FITS Al1L KM electronic OverDrive

CHECK HOLE SIZE! A paperclip should NOT fit
thru hole! A feed hole .035" or larger floods EPC
solenoid,causingrough shifts and excessbindup during 2-3 shift (not enoughpsi DROP when TCU pulses
EPC solenoid).If paperclip fits thru hole, replacejet
with extra alum plug provided in kit. Removejet, insert plug' in hole and smack with hammer to spread
tight. Drill a new .031-.033" hole in centerof plug
(fractional size 1/32").NOTE:1/32" drill not provided.
FITS Al1L KM electronic OverDrive
The VB mmodels with trans on driver side are tJ..e
MIRROR IMAGE of~th1tshown in the instrUctions:
~
You're gonna love this product!
The large high rez pictures and clear instructions
make it nearly fool proof. I have to say nearly
sincetherewill alwaysbe that one rocket scientist
to prove me wrong. But for most of you DSM' erg
and rice rocket fans.. take your time, pay
attention, don't get careless,and success.is just
around the comer. Hundreds of nonprofessionals
haveinstalledthis kit without complications.
Please follow the installation exactly as shown
and do not /week our recommendationsand
settingstrying to get "fimler shifts" beforeyou've
even roadtestedit. This kit provides fast, firm,
high quality shifts right outa the box!
Dean Mason
TransLabProduct S\;lpport
2740 W. Ball Rd. / uirit D2
Anaheim,California USA [92804]
HOTLINE 714-484-6657
FAX
714-484-6697
email = [email protected]
ALL CONTENTS PRODUCED BY TRANSLAB C DEAN MASON I TRANS LAB MAR.
1998 all rights reserved I revision 07-01-04
UseFIVE DRILL BITS SUPPLIED
IN KIT [ 4 numbered / 1 fractional]
to enlarge holes shown above!!
#42 =
#35
.093"
= .110"
3/16"
= .1"87"
page3
Hi tensUestrength ...won't pushthru the hole
Low speclflc gravity... won't beatup or rifle thru the plate
UPPER
VALVE
BODY
2-3 /4-3 shift
1-2 shift
rear clutch exhaust
stopB
stop A
plug A
large GRAY
I
FACES
0 UT !
\
TC control
U_11~11_1UJJ
flat sides
/
softer
rt
:/inner
4
ORIGINAL
RED
IrmI.-1
after two screw retainer
/
PREFER LESS FIRM SHIFTS
(more comfortablecoastdownshifts).
USE RED SPRING
NOTE: upshiftswith red spripg are
still much firmer than Stock.
~
SHIFf CONTROL VALVE ASSEMBLY
r
bracketis mountedon.
-~
PRESSURE
downshifts)
(useyour car to and from work) .
~
shift wI vlv
SILVER
SHIM SPRINGEND OF N-D VALVE.
Valve will NOT move
BLACK
IF YOU...
HA VB AN UNMODIFIED CONVERTER.
DO NORMAL STREET DRIVING
-
!
r
, PUSHONTO INNER
~
ALL PERFORMANCEAPPLICAnONS INSTALL
BLACK SPRING FOR FIRMEST SHIFTS.
(you will be IbIe k>feci ~t
I.
\,
- -N~Dcontrol
~sure
control
c'
;
~
/
holein valve
/
.. (lllAAAAI
~
PR adjustment:
1/2 - 1 thread
sticking out at
inner end of
adjuster
tX
shift control
pressureregulator
ORANGE
plugB
J~
1.I.lll.lJ.lllllll.lI!I~1
=
,
fJTJTJmnJ
PURPLE
fj,AAMA,wJ
-B-
-A-
-:~>:
~
Iill1UillW1
wrong
gear
starts...
common
assembly
error...
valvestop
incorrectly
installed
here
\
;.
lilLUl,!,I,!,U1U-W-lj
Plugs must go outsidethe valve stops.Outer endsof shift conuol valve
must be able to go thru legs of valve stopswhen moving left and right.
REGULATOR
VALVE
CONVERTER LAND
bevel on
angle if
nub is
gone
IF TRANS HAs NEVER BEEN WORKED ON YOU CAN
SKIP THIS PORTION. IT'S A REPAIR TIP FOR
INCORRECfL Y MODIFIED PR VALVE.
A tiny bevel ( 1/32" max) on one side of the converterland
is ok. but land must close completely when PR valve is
bottomed in it's bore. View land at notch in casting (see
white circle/arrow above).
,:t!:
CAUTION: If land is ground all the way'aroUndand is open
when bottomed, replacevalve. End clutch damageand coast
downshift neuttaling could occur. If land is only slightly
ope.nit may be repairable by grinding off someof the nub
on inner (right) end to let PR valve sink deeperinto the bar::.
If nub is completely ground off, bevel end on angle shown
aboveto allow balancepressureunderinner endof valve.
LOWER VALVE BODY
END clutch
Light
Brown
Yellow
JmrtiYfffTTn
damperclutch control
«
MWm
N-R engagementcontrol
reducing
light or dark
Blue
MATCH VALVE TO
CORRECT SPRING
MEASURE REDUCING
VAL VB LAND DIAMETERS
t
TYPE 1
ADJUST AS SHOWNBEWW.
ADD 1 ADDITIONAL 1URN
CLOCKWISE FOR m-po USE
TYPE 2
If a valve with lands that
differ by more than +/.001" is found USE
ORIGINAL SPRING
and please contact us
with vehicle VIN # .
W\AAAAAAt
Light Blue
.393" .493"
-
ADJUSTMENT adjuster flush with casting
.393" .393"
ADJUSTMENT - Use .125"
a feeler guage between
adjuster and valve body
(1/8") drill bit like
the bottom of the
ca~ting
.
NON-LOCKUP MODELS:
NO SPRING INSTALLED
Factory replaced damper clutch
control valve and spring with
a one piece non-moving plug.
ATTENTION!
Examineball seatin plate and areaof alum
casting in lower channel plate that guides
ball & spring. If beginning to showdamage
from ball bouncing around, line pressure
relief been very active. Replacesteel ball
\PRESSURE
RELIEF
with hi tensionball furnished,andreusea
11
steel at one of the other locations that
showsNO WEAR mark in plate.
./
1/4- STEEL
CHECKBALL
!
~
/,
LINE
I
~
~
0
~REEN
ACTUAL SIZE SHOWN
SAMPLE VAL VB BODY SHOWN IS KM175-177.
W4A321 F4A33 I A4EFI MAY VARY SLlGHTLY
. Lay middle castingon upperVB. Install the #3 bolts fingertight.
. Placelower VB on middle casting,gentlypushdown to
G) {~_.
~
.385"
.745"
compressrelief valve spring andinstall #6 with washer.
. Insertalignmentpins in holesasshown.
@
Late W4A33,
F4A33, &A4AFI
USE LONGER
BOLTS IN 2
PLACES
.855"
. Install all othersshownexceptsolenoidmountingbolts but do
not tighten.
. Checkseperatorplate alignmentthru VB to CASE ( lOmm
bolt) holesaroundouter edge.
. SNUGbolts in this order: #6 with washer,two #7's, all #6's,
all #5's, two #2's, then all #3's.
. TORQUEbolts to 55-60 inch Ibs in sameorder.
(70+ inch lbs will strip threads).
.
@
1 .1 75"
@
1.330"
@
1.570"
IMPORT ANT: Insert scribe through cover plate hole and
stroke damper clutch valve. It must movefreely! Stuck
dampervalve cancauseplanetarybum out (no cooler flow).
measure length
1
CAREFULnot to overtighten & strip threads.
2 lower VB mounting bolts don't thread deep.
Torque 40-45 inch Ibs.
lower VB mounting bolt
or#3
#6 with washer
ALIGNMENT
PINS
attach
EPC
ground
wire
here
lower VB mounting bolt
~
WARNING:
Filter bolts
too long will
damageVB!
( bottomin
castingand
distortlower
VB, binding
dampervalve
or breakthe
castingat
innerendof
reducing
valvecausing
neutraling,
slips,flares,
andirratic
shifts.)
cover plate has hole here
view damper valve movement through opening
page6
Early type flat bottom shift solenoids
EARLY TYPE SOLENOmO-RINGSshouldhavesomepress.
That is, thereshouldbe a slight gap betweensolenoidandalum
A
0
/
/
body that closes up when screws are tightened. With screws
removed there is a very slight "spring" feel when squeezing o-rings.
LATE PUSH-IN TYPE SHIFT SOLENOmS, use original or new
-- -,
from overhaulkit, whicheverhasfit tighter.Oiledringsmusthave ~
0
<D
slightdrag(pressfit in bore).
r7
Rubber gasketsmust compressto seal when solenoidsare tightened. Replaceif
flattened out. Removescreensbefore blowing out solenoids.They'll go sailing
e
across
lock-up
the room
never to be found.
Reinstall
after solenoids
are cleaned
IN
.
t
screens
EPC
J
.&
t
","
First designEPCusesTWO orings!~~~
/
I
enlarge hole for plug in this portion only!
LOCATE PLUG HERE
DOWN INSmE VALVE
'
and tested.
1. Drill hole in cup plug furnished.
Installing plug without drilling hole causesreversebind
shortly after engagement.
1
---,
l:
INSERT
PLUG
HERE
BLUE-EPC
[ 2-4 ohms]
2. Push plug flush with end of valve with thumb.
WARNING:forcing plug can break end of valve.
Ifplug won't pushflush with only thumb pressure,remove
sharpbevel insideenu of valve. Easiestis witt. high speed
rotary file (carbide"burr") in drill or die grinder.
3. Stand valve on end on vise or hard surface.
4. Carefully tap plug into position shown with a
hammer and small punch (approx
3/16"diameter).
RED - lockup [ early 2-4 ohms]
[ late 13 ohms]
-
ORANGE shift A [ 20-30 ohms]
-
YELLOW shift B [ 20-30 ohms)
page7
ground lead goes between shift solenoids and attaches here with #2 screv.
page8
BAND ADJUSTMENT CRITICAL
no tighterthan 2 turns,
no looser than 2112
turns.
Here's how to check it...
Insert .062" (1/16") drill bit in gap so servo pin
cushion can't compress. Air check through the
band apply hole and measure pin travel. With
cushion blocked, total servo travel should
be .065" - .085" .
r
~;;
~
(at least 1/16", but less than 3/32")
adjustment
--locknut
Only teflon is availablefor largeservowide bandunits (W4A33/ F4A33).
Whenusing poly sealsscotchbritethe servobore beforewashingcase.
USE POLY "D" RINGS (rubber) ON
SERVO PISTON whenever available
cushion
~
cushion gap
in end of
servo pin
t
Please always use
FACTORY ORiGINAL
servo release spring
[tension= 75-85Ib.@ 1"]
Without this kit a weakerservosprin~
may reduce2-3 flare but caus~ coast
3-2 bump& part-throttle3-2 bang.
reducing PSI
band release
band apply
SERVOSWITCH TEST
Adjust bandand install
servocover.Attach one
volt metertest probeto
servoswitch connector
andthe other meter
probeto transcase...
SelectOHMS and air
checkthe servo
CORRECTREADINGS:
With bandreleased...
.1 - .3 OHMS
Wid1bandapplied...
"OL" (out of limit)
i.e., OPENcircuit
cooler
'1 .
-~~
'"
"
.
TCC
release
pump
suction
-
pump
pr~ssure
.
..
TOO
apply
/ forward clutch
(drum with shaft)
.
3rd 'reverse
(front) clutch
'\
...,
.
.
..
(
SOLENoms MUST BE CLEANED WELL
\ Submergein solvent until air bubbles stop. Swish
t them around.Remove and blow lots of air into every
':' hole and seamfor 20-30 secondseachsolenoid,then
-
backin solvent.Repeat10 times or until no more
~ black
sooteach
(carbon/metal
particles)
depositon
your
hand after
air blast. The
contamination
content
'"
,
! inside is surprising.
TESTING TRANS (remote shift control)
-rmns stuckin failsafe? (full-time 3rd gear/ no power
to\SOlenoids).Shift functions can be checkedeasily.
-.,'--:'.;::;
,
'.~,~
. '1
i Get two 12v DC toggle switches, some small 14"
This kit ~ beent~stedand-proven in almost every ~ alligator clip leads,a large alligator for the battery +
post, and a roll of 16 gauge wire (all Radio Shack
make andmodel car with every variation of the KM
items). Fabricatetest leads to supply battery voltage
trans. It providesadjustableshift feel and component
thru
two toggle switches,which output to two small
timing for variationsin engine size,performance,or
alligator clip leads. Trans solenoid connector is
TCU software.This kit plus correctedendplay fixes
usually clipped to air box mounting bracket.Unplug
all the problemslisted front pageof install portion.
it andattachthe small clip leadsdirectly to transshift
1 week (200 mile) check is strongly recommend.
solenoids(YELLOW and ORANGE wire pins). Shift
Roadt~1eakcheck,
and look over install. Catching
y
trans with toggles following the application shown
leaks earl~1especially axle seals) reduces costly
below!
come;;.backs.
A good hot road test reveals ~hat the t
customer has experienced during the break-in
period.
COMPLETELY STRIP AND CLEAN THE VB
i
""
It's usually..Joadcd v.ith-carbon.and mctal [lu!l! 3(&"
J
or END clutch. Empty VB castings must be
thorou~y" flushed and blown dry to remove all
deb~ ~~..
valve sticking. This requires a good
hi pre~i/:W4'olume blow gun Everything needed
for error-freeassemblyis included,No worries!
I
IN-CAR ADJUSTMENTS
I
ReducingValve adjustment
{ use 4mm socket or wrench}
If,.turn small but noticabledifference
I turn makesobvious difference
1If,.turnsmakea big difference
~
COUNTER-CLOCKWISE for softershifts
\(1 <J { higher reducing pressure = lower shift psi}
~
CLOCKWISE for firmershifts
V' 01 { lower reducing pressure = higher shift psi}
I
REPAIR TIPS, TRICKS, CORRECTIONS
Valve sticking? Here's the best
way in the universeto unstick itl
DELAYED REVERSE / NO REVERSE / NO ENGAGE FROM PARK
TO REVERSE, BUT WILL ENGAGE AFTER P-N-R! UNPLUG the
SOLENOID CONNECTOR and TRY AGAIN! If R engagesnow the trans
is ok. Problem is external electrical, possibly induced by INHffiITOR SW
(no R position signal to TCU), or SPEED SENSORmalfunction.All KM's
havereverseinhibit safety function. EPC is pulsedto hold N-R engagement
control valve closed, blocking low/rev clutch feed from manualvalve. This
is done when TCU detectsforward motion (speedsensorsignal) or some
other condition that could causehazardousor damagingoperation.
Lay thick steel plate on VB casting over
sticking valve and give it a good smack!
Restores
bore clearance with
valve
installed. Shown is a ST300 VB spacer
plate stiffener. A 604 solenoid body plate
works. A THM350 front plate will work
but bends easier. Thicker is Better! Best
is to bum a piece of 1/4" plate from local
machine shop.
CONNECTOR LEAKS.. The secretfor a good
sealis cleandry connectorand casearea. Install
o-ring dry and put a bead of silicon all the way
around.Slowly push connectorthroughcasejust
far enoughto install the horseshoeclip. A snug
fit clip supportsthe connector.Let silicon dry
before adding A TF. New Horseshoe clips are
available:Chrysler/Mitsu pt# MD728163
PREVENT PUMP BUSHING FAILURE DURING INITIAL START-UP & FILL... During transinstall,
Prelubeconverterhub & bushingwith lots of petroleumjelly. Pull converterflush with flywheel, install bolt in
snug,then back out 1 turn. Install ALL converterbolts BEFOREllOHTENINO. This allows converterto center
and align with crank pilot and pumpbushing.After rebuild... add 5 quartsbeforestartingengine.Haveanother4
readyto pour. AL WAYS fill andchecklevel in NEUTRAL, not park. FRONT SEAL LEAK.. Drill drainback
hole (behindfront seal)with 1/4" bit. Pumpbushingto cOnverterhub clearanceshouldbe .0015- .003".
-ELECTRICAL CONNECTIONS- Usenon-corrosive,non-residueelectricalcontactcleaner:CRC Lectra-MotiveClean( product
# 05018- lib 3 oz can) ...or Radio ShackTunerCleaner. Sprayinto harnessconnectorsand blow dry with compressed
air. Measure
pins, find comparabledrill bit, 8;J)d
checkfemaleside of connectorswith drill for sufficient installedtension.CRC cleaneralsogood to
flush solenoids! Silicon di-electric compoundkeepscorrosionand moistureout!
2-1 DOWNSHIFT CLUNK TPS& acceleratorpeddle/closedthrottle switch out of adjustment.Lift completely
off gaswhen stopping.Closedthrottle switch function is checkedwith PSI guageon bandapplyport (right side
of servo).In D at a stop, pressureshouldread0-25-0-25whenlightly touching on-off-on-offgas peddle.
ALL CONTENTS
PRODUCED
BY TRANsLAB C DEAN MASON / TRANSLAB MAR
1998all rights reserved I revision09-24-03