3/8" diarneter metal rod shown
in Figure 60.
3. fnstall
c a p s u l e s o t h a t t t W i n d o w s t ti n
the capsul e are as shor+ n i n Figur e
57, viewed thru the servo bore
4. Depth from case should be Approx.
1.653" (See Figure 60).
iE/
78
79
80
81
82
83
84
85
86
87
8E
89
90
P L U G ,S T E E LC U P
SHAFI PARKINGBRAKEPAWL
SPRING,PARKINGPAWLRETURN
P A W L ,P A R K I N GS R A K E
S E A L ,M A N U A LS H A F T
RETAINER
M,A N U A LS H A F T
S H A F TM
, ANUAL
ACTUATOR
A S S E M B L YP, A R K I N GL O C K
BRACKET,
PARKINGLOCK
BOLI PARKINCLOCKSRACKET
L E V E RI,N S I O ED E T E N T
LINK,MANUAL VALVE
N U T ,H E X H E A D
Figure 56
SERVICE
GROUP
TRANSMISSION
AUIOMATIC
42
fi|RrsE
A
C
D
40
3 R DA C C U M U L A T O E
RO R E
C A S EI N T E R I O R
2 . 1 S E R V OE O R E
RETAINER
& BALLASSEMBLY,3RDACCUM,
Figure 58
O R I V EU N T I LS C R I B E
MARK
I S F L U S HW I T H C A S €
A 2 . { S E R V OB O R E
B SERVO€XHAUSTHOLE
c
o
2ND 7 lTH BAND APPLYPASSAGE
3RD ACCUM.PRESSURE
TAP PASSAGE
I t PLUG,CASESERVO
40 R E T A I N E R
A N D B A L LA S S E M B I Y3, R DA C C U M
Figure
57
'
J
Figure
9.
10.
A 3.' ACCUMULATOR8OR€
3 8 P L U G ,T R A N S M I S S I O N
CASE
{ A C C U MS
, LEED}
11.
Figure 59
12,
13.
L4.
60
Install
new manual shaft seal into the
case with a 9/16" deep socket, and ensure that it is recessed as shown in
Figure 61.
Lubricate manual shaft with TransJel
and install
into the case bore.
Install
parking rod int,o the rooster
comb and install
on manual shaft on
the inside,
making sure that the flats
are engaged on the manual shaft.
Install
the inside manual shaft nur on
the manual shaft and torque to 23 ft.lb,
Install
the manual shaft retainer
onto
the manual shaft.
Refer to Figure 56 for assembly.
(Continued
on next
Page).
ISSIONSERVICE
TRANSM
GROUP
AUTOMATIC
43
lZ|RrsE
82 S E A L ,M A N U A L S H A F T
8 1 SHAFT,MANUAL
9 V E N TA S S E M B L YT R A N S M I S S I O N
Figure 62
Figure 61
693
694
695
Sgsves
ro&
REVERS€
CLUTCH
PISTON
CASTINc NU}IEER
8681725,
NEVERRE.USECASTINGNUMBER
PISTON
ALWAYSREPLACETHE LOW/REVERSE
8685550.
WITH CASTINGN1JMBER
I C A S E ,T R A N S M I S S I O N
E L U T C HR E T A I N E R
6 9 3 R I N G ,L O A N O R E V E R S C
CLUTCH
6 9 4 S P R l N GA S S E M B L YL,O A N O R E V E R S E
ELUTCH
695 P I S T O NL, O A N D R E V E R S C
E L U T C H'
696 S E A L ,T R A N S M ] S S I O {NL OA N D R E V E R S C
, NER)
O U T E RC
, E N T E RI N
8685549
OEMPART NTJMBER
C o n t inued
f r om
Figure 64
63
Figure
Pa g e 4 3 .
the Low/Reverse piston into the
18. Install
case, while indexing the tab on piston
with the notch in case.
the Low/Reverse piston return
19. Install
spring assemblY onto the Piston as
shown in Figure 64.
20. Set snap ring on top of the spring
reta iner .
2 t . Install spring compressor J-23327 as
shown in Figure 65, and comPress the
spring assembly Past the snaP ring
groove in case hub.
15. Inspect the casting number on the
If it has casting
Low/Reverse piston.
number 8681725, rePlace it with one
that has casting number 8685550.
under OEMpart number
It is available
(
S
"
"
Figure 63).
8685549
3 new seals on the Low/Rev
16. Install
with
piston assembly and lubricate
TransJel.
L7. Lubricate the case with TransJel.
S E R V IG
CR
E OUP
TRANSMISSION
AUTOMATIC
44
fi-RrsE
J 23327
C A S ET
, RANSMlSSION
R I N G ,L O A N O R E V E R S E
C L U T C HR E T A I N € R
S P R I N GA S S E M E L YL,O A N D R E V E R S C
E LUTCH
P I S T O NL, O A N D R E V E R S C
E LUTCH
Fi.gure 65
22. Install
the snap ring into the groove
in the case hub and ensure that it is
ful1y seated (See Figure 65).
23. Remove spring compressor J-23327 from
transmission case.
662 C A R R I E R
A S S E M B L YI N
, P U T{ C O M P L E T E )
690 S L E E V EO, U T P U TS H A F T
REACTION GEAR SET AND LOW/REVERSECLUTCH
1. fnspect the reaction carrier
and the
input carrier
for proper pinion end
play as shown in Figure 67.
2, Proper end play is .008" to .024".
3. Inspect the trapped bearings in the
carriers
by placing a bushing or
output shaft sleeve on the bearing
race (Oo not contact pinion gears),
and turn it with the palm of your
hand. Any imperfections will
be felt
through the sleeve (See Figure 66),
P I N I O N E N D P L A Y . O O 8' ' -
Figure
66
4 . Install
the reaction
ring gear onto the
output shaft with lock-tite
adhesive
and let it dry.
5 . fnstall
thrust bearing on back of the
ring gear support and retain with a
small amount of TransJel (Figure 68).
6 . fnstall
thrust
bearing into front side
of ri ng gear support as show n in
Figure 68.
.024"
Figure 67
GROUP
SERVICE
TRANSMISSION
AUTOMATIC
45
Ul-RrsE
8 C A S ET
, RANSMISSION
A S S E M B L YR E A C T I O N
681 CARRIER
CARRIER/
6 8 3 B E A R I N GA S S E M S L YT,H R U S TI R E A C T I O N
SUPPORT}
}NTEBNALBEACTION6EAB
585 SUPPORT,
692 8RG.,REACTIONGEARSUPPORTTO CASE
Figure
68
7. Install
inspected reaction carrier
in
ri.ng gear and output shaft assembly
by rotating
into position.
8. Install
the complete assembly into
the transmission
case and verify
that it turns freely.
9 . Now would b e a g o o d ti me to i n s p ect
the parking linkage by placing the
manual shaft in the park position
to
verify
that the parking pawl engages
the lugs on the ring gear.
10. See LowlReverse Clutch selection
beginning on next page.
A . T R A N S M I S S I O NC A S E
B . R E A C T I O NR I N G G E A R / C A S TB R G ,
c , R E A C T I O NR I N G G E A R S U P P O R T
D . REAC?IONRING GEAR
E . R E A C T I O N C A R R I E R / S U P P O R TB R G
F . L O W . R E V E R S EC L U ? C H P L A T E S
G . O I L D E F L E E T O R( U S E D O N H I G H
P E R F O R M A N CM
E O D E L S O N L Y)
H . R E A C T I O NC A R R I E R A S S E M B L Y
Figure
69
CR
E OUP
A U T O M AT R
46
[7|RrsE
679
INSTALLTHE APPROPRIAT€
SELECTIVE
S P A C E RP L A T ET O T H E F I N A L
A S S E M B L YA F T E R O I M C N S I O N" C I "
I S O E T A I N E D .I O E N T I F I C A T I O S
NI O EU P
882D
682tAl
682C
6 8 2r B )
WAVEO
679
6824
6828
682C
6820
S T A C KU P F O R
MEASURING
Figure
Lottl/REvERSECLUTCHSELECTIVE PLATE
1. To measure for the proper selective
FL U T C H
S U P P O RA
T S M , ,L O A N D R E V E R SC
P L A T EL, O A N D R E V E R S C
E L U T C H( W A V E O }
E L U T C H( S E L E C T I V E }
P L A T ES
, PACER
E L U T C H{ F I 8 E 8 }
P L A T EA S S E M B L YL O A N D R E V E R S C
P L A T EL, O A N D R E V E R S C
E L U T C H{ S T E E L }
70
5. Now install
spacer plate, stack the lo/reverse
assembly on a flat
work surface,
3S
shown in Figure 7A, in the following
order:
l. One waved plate (6828).
2. Five lined and four steel plates
starting
with a lined plate on
with
the waved, and alternating
stee1.
3. Lo/Reverse clutch support.
load to
2. Apply an evenly distributed
t he t op o f th e L o /R e v e rs e s u p p ort
assembly with your hand. Approx 5 lbs.
start
NOTE: Excessive pressure will
t o fl a tte n
th e w a v e p l a te and
will
resul-t in an inaecurate
m ea s u re m e n t.
3. Measure the height of the clutch pack
from the work surface to the top of
the Lo/Reverse clutch support. This
will
be dimension ttD", as shown in
Figure 74.
4. Use dimension ttDrr to select the proper
plate from the
thi.ckness selective
chart in Figure 72.,
the proper selective
plate
betw een the w ave pl ate and the f ir st
lined plate, with the i.denti.fication
side faci.ng up.
6. THE OVERALL HEIGHT FOR DIMENSION ''DII
WITH THE SELEC?IVE PLATE INCLUDED,
S H O U L DB E 1 . 2 0 0 " T 0 1 . 2 4 A " .
7, When this dimension has been achieved
the Low /R everse cl utch pack i s r eady
to install.
LO AND REVERSECLUTCH
2.42mm
{,095')
PLATE. WAVEO
PLATE- SELECTIVE
See Fig.
PLATE- COMP.FACED
PLATE- FLATSTEEL
1.75mm
{,069'}
Figure 71
CR
E OUP
A U T O M AT
TR
47
72
2,2 5m m
(.088')
E|RrsE
CHART
LO AND REVERSECLUTCHSPACERPLATESELECTION
PLATE
USETHISSELECTIVE
"0" IS
IFGAGEDIMENSION
PI.ATETHICKNESS
IDENTIFICATION
FROM
TO
29.559mm
{1.161',}
28.844mm
{ 1. 13 6 " )
NONE
1.684mm
(.066',1
1.829mm
1.a72'l
30.087mm
(1 , 1 8 5 ' )
29,347mm
{1,155'}
0
1.314mm
(.052')
1 .1 6 8 m m
(.046'!
29.057mm
{ 1 . 14 4 ' }
28.317mm
{ 1. 11 5 " }
1
2.198mm
{.087'}
2.3tftlmm
{.092'}
Figure 7Z
INSTALL LOW/REVERSECLUTCH PLATES
the Lo/Reverse clutch waved
1. Install
against
plate into the case first
the piston (See Figure 74).
plate
the correct selective
2. Install
p
l
a
t
e
.
w
a
v
e
d
on top of the
a lined plate while engaging
3. Install
the teeth wi-th the lugs on reaction
with steel
carrier,
and alternate
five
you have installed
plate, until
friction
and four steel plates. You
plate
should wind up with a friction
going in last.
teeth of the steel
4. Index the external
plates in the case as shown in Figure
73.
692
6828
682A
883
684
, RANSMISSION
8 CASET
682 P L A T EA S S E M B L Y ,
EL U T C H
L O A N O R E V E R SC
C A S ET
. BANSM'SS'ON
C A R R I E FA S S E M E L YR, E A C T I O N
CLUTCH
P L A T EA S S E M S L YL, O A N D R E V € R S E
CLUTCHIWAVED)
PLATE,LO ANO REVERSE
€ LUTCH
P L A T ES
, PACER
(SELECTIVEI
CARRIER/
6 8 3 E E A R I N GA S S E M B L YT H R U S T{ R E A C T I O N
SUPPORT}
L EACTION
6 8 4 G E A R I, N T E R N A R
N EAR
L EACTIOG
6 T J 5 S U P P O R TI N
, T E R N AR
N E A RS U P P O R T O C A S E
, E A C T I OG
6 9 2 B R G .R
6 9 7 D E F L E C T OO
R I, L ( H I G HO U T P U T
M O D E L SO N L Y )
8
681
682
6824
6828
682
,4
I
t ' )
F i . g u r e 74
Figure 73
GROUP
SERVICE
TRANSMISSION
AUTOMATIC
48
f,;-RrsE
877
A T I G NW I D EN O T C H
W I T HW I O EC A S EL U G ,
Figure 76
678
oeo;f._
679
877
A
8
675
677
UP
LOCKEO
F R E EW H E E L S
CLUTCH
EO L L E R
R A C E t, O A N D R E V E R SR
(ROLLER
R I N G .L O A N D R E V E R SFEE T A I N E R
ASSEMELYICAM}
ROLLER
6 7 8 C L U T C HA S S E M B L YL O A N D R E V E R S E
E LUTCH
A S M , ,L O A N D R E V E R S C
679 SUPPORT
EL U T C H
6 8 0 S P R I N GT, R A N S M I S S I O{NL OA N D R E V E R SC
S U P P O RR
T ETAINER}
Figure
8 C A S ET
, RANSMISSION
EOLLER
6 7 8 C L U T C HA S S E M B L YL O A N D R E V E R S R
ELUTCH
A S M , ,L O A N D R E V E R S C
679 SUPPORT
L OA N D R E V E R SC
EL U T C H
6 8 0 S P R I N GT, R A N S M I S S I O(N
RETAINER)
SUPPORT
Figure
77
75
IoW/RNVERSE SUPPORTASSEMBLY
clutch Asm' for
1. Inspect the low roller
any wear andlor damage.
clutch assembly in
the roller
2, Install
the carn and suPPort assemblY'
the snaP rings if so equipped'
3. Install
Most of these units should have a
clutch that does
plastic
caged roller
as theY snap
r
i
n
g
s
not require snaP
a
s
s
e
m
b
ly with tabs
into the support
c
a
g
e
on the Plastic
clutch inner race
the roller
4. Install
c
l
o
c
k
w
i
s
e with a little
by rotating
downward Pressure.
5, P us h dow n fo r fu l 1 e n g a g e m e n t onto
carrier'
the tangs on the reaction
6.
7,
8.
9.
10.
11,
Check for proper operation by rotating
the inner race as shown in Figure 75'
The i nner race shoul d l ock when t ur n
and shoul d f r eewheel
countercl ockw i se
when turned clockwise (See Figure 75)'
spri-ng into
the anti-clunk
Install
F
i
g
ure 77, and
the case as shown in
ret.ain with TransJel.
the compl ete support assem bly
fnstal l
into the case as shown in Figure 76,
hanr ner '
and tap i nto pl ace w i th l i ght
o
f the
t
o
p
o
n
r
i
n
g
s
n
a
p
t
h
e
Install
g
r
o
o
ve'
c
a
s
e
t
h
e
i
n
t
o
a
n
d
support,
t he
ar
ound
ri
ng
snap
the
Ori
ent
N OTE :
sPring as shown in
anti-clunk
Figure 77Push inner race down and rotate until
carrier'
engaged on lugs on reaction
GROUP
SERVICE
IRANSMISSION
AUTOMATIC
49
fi|RrsE
11
j
I . INPUT RING GEAR
2. INPUT CARRIER
3. INPUT CTRRIER SNAP RING
4. 2-4 BAND ASSEMBLY
5. INPUT SUN GEAR
6. INPUT CTRRIER THRUST WASHER
7. INPUT EARRIER BEARING
LZ
13
8.
9.
10.
1I .
L2.
13.
14.
Figure
SUN GEAR SHET,T,/R
ING GEAR WASHER
SUN GEAR SHELL
REAETION SUN GEAR SNAP RING
REAC?ION SUN GEAR
SUN GEAR/INNER RACE WASHER
LOW ROLLER CLUTCH INNER RACE
T R A N S M I S S I O NC A S E
78
SERVICE
GROUP
TRANSMISSION
AUTOMATIC
50
ARrsE
I
B.
c.
I N P U T C A R R IE R A S S E M B L Y
I N P U T C A R R IE R / R I N G G E A R S U P P O R T B E A R I N G
INPUTRINGGEARANDSUPPoRTASSEMBLY
Figure 79
EACTION SUN GEAR AND SHELL
inner race
the low roller
1. Install
wa s h e r i n to th e i n n e r race
t hr us t
and retain with TransJel.
2. Inside tangs of the thrust washer
should engage in four slots of the
inner race (See Figure 78)'
the reaction sun gear with
3. Install
the snaP ring on gear, bY rotating
into Posi-tion.
the reaction sun Bear shell
4. Install
onto the sPlines of reaction sun
gear (See Figure 73).
sun gear shell thrust wash5. fnstall
err with four outside tangs, engaged
into slot.s of sun shell and retain
with TransJel.
input ring gear and support
fnstall
to insure ring gear suby turnlng
pport sPlines are engaged into the
react i.on carr ier .
the thrust bearing into the
7. Install
input ring gear suPPort with outer
race toward the suPPort as shown
in Figure 79.
into the
8. fnstalL the input carrier
into
r
o
t
a
t
i
n
g
g
e
a
r
b
Y
input ring
p o s i t i . o n.
9.
10.
I l.
I2.
13.
I4.
6.
If output shaft has not yet been installand inspeed sensor rotor,
ed, install
t
r
a
n
s
mission
i
n
t
o
stal1 the output shaft
w
ith the
s
p
l
i
n
e
s
by turning to index the
mati.ng Parts.
tool if
Use the output shaft retaining
necessary.
of the speed
Removal and installation
Figure 80 '
i
n
s
h
o
w
n
i
s
sensor rotor
snap ring on
c
a
r
r
i
e
r
the input
Install
J
2
9837 tool if'
u
s
i
n
g
s
h
a
f
t
,
the output
necessary.
remove
After snap ring is installed,
p
r
e
v
i
o
usly
i
f
t
o
o
l
s
h
a
f
t
o
u
t
p
u
t
the
used.
the input sun gear into the
Install
into position'
by rotating
c
a
r
rier
input
P
GROU
SERVICE
TRANSMISSION
AUTOMATIC
5l
ARrsE
INSTALLATION
REMOVAT
PRESS
36352.6
36352.4
699
687
687 SHAFT,OUTPUT
TRANSMISSIOS
N P E E DS E N S O R
6 9 9 R O T O R I, N T E R N A L
8 CASET
, RANSMISSION
687 SHAFT,OUTPUT
Figure
Figure 80
81
INPUT HOUSING DISASSEMBLY
1. Use Figure 83 to disassemble t.he input
housing.
2. A spring compressor or foot press will
be required during disassemblY.
3. Remove and discard all lip seals, all
t'Ott ring, and the
solid teflon seals,
housing to outPut shaft seal.
in solvent.
4. Clean all parts thoroughly
I
858
661
662
G E A R ,I N P U TS U N
RET.,OUTPUTSHAFTTO 'NPUT CARRIER
A S S E M B L YI N P U T( C O M P L E T E }
CARRIER
Figure 82
GROUP
SERVICE
TRANSMISSION
AUTOMATIC
52
7|RrsG
698
L
6i t ooo;2, 672 624 6?3
|
632
E34
836
635
648
#
600
617
618
619
624
621
622
623
624
625
626
627
628
629
630
631
632
633
634
635
636
637
638
639
64L
S P R I N GA S M , 3 . 4 C L U T C HB O O S T
BALL CAPSULE,TURBINESHAFT
I I O I IR I N G , T U R B I N E
SHAFT
SOLID OIL SEAL, TURBINESHAFT
BALL CAPSULE,INPUT HOUSING
HOUSINGAND SHAFTASM, INPUT
SEAL, f'oil RrNG, rNpUT T0 FWDHSG
P I S T O N ,3 . 4 C L U T C H
LIP SEAL, 3.4 CLUTCH
RING, 3-4 CLUTCHAPPLY
RETURN
S P R I N G ,3 - 4 C L U T C H
BALL CAPSULE,FWDCLUTCHHSG
HOUSTNG,FORWARD
CLUTCH
LIP SEALS, FORWARD
CLUTCH
PISTON, FORWARD
CLUTCH
LIP SEALS, OVERRUN
CLUTCH
PISTON, OVERRUN
CLUTCH
BALL CAPSULE,OVERRUN
CLUTCH
RETURNSPRINGASM, OVERRUN
CLUT
SNAPRING, OVERRUN
CLUTCHRET.
SEAL, INPUT HOUSINGTO OUTPUTSHFT.
BEARINGASM, INPUT SUN GEAR
SNAPRING, OVERRUN
CLUTCHHUB RET.
HUB, OVERRUN
CLUTCH
RETAINERAND INNER RACE, SPRAG
INPIJT
CI-T'TCI.I
642 FORWARD
SPRAGASSEMBLY
643 END BEARINGS,SPRAGASSEMBLY
644 RACE OUTER, FORTJARD
SPRAG
645A PLATE, OVERRUN
CLUTCHSTEEL
6458 PLATE, OVERRUN
CLUTCHFRICTION
646 PLATE, FORWARD
CLU?CHAPPLY
648 PLATE, FORWARD
CLUTCHWAVED
649A PLATE, FORWARD
CLUTCHSTEEL
6498 PLATE, FORWARD
CLUTCHFRICTION
650 rLATE, FoRwARDcLUTcH BAcKrNc (sel. )
651 SNAPRING, FORWARD
CLUTCHBACKING
652 PLATE, 3-4 CLUTCHRING RETAINER
653 PLATE
A P P L Y( s r r p p n n ) .
, 3-4 CLUTCH
6 5 4 A P L A T E , 3 - 4 C L U T C HF R I C T I O N
6548 PLATE, 3-4 CLUTCHSTEEL (THIN)
654C PLATE, 3-4 CLUTCHSTEEL (THTCK)
655 PLATE, 3.4 CLUTCHBACKING(SEL. )
656 SNAPRING, 3-4 CLUTCHBACKINGPTATE
698 ORI}'ICED CUP PLUG, 3-4 CLUTCH
F{OT'S
TNG
ASSEMBI-Y
Figure 83
GROUP
SERVICE
AUIOMAIICTRANSMISSION
57
lZ|RrsE
INPUT CLUTCH HOUSING ASSEMBLY
1. Inspect the following:
Jr fnput housing for porosit.y
:k Turbine shaft assembly for
TCC
1.
2.
3.
A L U B EP A S S A G E
6 1 5 B E A R I N GA S S E M E L YS T A T O RS H A F T/ S E L E C T I V E
WASHER
6 1 6 W A S H E RT, H R U S T( S E L E C T I V E )
620 RETAINER
A N D C H E C K B A LA
LS S E M E L Y
6 3 6 S E A L ,I N P U TH O U S I N GT O O U T P U TS H A F T
687 SHAFT,OUTPUT
6 9 8 P L U G ,O R I F I C EC
DU P
Figure
4.
5.
6.
84
INSTALL
w ear and/or darnage.
)' 3 P resence of the three bal l s
in t he
back side of turbine shaft.
The
open hole is the lube oi1 passage
which feeds the output shaft.
See
p a s s a g e r fA r t i n F i . g u r e 8 4 .
2 ' (P r e s e n c e o f o r i f i c e d
cup plug in the
top of the input housing, Figure 84.
;' c Turbi ne shaft oi 1 ri ng grooves f or
damage.
;k Ball capsule assembly in the front
of turbine
shaft.
The ball must move
freely
in the capsule.
;k Air check all oil feed passages.
BALL CAPSULE REPLACEMENTPROCEDURE
Straighten
the tangs of the retai.ner
and remove the bal l .
R emove the capsul e usi ng a l l t+ scr ew
extractor
as shown i.n Figure 85.
New TCC ball capsule assembly:
t's Part number for 245mrn converter
is 8647037.
> k P art number for 298mm convert er
is 8639284.
fnstall
new ball capsuJ-e assembly
punch, and seat
using a 3/8" drift
the retaj.ner 1/8t' belor.r top surface
of the turbine shaftr ES shown in
Figure 85.
Be certain
that the ball is loose
in the capsule after installation.
NOTE: The ball can be left
out of
the capsul e on heavy duty
applications
only, for firmer
TCC app1y. Always reinstall
the capsule.
INPUT HOUSING CAPSULE REPTACEMENT
1. If replacement of the ball capsule
in the input housing is necessary,
use Figure 86 for replacement procedures.
A f 4 E A S YO F F
B T U R B I N ES H A F T
C 9 . 5 m m ( 3 / 8 . )M E T A LR O D
RN D B A L LA S M . C H E C KV A L V E
6 1 7 R E T A I N EA
Figure
or damage.
spline
85
GROUP
SERVICE
TRANSMISSION
AUTOMATIC
54
li|RrsG
INPUT CLUTCH HOUSING ASSEMBLY
- (Al
5.71Smm
1. Place the input housing assembly on
the bench, with the turbine
shaft
through a hole in the bench.
2. Inspect the 3-4 clutch piston for
cracks or damage.
3. Install
the inner and outer 1ip seals
on the 3-4 clutch piston,
lubricate
with TransJel. Lip seals must face
the direction
shown in Figure 87,
4. fnstall
the 3-4 clutch apply ring on
top of the 3-4 clutch piston,
shown
in Figure 88.
5. Install
nevr rrof' ring into input housing groove as shown in Figure 88.
6. Install
the 3-4 clutch return spring
assembly on top of the apply ring.
(See Figure 88).
7. fnstall
the forr.rard clutch housing
into the inpuL housing as shown in
Figure 88.
8. fnspect the forward clutch piston for
cracks andlor damage.
9. Install
new inner and outer lip seals
on the forvard clutch piston.
The
lips on the seals must face direction
shown in Figure 88.
10, Install
the forr.rard clutch piston in
forward clutch housirg, using tool
J-29883r BS shown in Figure 88.
NOTE: The forward clutch apply
must be indexed with the
clutch apply ring legs.
n t4"l
DIAMETER
ROOSTOCK
698
421
'z;
'/
REMOVAL
620
P R E S ST O
SHOULDER
INSTALLATION
legs
3-4
A
620
621
698
11. Firmly seat the assembly.
L2, Inspect the overrun clutch piston for
cracks and/or damage.
13. Install
the inner and outer tip seals
on the overrun clutch piston,
and
lubricate
with TransJel. Lip seals
must face direction
shown in Figure
89.
14. Install
the overrun clutch piston
over tool J-79882, with hub facing
up as shown in Figure 89.
15. fnstall
the overrun clutch return
spring assembly onto the overrun clutch
piston,
locating the springs on piston
tabs.
16. fnstall
spring compressor too1, shown
in Figure 90, compress spring assembly
and install
snap ring ensuring that
snap ring is seated j.n groove.
(Continued
on next
ROOSTOCVDRIFT,
5.715mm{1/'t'} OlA.
RETAINER
AND CHECKBALL
ASSEMELY
H O U S I N GA N D S H A F TA S S E M B L YI N
, PUT
P L U G ,O R I F I C EC
DU P
Figure 86
, PUT
6 2 1 H O U S I N GA N D S H A F TA S S E M B L YI N
D N D 4 T HC L U T C H
6 2 3 P I S T O N . 3 RA
6 2 4 S E A L ,3 R DA N D 4 T HC L .{ I N N E RA N D O U T E R )
Page).
Figure 87
GROUP
SSIONSERVICE
TRANSMI
AUTOMATIC
55
fl-RrsG
1 . 3 - 4 C L U T C HR E T U R NS P R I N G A S M
2 . F O R W A R DC L U T C H P I S T O N
3 , 3 - 4 C L U T C HA P P L Y R I N G
4 , INPUT HOUSING IIOII RING
O V E R R U NC L U T C H P I S T O N
O V E R R U NE L U T E H P I S T O N S E A L S
INPUT HOUSING
F O R W A R DC L U T C H P I S T O N
3.4 CLUTCH APPLY RING
F O R W A R DC L U T C H H O U S I N G
3-4 CLUTCH RETURN SPRING ASM
3-4 CLUTCH PISTON
5 . FORWARD
ELUTCH INNER SEAL
6 . I N P U T H O U SI N G
1
F O R W A R DC L U T C H O U T E R S E A L
8 . F O R W A R DC L U T C H H O U S I N G
9 . 3 - 4 C L U T C HP I S T O N
Figure
88
Figure
89
L7. Remove the spring compressor tool
shown in Figure 90.
18. Place the input housing assembly on
the bench, with the turbine
shaft
through a hol e i n the bench, shown
in Figure 91.
INPUT HOUSING ASSEMBLEOVERRUNCLUTCH
1. The overrun clutch assembly is the
first
of the clutch packs that go
into the input housi.g,
and they
are the smallest of the clutch packs.
?, Install
a overrun clutch steel plate
first
as shown in Figure 92,
3. Make sure the the teeth on the plate
are between the legs on the piston.
(See Figure 93).
4. fnstall
the rest of the overrun clutch
plates (Friction,
Steel, Friction)r
ts
shown in Figure 92,
5. This clutch pack requires two steel
plates and two friction
plates on all
models as shown in chart (Figure 93).
DO NOT INSTALL ANY MORE THAN THIS !
H O U S I N GA N D S H A F T
A S S E M E L YI ,N P U T
Figure 90
GE
ROUP
SERVIC
TRANSMISSION
AUTOMATIC
56
E|RrsE
o
ffit
Figure 92
Figure
91
OVERRUN
' A L I G NW I D EN O T C H E S
T O C A S EL U G S
OVERRUN
CLUTCH
FLATSTEEL
MOOET
ALL
MOOELS
NO.
THICK.
NESS
2
2 2 4 8 m m- 2 . 4 0 0 m m
( . 0 8 9 '- . 0 9 4 ' , )
Figure
SERVICE
GROUP
TRANSMISSION
AUTOMATIC
57
COMP,FACED
93
N O.
I
THICK.
NESS
2.03mm
( . 0 97 ' )
7-RrsG
\
T e c h n i c a fS e r v i c e I n f o r r n a t i o n
63ZJ
Figure
Continued from page 56.
94
6 . fnstall
the input housing lube oi1 seal
into the input housing r Bs shown in
Figure 94.
7 . fnstall
the thrust bearing assembly in
the input housing as shown in Figure
94,
8 . Refer to Figure 95 for direction
of the
thrust
bearirg,
and use a small amount
of TransJel to retain in position.
FORWARDCLUTCH SPRAG ASSEMBLY
l. Disassemble the forward clutch
sprag
assembly and inspect the foliowing:
r ' r F or war d s p ra g
i o , w e a r o r d a mage,
and/or broken ribbon tabs.
:t Overrun clutch
hub for spline
.: t d a m a g e , o r p l u g g e d l u b e i r o l e s .
f nner a n d o u te r s p ra g ra c e s for
wear or darnage, surface finish
for wear or damage, and splines
f or r { r e a r o r d a ma g e .
2. Install
the forward sprag assembly into
the outer race from tie iia.
opposite
the recess, 3s shown in Figure b7.
3. The notches in the sprag assembly
cage
must face upward as
Figure 96
"fro""
and Figure 97.
4. fnstall
the inner race into the sprag
assembly. fnsert the race by pushing
in and turning
to the left
as- shown
in Figure 98.
5. fnstall
the remaining L/ear plate.
6. Install
the overrun
irub, and
t h e o v e r r u n h u b s n a p " trui nt "gh.
A . INPUT HOUSINGASSEMBLY
B . BEARINGASSEMBLY
Figure 95
7. Test the forward sprsg assembly for
proper operation as shown in Figure
99.
8. Install
forward sprag assembly into
the input housing by turning,
and
indexing the overrun clutch hub into
the overrun clutch friction
plates,
as shorvn in Figure 100.
AUTOMATIC
TRANSMISSION
SERVICE
GROUP
58
AsrsE
,K\\
/ \
V;
837 638
T H EN O T C H E S
A B O V EE A C H
S P R A GM U S TP O I N TU P A S
S H O W NW H E NA S S E M B L E O
I N T OT H EO U T E RR A C E
637 BEARING
A S S E M B L YI N P U TS U N G E A R
6 3 8 S N A PR I N G O
, VERRUN
C L .H U 8 R E T A I N I N G
6 3 9 H U B ,O V E R R U N
CLUTCH
RN D R A C EA S S € M 8 I Y S P R A G
642 FORWARD
S P R A GA S S E M B L Y
RI N G S S
. P R A GA S S E M B L Y
6 4 3 R E T A I N ER
, ORWARD
6 4 4 R A C EF
C L U T C H( O U T E R }
A.
B.
C.
f).
ii.
Figure 96
A
I .
2.
3.
4.
R E C E S S E DE D G E
F O R W A R DS P R A G O U T E R R A C E
F O R W A R DS P R A G A S S E M B L Y
N O T C I I N S P OI N T U P W A R DA S S H O W N
LIPPED EDCE
Figure
97
P U S HI N A N D T U R N C O U N T E R C L O C K W I S E
TO INSTALL
F O R W A R DS P R A G I N N E R R A C E
F O R W A R DS P R A G A S S E M B L Y
INNER RACE RETATNER
Figure 98
]\,1UST
T H EO V E R R U N
C L U T C HH U BM U S TT U R N
C L O C K W I SB
EU
, TN O TC O U N T E B C L O C K W I S E
1.
2.
O V E R R U NC L U T C H H U B
Figure
99
Figure 100
GROUP
SERVICE
TRANSMISSION
AUTOMATIC
59
[5|RrsE
Figure
101
Figure
IO2
FORWARDCLUTCHINFORMATION
CHART
PLATE
TYP€
THICXNESS
OUANTITYREOUIRED
FORWARD
C L U T C HP A C K
ALLMODELS
APPLYPLATE
1.30mm
( . 16 9 ' )
1
WAVED
STEEL
PLAT€
CLUTCH
1.79mm
( 070'l
1
FLAT
STEEL
CLUTCH
PLAIE
2.29mm
( 090')
5
c0MPostTt0N
FACEO
CLUTCH
PLATES
1.78mm
{0,70'}
5
BACKINGPLATE
SELECTIVE
1
Figure
A L I G NW I O EN O T C H E S
T O C A S EL U G S
Figure 104
INPUT HOUSING ASSEMBLEFORWARDCLUTCH PACK
1. Install
the forward clutch APPLY plate
as show n i n Fi gure 101. l f i g;Tfr'"
t eet h
on the apply plate so that the wider
tabs are on top of the forrlard clutch
piston 1egs.
2. Note also that the apply plate is the
thicker of the plates (.169,') as shown
in Figure i03.
3. Install
the forward clutch wave plate
on top of the apply plate with teeth
aligned to the apply plate (fig.
102).
4. Install
a forward clutch flat steel
plate on top of the wave plate and
align as shown in Figure 104.
103
GROUP
SERVICE
TRANSMISSION
AUTOMATIC
60
ARrsE
Figure 106
Figure
FORWARDCLUTCH
EACKINGPLATESELECTION
105
ALL MODELS
5. Continue installing
the forward clutch
plates alternating
with friction
and
steel until
you have installed
five
frictions
and five flat steel plates.
6. fnstall
the forward clutch backing
plate as shown in Figure 105.
7. Install
the forward clutch backing
plate snap ring as shown in Figure
106.
8. Check forward clutch pack clearance
with a feeler gage as shown in Figure LA7.
9. Forward clutch clearance should be
minimum .030tt and maximum.063".
10. Change the forward clutch backing
plate as necessary to achieve the
reconmended clutch clearance using
the chart in Figure 107.
Continued
on next
pLArE
. l.u#f,, irttJTl
BAcKTNG
TRAVEL
IDENTIFICATlON
6 . 9 7 m m- 7 , A 7 m m
1.274'. ,278"1
6.38mm.6,48mm
( . 2 5 0 ' ,. . 2 6 5 " 1
5 . 7 9 m m- 5 . 8 9 m m
1.227'- .232',"
5.2omm- 6.3omm
(.205' ,- .208' ,t
4 . 6 1 m m- 4 , 7 1 m m
( , 1 8 0 "- 1 8 5 " )
650
Page.
621 H O U S I N GA N O S H A F TA S S E M B T YI N P U T
650 P L A T EF, O R W A R DC L U T C HE A C K I N G( S E L . }
6 5 1 R I N G ,F O R W A R DC L U T C HB A C K I N GP L A T ER E T A I N E R
Figure L07
S IEORNV IG
CR
EOUP
A U I O M A TTIRCA N S M I S S
6l
fi|Rrs6
Figure
Figure
108
109
INPUT HOUSING ASSEMBLE 3-4 CLUTCH PACK
1. fnstall
the 3-4 clutch retainer ring,
as shown in Figure l0g. Be sure that
each tab on the retainer
is snapped
over the outside of the legs of the
apply ring. This retainer
ring is
used to keep the legs of the ippfy
ring from spreading under 1oad.
2. fnstall
the 3-4 "Stepped" apply
plate with the stepped side lacing up
as shown in Figures 109 and 111.
3. THERE ARE 5 AND 6 PLATE 3.4 CLUTCH
A S S E M B L T E S ,A S S H O W NI N F I G U R E 1 1 1 .
TWO STEEL PLATES ARE STACKED TOGETHER
ON SOME MODELS, TN TWO PLACES, TO
PROVIDE THE SAME STACK-UP AS A SIX
P L A T E C L U T C HP A C K ( S E T F I G U R E 1 1 1 ) .
4. fnstall
the 3-4 clutch plates, both
lined and steel, using Figure 111
as a guide, depending on model.
-Q-/^
N0TE; There is now available
under OEM
part number 8690923r i D updat ed
3-4 clutch service package that
includes the following:
1. New apply ring with shorter legs
2. New apply p1ate.
3. New (fUfCfnn) steel plates.
4, New selective backing plates.
5. Instruction
sheet.
ATSG RECOMMENDS
THAT YOU REMOVEAND
DISCARDTHE 3-4 LOADRELEASESPRING
ASSEMBLIES
SHOWN
ABOVE,ALL MODELS,
FOR A MUCHIMPROVED
2-3 bgrrrl
Figure 110
(Continued
on page 64)
AUTOMATIC
TRANSMISSION
SERVICE
GROUP
62
ARrsG
PI-ATE
3-4
CI-I.J:TCI{
PACK
SELECTIVE
BACKINGPLATE
HOUSING
BACKINGPLATE SNAPRING
STEPPED
APPLY PLATE
TW0 DOUBLED
SETS
OF STEEL PLATES
PI-ATE
3-4
CI-L'TCI{
PACK
SELECTIVE
BACKINGPI"ATE
INPUT HOUSING
BACKINGPLATE SNAPRING
STEPPED
APPLY PLATE
Figure 111
GROUP
SERVICE
TRANSMISSION
AUTOMATIC
63
fi|RrsG
T e c h ni c a f S e r v i c eI n fo r m a t i o n
o
-\---a-z/
o
l-ot
Figure I72
Figure 113
5.
6.
7,
8.
9.
10.
11.
fnstall
the 3-4 clutch backing plate
as shown in Figure LlZ,
Install
the 3-4 clutch backing plate
snap ring as shor+n in Figure 113.
Check the 3-4 clutch clearance with
a feeler gage, between the backing
plate and the first
p1ate,
friction
Clearance should be .060" to .085".
Change the selective
backing plate
as necessary to obtain the correct
3'4 clutch clearance, using chart
in Figure LI4.
Air check the 3-4, forward, and the
overrun clutches by applying air
pressure at the feed holes in the
turbine shaft (See Figure LL7).
When the overrun clutch is checked
air will
exit the forward clutch
feed hole in the turbine shaft.
T HI S I S NO R MA L .
(Continued
NOTE: ATSG RECOMMENDS
THAT YOU REMOVEAND
DISCARDTHE 3-4 LOADRELEASESPRING
ASSEMBLIESSHOWN
ABOVE, ALL MODELS,
FOR A MUCHIMPROVED
2-3 SHIFT.
( s u sF r c u R tEl o ) .
on Page 66).
GROUP
SEBVICE
MISSION
TRANS
AUTOMATIC
64
ARrsE
3 . 1 B A C K I N GP L A T ES E L E C T I O N
MOOEL
BACKINGPIJTE
TRAVEL
U r c B r c h i n gP l a t c
W h i c hG i v c r
CorrcctTtcvcl
DIM.
/Z\
v
666
'BACKING PTATE
855
-#
r.o.
6.58mm.6.3Ernm
5
. .251'l
(.259'
w
F8M,SAM
5 . 7 5 m m . 5 . 5 5 m m€
{ ?26",?1E'}
ALL OTHERS
2.{0mm - l.52mrn
(.09.'- .060')
1 . 9 ? m .m{ . 7 ? m r n
(.r9." rE6')
I
7
6s4B<2=\',
\\=:-/
{.09mm'3,E9nm E
(.161'.,153'l
664A-rffi,
w
654C
653
652
651
650
6 5 4 P L A T EA S S E M B L Y3,R DA N D 4 T H C L U T C H
A N O 4 T HC L U T C H
655 PLATE,3RD
B A C K I N G( S E t . )
ILL.
NO.
600
621
646
648
619A
6198
650
651
652
653
654A
6548
654C
655
656
Figure 114
DESCRIPTION
A S M , 3 . 4 C L U T C HB O O S T( 5 }
SPRTNG
H O U S I N GA N O S H A F TA S S E M E I YI,N P U T
PLATE,FORWARDCLUTCH(APPLY}
PLATE,FORWARDCLUTCH(WAVED)
PI-ATEASSEMBLY,FORWARDCLUTCH(FIBER)
PLATE,FORWARDCLUTCH(STEEL)
PI3TE, FORWARDCLUTCHBACK]NG(SEL.)
C L U T C HB A C K I N GP L A T ER E T A I N E R
R I N G ,F O R W A R D
P L A T E3, R OA N D l T H C L U T C HR 1 N GR E T A I N E R
P L A T E3, R OA N D l T H C L U T C HA P P L Y( S T E P P E D }
P L A T EA S S E M B L Y3.R DA N D 4 T HC L U T C H( F I B E R )
PLATE,3RA
D N O 4 T HC L U T C H( S T E E I )
P L A T E3, R DA N D 4 T HC L U T C H( S T E E L )
A N D 4 T H C L U T C HB A C K I N G( S E L , }
PLATE,3RO
RING,3RDAND 4TH CLUTCHBACKINGPLATE
RETAINER
Figure
115
CR
E OUP
A U T O M AT R
65
F5|RrsE
6 45 B
821
624 623
824
626
622 6 2 9
631 630
631
626 628
645A 6498
646
852 6 5 4 C
648
653
49A
858
644
6648
665
664A
639
843
819
TWO S€TS OF
STE€t PLATES
F8M,MBM,
SAM
M O O E T SO N L Y
ocT 63c
642
638
635
637
836
600
619
620
621
622
623
624
625
626
628
629
630
631
632
634
635
636
637
638
639
S P R I N GA S M . ,3 . 4 C L U T C HS O O S T( 5 I
RINGO
, I LS E A L{ S O L I D }
R E T A I N EA
RN D C H E C K E A LALS S E M B L Y
H O U S I N GA N D S H A F TA S S E M E L YI N P U T
S E A L ,O - R i N Gt N p U TT O F O R W A q DH S G ,
P I S T O N3, R DA N O 4 T H C L U T C h
S E A L ,3 R DA N O 4 T HC L .( I N N E RA N D O U T E R )
R I N G ,3 R OA N D 4 T H C L U T C H( A P P L Y )
S P R I N GA S S E M E L Y3 R DA N D 4 T HC L U T C H
H O U S I N GF, O R W A R O
CLUTCH
S E A L ,F O R W A R O
C L U T C H{ I N N E RA N D O U T E R }
P I S T O NF, O R W A R D
CLUTCH
S E A L ,O V E R R U N
C L U T C H( I N N E RA N D O U T E R )
P I S T O NO
, VERRUN
CTUTCH
S P R I N GA S S E M E L YO V E R R U N
CLUTCH
S N A PR I N G ,O V E R R U N
C L U T C HS P R I N GR E T A I N E R
S E A L ,I N P U TH O U S I N GT O O U T P U TS H A F T
B E A R I N GA S S E M B L YI ,N P U TS U N G E A R
S N A PR I N G ,O V E R R U N
C L ,H U B R E T A I N I N G
H U 8 ,O V E R R U N
CLUTCH
F N D R A C EA S S E M B L YS, P R A G
642 FORWARD
S P R A GA S S E M B L Y
6 4 3 R E T A I N ER
RI N G SS
. P R A GA S S E M B L Y
D L U T C H( O U T E R )
, ORWARC
6 4 4 R A C EF
6 4 5 A P L A T EA S S E M B L Y
O,V E R R U N
C L U T C H( F I B E R )
, VERRUN
6 4 5 8 P L A T EO
C L U T C H{ S T E E L }
646 PLATE,FORWARDCLUTCH(APPLY)
648 PLATE,FORWAROCLUTCHIWAVED)
6494 PLATEASSEMELY,
FORWARDCLUTCH{FIBER)
6 4 9 8 P L A T EF, O R W A R D
C L U T C H{ S T E E L )
6 5 0 P L A T EF, O R W A R D
C L U T C HB A C K I N G( S E L . }
6 5 1 R I N G ,F O R W A R D
C L U T C HB A C K I N GP L A T ER E T A I N E R
6 5 2 P L A T E3, R DA N D 4 T H C L U T C HR I N GR E T A I N E R
6 5 3 P L A T E3, R DA N D 1 T HC L U T C HA P P L Y( S T E P P E D }
6 5 4 A P L A T EA S S E M B L Y
3 R DA N D 4 T HC L U T C H( F I B E F )
6 5 4 8 P L A T E , 3 RA
D N D 1 T HC L U T C H( S T E E L I
654C PLATE,3RD
A N D 4 T H C L U T C H( S T E E L )
6 5 5 P L A T E3, R DA N D 4 T H C L U T C HB A C K I N G( S E L , }
6 5 6 R I N G ,3 R DA N D 4 T HC T U T C HB A C K I N GP L A T E
RETAINER
Figure 116
SEALING RING INSTALLATION
i.
Set input housing on bench with the
turbine shaft facing up, as shown
in Figure lI7.
2. fnstall
the four "Solid" turbine
shaft sealing rings onto the input
shaft beginning with the bottom
ring, BS shown in Figure LL7.
3. SOLID Teflon sealing rings are
mandatory in this position.
4. The solid sealing rings will
require
an installation
tool, and re-sizing
tool as shown in Figure LI7.
5. Set the input housing aside until we
have the reverse input housing built
and ready for installation
into case.
(Continued
on Page 68)
NOTE: It would be advisable to leave
the resizing tool installed
on the
turbine shaft sealing rings until
ready for final assembly. This will
ensure no damage during installation.
GROUP
SERVICE
TRANSMISSION
AUIOMATIC
66
ZRrsE
T -1574
RESIZING
TOOL
T- I 574
I N S T A L L A TI O N
TOOL
S O L ID
S E A L IN G
RING
I NPUT
HOUSING
-t;
\ l -
OVERRUN
C L U T CH
PASSAGE
FORWARD
C L U T CH
PASSAGE
3-4
C L U T CH
PASSAGE
I
_
\ :
TURBINE SHAFT
SOLID TEFLON SEALING RINGS
Figure
LL7
GROUP
SERVICE
TRANSMISSION
AUTOMATIC
67
[Z|RrsG
T e c h n i c a lS e r v i c e l n f o r m a t i o n
MO])TFY
REVERSE
TNPI.I
T
CI-IJTCI{
P:ISTON
INSTALL ORIFICE CUP PLUG, OEMPART NI.JMBER
8631T46, INTO THE BACKSIDE OF THE REVERSE
INPUT CLUTCHPISTON, AS SHOWN,AND THEN
D R I L L C U P P L U GO U T T O T / T O T N C H .
Figure
118
REVERSE INPUT HOUSING ASSEMBLE
1. fnspect atl components of the reverse
input clutch assembly for damage or
wear.
2, Inspect the reverse input clutch housing with a straight
edge, ES shown in
Figure 119, for flatness.
3. If the tangs of the reverse input housing and the tangs of the sun gear shell
have ttFlaredtt out, replace th; input
sprag assembly regardless of how good
it happens to look and/or check.
4. Modify the reverse input clutch piston
as shown in Figure ll8, by installing
orifice
c u p p l u g , O E MN o . g 6 3 l L 4 6 , i n
the back side of piston and then dril1
cup plug out to IlL6 inch.
5, Look carefully
at the reverse input
housing feed hole located between the
sealing rings inside the housing. This
hole has changed back to the large
square in the housing, and stil1
has
the aluminum piston. The 4L60-E must
use this type of housing.
A C H E C KF O RD I S H I N GA T T H I SP O I N T
6 0 5 H O U S I N GA N D D R U MA S S E M B L Y ,
R E V E R SIEN P U TC L U T C H
Figure 119
SERVICE
GROUP
MATICTRANSMISSION
AUTO
68
ARrsE
J 23327-1
614
Sr
613
J 25018-A
UNDER
J 23327-1
612A
6 12 B
6 0 5 H O U S I N GA N D D R U MA S S E M B L Y ,
R E V E R SIEN P U TC L U T C H
Figure 120
6. Install
the inner and outer lip seals
onto the reverse input piston, and
Iubricate with TransJel, Lips on the
seals must face direction
shown in
Figure LZI.
7, NOTE: Always install
a "Long" 1ip
seal in the outer position
on this piston. DO NOT use
a short lip r""ll8. Lubricate reverse input housing seal
surfaces with TransJel.
9, Install
the reverse input piston into
the housi.g, using care not to damage
the lip seals.
10. Install
the return spring assembly on
top of the reverse input piston.
11. Install
spring compressor, as shown
in Figure 120, compress the return
spring assembly and install
snap ring.
L2. Remove the spring compressor.
(Continued
on Page 7O).
ILL.
NO.
DESCRIPTION
H O U S I N GA N D D R U MA S S E M B L YR E V E R S E
INPUT
CLUTCH
6 0 7 P I S T O NA S M . .R E V E R S IEN P U TC L U T C H
6 0 8 S E A L S ,R E V E R S IEN P U TC L U T C H
( I N N E RA N D O U T E R I
6 0 9 S P R I N GA S M . .R E V E R S I€N P U TC L U T C H
6 1 0 R I N G .R E V E R SIEN P U TC L U T C HS P R I N GR E T A I N E R
6 ' I 1 P L A T ER, E V E R SIEN P U TC L U T C H( B E L L E V I L L E )
6 1 2 A P L A T EA S M . , R E V E R S E
I N P U TC L U T C H( F I B E R )
6 1 2 8 P L A T ER
, E V E R S IEN P U TC L U T C H( S T E E L }
6 1 3 P L A T ER
, EVERSE
I N P U TC L U T C HB A C K I N G( S E L E C T I V E )
6 1 4 R I N G ,R E V E R SIEN P U TC L ,R E T A I N I N G
605
Figure LzL
GROUP
MISSIONSERVICE
TRANS
AUTOMATIC
69
ARrsE
REVERSEINPUTCLUTCH
E E L L E V I L LPEL A T E
(,091")
2.311mm
2 2 ' l 0 m m( , 0 8 7 ' )
F L A TS T E E L
C L U T C HP L A T E
2 . 0 4 5 m m( 0 . 8 1 ' )
1 . 8 9 2 m m( 0 . 7 5 ' )
C O M P O S I T I OF
NA C E D
CLUTCHPLATE
1 . 8 8 0 m m( . 0 7 4 ' )
1 . 7 3 0 m m( . 0 6 8 ' )
0r2B
S EL E C T I V E
B A C K I N GP L A T E
F i,gure 122
REVERSEINPUTCLUTCH
SELECTION
BACKINGPT-ATE
H O U S I N GA N D D R U M A S S E M B L YR E V E R S IEN P U T
CLUTCH
6 0 7 P I S T O NA S M . ,R E V E R S IEN P U TC L U T C H
6 0 9 S P R I N GA S M . ,R E V E R SIEN P U TC L U T C H
6 1 0 R I N G .R E V E R SIEN P U TC L U T C HS P R I N GR E T A I N E R
6 1 1 P L A T ER, E V E R SIEN P U TC L U T C H( B E L L E V I L L E )
6 1 2 A P L A T EA S M . , R E V E R S IEN P U TC L U T C H( F I B E R )
I N P U TC L U T C H( S T E E L )
, EVERSE
6 1 2 8 P L A T ER
I N P U TC L U T C HB A C K I N G{ S E L E C T I V E )
6 1 3 P L . A T ER, E V E R S E
6 1 4 R I N G ,R E V E R SIEN P U TC L .R E T A I N I N G
605
ALL MODELS
pLArETRAVEL
- tt|Til . .t;:T'
BAcKTNG
7 . 2 4 9 m m- 7 . 4 0 9 m m
( . 2 8 5 '- . 2 9 ? " 1
6678mm-6519mm
( , 2 6 3 "- 2 5 7 " 1
Figure
5 . 9 4 7 m m- 5 . 7 8 7 m m
(.234' - .228'l
Figure
Figure
Continued
124
L23
from Page 69.
ttBelleville"
the reverse input
13. Install
Concave Side Down, into reverse
plate,
input housing as shown in Figure L75'
the reverse input clutch plates
L4. Install
steel plate, 8s
beginning with a flat
L
2
6
,
F
i
g
u
r
e
i
n
shown
and steel plates
friction
15. Alternate
four friction
i
n
s
t
a
lled
y
o
u
h
a
v
e
until
(
F
i
g
ure L23)'
p
l
a
t
e
s
s
t
e
e
l
f
o
u
r
and
and 4
4
f
r
i
c
t
i
o
n
r
e
q
u
i
r
e
m
o
d
e
l
s
A
f
l
16.
steel plates (See Figure L2.2).
the reverse input clutch backL7. Install
ing plate, chamfered side uP, shown
in Figure L27.
the reverse backing plate snap
18. Install
ringr ;rs shown in Figure 129.
19. Air check reverse input housing to ensure no damage was done to liP seals
during the assernblY Process.
20, Check the reverse input clearance with
a feeler gage between the backing plate
and the snap ring.
2L. Clearance should be .040" to .075" '
backing plate as
Change the selective
t
h
is clearance'
o
b
t
a
i
n
t
o
necessary
F
i
g
ure L24'
i
n
c
h
a
r
t
t
h
e
using
GROUP
SERVICE
TRANSMISSION
AUTOMATIC
70
ZRrsE
Figure 127
C H E C KF O R
(.040'-.075.)
EACKINGPLATE
TRAVEL
Figure I29
Figure
L28
GROUP
SERVICE
IRANSMISSION
AUTOMATIC
7l
U|RrsE
CORRECTLY
INSTALLED
Figure
615 EEARING
A S S E M B L YS,T A T O R
S H A F T/
S E T E C T I VWEA S H E R
(SELECTIVE)
6 1 6 W A S H E RT, H R U S T
6 2 1 H O U S I N GA N D S H A F TA S S E M B L YI N
, PUT
131
ASSEI'IBLEREVERSE INPUT CLUTCH AND
INPUT CLUTCH HOUSINGS
1. Make sure that your selective
washer
and thrust bearing assembly have been
installed
properly onto the input
housirg, as shown in Figure 130.
2, The thrust
bearing assembly should be
installed
with the black side facing
up.
3. Install
the reverse input housing onto
the input clutch housirg,
as shown in
Figure 131.
4. Rotate and index the reverse input
clutch plates onto the hub of the input
clutch housing.
5. When installed
properly,
the thrust
bearing will
turn with the reverse
input clutch housing.
6, Install
the reverse input and input
clutch assembly into the transmission
case as shown in Figure I3Z.
7, There will
be three items to index
properly during installation.
rk 3-4 clutch plates must
be indexed
onto the input ring gear.
:t fnput sun gear must be indexed
into
the forward sprag inner race.
;'r Reverse input housing
tangs must be
indexed into the sun gear sheLl.
8. Great care must be exercised to ensure
that all clutch plates are fully
seate3.
9. When properly assembled, the reverse
input housing will
be located just
below the case oil pump face.
Figure 130
605
621
A B A N OA N C H O RP I N L O C A T I O N
' 1 1 P l N , E A N DA N C H O R
6 0 5 H O U S I N GA N O O R U MA S S E M B L YR E V E H S E
I N P U TC L U T C H
6 2 1 H O U S I N GA N D S H A F TA S S E M E L YI N P U T
Figure L32
AUTOMATIC
IRANSMISSION
SERVICE
GBOUP
72
eRrsc
S
Figure
8 C A S ET
, RANSMISSION
6 0 2 B A N OA S S E M E L Y2,- 4
6 0 5 H O U S I N GA N D D R U MA S S E M E L YR E V E R S E
I N P U TC L U T C H
133
Figure I34
.\STALL 2-4 BANDASSEMBLY
l.
2.
3.
4,
5.
6.
Rotate the transmission so that the
case oi.l channels are facing up.
fnstall
the 2-4 band assembly beginning as shown in Figures 133 and I34.
Line up the anchor pin hole in the
band with the hole in the case, and
the clip end of the band as shown in
Figure 135.
fnstall
the band anchor pin into the
case hole as shown in Figure 136.
Index the 2-4 band onto the band
anchor pin.
Anchor pin will
be just below valve
body surface when properly installed.
Figure
Figure
135
136
GROUP
SERVICE
TRANSMISSION
AUTOMATIC
73
fi|srsE
ILL.
NO,
241
230
2 3 3 236
22
22
*236
- 236
236239
- 236
",238
21
- 210
,/ 212
A -.-- 213
- 211
223
210
lZt
'-&p7
OTL
PIJMP
DESCRIPTION
2 O OB O D Y P U M P
2 0 1 R I N G ,O I L S E A L( S L I D ET O W E A RP L A T E )
2 0 2 S E A L ,O . R I N G( S L I D ES E A LB A C K . U P )
2 0 3 S L I D EP
, UMP
2 0 4 S P R I N GP, I V O TP I N
2 0 5 P I N ,P I V O TS L I D E
2 0 6 S P R I N GP, U M PS L I D E( O U T E R )
2 0 ? S P R I N GP, U M PS L I D E( I N N E R }
2 0 8 S U P P O R TP, U M PS L I D ES E A L
2 0 9 S E A L ,P U M PS L I D E
210 RINGP
, U M PV A N E
2 1 1 G U I D ER
, OTOR
2 1 2 R O T O RO, I LP U M P
213 VANEP
, UMP
2 1 4 S H A F TS
, TATOR
2 1 5 C O V E RP, U M P
2 1 6 V A L V EP, R E S S U RREE G U L A T O R
2 1 7 S P R I N GP, R E S S U RREE G U L A T OVRA L V E
2 1 8 S P R I N GP, N E S S U RR
E E G U T A T OIRS O I , A T O R
, EVERSEOOST
2 1 9 V A L V ER
220 SLEEVE,REVERSE
BOOSTVALVE
2 2 1 R I N G ,O I L P U M PR E V E R S E O O S TV A L V E
RETAINING
222 RINGO
, I t P U M PC O N V E R T ECRL U T C HV A L V E
RETAINING
2 2 3 V A L V ES
, TOP
224 VALVE,CONVERTER
CLUTCH
2 2 5 S P R I N GC
, O N V E R T EC
RL U T C HV A L V E( I N N E R }
2 2 6 S P R I N GC
. O N V E R T EC
RL U T C HV A L V E( O U T E R )
227 RIVEI,PRESSURE
RELIEFBOLT
2 2 8 B A L L ,P R E S S U RR
EE L I E F
2 2 9 S P R I N GP R E S S U RF
EE L I E F
2 3 0 R I N 6 ,O I L S E A L( S T A T O R
SHAFT)
231 SEALO
, I L P U M PC O V E RS C R E E N
2 3 2 S C R E E NO, I LP U M PC O V E R
233 BOLI M8 X 1.25X 10 (COVERTO BODY)
2 3 4 B U S H I N GS, T A T O RS H A F T( F R O N T }
2 3 5 P L U G ,O I L P U M PC O V E R( F W DC L U T C HF E E D )
2 3 6 P L U G ,O I L P U M PC O V E R
237 RETAINEA
R N D B A L LA S S E M B L VC H E C KV A L V E
238 ORIFICE
C,O N V E R T ECRL U T C HS I G N A L
{ C U PP L U G )
( C U PP L U G )
239 ORIFICE
O,I LC O O L E R
, U PO R I F I C E
2 4 0 P L U GC
2 4 1 B U S H I N GS
, T A T O RS H A F T( R E A R )
2 4 2 B U S H I N GP, U M PE O D Y
2 4 3 S E A LA S S E M B L YO I L
244 RETAINER
F ,R O N TH E L I X
ASSEMBLY
Figure
I37
SERVICE
TRANSMISSION
GROUP
AUTOMATIC
74
ARrsE
OIL PUMPROTORSELECTION
CHART
T H I C K N E S {Sm m }
(ln.l
THICKNESS
r 7 . 9 4 81 7 . 9 6 11 7 . 9 7 4.
1 7 , 9 8 7.
1 8 . 0 0 0-
o . 7 0 6 8- 0 . 7 0 7 1
4 , 7 0 7r . 0 . 7 0 7 6
0.7074. 0.7081
0 . 7 0 8 1. 0 . 7 0 8 6
0 . 7 0 8 8- 0 , 7 0 9 1
17.981
17.974
17,987
18.000
18.013
O I L P U M PS L I D ES E L E C T I O C
NH A R T
(mm)
THICKN€SS
THICKNESS
lln,)
1 7 " 9 4 8 .1 7 . 9 6 1
1 7 , 9 6 1- 1 7 . 9 7 4
1 7 . 9 7 4 .1 7 . 9 8 7
r7 987.18.0OO
18 . 0 0 0 - 18 . 0 13
0 , 7 0 6 6, O . 7 0 7 1
o . 7 0 7 1- O . 7 4 7 6
o . 7 0 7 6- 0 , 7 0 8 1
o . 7 0 8 r- o . 7 0 8 6
0.7086- 0 709'l
2 0 1 R I N G ,O I L S E A L( S L I D ET O W E A RP L A T E }
2 0 2 S E A L ,O . R I N GI S L I D ES E A LB A C K . U P }
2 0 4 S P R I N GP, I V O TP I N
2 0 5 P I N ,P I V O TS L I D €
2 0 8 S U P P O R TP,U M PS L I O ES E A L
2 0 9 S E A L ,P U M PS L I D E
Figure
138
ASSEMBLE PI.]MPBODY AND PU}'IP COVER
i.
2.
3.
4,
5,
6.
7.
8.
Install
a new pump body bushing in
p u T n pb o d y i f n e c e s s a r y . B u s h i n g m u s t
be driven out from the seal side of
body and reinstalled
from the pump
pocket side of pump body.
Install
new front pump seal, and seal
(See Figure 137).
retainer
,Off ring
fnstall
back-up and oil seal
ring into the groove on the back side
of the pump slide (See Figure 138).
Install
slide seal support and the
Teflon slide seal onto pump slide and
retain with TransJel (Figure 138).
Install
pump slide assembly into purnp
pocket being carefull
not to disturb
slide seals.
Proper selection
of rotor and slide
sizes are very irnportant. Refer to
the chart in Figure 139 for proper
rotor and slide selection.
Pull the purnp slide straight
towards
the slide seal with one hand, and
with the other hand install
pivot pin
and spring (See Figure 138).
f ns ur e t h a t p u rn p s l i d e rn o v e s b ack and
forth freely
in the punp pocket.
2 0 3 S L I D EP, U M P
2 1 2R O T O R
O,I LP U M P
Figure
9.
10.
11.
12.
13.
L4.
15.
16.
L7.
139
fnstall
both of the pump slide springs
(See Figure 137).
Install
rotor guide onto pump rotor
and retain with TransJel.
Install
vane ring into pump pocket.
pump rotor and guide assembly
fnstall
into pump pocket with guide towards
the pump pocket (Figure 137).
fnstall
ten vanes into pump rotor.
Install
remaining vane ring into the
pump rotor (See Figure I37).
Align and install
oil pump cover onto
the oil pump body.
Install
f i v e p u m p c o v e r t o p u m p bod'. bolts,
but do not tighten.
Install
alignment tool J-21368 onto
the oil pump assembly as shown in
Figure 140.
(Continued
on Page 76).
GROUP
SERVICE
TRANSMISSION
AUTOMATIC
75
T e c h n i c a fS e r v i c el n fo r m a t i o n
ARrsG
4 P U M PA S S E M B L YO, I L
6 0 1 W A S H E RT, H R U S T
( P U M PT O D R U M )
601
.f.21369
Figure
Figure i41
140
the thrust washer on back of
Install
tha t washer
the pump cover, i nsuri ng
tabs are engaged in slots.
31. Retain thrust washer with TransJel.
30.
18. T or que t h e fi v e p u mp c o v e r to P urnp
body bolts to 18 ft. lbs. while the
alignment strap is tight.
19. Remove tool J-71368 from pumP.
inner and outer converter
20. Install
clutch apply valve springs into the
pump cover (See Figures I37 and I42),
the converter clutch apPly
2L. Install
valve into the same bore, with the
exactly as shown in
valve installed
Figure L42.
converter clutch valve stop,
22, Install
and inpush down with screwdriver,
side
stall
snap ring with the flat
facing out.
23, Grind two "Flatst' on the second land
valver 3s
of the pressure regulator
shown in Figure 142, or purchase the
valve.
updated pressure regulator
modified pressure regulator
24. fnstall
valve
valve into pressure regulator
bore in the pump cover (Figure L37).
25. fnsure that the valve moves freely
in t he p u m p c o v e r b o re .
pressure regulator valve
26. Install
into
both inner and outer,
springs,
I37 and I42).
the same bore (Figures
the boost valve into sleeve
27. fnstall
as shown in Figure I4Z,
boost valve and sleeve asm'
28. Install
int o t he s a me b o re , p u s h d o w n w i th
snap ring
and install
screwdriver,
side facing out.
with the flat
and
valve train,
79. Pressure regulator
MUST
clutch valve train,
converter
be ins t all e d
" EX AC T L Y" a s s h o w n i n
Figure I42, or damage to the transmission could result.
(Continued
on Page 78).
GROUP
MISSIONSERVICE
TRANS
AUTOMATIC
76
ARrsG
''IJPI)ATED''
PR.ESSIJR.E
( wITI{
R.EGIJI,ATORFI..ATS
)
\/AI.\/E
- 217
tt€l{
t a 4 t -
r6R)
trz---\\
( N\---4
225
1
\-7
Y,"
K"'
A--,,,
FLATS
ADDED
S M AL LE R
DIAMETER
PASSAGE
A
NO
FTATS
LARGER
DIAMETER
PASSAGE
NEW
PRESSUBE
REGULATOR
VALVE
6
PERVIOUS
PRESSURE
REGULATOR
VALVE
@'/223
,--222
r \--''22',1
V
tu
6-
ALWAYSINSTALL UPDATEDPRESSTJRE
VALVE, OR GRIND FLATS
REGULATOR
ON ORIGINAL AS SHOWN.
EE G U L A T O R
2 1 6 V A L V EP, R E S S U RR
EE G U L A T OVRA L V E
2 1 7 S P R I N GP, R E S S U RR
SOLATOR
EE G U L A T OIR
2 1 8 S P R I N GP, R E S S U RR
, EVERSEOOST
2 1 9 V A L V €R
BOOSTVALVE
220 SLEEVE,REVERSE
B O O S TV A L V E
2 2 I R I N G ,O I L P U M PR E V E B S E
RETAINING
RL U T C HV A L V ER E T A I N I N G
2 2 2 R I N G .O I L P U M PC O N V E R T EC
223 VALVE,STOP
, O N V E R T EC
2 2 4 V A L V EC
RL U T C H
2 2 5 S P R I N GC, O N V E R T ECRL U T C HV A L V E( I N N E R }
2 2 6 S P R I N GC, O N V E R T ECRL U T C HV A L V E( O U T E R )
Figure L42
GROUP
SERVICE
TRANSMISSION
AUTOMATIC
77
ARrsG
SOLID
SEAL
N O .1
:TEFI-ON
SITATOR.
SEAL
N O .2
STATOR SHAFT
SEALING RINGS
SEAI-II\IG
R.I\IGS
solrq _TEFLONRrNG TOOLSEqR STATOR
J - 3 9 8 5 5- 1 = INSTALLERFOR RING NO.I
J - 3 9 8 5 5- 2 = INSTALLERFOR RING NO.2
J - 3 9 8 5 5- 3 = RESIZERFOR BOTHRINGS
CORREETLY
I N S T A L L ED
Figure I43
32. fnstall
new "SOLID" Tef1on sealing
rings on stator shaft, using the
new installation
and resizing
tools
shown in Figure L43.
33. fnstall
the oil pump to case tfgtr
ring into the groove in the oil
pum p body.
34. The chamfered edge of the 'rort ring
should be facing eut, and make sure
that it is not twisted in groove.
35. Lubricate the I'Ott ring with TransJel
and also the sealing rings.
36. Oil pump assembly is now ready for
assembly into the transmission,
3 7 . I t i. s r ec o m m e n d e d to l e a v e th e
resizing
tool in place over the
solid Teflon seals until
you are
ready to install
the oil pump.
5.
fnstall
the complete oil purnp assembly
into the transmission
case using the
alignment dowels as shown Figure I44.
6. fnstall
oil pump retaining
bolts, and
remove the alignrnent dowels, install
the remaining bolts.
7. Torque all oi1 pump retaining
bolts to
18 ft. Ibs.
8. Install
the proper tto'r ring on turbine
shaft A FTE R end cl earance
i s c hecked
and properly set (See Figure 146).
C A U TION :
There shoul d be cl earance between t he
reverse input housing and the sun gear
shell,
A A L I G N M E NP
TI N S
4 P U M PA S S E M B L YO. I L
INSTALL OIL PITMPASSEMBLY
1.
fnstall
oil purnp to case gasket into
the case and retain with TransJel.
2. fnstall
alignment dowels into the
transmission
case as shown in Figure
144.
3. Lubricate
case pump bore where the
rrorr
ring rides with TransJel for ease
of installation.
4. Install
new ilOrt rings onto the front
pump retaining
bo1ts.
Figure
L44
GBOUP
SERVICE
TRANSMISSION
AUTOMATIC
78
ARrsE
T e c h ni c a l S e r v i c el n fo r m a t i o n
TURBINE SHAFT
''o'' RING
P A R T SH A V EA N O R M A L
X . 3 . 8 m m( 1 5 0 " )
M 8 L Y ,R E V E R SIEN P U T
Figure 145
JAUTION:
There should be clearance between the
reverse input housing and the sun gear
shell,
as shown in Figure L45. When
i.nstalled these two parts have a normal
end clearance of approximately .150".
DO NOT try to shim the internal
parts
because of this clearance.
Figure
146
GROUP
SSIONSERVICE
TRANSMI
AUTOMATIC
79
IZRrsG
TRANSMISSIONEND PI.AY
WASHERSELECTIONCHART
WASHERTHICKNESS
'l
87.197mnr
2 , 0 4. 2 . 1 4m m
2 . 2 1- 2 . 3 1m m
2 , 3 8. 2 . 4 8m m
(.074"-.078")
67
{ . 0 8 0 "- . 0 8 1 ' }
( . 0 8 7 -' . 0 9 1 ' )
68
70
2 , 5 5 - 2 . 6m5 m
( . 1 0 0 ' -. 1 0 4 ' l
71
272-282mm
2 . 8 9' 2 . 9 9m t n
(.107'-.111'.)
72
(113,.118.)
73
3 . 0 6. 3 . 1 6m m
(.120". 124')
74
Figure 148
A 2 9 8 m m T U R B I N ES H A F T
I 2 4 5 m m T U R B I N ES H A F T
Figure
I47
D I A LI N D I C A T O R
2 7 8 m m( 1 ' l ' )B O L T
L O C KN U T
J 24773-A
A S S E M B L YS,T A T O R
S H A F T/
615 EEARING
S E L E C T I VW
EA S H E R
6 1 6 W A S H E RT, H R U S T{ S E L E C T I V E )
Figure L49
Figure 150
GROUP
SERVICE
TRANSMISSION
AUTOMATIC
80
69
(.09'l'- .098')
ARrsG
- : { E C K I N GT R A N S M I S S I O NE N D P L A Y
:, Remove a front pump bolt and install
an ll" bolt and lock nut, as shown
in Figure 149.
l. Install
J-25022 adapter, or J-34725
adapter, as shown in Figure I47, on
the turbine shaft.
3. Install
lifting
tool J-24773-A and
dial indicator as shown Figure L49.
i. Set the dial indicator to zero.
5. Pull up on lifting
tool J-24773-A
and observe the reading.
5. Proper end play is .015" to .036".
N O T E : NE V E R S ET EN D P L AY A N Y C L O S E R
T H A N . 0 1 5 ' " B E C A U S EA L U M I N L M
P UM P W IL L E XP AN DO R ' ' GR O W ' '
AND YOU COULD END UP WITH A
NE G A TIV E EN D C L E AR AN C E .
NOTE:
The seleetive washer which controlls
the
end play is located between the input
housing and the thrust bearing that rides
on the oi1 pump cover hub (Figure 150).
If more or less end play is required,
select the proper washer from the chart
in Figure 148 and install.
If dial indicator
shows no end play, the
selective
washer and thrust
bearing may
have been misassembled. See Figure i50
for proper assembly.
GROUP
SERVICE
TRANSMISSION
AUTOMATIC
8t
fi|srsG
AND
O E
v
1
.
\
l'
c
)
0' l @T '
o
\-/c-
-
O.
o
E
oo
LJ
v/
l
-
J
, c
n n
\_/ [J
O
o
\ . /
\J\r
oo.0
o
0
r-'\
w
o
t t t l
o
ooc
o "?o
co
t-lf-lo
' o b o
c
o
C)o
F
!,-
o u
og g
oooc, c c
9 uocco o
_
cl
Ooo';
-%
o
000
o
,_,0
"
0
(J
o
LJ_
CF{AR.T
I-OCATION
'
Io
^ O Cc ' 0 !
C
PI-AITE
SCR.EEN
SPACER
PI-ATE
4I-6O-E
SPACER.
n
\J
-qc
u c o
4
c
0 c
8
0oo c3 e
oC
)nbU
b
co
CCf
o Q
o
n
L-i
ful
D
O
of-]
n
' Rr a?
C o
o
nU
Cc:
\o
c
c=@
CODE
IDENTITICATION
49 SPACERPLATE SCREENSNAPSINTO PLATE FROMCASESIDE.
50 SPACERPLATESCREENSNAPSINTO PLATE FROMCASESIDE.
(ITOTUSEDALL MODELS
51 SPACERPLATE SCREENSNAPSINTO PLATE FROMVALVE BODYSIDE
P A R T N O.
CODE
FITS
THESE
MODELS
I_ 9 93
8684122
=========
8684123
8684L24
J><
JV
MJD
MND
MSD
TAD
TBD
MDD
MODEI-
ccD
SHD
TLD
CAD
CBD
KAD
TWD
C FD
KBD
SPACER"
PI-ATE
8684L26
8 6 8 412 5
JY
CHD
KCD
CJD
I
I
I
CI{AI?":T
Figure 151
GROUP
SERVICE
TRANSMISSION
AUTOMATIC
82
CKD
CLD
KDD
ePrsE
T e ch n i c a l S e r v i c el n fo r m a t i o n
1993
MODELS
77
53
t.2 ACCUitUtATOR 3.4 ACCUMULATOR
SPRINGCOLOR
SPRING
COLOR
CHD,CJD,KCD
ORANGE,
tT.GREEN,
WHITEORPLAIN
VIOLET
CAD,CBO,I(AO,
M J D ,M N D
ORANGE,LT.GREEN,
WHITEORPI-AIN
DK,GREEN
cco,cFD,
K80
ORANGE,
LT.GR€€N,
WHITE
ORPLAIN
REO
SHD,TLO
DK.GREEN
CKD,CLO,KDO,
ORANG€,
LT.GREEN,
MDD,MSD,TAO,TBO WHITEORPL,AIN
46 S P R I N G3, . 4 A C C U M U L A T O R
1 7 GASKET,SPACERPLATETO CASE
1 8 PLATE,VALVEEODY SPACER
5 2 GASKEI SPACERPLATETO VALVEBODY
53 PLATE,SPACERPLATESUPPORT
5 1 S P R I N G1
, . 2A C C U M U L . A T O R
5 7 C O V E RA N D P I N A S S E M B L Y1, . 2A C C U M U L A T O B
58 B O L TA
, CCUMULATOR
COVER
59 BOLTA
, CCUMULATOR
COVER
7 7 8OLT,SPACERPLATESUPPORT
Figure
Figure
8.
LT,BLUE
YETLOW
153
fnstall
the spaeer plate to case gasket
identified
with a I'C'f over the dowel
pins and onto the case (Figure 152).
9, fnstall
the three screens into the pro_
per spacer plate. See Figure 151 for
spacer plate screen locations.
10. Use the chart in Figure 151 to insure
proper spacer plate usage.
11. fnstall
proper spacer piate over the
dowel pins and onto the case (fig , L52),
12. Install
the valve body to spacer plate
gasket identified
with a ,rvil over the
dowel pins and onto plate (Figure 152).
13. fnstall
the spacer plate suppJrt plate
as shown in Figure L5Z, and torque the
three retaining
bolts to g ft.lb.
14, fnstall
a ner{ seal on l-2 accumulator
piston,
15. Lubricate the l-Z accumulator housing
bore with TransJel, and install
the
piston assembly into the housi.ng with
the three legs facing the
p1ate.
16. fnstall
t h e l * Z a c c u m u l a t o "r p "s"p" ri i n g i n
the housing using the chart in Fig 153.
L7. fnstall
the I-Z accumulator assembly
on case and torque the three bolts to
8 ft. 1bs.
152
ASSEMBLEVALVE BODY RELATED PARTS
1. Rotate transmission to hori zonLal as
shown in Figure I5Z,
?. fnstall
one checkball into the proper
pocket r BS shown in Figure 154.
3. fnstall
dowel pins into two locations
of the valve body bo1ts.
4. fnstall
the 3-A accumulator pin into
the case.
5. Install
new seal on the 3-4 accumulator piston.
6. Lubricate the 3-4 accumulator bore in
case with TransJe1, and install
the
3-4 accumulator piston into the case
wi.th the three 1egs facing the spacer
plate.
7. fnstall
the 3-L accumulator spring on
top of the piston, using the chart in
Figure 153 to deterrnine proper spring.
AUTOMATIC
TRANSMISSION
SERVICE
GROUP
83
F?|RrsE
T e c h n i c a lS e r v i c el n fo r m a t i o n
4T-60
-E
CFTECKBAI,L
LOCA:TIONS
CASE(BOTTOM}
an
f r-)r^
Yfl.
/n(Jun
L_JJ a?^\.,,-\
# t
\ v t
I
=n JJ4ltEpl
)l(effii/
==AJlr-.
SERVO
BORE
VALVEBODY(60}
Figure
154
GROUP
SERVICE
TRANSMISSION
AUTOMATIC
B4
esrsG
T e c h n i c a lS e r v i c eI n f o r r n a t i o n
:IECKING THE PRESSURE
SWITCHASSEMBLY
l. Two of the five switches in the pressure switch assernbly are normally
closed (N/C), and the other three are
normally open (N/O), as shovn in
Figure 155.
?. Set your ohnmeter so that lt emits a
"Tone" r.rhen the leads are connected.
3. Place the ohnmeter leads on the pins
on each side of the D4 sritch (N/0).
No tone should be heard (Figure 155)
,1. With the leads still
in place, using
a small flat punch, close the srritch
by carefully pushing down in center
of the ssitch. If the switch is good
a tone will now be heard from the
ohnneter.
5. Check the Lo switch (N/0) and Reverse
switch (N/O) in the same manner.
6. Place the ohmneter leads on the pins
on each side of the D2 slritch (N/C).
A tone should be heard fron ohrNneter
until you push down in the center of
the svitch vith snall flat punch, and
the tone will then stop.
7. Check the D3 switch (N/C) in the sarne
manner as the D2 sritch.
8, Refer to Figure 155,
9, To check the resistance values for
the transmission oil temperature
sensor, see Page 7 of this manual,
o
/A\
-V//A
^ll
b=ro
oFAV-(O
L J o v\ /
^ l v
r
o
oO
\y
o:
L
c
A
c l oc \ - / /
I - - - - -
Hffi
VoF-q
o F-g
PITESST_'RN
@ 03\a
SWTTC}{
Figure
ASSEMBI-Y
155
GROUP
SERVICE
TRANSMISSION
AUTOMATIC
85
U|RrsE
VAI-\/E
\,/IEvI
E)<PI-ODED
BODY
354 353
:uol
374
F
373
rro)ls-A)
\*
st7
395
378
R.EAR
381
.-\s 7360
ll 364::*
385
387
391
392
u ^d
381
\
gg4
),,
rN
FRON:T
2
v
Figure
156
GROUP
SERVICE
TRANSMISSION
AUTOMATIC
86
: l C V A L V EM
. ANUAL
350 VALVEASSEMELY,CONTROLBODY
3 5 3 S E A L ,F O R W A R O
ACCUMULATOR
OIt
? . 1 P I S T O NF
, ORWARD
ACCUMULATOR
: : 3 P l N ,F O R W A R D
ACCUMULATOR
3 : 6 S P R I N GF, O R W A R D
ACCUMULATOR
3 5 7 V A L V EF
, ORWARD
ABUSE
3 5 8 S P R I N GF, O R W A R D
A B U S EV A L V E
3 5 9 P L U G ,E O R E
3 6 0 P I N ,C O I L E DS P R I N G
361 VALVE,LOW OVERRUN
3 6 2 S P R I N GL, O W O V E R R U NV A L V E
3 5 3 C O V E RF, O R W A R D
ACCUMULATOR
3 6 4 8 O t T ,F O R W A R D
ACCUMULATOR
COVER
3 6 5 S P R I N G1, , 2S H I F TV A L V E
3 6 6 V A L V E1
, . 2S H I F T
3 6 7 A 1 . 2S H I F TS O L E N O I D
IAI
3 6 7 8 2 . 3 S H I F TS O L E N O I D
18}
368 VALVE,2.3 SHIFT
i 369 VALVE,2-3 SHUTTLE
3 7 0 S P R I N G 1, . 2 A C C U M U L A T O V
RA L V E
3 ? ' I V A L V E I, . 2 A C C U M U I . A T O R
3 } 2 S I E E V E 1. . 2A C C U M U L A T OVRA L V E
3 7 3 P L U G ,S O R E
3 7 1 V A L V EA
, C T U A T O RF E E OL I M I T
3 7 5 S P R I N GA, C T U A T O RF E E DL I M I TV A L V E
3 7 6 P L U G ,E O R E
3 7 7 P R E S S U RC
E O N T R O LS O L E N O I D
3 7 8 R E T A I N E RP,R E S S U R C
379 RETAINER
S,O L E N O I D
3 8 0 V A L V EC
, ONVEFTEC
R L U T C HS I G N A L
3 8 1 P L U G ,B O R E
3 8 2 S P R I N G4, . 3 S E O U E N C E
VALVE
383 VALVE,4.3 SEOUENCE
384 VALVE,3.4 RELAY
385 VALVE.3.1 SHIFT
380 SPRING,3.4 SHIFTVALVE
387 VALVE,REVERSE
ABUSE
3 8 8 S P R I N GR
, EVERSA
E E U S EV A L V E
3 8 9 V A L V E3, . 2 D O W N S H I F T
3 9 0 S P R I N G3, . 2 D O W N S H I F T
VALVE
391 VALVE,3.2
CONTROL
3 9 2 S P R I N G3, , 2 C O N T R O LV A L V E
3 9 3 S P R I N GE
, O R EP L U G
3 9 1 3 . 2 C O N T R O LS O L E N O ] D
3 9 5 R E T A I N E RB, O R EP L U G
VALVE BODYASSEMBLY
Clean the valve body assembly in clean
solvent thoroughly.
2 . Move the valves with a pick or a smal1
screwdriver
to ensure that anv debris
or dirt
is dislodged.
3 . Dry with compressed air.
4 , Position valve body on a clean and dry
flat work surface for disassembly.
5 . R emove val ve trai ns one at a tim e and
begin in one corner of the valve body.
6 . Some valves are under spring pressure
so cover the end of the bore when removing ro11 pins and/or retainers.
7 . Valves, springs, and bushings should be
l ai d out on a cl ean dry surface EXACTLY
the w ay they are removed.
8 . Clean all valves, springs and bushings,
then dry with compressed air.
9 . fnspeet all valve body parts for wear
and/or damage.
1 0 . Check all solenoids for the proper resistance value. Refer to Pages 5 and 6
for the resistance
values for each
solenoid assembly.
11. Use Figure 158 to identify
any of the
val ves i n val ve body and pump.
12. Use Figure 159 to identify
any of the
springs in valve body and pump.
13. Use the illustrations
in Figures 156
and L57, to reassemble the valves,
springs and bushings in their
proper
order.
L4, Replace all rfOt'ring seals on solenoids
before re-instal1i.ng
in valve body.
15. NOTE: Both of the shift
solenoids are
the same and will
interchange on
this transmissi.on.
L6. Va1ve body is now ready for installation
on the transmission.
Figure 157
GROUP
SERVICE
IRANSMISSION
AUTOMATIC
87
FZ|HrsG
V A Lv E sL O C A T E OI N T H E P U M P
V A L V E SL O C A T E O] N T H E V A L V EE O O Y
- t
Figure
158
GROUP
SERVICE
TRANSMISSION
AUTOMATIC
88
eRrsG
I N T H EV A L V EB O O Y
LOCATED
SPRINGS
I N T H EP U M P
LOCATEO
SPRINGS
3-4
sEo
Figure 159
GROUP
SERVICE
TRANSMISSION
AUTOMATIC
89
!7|RrsE
(
I
I
Dl
ii
l
I
88
340
6 3 S P R I N GA S S E M B L YM A N U A L D E T E N T
8 8 L E V E RI,N S I D EO E T E N T
8 9 L I N K ,M A N U A LV A L V E
3 4 0 V A L V EM
, ANUAL
Figure 161
2
3
1
5
6
8
12
3 R OA C C U M U L A T O R
R E V E R SIEN P U T
3 . 4 C L U T C HE X H A U S T
FEEO
OVERRUC
NLUTCH
OVERRUN
C L U T C HC O N T R O L
1 . 2U P S H I F T
FORWARD
C L U T C HA C C U M ,
Figure 160
aa.\ / - t l
*_\v/
,--'--I4:::--
-'1f,1r,=__l[]]
--L!'p7
v
cO
E
A M6X1,0X65.0
B M6X1,0X54.4
c
o
M6X1,0X47.5
M6X1.0X180
E M6X10X350
F M8X1.25X20,0
G M6X1.0X12.0
Figure L62
GROUP
SERVICE
TRANSMISSION
AUTOMATIC
90
ARrsG
INSTALL VALVE BODY & WIRING HARNESS
i. Install
7 checkballs into the proper
pockets in the valve body, 3s shown
in Figure 160, and retain them with
a small amount of TransJel.
2. Install
the valve body on transmission
and connect manual valve link to the
manual vale as you install,
3. Refer to Figure 161 for correct manual
valve alignment.
4. Be careful not to damage the spacer
plate screens when installing
the
valve body.
5. Install
the valve body retaining
bolts
except the three that also retain
the
wiring harness, D0 NOT TIGHTEN at this
t ime.
6. fnstall
new ftgtf ring on lock-up solenoid and luberieate
with TransJel.
7. Install
new 'tOtr ring on case connector
and lubricate
with TransJel.
8. Install
case connector into case bore
9. Route wiring harness as shown Figure
163, and install
lock-up solenoid in
oil pump bore.
10. Install
the two retaining
bolts for
lock-up solenoid and torque the bolts
(See Figure 162).
to 8 ft.lbs.
li.
Install
the three remaining valve
body bolts to retain the wiring
harness, and torque the valve body
(figure
bolts to 8 ft.lbs.
162).
12, Start in the center of the valve body
and follow the arrows in Figure L62
for torquing sequence.
13. Connect the pressure switch assembly
to wiring harness and install
the
pressure swi-tch assembly onto valve
body.
14. Install
the proper bolts (Z Short &
3 Long) itt pressure switch assembly
(fig.
and torque to 8 ft.lbs
16?),
15. Rotate the shift
solenoids so that
the connector is facing up, and
connect the wires to the shift
solenoids.
NOTE: The Red and Green wires Bo to
Shift Solenoid "A", and the
Red and Yellow wires go to
Shift Solenoid ilgrt (See Figure L64).
16. Rotate the Force Motor so that the
terminals
are facing the pan rail
(See Figure 164).
66 SOLENOID
A S S E M B L YW, I R I N GH A R N E S S
Figure
17, Install
the wiring harness connector
onto the Force Mot.or.
18. Rotate the 3-2 Solenoid so that the
terminals
are faci.ng the lock-up
solenoid (See Figure 164).
19. Connect the wiring harness connector
onto the 3-Z Control Solenoid, as
shor.rn in Figure L64.
20. Install
the manual detent spring and
torque the bolt to 18 ft.lbs.
2L. Insure that the manual detent spring
stays aligned with the inside detent
l e v e r ( S e e F i g u r e 1 6 1) .
GROUP
SERVICE
TRANSMISSION
AUTOMATIC
9r
163
Fi|HrsE
MO[)EI-
MODELCODE
3SHD
3TLD
3MJD
APPI-ICATTON
CFIAR.T
APPLICATION
4 . 3 L V 6 S - T R U C K& U T I L I T Y
4,3L V6 T-TRUCK
4 .3L V6 M.VAN
3MSD
4.3L v6 M-vAN(HrsHourpur)
3CAD
3CBD
3KAD
3CCD
3CFD
3KBD
3CHD
3CJD
3KCD
4.3L V6
4,3L V6
4.3L V6
5.OL V8
5. OL V8
5. OL V8
5.7L V8
5.7L V8
5.7L V8
C - T R U C K&
C . T R U C K&
K-TRUCK
C . T R U C K&
C-TRUCK
K-TRUCK
C . T R U C K&
C - T R U C K&
K-TRUCK
G-VAN
G.VAN
G-VAN
G-VAN
G-VAN
394
379
377
EI-ECTR.ICAI66
69
COMPONENTS
L O C K - U PS O L E N O I D .
(TOt SENSOR
IHSIDE).
P R E S S U RSEw I T C HA S S E M B L Y
377 FoRcEMoroR(coNrRolsLrNEpngssunn).
379
379
394
CLUTCHACCUMULATOR
SHIFT SOLENOID'IA'I ( CI,OSNSTTO FORWARD
).
r
t
B
'
r
(
C
t
O
S
e
S
r
T
O
A
C
C
u
l"tULltOn)
SHrFT SOLENOTD
L-2
3-z coNTRoL soLENorD ( pwt't)
Figure 164
GROUP
SERVICE
TRANSMISSION
AUTOMATIC
92
ARrsG
T e c hn i c a f S e r v i c eI n fo r m a t i o n
EI-ECTR.TCAI-
COMPONENTS
I
WIRING
H A R N E SASS S T M E L Y
5
S OLTN O| O
3-2C ON TR OT.
2
P N E S S UC
RO
E N T R OSTO L E N O I O
6
T O R Q UC
EONVERTC
ER
T U T CS
HO L E I I J O l O
3
i . 2 9 H I F TS O L E N O I D
7
I L U I OP R T S S U R
SE
WITCA
HS S E M S L Y
4
2 . 3 S H l r TS O L T N O | O
.c
FN
I U I OT E M P E R A T U R
SENSOR
TRANSMISSIO
( P A R To F r L u l o p R E s s u R sEw t T c HA S S E M E I Y )
Figure 165
GROUP
ISSIONSERVICE
TRANSM
AUTOMATIC
93
li|RrsE
CURRENT
OIL FILTER SEAL
O I L F I L T ER SE AL SCHEDULED
TO GO
INTO PRODUCTIONI N A P R I L , 1 9 9 3 .
Figure
166
OIL FILTER AND BOTTOMPAN
C.HECK2- 4 SERVO PIN LENGTH
1. Install
filter
seal on filter
neck if
you have the previous style seal.
See Figure i66 above.
2. If you are using the filter
seal that
is scheduled for production
in April
1993, install
bore
it into the filter
in t he oil " p u n p w i th s e a i d ri v e r.
See Figure 166 above.
3. Install
the bottom pan oil filter.
4, Install
the magnet into the bottom
pan in the appropriate
position.
5. Install
a new bottom pan gasket on
case, and install
the bottom pan
(See Figure 167).
6. Install
16 bottom pan retaining
bolts
and torque them to 9 ft.lbs.
( S e e F i g u r e 1 6 7) .
1. Install
servo tool J-33037, as shown
in Figure 168, with the servo pin you
are going to use.
2. Install
servo cover retaining
ring to
secure servo tool in bore.
3. Apply 98 in.lb.
torque, as shown in
Fi gure 168.
4. f f white line I'A,, appears in the gage
slot "Btt, pin length is correct (See
Figure 168).
5. Use the selection
chart in Figure 168
to determine the correct
pin length
if a new pin is needed.
6. Remove the servo tool J-33037 from
the servo bore.
GROUP
SERVICE
TRANSMISSION
AUTOMATIC
94
lZ|RTsE
T e c h n i c a lS e r v i c eI n f o r r n a t i o n
76
75
73
"-\.
. ' \
S-7'l--_
P I NI S P R E S E T
AT FACTORY
AND MUST NOTBE
READJUSTED
2.4 S E R V OP IN S E LE C TION
PIN LENGTH
8 C A S ET
, RANSMISSION
7 1 S E A I ,F I L T E R
7 2 FILTER
A S S E M B L YT,R A N S M I S S I OO
NI L
7 3 G A S K E TT, R A N S M I S S I O O
N I LP A N
7 5 P A N ,T R A N S M I S S I OO
NI L
7 6 S C R E WT, R A N S M I S S I O N
O I LP A N
65,82.66.1?
67.23.67,53
68.64.68.94
Figure L67
2,59.2.60
2.65.2
66
2.70-2.71
Figure
168
GROUP
SERVICE
TRANSMISSION
AUTOMATIC
95
1 GROOVE
2 GROOVES
NO GROOVE
fi|HrsG
2NDAPPLYPISTONAND HOUSINGAPPLICATION
r
CHD,CJO,CKD,CLD,
K C OK
, OD
4l.64mm
(1 . 7 8 ' ,
{5.54mm
(1. 7 9 ' )
CAD,CBO,CCO,CFD,KAD,K8D,
. N D ,M S O S
, HD,
M J D ,M O O M
TAM,TBM,TLO
57.85mm
(2.28')
58,71mm
( 2 . 31 . l
__J
II
rA
n
t-f--=----13
H
v
8-=-ILL.
NO.
12
13
11
I5
16
17
18
19
20
21
22
23
24
25
26
27
28
29
J L
12
1 7 P I S T O N2, N D A P P L Y
2 0 H O U S I N GS, E R V OP I S T O N( I N N E R )
Figure 170
DESCRIPTION
S P R I N GS, E R V OR E T U R N
P I N ,2 N D A P P L YP I S T O N
R I N G ,R E T A I N E R
{ 2 N OA P P L YP I S T O I . . I I
RETAINER
S,E R V OC U S H I O NS P R I N G
S P R I N GS, E R V OC U S H I O N
P I S T O Nz. N D A P P L Y
R I N G ,O I L S E A L( 2 N OA P P L YP I S T O N. O U T E R )
R I N G ,O I L S E A L( 2 N DA P P L YP I S T O N. I N N E R )
H O U S I N GS, E R V OP I S T O N( I N N E R I
S E A L ,O . R I N G
S P R I N GS, E R V OA P P L YP I N
W A S H E RS
, E R V OA P P L YP I N
R I N G ,R E T A I N E(RA P P L YP I N }
P I S T O N , . 4 TA
HP P L Y
R I N G ,O I L S E A L( 4 T HA P P L YP I S T O N. O U T E R )
S E A L ,O . R I N G{ 2 . 4 S E R V OC O V E R )
C O V E R2, . 4 S E R V O
R I N G ,S E R V OC O V E RR E T A I N I N G
Figure
J 22 269- 01
1 7 S E C O N DA P P L YP I S T O N
Figure 171
169
ROUP
CE
A U T O M AT R
96
ARrsG
J 29714
O 9 O S L E E V EO. U T P U T
SHAFT
09I S€ALO
. U T P US
THAFT
Figure 173
28
? O H O U S I N GS, E R V OP I S T O N
(INNER)
1 2 S P R I N GS, E R V O
R € T U R N 2 1 S E A LO
, RING
1 3 P I N ,2 N D A P P L YP T S T O N
2 2 S P R I N GS, E R V OA P P L YP I N
1 4 R I N GR
. E T A I N E{R2 N D
2 3 W A S H E RS, E R V OA P P L Y
A P P L YP I S T O N }
PIN
.I6
R E T A I N E RS,E R V O
(APPLY
2 4 R I N G ,R E T A I N E R
C U S H I O NS P R I N G
PIN)
1 6 S P R I N GS, E R V OC U S H I O N
25 PISTON,4TH APPLY
1 7 P I S T O Nz, N D A P P L Y
2 8 C O V E R2, . 4 S E R V O
1 8 R I N G ,O I L S E A L( 2 N D
2 9 R I N G ,S E R V OC O V E R
A P P L YP I S T O N. O U T E R }
RETAINING
19 RINGO
, I LS E A L( 2 N D
.
A P P L YP I S T O N I N N E R }
29
Figure
Figure
174
OUTPUT SHAFT SLEEVE
fnstall
the output shaft sleeve ,O'f
ring into the output shaft sleeve,
as shown in Figure L73.
2. Lubricate the rr0r' ring with TransJel.
3. Install
the output shaft sleeve onto
the output shaft (See Figure I74).
4. Do not push the sleeve past the machined surface on the output shaft.
1.
L72
ASS E M B LE2- 4 S E R V O
1. Check the dimensions of the Znd apply
piston and housi.g, as shown Figure
17A, to insure compatable parts and
proper size for model your building.
2, Assemble the 2-4 servo assernbly as
shown i.n Figure 169.
3. Use tool J-22269-0I, as shown in
Figure L71, to compress the eushion
spring, if necessary.
4, Install
the servo return spring onto
servo assembly, as shown in Figure
L72, and install
2-4 servo into the
case bore.
5. Compress the servo cover using the
tool shown in Figure 172, install
the snap ring.
NOTE: This sleeve is not used on al1
model transmissions.
P
GROU
SSIONSERVICE
TRANSMI
AUTOMATIC
97
lZlnrsE
687
8
t
l
l
I
I
,f?
ILL.
NO.
8
30
31
32
33
34
35
36
37
687
OESCRIPTION
H A R N I S SC O I { N I C T O R
2
o - R I N GS t A t
3
V E H T C LSEP t r OS E N S O(RV S s )
Figure 177
CASET
, RANSMISSION
NO C A S E
S E A L .C A S EE X T E N S I O T
EXTENSION
C ,A S E
B O L TC
, A S EE X T E N S I O T
NO C A S E
B U S H I N GC, A S EE X T E N S I O N
NIL
S E A LA S S E M B L YC.A S EE X T E N S I O O
BOLTS
, P E E DS E N S O RR E T A I N I N G
S P E E DS E N S O RI,N T E R N ATL R A N S M I S S I O N
S E A L ,O . R I N GI I T S ST O C A S EE X T E N S I O N )
S H A F TO
, UTPUT
Figure
t
L76
EXTENSION HOUSING AND SPEED SENSOR
1, Install
new bushing in extension
housing if necessary.
new extension housing seal
2. Install
into the extension housing.
3. Install
new fr0rr ring seal onto the
extension housirg, and lubrieate
with TransJel.
4. Install
the extension housing on the
torque
transmission with four bolts,
bolts to 76 ft.lbs.
5. Install
the vehicle speed sensor, if
used, and torque the retainer
bolt
to 8 ft.lbs.
6, The speed sensor used on four wheel
drive models is shown Figure I77,
and located on the transfer
case.
7. Remove the transmission from fixLure.
GROUP
SERVICE
IRANSMISSION
AUTOMATIC
98
[|RrsG
698
624
608
624
I
622
629
I
031
831
696
t
:
0
615
616
637
663
669
v
674
683
692
ILL
NO.
DESCRIPTIOT{
T ,H R U S T{ I N P U T
ASSEMELY
863 EEARING
NH A F T }
C A R R I E IFO R E A C T I O S
6 6 9 W A S H E RT, H R U S T( R E A C T I OSNH A F T /
SHELL}
SN
HELLI
6 7 4 W A S H E RT, H R U S T( R A C E I R E A C T I O
A S S E M B I YT, H R U S T( R E A C T I O N
683 BEARING
CARRIER/SUPPORT}
N E A RS U P P O RTTO C A S E
6 9 2 8 R G , .R E A C T I O G
6 9 6 S E A LT
, RANSMISSIO
{ LNO& R E V E R S E
C L U T C H- O U I E R ,C € N T € RI ,N N E R }
ILL.
NO.
D€SCRIPTION
6 0 1 W A S H E RT, H R U S TI P U M PT O D R U M }
6 0 8 S E A L S ,R E V E R S IEN P U TC L U T C H
( I N N E R& O U T E R I
6 I 5 B E A R I N GA S S E M S L YS,T A T O RS H A F T /
WASHER
SELECTIVE
8 1 6 W A S H E RT, H R U S T( S E L E C T I V E }
DS G .
6 2 2 S E A I , " Q " R I N GI N P U TT O F O R W A R H
8 2 4 S € A L ,3 R O & 4 T H C L . { I N N E R& O U T E R I
D L U T C H( I N N E F& O U T E N I
6 2 9 S E A L ,F O R W A R C
& OUTER)
, V E R R UC
N L U T C H( I N N E R
O3I SEALO
I N. P U TS U N G E A R
ASSEMELY
637 BEARING
Figure 178
AUIOMATIC
TRANSMISSION
SERVICE
GROUP
99
!7|RrsE
Vll
F
,66
>-----69
dF>,-'o
Figure L79
GROUP
SERVICE
TRANSMISSION
AUTOMATIC
100
ARrsE
ILL.
NO.
ILL.
NO
OESCRIPTION
OESCRIPTION
PLATE,VALVEBODYSPACER
S C R E E NS, H I F TS O L E N O I D S
S C R E E NP, R E S S U RC
L OLENOID
S C R E E N , 3 .C
2O N T R O S
GASKET,SPACERPLATETO VALVEBODY
PLATE,SPACERPLATESUPPORT
S P R I N G1, . 2A C C U M U L A T O R
RINGO
, I L S E A L( 1 . 2A C C U M U L A T O N )
P I S T O N1
, . 2A C C U M U T A T O R
COVERAND PIN ASSEMBLY1.2 ACCUMULATOR
BOLT,ACCUMUI-ATORCOVER
COVER
BOLI ACCUMULATOR
VALVEASSEMBLYCONTROLBODY
CHECKEALL
8OLT,VALVEBODY
S P R I N GA S S E M B L YM A N U A LD E T E N T
B O L TM
, A N U A L D E T E N TS P R I N G
CONNECTOR
SEAL,WIRINGHARNESSPASS.THRU
O.RING
A S S E M E L VW I R I N GH A R N E S S
66 SOLENOID
6 7 S E A L ,O . R I N G( S O L E N O I D )
, E XW A S H E RH E A D( S O L E N O I O }
6 8 B O L TH
NR E S S U R E
6 9 S W I T C HA S S E M E L VT.R A N S M I S S I O P
EW I T C HA S S E M B L Y
7 0 B O L TP
, R E S S U RS
7 1 S E A L ,F I L T E R
NIL
72 FILTER
A S S E M B L YT R A N S M I S S I O O
73 GASKET,TRANSMISSIONOIL PAN
74 MAGNET,CHIPCOLLECTOR
NIL
7 5 P A N ,T R A N S M I S S I O O
OIL PAN
76 SCREW.TRANSMISSION
77 BOLT,SPACERPLATESUPPORT
, T E E LC U P
78 PLUGS
79 SHAFT,PARKINGERAKEPAWL
8 0 S P R I N GP, A R K I N GP A W LR E T U R N
81 PAWL,PARKINGBRAKE
82 SEAL,MANUAL SHAFT
8 3 R E T A I N E RM, A N U A LS H A F T
8 4 S H A F TM
, ANUAL
85 ACTUATORASSEMBLVPARKINGLOCK
8 6 B R A C K E TP, A R K I N GL O C K
87 BOLT,PARKINGLOCKBRACKET
8 8 L E V E RI,N S I D ED E T E N T
89 LINK,MANUAL VALVE
90 NUT, HEX HEAD
91 NO. 10CHECKEALL
9 2 S C R E E NT,C C
48
49
50
51
52
53
54
55
56
57
58
59
60
51
62
63
64
65
1 T O R O U EC O N V E R T EA
RS S E M B L Y
2 8OLT.PUMP TO CASE
3 O.RING,PUMP TO CASEBOLT
1 P U M PA S S E M E L YO, I L
5 S E A L ,O I L ( P U M PT O C A S E }
6 G A S K E TP, U M PC O V E RT O C A S E
7 B U S H I N GC, A S E
9 V E N TA S S E M B L YT, R A N S M I S S I O N
1 0 C O N N E C T O RO, I L C O O L E RP I P E
1 1 P L U G ,C A S ES E R V O
1 2 S P R I N GS
, E R V OR E T U R N
1 3 P I N ,2 N O A P P L YP I S T O N
( 2 N DA P P L YP I S T O N }
1 1 R I N G .R E T A I N E R
S,E R V OC U S H I O NS P R I N G
15 RETAINER
1 6 S P R I N GS, E R V OC U S H I O N
1 7 P I S T O N 2, N O A P P L Y
1 8 R I N G ,O I L S E A LI 2 N D A P P L YP I S T O N. O U T E R I
1 9 R I N G ,O I L S E A L( 2 N DA P P L YP I S T O N. I N N E R )
, E R V OP I S T O N( I N N E R )
2 0 H O U S I N GS
2 1 S E A L ,O - R I N G
, E R V OA P P L YP I N
2 2 S P R I N GS
. E R V OA P P L YP I N
2 3 W A S H E RS
PIN)
2 1 R I N G .R E T A I N E(RA P P L Y
2 5 P I S T O Nl,T H A P P L Y
2 6 R I N G ,O I LS E A L( 4 T HA P P L YP I S T O N. O U T E R }
2 7 S E A L ,O . R I N G( ? . 4 S E R V OC O V E R )
2 8 C O V E R2, ' I S E R V O
2 9 R I N G ,S E R V OC O V E RR E T A I N I N G
30 SEAL,CASEEXTENSIONTO CASE
3 1 E X T E N S I O NC, A S E
32 BOLT,CASEEXTENSIONTO CASE
, A S EE X T E N S I O N
3 3 B U S H I N GC
OIL
3 4 S E A LA S S E M B L YC, A S EE X T E N S I O N
3 5 B O L TS
, P E E DS E N S O RR E T A I N I N G
3 6 S P E E DS E N S O RI,N T E R N A LT R A N S M I S S I O N
3 7 S E A I , O . R I N G{ I T S ST O C A S EE X T E N S I O N )
3 8 P L U G .T B A N S M I S S T OCNA S E( A C C U M .B L E E D )
3 9 P L U G ,P R E S S U R E
A N D E A I L A S S E M B L Y3 R DA C C U M
10 RETAINER
. 1 P I N ,B A N DA N C H O R
A N D B A L LA S M . ( D O U B L EO R I F I C E }
12 RETAINER
P]STON
4 3 P I N ,A C C U M U L A T O R
{ . P I S T O N 3, . 1 A C C U M U L A T O R
4 5 R I N G ,O I L S E A L( 3 . 1A C C U M U L , A T OPRI S T O N )
. 6 S P R I N G3, . 1 A C C U M U L A T O R
17 GASKEI SPACERPLATETO CASE
Figure 180
GROUP
SERVICE
TRANSMISSION
AUTOMATIC
101
[7|RrsE
I
301
__l
6i4
612 6i3
J
,
'
611 3?t
i
i
r|h A fr,+:,r
n t t t ,
l \ t / / E
firfr;-nr€ff
Rf \/ \!F
650
,
,Ab^
/-\\
\R/ rr---tr
\l2
YVI
0-680
Figure
181
GROUP
SERVICE
TRANSMISSION
AUTOMATIC
l02
651
_
I
lZ|RrsE
ILL.
NO.
ILL,
NO.
DESCRIPTION
6514 PLATE
ASSEMBLY
3ROAND'TH CLUTCH
{FISER}
(STEEL)
6519 PLATE,3RD
ANO'TH CLUTCH
(ST€ELI
651C PLATE,3RO
ANOaTHCLUTCH
(SEL.)
655 PLATE,3RO
AND'TH CLUTCH
BACKING
656 RING,3RD
ANO1THCLUTCH
BACKING
PLATE
RETAINER
657 EUSHING,
INPUTSUNGEAR{FRONTI
658 GEAR,INPUTSUN
659 BUSHING,
INPUTSUNGEAR(R€AR)
66,I RET,,
OUTPUT
SHAFTTOINPUTCARRIEN
562 CARRIER
ASSEMSLY,
INPUT{COMPLETEI
(INPUTCARRIEB
563 BEARING
ASSEMEtY,
THRUST
TO
REACTION
SHAFTI
664 GEAN,INPUTINTERNAL
665 BUSHING,
REACTION
CARRIER
SHAFT(FRONT)
666 SHAFT,
REACTION
CARSIER
607 BUSI{ING,
FEACIION
CARRTER
SHAFT{REARI
668 RING,REACTION
SHAFT/INTERNAL
GEARF€TAINER
THRUST
659 WASHEfi,
SHAFT/SHELI}
INEACTION
670 SHELL,
NEACTION
SUN
67I RING,R€ACTION
SUNGEARRETAINEF
672 BUSHING,
R€ACTION
SUN
673 GEAR,REACTION
SUN
(RACE/?EACTION
674 WASIJER,
THRUST
SHELL)
675 RACE,LOANOREVERSE
ROLLER
CLUTCH
676 RING,LOANDREVERSE
TO CASERETAINER
SUPPORT
677 RING.LOANDREV€RSE
RETAINEF
IROLLER
ASS€M8LY/CAM'
67E CLUTCH
ASSEMBLY
LOANOREVERS€
ROLLER
679 SUPPORT
ASM.,LOANOREVEFSE
CLUTCH
680 SPRING.
TRANSMISSION
tLOANDFEV€RSE
CLUTCH
SUPPOET
RETAINER}
681 CARRIER
ASSEMSLY
REACTION
(WAVEO)
6824 PLATE,
LOANDR€VERSE
CLUTCH
6828 PLATE,
LOANOR€VERSE
SPACER
CLUTCH
(SELECTIVE)
682C PLATE
ASSEMELY
LOANOREVERSE
CLUTCH
IFIBERI
682D PLATE,
LOANOREVERSE
CLUTCH
ISTEELI
683 EEARING
ASSEMSLY,
THRUST
{REACTION
CARiIER/
SUPPORTI
681 GEA8.INTERNAT
REACTION
685 SUPPORT,
INTERNAL
REACTION
GEAR
686 RING,REACTION
FETAINEN
GEAR/SUPPONT
687 SHAFT.
OUTPUT
690 SLEEVE,
OUTPUT
SHAFT
69I SEAL,OUTPUT
SHAFT
692 8RG..REACTION
GEARSUPPORT
TOCASE
693 RING,LOANDR€V€FSE
CLUTCH
RETAINEF
691 SPRING
ASSEMBLY,
LOANDREVERSE
CLUTCH
695 PISTON,
LOANOREVERSE
CLUTCH
695 SEAL,Tf,ANSMISSION
{LOANOREVERSE
CTUTCH
OUTER,
CENTER,
INNERI
697 DEFIECTOE,
OIL(HIGHOUTPUTMOO€LSONLY}
698 PLUG,OntFtCeD
Cup
699 ROTOR,
INTERNAI
TRANSMISSTON
SPE€DSENSOR
DESCRIPTIOT{
600
601
602
603
605
SPRING
ASM.,3.1CLUTCH
SOOST15)
WASHER,
THRUST
IPUMPTO DRUM)
EANOASSEMALY
2-il
EUSHING,
NEVERSF
INPUTCL,(FRONT}
XOUSING
ANODiUM ASSEMBLY,
REVERSE
INPU]
CLUTCH
606 EUSHING,
REVERSE
INPUTCLUTCH
{REARI
607 PISTON
ASM.,REVERSE
INPUTCLUTCH
608 SEALS,REVERSE
INPUTCTUTCH
(INNER
ANOOUTERI
609 SPRING
ASM.,REVERSE
INPUTCLUTCH
610 NING,R€VEFSE
INPUTCLUTCH
SPRING
BETAINER
611 PLAT€.REV€RSE
INPUTCLUTCH
IEELLEVILLEI
(FIBER)
6,12APLA'EASM.,REVEFSE
INPUTCLUTCI{
6128 PLATE,
REVEFSE
INPUTCLUTCH
{STEEL)
613 PLATE,
REVERSE
INPUTCTUTCH
EACKING
(SELECTIVE)
6'I' RING,R€VERS€
INPUTCL.RETAINING
615 BEANING
ASSEMELV
STATOR
SHAFT/
SELECTIVE
WASHER
616 WASHER,
THRUST
ISETECTIVE'
817 RETAINER
ANOBALLASM.,CHECK
VALVE
618 SEAL,O-RING
WASHER)
ITURAIN€
SHAFT/
S€LECTIVE
619 RING,OILSEALISOLIO)
620 RETAINER
ANOCH€CKBALL
ASSEMELY
62I HOUSING
ANDSHAFTASSEMBLY
INPUT
622 SEAL,O.RINGINPUTTO FORWARD
HSG,
623 PISTON,3RO
ANOlIH CLUTCH
82il SEAL,3RO
ANOlTll CL.0NNER
ANOOUTEi)
625 RING,3RDAND'TH CLUTCH
{APPLY}
626 SPFINGASSEMBLY
3RDAND4THCLUTCH
627 RETAINER
ANDSALLASSEMELY
FORWARD
CLUTCH
HOUSING
628 HOUSING.
FORWARO
CLUTCH
(INNER
629 SEAL,FORWARO
CLUTCH
ANDOUTER}
630 PISTON,
FOiWAROCLUTCH
631 SEAI,OVERRUN
CLUICH{INNER
ANDOUTERI
632 PISTON,
OVERSUN
CLUTCH
633 8ALL.OV€RRUN
CLUTCH
634 SPRING
ASSEMBLY
OVERRUN
CLUTCH
gPRINGRETAINER
835 SNAPRING,OVEiRUNCLUTCH
T3' SEAL,INPUTHOUSING
IO OUTPUT
SHAFT
637 EEARING
ASSEMEIYINPUISUNGEAR
838 SNAPFING.OVERRUN
CL.HUEREYATNING
639 HUg,OV€RBUN
CLUICH
6''I RETAINER
ANORAC€ASS€MBLY
SPRAG
6T2 FORWARO
ASSEMELY
SPRAG
643 RETAINER
RINGS,
SPRAG
ASSEMSLY
661 RACE,FOFWARD
CLUTCH
IOUTER)
615A PLATE
ASSEMELY
OVE8RUN
CLUTCI{
{F|8ER)
6'58 PLATE,
OVERRUN
C!UTC}iiSTEEL)
(APP!Y)
646 PLATE,
FORWARO
CLUTCH
648 PLATE,FORWAiOCLUTCH{WAVED)
6a9A PLAI! ASSEMBLy
FORWARO
CLUTCH
{FtEEnt
3198 PLAT€,FORWARO
CLUTCH
{STEEL}
FORWARD
650 PLATE,
CLUTCH
EACKING
{SEL.)
65I RING,FORWAFO
CLUTCH
PLATE
FETAINER
EACKING
652 PLATE,
3ROANO4THCLUTCH
RINGRETAINER
553 PLATE,
3ROAND 'IH CLUTCH
APPLY
lSTEPPEDI
Figure
L82
GROUP
SERVICE
TRANSMISSION
AUTOMATIC
103
!?|Rrs6
T e c h ni c a l S e r v i c el n fo r m a t i o n
---\-\_.\-_
"b-P
382{,
\/
sss;i
,tuI
389--r
381
O
sssi
Figure 183
GROUP
SERVICE
TRANSMISSION
AUTOMATIC
r04
fi|RrsE
T e c h ni c a f S e r v i c eI n fo r m a t i o n
340 VALVE,MANUAL
350 VALVEASSEMBLY,CONTROLBODY
3 5 3 S E A L ,F O R W A R D
ACCUMULATOO
R It
, ORWARD
3 5 4 P I S T O NF
ACCUMULATOR
3 5 5 P I N ,F O R W A R D
ACCUMULATOR
3 5 6 S P R I N GF, O R W A R D
ACCUMULATOR
357 VALVE,FORWAROABUSE
358 SPRING,FORWARDABUSEVALVE
3 5 9 P L U G ,E O R E
3 6 0 P I N ,C O I L E DS P R I N G
361 VALVE.LOW OVERRUN
3 6 2 S P R I N GL. O W O V E R R U NV A L V E
3 6 3 C O V E RF, O R W A R O
ACCUMULATOR
3 6 4 8 O L T ,F O R W A R D
ACCUMULATOR
COVER
3 6 5 S P R I N GI,. 2 S H I F TV A L V E
3 6 6 V A L V E I, . 2 S H I F T
(AI
3 6 7 A 1 . 2S H I F TS O L E N O I D
3 6 7 8 2 . 3S H T FS
T O L E N O T{O
B}
368 VALVE,2-3 SHIFT
369 VAIVE,2.3 SHUTTLE
3 7 0 S P R I N G1, . 2A C C U M U L A T OVRA L V E
3 7 1 V A L V E1, . 2A C C U M U L A T O B
3 7 2 S I E E V E 1, . 2A C C U M U L A T OVRA L V E
3 7 3 P L U G ,E O R E
3 7 4 V A L V EA, C T U A T O RF E E DL I M I T
3 7 5 S P R I N GA, C T U A T O RF E E DL I M I TV A L V E
3 7 6 P L U G ,E O R E
3 7 7 P R E S S U RC
378 RETAINER
P,R E S S U RC
EO N T R O S
L OLENOID
379 RETAINER
S,O L E N O I D
3 8 0 V A L V EC, O N V E R T ECRL U T C HS I G N A L
3 8 1 P L U G ,B O R E
3 8 2 S P R I N G4, . 3 S E O U E N C E
VALVE
383 VALVE,1.3 SEOUENCE
384 VALVE,3-1 RELAY
385 VALVE,3-1 SHIFT
386 SPRING,3.1 SHIFTVALVE
3 8 7 V A L V ER
, EVERSE
ABUSE
3 8 8 S P R I N GR, E V E R SA
EB U S EV A L V E
3 8 9 V A L V E3. . 2 D O W N S H I F T
3 9 0 S P R I N G3. . 2 D O W N S H I F T
VALVE
3 9 1 V A L V E3, . 2 C O N T R O L
392 SPRING,3.2 CONTROLVALVE
3 9 3 S P R I N GB, O R EP L U G
3 9 4 3 . 2 C O N T R O LS O L E N O T D
395 RETAINER
E.O R EP L U G
Figure
184
SERVICE
GROUP
TRANSMISSION
AUTOMAIIC
105
F5|HrsE
ILL.
NO.
22
211
230
233 236
2
236
236
239
='r33
237
zroQ\ 2 3 5
2'r0
226
225
212
0---
213
c
fl
DESCRIPTION
2OOSODY PUMP
2 0 1 R I N G ,O I L S E A L{ S L I D ET O W E A RP L A T E )
2 0 2 S E A L ,O - R I N G{ S L I D ES E A LB A C K . U P )
2 0 3 S L I D EP
, UMP
2 0 4 S P R I N GP
, I V O TP I N
2 0 5 P I N ,P I V O TS L I D E
2 0 6 S P R I N GP
, U M PS L I O E( O U T E R }
2 0 7 S P R I N GP, U M PS L I D E( I N N E R }
2 0 8 S U P P O R TP, U M PS L I D ES E A I
2 0 9 S E A L ,P U M PS L I O E
2 1 0 R I N G ,P U M PV A N E
2 1 1 G U I O ER, O T O R
, I LP U M P
2 1 . 2R O T O RO
2 I 3 V A N E ,P U M P
211 SHAFT,STATOR
2 1 5 C O V E RP, U M P
EE G U L A T O R
218 VALV€P
, R E S S U RR
RA L V E
E E G U T S T OV
2 1 7 S P R I N GP
, R E S S U RR
E E G U L A T O IRS O L A T O R
2 1 8 S P R I N GP
, R E S S U RR
219 VALVE,REVERSE
EOOST
220 SLEEVE.REVERSE
BOOSTVALVE
221 RING.OIL PUMP REVERSE
BOOSTVALVE
RETAINING
222 R I N G ,O I L P U M PC O N V E R T ECRL U T C HV A L V E
RETAINING
223 VALVE,STOP
CLUTCH
224 VALVE,CONVERTER
226 S P R I N GC. O N V E R T EC
RL U T C HV A L V E{ I N N E R )
226 S P R I N GC. O N V E R T ECRL U T C HV A L V E( O U T E R }
E E L I E FE O L T
227 R I V E TP, R E S S U RR
228 B A L L ,P R E S S U RR
EE L I E F
2 ? 9 S P R I N GP R E S S U R R
EELIEF
230 R I N G ,O I L S E A L{ S T A T O RS H A F T )
231 S E A L ,O I L P U M PC O V E RS C R E E N
232 S C R E E NO, I LP U M PC O V E R
233 801T. M8 X 1.25X 10 (COVERTO 80DY)
234 E U S H I N GS, T A T O RS H A F T( F R O N T }
2 3 5 P L U G .O I L P U M PC O V E R( F W DC L U T C HF E E D )
236 P L U G ,O I L P U M PC O V E R
237 RETAINERAND BALLASSEMBLY,CHECKVALVE
238 O R I F I C EC, O N V E R T EC
RL U T C HS I G N A L
( C U PP L U G }
239 O R I F I C EO, I L C O O L E R( C U PP L U G )
, U PO R I F I C E
240 P L U G C
241 EUSHING,STATORSHAFT(REARI
242 E U S H I N GP, U M PB O D Y
243 S E A LA S S E M B L YO I L
F ,R O N TH E L I X
244 R E T A I N E R
243
244
Figure 185
GROUP
SERVICE
TRANSMISSION
AUTOMATIC
106
lZ|RrsE
pPa
665
241
\
__l\
*--\r.
i
a
i
672
33
667
@
I
i
II
'-:-, i
]
__\l
l
i
)-
l-...J ,-i
.r
7
33
234
741
?42
603
606
E U S H I N GCASE
,
B U S H I N GC
, A S E€ X T E N S I O N
B U S H I N GS. T A T O RS H A F T( F R O N T )
B U S H I N GS, T A T O RS H A F T( R E A R }
B U S H I N GO, I L P U M PB O D Y
E U S H I N GR, E V E R SIEN P U TC L U T C H( F R O N T )
E U S H I N GR
. EVERSE
I N P U TC L U T C H( R E A R )
657
659
665
667
672
L5:-=lA
B U S H I N G I, N P U TS U N G E A R{ F R O N T }
E U S H I N G I, N P U TS U N G E A R( R F A R }
BUSHINGR
, E A C T I O NS H A F T( F R O N T }
B U S H I N GR
. EACTION
S H A F T( R E A R )
E U S H I N GR
, EACTION
SUN GEAR
TOROUESPECIFICATIONS
LOCATION
OTY.
ow.
srzE
SIZE
TOROUE
P A R KB R A K E
BRACKETO CASE
2
M8
1 . 2 5X 2 0 . 0
3'l N.m
( 2 3L B , - F T , )
LOCATION
TOROUE
ACCUMULATOR
C O V E RT O C A S E
2
M6
1 , 0x 3 5 . 0
'11
N.m
(8 LB..FT.)
ACCUMULATOR
COVERTO CASE
1
M6
1 . 0x 6 5 , 0
1 1N . m
{8 LB,.FT,)
PUMPCOVERTO
B OD Y
5
M8
1 . 2 5X 4 0 , 0
24 N.m
{ 1 8L B . - F T . )
D E T E N TS P R I N GT O
VALVEBODY
I
M8
125x200
2 4N . m
( 1 8L B . F T)
P U M PA S S E M B L Y
TO
CASE
7
M8
1 . 2 5X 6 0 . 0
24 N.m
{1 81 8 . - F T , t
F W OA C C U M C O V E R
TO VALVFBODY
J
M6
'1.0 17.7
x
1 1N ' m
(8 L8 -FT.)
C A S EE X T E N S I O N
TO CASE
1
Mr0
1.50X 30,0
35 N.m
( 2 6L B . - F T . )
SOLENOIO
ASSFMBLY
TO CASE
2
M6
1 . 0x 1 2 . 0
{ 8t B . - F T . }
M A N U A L S H A F TT O
I N S I D ED E T E N TT E V E R
1
M10
1 . 5 0N U T
31N.m
( 2 31 8 . - F T , )
T F A N S M I S S I OO
NI L
PAN TO CASE
16
M8
1 . 2 5x 1 93
1 2N . m
(9LB..FT.)
L I N EP R E S S U R E
PLUG
1
1/8 27
1 1N . m
{8 LB..FT.}
VALVEBODY
TO CASE
2
M6
1 . 0x 3 5 0
1 1N . m
(8 t8,-FT,)
C O N N E C T OC
RO O L E R
P IP E
2
1t4 18
VALVEEODY
TO CASE
9
M6
1 . 0x 4 7 , 5
1 1N . m
(8 LB.-FT.)
P R E S S U RS
EW I T C H
ASM. TO VALVEBODY
2
M6
1 , 0x 1 7 . 7
38 N'm
( 2 8L B . F T)
tt N'*
(8 LB,.FT.)
VALVEEODY
T OCA S E
3
M6
10x54.4
1 ' lN . m
(8 tB.-FT.)
VEHICLE
SPEED
S E N S O RR E T A I N E R
M6
1 . 0x 2 1 . 7
1 1N ' m
{8LB..FT.)
VALVESOOY
TO CASE
3 i
M 6
' 1 .0x 6 50
1 1N . m
( 8 L B , . F T)
S P A C E RP L A T E
S U P P O RT O C A S E
M6
1 . 0x 1 7 , 7
{ g 1 8 , - F T)
M6
1 , 0x 1 7 . 7
1 ' lN ' m
(8 LB..FT.}
PRESSUR
CE
ONTROL
S O LE NO ITOO
VALVEEODY
I
I
11N'm
'l
3
Figure 186
GROUP
SERVICE
TRANSMISSION
AUTOMATIC
107
11N.m
IZRrsE
ELECTRICAL
TRANSMISSION
CONNECTOR
The transmission
electricalconnectoris a very importantpan of the
HYDRA-MATIC 4L60-E operatingsystem.Anything that interferes
with the electricalconnectioncan cause the transmissionto set
DiagnosticTroubleCodesandlor operateincorrectly.
The tollowing itemscan affectthe electricalconnection:
Bentpinsin theconnectort'romroughhandlingdunngconnection
and disconnection
Wires backing away trom the pins or coming uncrimped(in
eit hert het r a n s mi s s i oonr v e h i c l ew i n n g h a rness)
Dir t c ont ami n a ti oenn te n n gth ec o n n e c tow
r heni t i s unconnected
or pushedout
P insin t heco n n e c tobr a c k i n go u t o f th e c o n nector
dunngc onn e c ti o n
wicking
Exces.sive
transmission
tluid leakinginto the connector.
up int o t he v e h i c l c w i ri n g h a rn e s sa n d degradi ngthe w i re
ins ulat ion{
- W at er / m ois tu re
i n tru s i o ni n th e c o n n e c l o r
- L o w p r nr e t e n t i o n
l i o m c x c e s s i vceo n n e c t i ounn dd i s c o n n e c t i o n
of t he winng h a rn e s s
- Pin corrosiontiom contamination
't The presence
connectoris
of transmission
tluid in the transmission
SOUEEZE
HERE
not har m lul in i ts e l f. T h e fl u i d o n l y a ffe c tsthe vehi cl eharness
w i r i n gi n s u l i r t i oinf t h e t l u i d w i c k su p t h a tf a r .
Pointsto rememllerrvhenrvorking rvith the transmissionelectrical
connect0r:
- To remove the connector.squeezethe two tabs towardseuch
ot herandpul l s tra i g hut p (Se ei l l u s tra ti o n ).
- Cr r r ef
removal .
duri n-rt
ully lim i t tw i s ti n go r w i g g l i n gth ec o n n ector
T his c anben dp i n s .
- DO NO T pr y th ec o n n e c toor tf w i th a s c re wdri ver
< >other
r
tool .
- To instull the connector.first orient the pins by lining up the
arrowson eaeh half ot'theconnector.Pushtheconnectorstraight
down r nt ot hetra n s m i s s i owni th o u ttw i s ti n gor angl i ngthemati ng
pan.s.
- T he c onnec tosr h o u l dc l i c k rn top l a c ew i th a posi ti vet' eeland/or
noisc.
- Wheneverthe transmissionpass-thruconnectoris disconnected
trom the vehicle harnessand the engine is running, multiple
DiagnosticTroubleCodeswill set. Be sure to clear thesecodes
the pass-thruconnector.
after re-connecting
DT C' s 59. 67 a n d 8 2 w i l l s e tw i th k e y o n . e ngi neotT.
DT C' s 59, 66 , 6 7 ,7 3 a n d 8 2 w i l l s e tw i th k e y on. engi neon.
Figure
187
GROUP
SERVICE
IRANSMISSION
AUTOMATIC
108
IZlnrsE
4L6O.E
COMPONENT
RESISTANCE
CHART
CO M P O N EN T
T E R MIN A L
WIRE
COLOR
PASS.THRU
P IN
RESISTANCE
@zo"c
CKT #
A
RED
E
B
G R NL T
A
A
RED
E
B
YEL
B
A
RED
E
B
WHT
S
A
PPL
c
B
BLU LT
D
A
BRN
L
B
GRA
M
455
&
c
PNK
N
1224
P RE S S URE
S W I T C HAS SE M BL Y
D
ORN
P
E
BLUEDK
R
A
RED
E
B
BLACK
T
1 . 2 S H I F TS O L E N O I D
r
20 - 40Ohms
*
9 - 1 4O h m s
3 . 5- 8 O h m s
1228
1229
2 . 9- 4 . 0k O h m s
SEE PAGE85
1227
1226
1225
I
20 - 40 Ohms
r S p l i c e di n t e r n a l l yt o P i n E .
188
GROUP
SERVICE
TRANSMISSION
AUTOMATIC
r09
1149C
897
T R A N ST E M P E R A T U BSEE N S O R
Figure
11 4 9 A
1223
3 . 2 C O N T R O LS O L E N O I D
T C CS O L E N O I D
11498
1222
2 - 3S H I F TS O L E N O I D
PRESSU
R EC O N T R O L
SOLENOID
29. 4AOhms
1149E
422A.
ARrsE
ACTIONS
TROUBLE
CODES
2l
22
28
NO 4TH CEARIF HOT MODE
ThrottlePositionSensorCircuit (High)
T hr ot t leP o s i ti o nSe n s o C
r i rc u i l(L o w )
37
S w i tc hA s s e m b l yF a u l t
F luid P r es s u re
BrakeSwitch Stuck"ON"
38 -
Brake Switch Stuck "OFF'
67
TCC SolenoidCircuit Fault
24
72
VehicleSpeedSensor[,ow
VehicleSpeedSensorLoss
2 N DC E A R
52 53
66
7S
LongSystemVoltageHigh
High
SystemVoltage
3-2ControlSoelnoid
CircuitFault
Voltage
System
Low
3RDGEARONLY
8l
CircuitFault
2-3ShiftSolenoid
2ND GEARONLY
OR
3RDCEARONLY
82
l - 2 S h i f tS o l e n o i d
2ND AND 3RD GEARS ONLY
OR
I ST AND 4TH GEARSONLY
69
TCC Stuck"ON"
E A R LY S H IFTS
Figure 189
GROUP
SERVICE
TRANSMISSION
AUTOMATIC
lI0
!/RrsG
CODEACTIONS
TROUBLE
DIAGNOSTIC
4L6O.E
1993HYDRA.MATIC
codeis set,thc PCM
with them.This meansif a particular
codeshave"actions"associated
Somemalfunction
fromdamage,
protects
components
way.
This
thc
transmission
to bchavein a cenain
commands
thetransmission
scrviccd.
andallowsthetransmission
to functionuntil it canbc
ACTIONS
TROUBLE
CODES
l4
t5
2l
22
2E
37
38
52
53
67
75
E ngineCo o l a n tT e mpS e n s o C
r i rc u i t(H i g h)
r i r c u i t( L o w )
E n g i n eC o o l a nTt e m pS e n s oC
TCCAPPLYWITH A COLDENGINE
r i rc u i t(H i g h )
T hr ot t leP o s i ti o nS e n s o C
ThrottlePositionSensorCircuit (Low1
NO TCC
Fluid PressurcSwitchAssemblyFault
BrakeSwitch Stuck"ON"
B r ak eS wi tc hS tu c k" O F F "
Long S y s te mVo l ta g eH i g h
SystemVoltageHigh
8r
TCC SolenoidCircuit Fault
SystemVoltageLow
2- 3 S hif t So l e n o i dC i rc u i tF a u l t
69
T CC S t uc k" O N "
T C CO N I N A L L C E A R S
2l
ThrottlePositionSensorCircuit (High)
ThrottlePositionScnsorCircuit (Low)
FIXEDSHIFTPOTNTS
2l
22
28
73
T h r o t t l eP o s i t i o nS e n s oC
r i r c u i t( H i g h t
T hr ot t lePo s i ti o nSe n s o C
r i rc u i t(L o w l
24
52
53
72
73
75
8l
82
V e h i c l eS p e e dS e n r o r. S i g n ,lr-lo w
L o n g S y s t c mV o l t a g eH i g l r
z2-
Fluid PressurcSwitchAssemblyFrult
PrcssureControl SolenoidCunent
MA X LINE
S y s t emV o l n g e H i 3 h
Vchicle SpcedSensorLoss
Pressure
ControlSolenoidCurrent
SystemVoltageLow
d i r c u rF
t lult
2 - 3 S h i l lS o l e n o i C
t o l c n o rC
l - 2 S h i l 'S
d r r c i r rI tr . r r r l t
Figure
190
GROUP
SERV]CE
TRANSMISSION
AUTOMATIC
llt
TOOLS
SPECIAL
/-RrsG
Rear Seol lnctrller
Oiel lndicator Set
Univcrul Removcr
..fn
[iP
Oil Pump Bocly& C o v e rA l i g n m e n t
HoldingFixturc& Eose
Sand
ffi,763.02
'#{^\
%re
Clutch Spring
g
i:ffJ.","7p
J 23456
J- 37789
J 23492-14
J 22269-01
Oil Pump Remover & End Play Checking
Fixturc
e
\J
J 25019-9
J 24773
J 25018
J 23327
l!,sJ
Pump Removor& Inctaller
J 25022
ClutcnSpring
Comprclror
ffi_
J 21368
End Play Chocking
Fixturc
Pump Oil Scal
J 21428
ClutchSpring
Comprecror
Press
S p e e dS o n g o r
Remover
UniversclRcmovcr
^\A-2fr1J7
U
End Ploy Fixturc
Adrptor
B u s h i n gR c m o v o r
Adaptor
m
A
w
€
J 34725
J 39119
f4-,n
I '\--t
J 30418-1
\-
(-'\'' r
J 29369-1
J 36418-2
ri
-Jtt
I
Inner Ovgrrun Clutch Seal Protector
Speed Sonror Rotor Installer
J 29837
2-4 Bcnd Apply Pin Toole
EushingSet
[:D
J 33037
O i r l l n d i c r t o rS t a n d& G u i d sP i n S e t
J 35944
J 36352
S p e e d o m e t eGr e a rI n s t a l l e r
-
I
I
q;D
J 5590
-,4
Handlo
-<-'-'l
e
€
J 29883
Coolcr Flurhcr
J 29369-2
Output Shcft SupportFixturc
-L
J 29714
lnner Forward Clutch Seal Protoctor
J_/
!5
s
Ai:'F"
u ' \ - ' J z 1 4 z 7 - 0&
1J8433
u
B u r h i n g& U n i v c r r c lR c m o v o rS c t
ServoCover Compressor
J 24036
J 25019-14
S p e e d o m s t e rG e a t P u l l e r & A d a p t e r
T u r b i n gS h a f t
Seol Sizer
Turbine Shcft
J 25019-16
J38
J 25019-4
J 23907
IEn!-ID
0l
EE-*6
J 25025-B
GROUP
SERV]CE
TRANSMISSION
AUTOMATIC
l12
ri
\L---t
'\
(+1,/
/4\
J 34196
4L6OE.MANO1
7,HT5E
--|l.-
-
DODD/PR
l-
OMATIC TRANSMISSIONSERVICE GRV
P R I N T E DI N U . S . A 1
. 1/OB

7,HT5E

Transcription

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