atsg rebuild manual transmission service overhaul manual pdf

8/18/2019 ATSG Rebuild Manual Transmission Service Overhaul Manual PDF

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INDEX

DI AGNOSTI C F AUL T CODES 6

HYDRAUL I C AND GOVERNOR PRESSURE TESTS 7

EL ECTRONI C GOVERNOR COMPONENTS 8

WI RI NG SCHEMATI C 12

~. DI AGNOSTI C CONNECTOR L OCATI ON 14

TRANSMI SS I ON DI AGNOSI S CHARTS 15

TRANSMI SS I ON DI SASSEMBL y 30

TRANSMI SS I ON SUBASSE MBL I ES 38

CHECKBAL L L OCATI ONS 59

TRANSMI SS I ON ASSEMBL y 67

BAND ADJ USTMENTS 73



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O IL PUM P A N D

RE A CTlON SH A FT

S U P P OR T A S S EMB L Y

CHRYSLER

2WHEEL

TR A NSMISSION

OVERRUNNING

CLUTCH

42RE (AS OOSE)

DRIVE MODEL

OVERDRIVE

UNIT

PISTONRETAINER

OVERDRIVE

CLUTCH

REAR

CLUTCH

FRONT

PL ANET ARY

GEAR DIRECT

CLUTCH

SPRING



( ~ Q T 5 G )

T OR QUE C ONV E R T E RA t hr ee el ement t or que conver t er i s used

f or al l appl i c at i ons i n t he 42RE. Tor que

conver t er el ement s consi st of t he t ur b i ne,

st at or and i mpel l er . The conver t er al so

cont ai ns an over r unni ng cl ut ch and a

conver t er cl ut ch pl at e.

The conver t er cl ut ch i s el ect r oni c al l y

cont r ol l ed. The conver t er cl ut ch pr ovi des

r educed engi ne RPM and gr eat er f uel econ-

omy when i t i s engaged. Conver t er cl ut ch

engagement al so pr ovi des much r educedt r ansmi ssi on f l ui d t emperat ur es.

The conver t er cl ut ch wi l l engage i n 4t h

g~ar , and i n 3r d gear when t he overdri ve

c ont r ol s wi t c h i s i n t he OF F pos i t i on.

The over r unni ng cl ut ch i s mount ed i n t he

s t at o r hub, and pr event s t he s t a t or f r om

r o t at i ng i n a di r e ct i on oppos i t e t o t he

engi ne r o t a t i on. Thi s r e t a i ns t he t or que

mul t i pl i cat i on f eat ur e of t he conver t er . The t or que conver t er shoul d be r epl aced

as an assembl y when di agnosi s i ndi cat es

a mal f unct i on has occur ed.

REC OMMENDED F L U I D The onl y f l ui d r ecommended f or t he 42RE

t r ansmi ssi on i s Mopar ATF Pl us t ype 7176.

Do not us e Dexr o n I I except i n emer gency

or i f ATF Pl us t ype 7176 i s not avai l abl e.

E L E C T RON I C GOV ER NOR COMP ONENT SGover nor pr essur e i s devel oped and cont -

r o l l ed el ec t r oni c al l y i n t he 42RE. Thecomponent s us ed f or t he devel opment and

c ont r o l of gover nor pr essur e i ncl ude:

• Gover nor Body

• Val ve Body Tr a ns f er Pl at e

• Governor Pressur e Sol enoi d

• Governor Pressur e Sensor

• Fl ui d Temper at ur e Thermi st er

• Tr ansmi s si on Speed Sensor• Thr ot t l e Posi t i on Sensor

• Tr ansmi ssi on Cont r ol Modul e ( TCM)

GOV E RNOR P R E S S UR E C UR VE S Ther e ar e f our gover n or pr e s sur e c ur ves

pr ogr amed i nt o t he TCM. The f our di f f er e nt

al l ow t he TCM t o adj ust gover nor pr es sur e

f or var yi ng condi t i ons.

Cur ve 1 i s us ed f or operat i on when f l ui d

t emperat ur e i s at , or bel ow 30°F.

Cur ve 2 i s us ed f or oper a t i on when f l ui d

t emper a t ur e i s at , or above 31°F, dur i ng

normal ci t y, or hi ghway dr i vi ng.

Cur ve 3 i s used dur i ng wi de open t hr o t t l e

oper at i on.

Cu~ve 4 i s used when dr i vi ng wi t h t r ansf er

c as e i n 4WD Low r ange.

T R A NS Mi S S I O N S H I F T I N G



(~ Q T 5 G I

C ON V E R T E R C L U T C H E N G A GE M E N T The Tor que Conver t er Cl ut ch ( TCC) i s en-

gaged by t he TCC Sol enoi d on t he val v ebody. The TCC c an be enga ged i n 3r d and4t h gear , dependi ng on t he overdr i ve con-t r ol swi t ch posi t i on.

I f t he ov er d r i v e c ont r ol s wi t c h i s i nt he nor mal ( ON) posi t i on, t he TCC wi l lengage af t er t he shi f t t o 4t h gear , andabove appr oxi mat el y 45 MPH.

I f t he ov er d r i v e c ont r ol s wi t c h i s i n

t he OFF posi t i on, t he TCC wi l l engageaf t er t he s hi f t t o 3r d gear , and abov eappr oxi mat el y 35 MPH at l i ght t hrot t l e.

O VE RDR I V E OF F S WI T C H The Over dri ve OFF Swi t ch i s l ocat ed i n

t he i nst r ument panel . The OlD OFF swi t chi s a moment ar y cont act devi ce t hat si gnal st he TCM t o t oggl e cur r ent s t at us o f t he

overdri ve f unc t i on. At K ey- On, overdr i v eoper at i on i s al l owed.

Pressi ng t he swi t c h onc e c auses t he O lD

OFF mode t o be ent er ed, and t he overdr i veOFF swi t ch l amp t o be i l l umi nat ed. I f youpr ess t he swi t ch a 2nd t i me, t hi s causesnor mal over dr i v e oper at i on t o be r es t or edand t he over dr i ve l amp t o t ur ned of f . The norma l posi t i on f or t he overdr i ve

cont r ol swi t c h i s t he ON posi t i on. Theswi t c h must be i n t hi s posi t i on t o ener-

FAULTF AULT DESCRIPTION

CODE

11 Engine RPM input

12 Output shah sensor input

13 Vehicle speed input

14 Governor pressure senso~ input

15 Thr ottle position sensor input

16 Transmission f luio temperotur e input

17 Overdrive override (control) switch input

18 System voltage

19 Internal f ault in module

21 Governor pressure solenoid output

22 Overdrive solenoid output

23 Conver ter clutch solenoid output

24 Overdr ive over r ide (control switch) lamp output

25 Internal f ault in module

26 Governor pressure sensor of f set drift

55 End of code transmission

RO AD T E S T I NG

Bef or e r oad t es t i ng, be s ur e t he f l ui dl evel i s cor r ec t and al l c abl e adj ust ment s



CONVE RT E R CL UT CH E NGAGE ME NT The Tor que Conver t er Cl ut c h ( TCC) i s en-

gaged by t he TCC Sol enoi d on t he val vebody. The TCC c an be e nga ge d i n 3r d a nd4t h gea r, de pe ndi ng on t he ove rdri ve c on-t r ol swi t ch posi t i on.

I f t he ov er dr i ve c ont r ol s wi t c h i s i nt he nor mal ( ON) posi t i on, t he TCC wi l lenga ge af t e r t he s hi f t t o 4t h ge ar , a ndabove appr oxi mat el y 45 MPH.

I f t he ov er d r i v e c ont r o l s wi t c h i s i n

t he OFF posi t i on, t he TCC wi l l engageaf t er t he s hi f t t o 3r d gear , and abo veappr oxi mat el y 35 MPH at l i ght t hrot t l e.

O V E R D R I V E O F F S WI T C H The Over dr i ve OFF Swi t c h i s l oc at ed i n

t he i nst r ument panel . The OlD OFF swi t chi s a moment ary cont act devi ce t hat si gnal st he TCM t o t oggl e c ur r e nt s t a t us of t he

over dr i ve f unc t i on. At Ke y- On, ove rdri veoper at i on i s al l owed.

Pre s s i ng t he s wi t c h onc e c aus e s t he OlD

OFF mode t o be ent ered, and t he over dri veOFF swi t ch l amp t o be i l l umi nat ed. I f youpr e s s t he s wi t c h a 2nd t i me, t hi s c aus e snorma l ove rdri ve ope ra t i on t o be r e s t ore da nd t he ove rdri ve l a mp t o t ur ned of f .

The nor mal pos i t i on f o r t he over dr i ve

c ont r o l s wi t c h i s t he ON po si t i o n. T hes wi t c h mus t be i n t hi s pos i t i on t o e ne r-

FAULTFAULT DESCRIPTION

CODE

1 1 Engine RPM input

12 Output shaft sensor input

13 Vehicle speed input

1<1 Governor pressure senso~ input

15 Throttle position sensor input

16 Transmission fluiCl temperature input

1 7 Overdrive override (control) switch input

18 System voltage

19 Internol fault in module

21 Governor pressure solenoid output

2 2 Overdrive solenoid output

23 Converter clutch solenoid output

2<1 Overdrive override (control swifch) lamp output

25 Internal fault in module

26 Governor pressure sensor offset drift

55 End of code transmission

ROA D T E S T I NG

Bef o r e r o ad t es t i ng, be s ur e t he f l ui dl e ve l i s c or r e ct a nd a l l c abl e a dj us t me nt s



H Y D RA U L I C P R E S S U R E T E S T Ther e ar e pr es s ur e t es t por t s at t he acc-

umul at or , f r ont s er v o and r ear s er vo. Al s o

gov er nor and ov er dr i ve c l ut c h pr es s ur e c anbe checked wi t h gauges.

L i ne pr essur e i s checked at t he accumu-l at or t es t por t , but mus t be i n t he dr i v epos i t i on, as i t i s r e ar c l ut c h oi l t hat i sbei ng measur ed. F ront cl ut ch oi l ( 3r d&Rev)i s avai l abl e at t he f r o nt s er vo pr es s ur epor t . Al l pr es s ur e por t l oc at i ons ar e s eeni n F i gur e 5.

Use t he chart i n F i gur e 6 t o det ermi nec or r ec t oi l pr e ss ur e s. Us e a 100 P SI gaugef or t es t i ng l i ne pr es s ur e and gov er nor pr e-s s ur e. A 300 PSI gauge wi l l be r e qui r edf or t est i ng r ever se.

Compare r esul t s of pr essur e t est s wi t h t he

anal ys i s c har t i n F i gur e 7.

GOVERNOR PRESSURE TEST

Thi s t es t checks gover nor oper at i on bymeasur i ng governor ores sur e r esponse t ochanges i n v ehi c l e speed. Thi s t est shoul dbe per f or med on a hoi s t t hat wi l l al l ow t her ear wheel s t o r ot at e f r eel y .

1. Connect 100 P SI gauge t o t he gover norpr es s ur e por t ( See F i gur e 5) .

2. St ar t engi ne and pl ac e s el ec t or l ev eri n t he Dr i v e posi t i on. At i dl e wi t h t he

v ehi c l e s t opped, pr es s ur e s houl d be 0t o 1 1/ 2 PSI maxi mum I f pr essur e does

GOVERNOR

TEST PORT

5. Compar e r es ul t s of pr es s ur e t es t wi t h

t he anal y s i s c har t i n Fi gur e 7.



[~ ~ T S G )

T E S T CONDmON INDICATION

Line preuure OK during Pump and regulator valve OK

anyone le$t

Line Pressure OK in R Leakage in rear clutch area (servo, but low in D, 2, 1 clutch seals, governor suppor t

seal rings)

Preuure Low in D Overdrive clutch piston seal, or Fourth Gear Range check ball problem

Pressure OK in 1, 2 but Leakage in front ~utch area (servo,

law in D3 and R clutch seals, retoiner bare, pump

seal rings)

Pressure OK in 2 but low Leakage in rear servo

in Rand 1

Front servo pressure law Leakage in servo; broken servoin 2 ring or crocked servo piston

Pressure law in all positions CI~ged filter, stuck regulator valve, worn or faulty pump, plugged Auid cooler

Governor pressure too high Governor pressure solenoid at idle speed valve foulty

Governor p'ressure low Faulty governor pressure solenoid ,at all mph ngures transmission control module, or

governor pressure sensor

Lubrication/line pressure Clog1

ed Auid cooler or lines, seallow at all throttle positions rin~s eaking, output shaft plugged

wi debris, worn bushings in pump or clutch retainer

GOVERNOR

BODY

GOVERNOR BODY AND NEW TRANSFER PLATE

A new T r a ns f er P l a t e i s us e d wi t h t he 42REval v e body. T he t r a ns f er pl at e i s des i gnedt o suppl y l i ne pr es s ur e t o t he go ver no rpr essur e s ol enoi d, and t o r et ur n gover norpr es s ur e t o t he v al v e body.

The gover nor pr e s s ur e s ol enoi d i s mount edi n t he gover nor body, and t he body i s bo l t -ed t o t he l o wer s i de of t he new t r ans f er

pl a t e ( Se e F i gur e 9) .



[~ ~ T 5 G )

VI EW LOOK I NG I N TO THE

GOVERNOR PRESSURE

SOLENOI D CONNECTOR

VI EW LOOKI NG I NTO THE

GOVERNOR PRESSURE

SOLENOI D HARNESS



( ~ Q T S G )


GOVERNOR PRES SURE

SENSOR CONNECTOR


GOVERNOR PRES SURE

SENSOR HARNESS



VI EW LOOKI NG I N TO THE TRANSMI S SI ON CASE CONNEC TOR

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GOVERNOR

PRESSURESENSOR



( ~ Q T 5 G I Technical Service Infor mation

ceo DATA UNK CONNECTOR

(BEHIND DASH, RIGHT SIDE OF COlUMN)

TRANSMI SSI ON CONTROL MODULE ( TCM)

The TCM c ont r ol s o per a t i o n of t he TCCSol enoi d, t he Over dr i ve Sol enoi d, and t heGover nor Pr essur e Sol enoi d. The T CM i s l o -cat ed behi nd i nst r ument pa nel t o t he l ef to f t he st eer i ng c ol umn ( Fi gur e 16) . The TCM, det er mi nes t r ansmi ssi on shi f t

poi nt s bas ed on i nput s i gnal s f r om t he

t her mi st er, t r ansmi ssi on speed sensor ,cr anksha f t po si t i o n senso r , vehi c l e speed

CCDOATAUHK

CONNEC TOR

CA V COLO R FUNC TION

2 RO 6+

: s WT/GY CCOBUS (.)

4 VT IBA ceo BUS (+ )

8 BKI T N GROUND

TRANSMISSIO N

CO NTR Ol MODULE



Condition Possible Cause Correction

HARSH ENGAGEMENT 1. Engine idle speed too high 1. Check/adjost idle speed

(FROM NEUTRAL TO DRIVE2. Driver "riding" accelerator pedal during shif! 2. Advise owner/operator

OR NEUTRAL TO REVERSE)

3. Throttle coble misodjusted or bind ing 3. Adjust coble selling

(reverse only)

4. Bond adjustment needed N 4. Adjusl rear bond "

5. Loose mounting bolts 5. Check en~ne, transmission, propeller shaft,

crossmem er , and axle bolt torbe; lighten

loose bolts and replace missing olts

6. Worn or damaged U-joints 6. Remove propeller shaft and replace. • .

U-joinls

7. Loose axle pinion nut 7. Rer:lace nut and check pinion threads

be ore installing new nut; replace pinion

gear if threads are damaged

8. Hydraulic pressure is incorrect \i 8. Check pressures; remove, overhaul, or

adjusl valve body as needed ; repair oil

Note: The shift from neutral to pump if necessary ~.

reverse is normally quite firm.9. Engineltransmission mounts worn or 9. Replace as necessar y

Hydraulic pressure at the rear damaged

servo can approach 300 psi

in reverse gear . Do not 10. Faulty converter lockup clutch (if equipped) r r , 10. Replace converter and f lush cooler and

confuse a firm engagement lines before installing new converter with a truly harsh engagement 11. Clutch, bond, or planetary component is 11. Remove, disassemble, and repair

damaged -"J transmission as necessary

DELAYED ENGAGEMENT 1. Engine idle speed too low - 1. Adjust idle speed

(fROM NEUTRAL TO DRIVE2. Low f luid level 2. Correct level and check for leaks

OR REVERSE)-

3. Gearshift linkage out of adjustment 'i 3. Adjust linkage and repair linkage jf worn

or damaged

4. Rear bond out of adjustment 4. Adjus1 bond

5 V l b d filt l d 5 R l fl id d filt If il d ld



Cewtlltl_ •••••Iltl. c .. _ CofToctI_

NO DRIVERANGE 1 . Gear shif t link age either loose, d amaged 0<"out of 1 . Re pair 0<"re place link age com pooenn

(REVERSEOK) adjustment

2. Low Auid level 2. Cor rect Auid level and check f or leak s

3. Valve bod y malf unction (manual valve 0<"shaft 3. Remove and d i50ssemble valve body; re ploce as

damaged or 1· 2 shift valve stuck I assembly if any valves 0<"wes are damaged

4. Rear clutch failure 4. Remove and d i50ssemble transmission and r ear clutch; re pair /re place wor n, d omoged ports osnoed ed

5. Transmission overrunning clutch failure 5. Remove and di50ssemble transmiuion; r e place

overrunning clutch

6. Input shaft ~I r ings wor n or damaged 6. R emove and d i$Ossemble transmiuion; replace

seal r ings and any olher worn 0<"damaged por ts

NO DRIVE0 R REVERSE 1 . Low Auid level 1 . A dd Auid and check f or leak s if d r ive is r estor ed

(VEHICLEWlU NOT MOVEI2. Gearshift link age loose, damaged , or mi50ssembled 2. Inspect, adjust, and reassem ble link age as noed ed ;

replace worn, damaged por ts

3. Failure of driveline component, such as U'joint, axle 3. Per f orm pr eliminar y ii15pection pr ocedure f or

h ft t f t t hi l th t ill ! f t d i

( Q T S G ]



( ~ Q T S G ]

Condition POlllble Cau •• Correction

SHIFTS DELAYED OR 1. low fluid level 1. Correct fluid level and check for leaks

ERRATIC (SHIFTS ALSO2. Throllie coble out of adjustment 2. Ad just cable as descr i bed in service section

HARSH AT TIMES)

3. Thrallie cable binding 3. Adjust cable, replace if worn, or damaged

4. Gearshift linkage out of adjustment 4. Adjust linkage as described in service

section

S . Fluid filter partially clogged S . Replace filter. If filter and fluid contained

clutch material or metal particles, on

overhaul may be necessary

6. Air in fluid due to overfill condition or air 6. Drain fluid to correct level if overfilled . If leakage into pump suction passages fluid is highly aerated (full of bubbles and

f oa 7) ' oil pump gasket or s ea l may havefaile , or pump body is porous or crocked

7. Clutch or servo problem 7. Remove valve body and air test clutch,

bond and servo operation; disassemble and

repa'ir transmission as needed

8. Front bond out of adjustment (may couse harsh 8. Adjust bond 1·2 shift)

9. Accumulator springs/seals worn or damaged 9. Inspect/replace as required

10. Governor pressure control system faull 10. Check with DRB II scan tool or flash code,and repair 0' necessary

NO REVERSE (0 RANGES 1. Gearshift li nkage is eithe r a ut of ad justment or 1. Repair or replace linkage por t, os ne eded OK) damaged

Ht~ :' A \ J , Ht : I\ j t()P , A 2. Ritar bond is out of adjustment 2. Adjust bond

3'1 t-P e , ~ H v ! 1 ' 0 . b

3. Valve body malfunction (stuck/damaged manual 3. Remove and service valve body; replacevalve re gula tor valve or check boll) valve body if any valve or valve bore are

[ Q T 5 G )



[ ~ Q T 5 G )

Condition POlilbl. Cau•• Corr .ctlon

MOVE S I N 2ND OR 3R D 1.

Governor circuit fault \v 1. Test governor components with DRB " scanGEAR, ABRUPTLY toolDOW NSHIFTS TO LOW

2. Valve body malfunction .J 2. Remove, c le an , a nd ins pect; look f or stuck

1-2 valve or governor plug

SLIPS IN LOW GEAR D 1. Transmission overrunning cl utc h fa ulty, not 1 . Replace overrunni ng c lutchONL Y, BUT NOT IN 1 hold ing

POSITION

SLIPS FORWARD DR IVE 1. Low Auid level 1 . Add fluid and check f or leaksRANGES

2. Air in fluid (fluid is f oamy, full of bubbles), 2. Chec k f or b od pum p gasket or seals, dirtshifts are spongy, caused by air gelling into between p'ump halves, and loose pum p bolts

pump suction passages or defective O-ring at filler tube

3. Gearshift linkage or thr ottle coble out of 3. Adjust as needed adjustment

4 . Low hydraulic pressur e due to worn pump, 4. Per f orm hydraulic and air pr essur e tests toincorr ect control pressure adjustment, valve determine couse

body warpage or malf unction, sticking

r.0vernor , leaking seal r ings, clutch seals

eaking, servo leaks, clogged filter , or cooler lines

5. Accumulator piston crock ed , spr in g b roken or 5. Inspect and re pair as necessar yseal worn

6. Clutch or ser vo m alfunction, leaking seals or 6. Air pr essure check c1utch.servo operationworn plates a nd r e pair as r equir ed

7. Overrunning clutch worn, not holding (slips in 1 7. Re place clutch

only)

( QT51i)



(~QT51i)


NO KICKDOWN OR 1. Incorrect throttle coble adjustment 1. Adjust coble

NORMAL DOWNSHIFT2. Incorrect gear shift linkage adjustment 2. Adjust linkage

3. Front bond out of adjustment 3. Adjust bond

4. Hydraulic pressure too high or too l ow due t o 4. Perform hydraulic pressure tests to

valve body malfunction, or incorrect hydraulic determine couse and repair as required.

control pressure adjustment Correct valve body pressure adjustments as

required

5. Front servo, bond , or linkage malfunction 5. Air pressure test operation and repair as

necessary

6. Clutch or servo malfunction 6. Air pressure test operation and re pair as

necessary

7 . Governor fault 7 . Check with ORB \I scan tool or flash codes and

repair as needed

8. TPS fault 8. Check for TPS fault at transmission control

module with DRB \I scan tool or f lash codes

, . . . . . "

STUCK IN LOW GEAR (WILL 1. Gearshift l inkage or thrallie coble out of 1. Adjust and repair linkage or coble if worn NOT UPSHIFT) adjustment. or damaged

2. Front bond out of adjustment 2. Adjust bond

3. Governor component fault, loose output shaft 3. Check operating pressures, and test ~overnor

suppor t, worn pump, leak ing seal rings, or component with DRB II scan tool or f ash

valve body problem (i.e., stuck 1-2 shift valve codes. Repair as needed

or governor plug)

4. Clutch or servo malf unction 4. Air pressure check operation of clutches and

bonds; repair faulty component




CREEPS I N NEUTRAL 1. Gearshif t linkage out of adjustment 1. Ad just linkage

2 . Valve body malfunction (warped bod y , c ross 2 . Per f or m hydraulic pr essure test to del ermine

leak age, loose scr ews) cause and re pair as r equired

3 . Clutch dragging 3 . Air pressure check operation of clutches and

r e pair as r eq uired

DRAGS OR LOCK S UP 1. Fr ont or r ear b an d o ut of adjustment 1. Ad just band s

2 . Servo band or linkage malfunction (i.e., 2 . Air pr essur e check servo operation and

bind ing linkage, wa rp ed b and , s er vo piston repair as required

stuck)

3 . Dragging clutch (does not release f ully) 3 . Air pr essur e check clutch operation and

re pair as requir ed

4. Broken or seized planetar y gear s 4. Remove, i ns bect, and r epair as requir ed

(look f or d e ris in oil pan)

5. Overrunning clutch worn, br ok en, or seized 5. R emove and ins pect clutch, re pair as

r equir ed

GROWLING, GRATI NG OR 1. Planetar y gear set broken or seized 1. Check f or debr is in oil pan and repair as

SCRAPI NG NOISES r equired

2. Over r unning clutch wor n, seized , or br oken 2 . Ins pec t a nd check f or d ebris in oil pan;

re pair as required

1 ~ ~ T 5 G I



1 ~ ~ T 5 G I


OIL COMES OUT FILLER TUBE 1. Transminion overfilled 1. Dr ive fluid to correct level; remove neutral

switch and drain through s witch hole with

suction gun

2. Breather vent in oil pump blocked 2. Inspect and clear blockage

3. Fluid cooler or cooler lines plugged 3. Flush cooler and lines

4. Air in fluid (aerated) 4. See "Slips In Forward Dr ive Ranges"

5. Oil f ilter clogged 5. Replace filter; determine the reason for

clogged condition and repair

6. Rear servo piston or seal failure 6. Check hydraulic pressur e of servo inreverse (will register low or fluctuate

rapidly). Repair/replace s ervo piston and

seal. Replace case if servo bar . is damaged

7. Valve bod y switch valve stick ing 7. Remove and clean valve

OIL LEAKS (ITEMS LISTED 1. Speedometer adopter 1. Replace both adopter seals

REPRESE NT POSSIBLE LEAK 2. Pan gasket 2. Tighten pan screws to 150 inch-pound s; if

POINTS A ND SHOULD All

BE CHECKED) leaks persist, replace gask et; do not

overtighten scr ews

3. Filler tube (where tube enters case) 3 . Replace O-ring seal

4. Fluid lines and fiMings 4. Tighten fillings; if leaks persist, re place

fillings and lines if necenary



I~QT51i)

OVERHEAT D URINGCO M M ER CIA L O P E RAT IONOR W HILE TRAILERTOWING(F LU I D D A R K A N D B U R N E DW I T H S O M E S L U D G EFORM ATI ON)

OVERH EAT DU RING N ORM AL

1. Vehicle not proper ty equi pped for tr ailer towing or

com~cial u~

3. Exlensive id ling time or oper ation in heavy traf fic in

hot weather

A. Tow vehicle over loaded {exceed ing vehicle tow

capacityl

5. Air R ow 10 auxiliar y cooler block ed by mow plow,

f r ont mounted ~ por e tir e, bug ~reen, or ~imilar item

1 Low Ruid level

1. Be sur e vehicle is eq ui p ped with r ecommend ed

o ptional components (i.e, HD springs,

tran~ission, axle, larger C1D engine, auxiliar y

cooler, cor r ect axle r atio, elc.l. If vehicle i~ not ~

equipped , it ~hould not be u~ lor sever e

service operation

2. Drain Auid , change filter , and install auxiliar y

cooler

3. Cut down on id ling time; shih into neutral ever y

so often and run engine at 1000 rprn 10 help

cir culate Ruid through cooler

A . Be sure vehicle is pr oper ty equi p ped 10 handle

load ; do nol tow Closs III-type load s with a

vehicle that is only r ated lor Closs I or II

operation

5. Remove or repo~ition item cou~ing air Row

block age

1 Add R id d h k f l k

( ~ Q T 5 G J



( Q T 5 G J

Condition Posslbl. Cau•• Correction

NO START IN PARK OR 1.Gearshift linkage out of adjustment

1.Ad just linkage NEUTRAL

2. Pork/neutral position swilch wire broken or 2. Check continuity with lest lamp; repair as

open required

3 . Faulty park/neutral position switch 3 . Refer to service section for test and

replacement procedure

4 . Valve body manual lever assembly bent, worn, 4 . Inspect lever assembly and replace if

broken, or not aligned with switch damaged

SLUGGISH ACCELERATION 1. Poor engine performance: 1. Check engine and repair as required AT LOW SPEEDS OR

2. Gearshift linkage or throttle cable out of 2. Adjust as needed REQUIRES EXCESSIVE

THROTILE OPENING TO adjustment

/"

MAINTAIN HIGHWAY 3 . Transminion clutches slipping 3 . Perform stoll test and repair as required

SPEEDS4 . Overrunning clutch in converter stator not 4 . Perform stoll lest and replace converter if

holding clutch has foiled

5. Converter stator overrunning clutch seized 5. Replace converter as assembly---

FLUID CONTAMINATED 1. If cantaminalion occurred shortly after 1. If contamination is severe, cooler flushing,(DISCOLORED, FULL OF overhaul, fluid cooler and lines were not converter r eplacement, and another

SLUDGE AND/OR METAL flushed and flow tested. This il especially true overhaul may be necelsary; particularly

AND FRICTION MATERIAL when original overhaul was fa correct a if shift problems were also pre,enl.PARTICULAR) problem that generated a large amount of

de br is , suc h a s a g ea r failure or a clutch pock

failure



SLIPS IN OVERDRIVE

FOURTH GEAR

1. Four th geor overdr ive switch (in dosh) in OFF 1. Turn control switch to ON position position

3. Four th gear overdr ive switch shorted , open, 3. Replac e switch if shorted or o pen and

wir es loose r epair loose or damog ed wire s

4. Overdr ive solenoid or circuit wire loose, 4. Check wir es/connections with 12V test lamf

shorted , open and voltmeter ; repoir d amaged or loose

wir es/connections as necessar y

5. Solenoid f eed or if ice in valve bod y is blocked 5. Remove, d isassemble, c1eon valve bod yor blown out thoroughly

6. Fourth gear overdr ive solenoid failure 6. Verif y solenoid f ailur e with test lam p and

r e place solenoid

7. Sensor or fluid temperature Ihermi"er f ault 7. Test with ORB II scan tool or ohmmeter .Replace sensor or thermister as needed

8. Over dr ive pislon seol f ailure 8. R e place bOlh seals

9. Wr ong over d r ive piston s pacer 9. Remove u nit, check end ploy, an d install

cor rect spacer

10. Low hyd r aulic pr essure 10. Pressure lest tr ansmission to determine

couse

1 1 . Transmission f luid overheat (aver 260 0 Fl 11. See overheal inf ormation in t r ansmission

d iagnosis char lS

1. Low fluid level

2. Overdr ive piston or seal malfunction1. Add fluid and check f or leak s2 Remove overdrive unit; replace pislon Sf

( T 5 G )



( ~ ~ T 5 G )


OELA YEO 3·4 UPSHIFT 1. Low fluid level 1. Add fluid ond check for leoks

(SLOW TO ENGAGE)2. Overdrive solenoid or wir ing is f aulty 2. Test solenoid and check wiring for

loose/corroded connections, or

shorh/ground; replace solenoid if faulty and

repair wiring if necessary

3. Overdrive piston spacer too thin 3. Remove unit; measure end play and select

proper spacer

4. Overdrive clutch pock worn 4. Remove unil and rebuild clutch pack

5. T.P.S. faulty 5. Replace T.P.s.

6. Overdrive clutch bleed orifice in retoiner

6. Disossemble transmission and r eplace ori fi ce

plugged or blown out

~

' ' - . . -

3·4 UPSHIFT OCCURS 1 . Overdrive solenoid connector or wiring 1. Test connector and wiring for loose connections,

BEFORE COMPLETION OF problem shorts, or ground, and repair as needed

2·3 UPSHIFT2. Overdrive solenoid malfunction 2. Replace solenoid

3. Coolant temperature or T.P.S. malfunction 3. Tesl sensor at TeM with DRB II scan tool

and replace as necessary

4. Valve body malfunction 4. Remove, disassemble, clean, and inspect

valve body components; make sure all

valves and plugs slide freely in bores; polish

valves with crocus cloth if needed



(~ QTSG] Technical Service Information

TRANSMISSION DIAGNOSIS


NO 4-3 D O WNS HI FT 1 . Cir cu it wir ing and/or connector s shor ted 1. Tesl wiring and connectors with lest lamp

and volt/ohmmeter ; r e pair wir ing as

nece ssar y; rep lace conne ctor s and /or

h ar ne ss a s re quired

2. Converter clutch solenoid nol venling 2. Remove valve body and r e place soleno id if

seized or sho r ted

3. Overdr ive solenoi d nol venting 3. Rem ove valve body and r eplace soleno id if

seized or s ho r ted

4. 3-4 shift or accumulato r m al fu nc ti on 4. Remove va lve body; r emo ve and disassemble

lower h ou sing and 3-4 accum ulator housing;

r ep la ce s ea ls a nd c le an valves as necessary;

b. sur. all va lv.s slid . f re ely in bor.s

5. Transm ission conlrol m odule ma lf unc tion 5. Check ope r ation with DR B II scan tool,

r e place module only if f au lty

6. T.P.S. malfunctian 6. Chec k o per ation with DR B II scan 1001.

R e place TPS only if f aulty iI

I

I

I

NO 4· 3 D O WNS HI FT 1 .Overdr ive sol enoid wir ing or conneclo r s faulty 1 . Chec k solenoi d wir ing and connections for

WH EN CO NT ROL SW ITCH2. Over dr ive or lock up solenoid nol venling shor ts/gro unds; r e pair as necessary

IS T U R NED OFF

I( OV ER DR IV E O FF A N D 2. Te sl solenoids and replace if seized or

shorled !LAMP IS ILLUMINA TED )



[ Q T 5 G )



[ ~ Q T 5 G )

Condition Poulbl. Cau•• Corr.ctlon

NO R EVERSE (OR SLIPS I N 1. Dir ect clutch spring collapsed or broken 1. Remove and di sasse mble unit; check clutch

REVERSE) pock and replace s pr ing

2. Direct clutch pock worn 2. Disassemble unit and rebuild clutch pack

3. Rear band out of adjustment 3. Adjust band

4. Front clutch malfunction 4 . Air pressure test clutch operation; r emove

and rebuild if necessar y

5. Overdrive thrust bearing failure 5. Disassemble geartrain and r eplace bearings

NO 1-2 OR 2-3 UPSHIFT 1. Governor fault 1. Test governor com ponents with O R B II scan

(HAS LOW AND REVERSE tool and r e pair as needed

O NLY)



6'(

d n 08 8 3 JI1 \8 3 S N O I S S IV 'JS N V 8 1 Jll V V 'J O l nV

x x x x x x x x I N3W3DVDN3H )lnD M 31~V M3aanHS

x x lV3S dWnd MO 39m lll~ ~O lnoD N IW O ) 1 10 :DNIlV3HM3AO

x lV~lln3 N NI"03AA3M,, N3HM NO/IVM9IA

x x x x IN3W3DVDN3H )l nD ~ 31 ~V N O II v~ aI A

x x x x IN 3W 3 DV D N3 H )ln D D NI~ na~ 3a an H S ~ O N OI Iv ~a IA

x x x (0l0))-IN3W3DVDN3H )lnD D NI~na ~311VH)

x x x x x 3 S~ 3A 3 ~ N IH51DDnlS 51 ~O 51lVIS



llmm

SOCKET

I ~ Q T 5 G )



)

10. I f over dr i ve uni t does not r equi r e any

ser vi ce, i nst al l al i gnment t ool 6227- 2

i n over r unni ng cl ut ch and t he pl ant ar y

spl i nes t o mai nt ai n al i gnment , shown

i n Fi gur e 5.

11. Remove t he t hr ust bear i ng and sel ect i ve

t hr ust washer f r om overdri ve pi st on,

as shown i n Fi gur e 6.

12. Remove t he overdr i ve pi s t on f r om t he

r et ai ner , as s hown i n Fi gur e 7.

13. Pl ace t r ansmi ssi on i n a hor i zont al po-

si t i on, wi t h pan f aci ng up.

14. Remove t he bot t om oi l pan and gasket ,

TH R U ST

BEARING OVERDRIVE

PISTON

( Q T S G )



( ~ Q T S G )

V ALVE

BODY

ACCUMULATOR

PISTON

Fi gure 12

ACCUMULATOR

PIST O N

OUTER

SPR I N G

( Q T 5 G ]



( ~ Q T 5 G ]

OIL PUMP AND REACTION

SHAFT SUPPORT ~SSEMBLY



__ \' r

I N T E R M E D IA T E

SH A FT

T H R U S T P L A T E

[ ~ Q T S G )



[ )

ETA IN ER

B O lT S

I ~ Q T 5 G ]



I ~ Q T 5 G ]42. Remove t he l ow/ r ev er s e dr um and r ear

band as an as s embl y , as s hown i n Fi gu27. Tur n dr u m cl ockwi se and pul l out

r emove i t f r om over r u n ni ng cl ut ch.43. Remove t he bol t s at t achi ng ove r r u nni ngcl ut ch cam t o case, as s hown Fi gur e 28

44. Che ck t he o ver r unni ng c l ut c h c am f or" Al i gn Mar ks " on t he cam and cas e, ass hown i n Fi gur e 29. Thes e mar k s ar e to

i dent i f y t he Non- t hr eaded hol e i n t heover r unni ng cl ut ch cam.

45. I f t her e a r e no pai nt mar ks t o i dent i f

t he non- t hr eaded hol e, put some t her ef or r eas s embl y purpos es , bef or e r emov aRef e r t o Fi gur e 29.

46. Remove over r unni ng cl ut ch cam and t her ol l er cl ut ch assembl y as a uni t . Turn

cam back and f or t h and t i l t i t i nwar dt o r emove i t f r om cas e ( Fi gure 29) .

47. Compr es s f r ont s er vo r od gui de about

1/ 8" wi t h compr es sor , as s hown i n Fi g-ur e 30, an d r emove s na p r i ng.

48. Exer c i s e caut i on when r emovi ng snapr i ng as se r vo bor e c an be damaged.

49. Remove compr ess or t ool s an d r emove t hef r ont s er vo par t s .

50. Co mpr es s t he r ear s e r vo s pr i ng r et ai neabout 1/ 16" wi t h s p r i ng compr es sor , as ,

shown i n Fi gur e 31 and r emove t he s nar i ng

( ~ Q T S G ]



( ~ Q T S G ]

OVERHAUL SERVI CE I NFORMA TI ON

I nspect t he t r ansmi ssi on bushi ngs dur i ng

over haul . Bushi ng condi t i on i s i mpor t ant

as wor n or sc or ed bushi ngs cont r i but e t ol ow pr essur es, cl ut ch sl i ppage and wear of

r el at ed part s. Repl ace bushi ngs onl y when

t hey ar e act ual l y wor n or scor ed.

Us e r e commended t ool s t o r epl ace bushi ngs

as t hey are desi gned t o r emove and i nst al l

bushi ngs cor r ect l y.

Pr e - s i z ed ser vi c e bushi ngs ar e avai l abl e

f or r epl acement pur poses. Onl y t he s un gear

bushi ngs ar e not s er vi c ed. The sun gear i s

r epl aced as an ass embl y i f t he bushi ngs ar edamaged.

Hel i - Coi l i ns er t s can be used t o r epai r

damaged, st r i pped or wor n t hr eads i n any

al umi num part s. These i nser t s ar e avai l abl e

f r om mos t aut omot i ve j obber s. The s t ai nl ess

st eel i nsert s are r ecommended.

The use of cr ocus cl ot h i s permi ssi bl e i f

i t i s us ed car ef ul l y. When used on s haf t s ,

or val ves, us e ext r eme car e t o avoi d r ound-i ng of f s har p edges. Sharp edges ~r e vi t al

as t hey pr event f or ei gn mat er i al f r om get t -

i ng between t he val ve and val ve bor e.

Do not r euse oi l seal s, gasket s, " 0" r i ng,

seal r i ngs or f i l t er dur i ng over haul . These

ar e mandat or y r epl acement par t s . Al s o don' t

r euse snap r i ngs or " E- Cl i ps" t hat ar e bent

or di st or t ed. Repl ace t hese part s as wel l .

Lubr i cat e t r ansmi ssi on par t s wi t h Dexr on

or 7176 t r ans mi s si on f l ui d dur i ng ass embl y.



TRANSMI SSI ON CASE

1. Cl ean t he t r ansmi ssi on case i nt ank wi t h c l ean s ol vent . Fl us h al l of t he bor es and passages t hor oughl y , adr y wi t h compr es s ed ai r .

2. I ns pect t he cas e c ar ef ul l y f or cr a c kspor ous s pot s , wor n bor es , or damagedt hr eads .

3. Damaged t hr eads can be r epai r ed wi t hHel i - Coi l t hr ead i ns er t s .

4. L ubr i c at e t he f r ont band ad j us t i ng s cew t hr eads wi t h a s mal l amount of t he

Tr ans - J el , and t hread t he s cr ew par tway i nt o t he case. Be s ur e t he s cr ewt ur ns f r e el y .

5. Cl ea n t he over r un c l ut ch par t s wi t hcl ean sol v ent , and dr y wi t h compr e s sa i r .

6. I nspect al l par t s f or . damage.

7. I ns t al l t he r ol l er s i nt o over r u ncage, as s hown i n F i gur e 32.

8. I f t he over r unni ng cl ut c h and c am caout wi t h t he l ow/ r ever s e dr um, t hr eadt wo cam bol t s i nt o t he cam, as shownFi gur e 33.

9. L i f t t he cl ut c h and cam out of t he dwi t h t he bol t s ( See Fi gur e 33) . Rot att he c am i f nec es s ar y t o eas e r emoval .

10 Exami ne t he bol t hol e s i n t he o ve r r un

( ~ Q T S G )



( Q T S G )

18. I ns t a l l t he f i v e o ve r r unni ng c l ut c h c ambol t s i n t he posi t i ons shown i n F i gure37.

19. Ver i f y t hat y our mar k s ar e a l i gned a sshown i n F i gure 36.

20. Tor que t he f i ve ov er r un c l ut c h bol t st o 13 f t . l bs. ( S ee F i g ur e 37) . Not et hat t he c am bol t s ar e s hor t e r t han t hepi st on r et ai ner bol t s.

21. L ubr i c at e t he ov er r un c l ut c h r o l l er swi t h t r ansmi ssi on f l ui d.

NON-THREADED

HOlE

AUGN MARKSIDENTIFYING



CUSHION

SPRING

PISTON

PLUG

SNAP 0RING

l ~ S E R V OPISTON

Fi gur e 38B E S U R E

S E A L U P

I S T O W A R D

S E R V O

R E A R

S E R V O

PIST~

25. Lubr i cat e t he r ever s e s er vo pi s t on an

seal wi t h l i ber al amount of Tr ans - J el

I ~ Q T S G I Technical Service Information



32. I ns t a l l ne w s ea l r i ngs ( 2) , o n f r onts er vo pi s t on and l ubr i cat e wi t h s mal la mo un t o f T r a ns - J e l ( S ee F i g ur e 42) .

33. I ns t al l new " 0" r i ng s eal on t he s er vopi s t on r od, and l ubr i cat e wi t h s mal l

a mo un t o f T r a ns - J e l ( S ee F i g ur e 42) .34. I n s t a l l s e r v o p i s t o n r o d i n t o t he f r o nt

s er v o pi s t o n a nd i ns t a l l s na p r i ng, a ss h own i n F i g ur e 42.

35. L ubr i c at e t he f r o nt s e r v o c as e bor ewi t h a s mal l amount of Tr ans - J e l .

36. I ns t a l l t he f r o nt s e r vo pi s t on assembl yi nt o t h e c a s e b or e .

37. I ns t a l l t he s e r v o pi s t o n r et ur n s pr i ngo n t o p o f t he f r o nt s e r v o pi s t o n.

38. I ns t a l l ne w " 0 " r i ng on pi s t on r o dgui de and l ubr i cat e wi t h smal l amountof Tr ans- J el .

39. I n s t a l l p i s t o n r o d g ui d e, c o mpr e s s t h eassembl y wi t h compr essor t ool , showni n F i g ur e 43.

40. I ns t al l s nap r i ng on t op of pi s t on r odgui de , a s s ho wn i n F i gur e 43.

41. Remove t he compr essor t ool s.

42. Set t he t r ans mi s s i on cas e as s embl yas i de f or f i nal as s embl y.

PISTON

ROD

SERVO

SNAP

RING

( Q T 5 G l



( ~ Q T 5 G l

o-RING

SEAl

SPEC IAL

TOOL

(-4171

RE ACTION SHA FT

SUP POR T

THRUSTWASHER

~QT5G)



)

PREVIOUS

DESIGN

NEW

DESIGN



( ~ Q T S G )27 L b i t l i t i h f t



27. L ub ri cat e sp l i nes on r eact i on shaf twi t h a smal l amount of Trans- J el t ohel p on conver t er i nst al l at i on.

28. Ens ur e t hat f r o nt pump ge ar s r ot at ef r eel y i n oi l pump.

29. Set oi l pump assembl y asi de f or f i nalas s embl y.

SPECIAL

TOOL

C·o4193

PUMP

BODY

PUMP

SEAL

SEAL

RINGS



R E T A IN ER H U B

S EA LCLUTCH

PISTON

PISTONSPRING

R E T A I N E R

C H E CK B A LL

S NA P R ING

(WAVED)

SP RING

RETAINER

S NA P R IN G

PR ES SU RE

PLATE

SPRING

RE TAINER



F R O N T

C L U T C H

RET A I N ER

C L U T C H

PISTON

SPRING

R E T A I NE R " ' "

(~~ T 5G )



INPUT

SHAFT

SNAP

RING

REAR

CL UTCH

RETAINER

R E A R

CL UTCH

THRUST

S HA FT W AS HER

F RO NT (F IB ER )

SEAL

RING( T EF L O N) C L U T CH

PACK

SNAP

RING

(S EL ECTIVE )

/RETAINER

SEA L R ING

l ~~T S G ) .



BE SURE

R I N G E N DS

ARE HOOKED

TOGETHER

AFTER INST ALLATION

METAlREAR

SEAl

RING .

TEflON

FRONT

SEAL

RING

REAR

CLUTCH

THRUST

W ASHER (FIBER)

( ~ ~ T S G ) Technical Service Information



I

DRIVING L((il~SHELL~

REAR

THRUST

PLATE

SUN GEAR REAR PLANETARY ANNULUS GEAR

LOCK RING THRUST WASHERS GEAR SUPPORT

7mut[in

y CI$!()

INTERMEDIATE INTERMEDIATE

SHAFT THRUST SHAFT

PLATE

SELECT

F ITPLANETARY

SUPPORT

SNAP

RING

FRONT

ANNULUS

GEAR

FRONT

ANNULUS

THRUST

WASHER

P L A NE T A RY GE A RT R AI N A S SE MB L Y

1. Cl ean al l pl anet ar y gear t r ai n compon-

ent s wi t h cl ean sol vent ( Fi gur e 72) .

2 I nspect al l pl anet ar y component s f or

CLUTCH

CAM

CLUTCH

C AM BO LT S

REAR

ANNULUS

GEAR

( ~ Q T 5 G )REAR ANNULUS



REAR ANNULUSAND PLANETARY G EAR

ASSEMBLY

FRONTTAB8ED

THRUST

WASHER

REAR

HRUST

P L AT E

( ~ Q T S G ]



DRIVI NG

SHE LL

REAR

THR US T

PL ATE

12. Wi t h t he s un gear and s hel l s et t i ng on

wood bl ock, al i gn r ear t hr us t pl at e and

i ns t a l l t he s un gear l ocki ng r i ng, as

shown i n Fi gur e 80.

13. Keep t he wood bl ock handy as i t wi l l

al so be used f or t he gear t r ai n endpl aycheck.

14. I nst al l t he assembl ed sun gear / dr i vi ng

s hel l ont o t he i nt er medi at e s haf t , as

shown i n Fi gur e 81, engagi ng i t i n t he

r ear pl anetar y gears.

15. I nst al l r ear t hr ust washer ont o f r ont

pl anet ar y and r etai n wi t h Tr ans- J el ,

as shown i n Fi gur e 82.

16 I ns t al l f r o nt t hr ust washer ont o f r o nt

[ ~ Q T S G )



S N AP R IN GFRONT

PLIERS ANN ULU S

GEAR

Fi gur e 84 Fi gur e 86

WASHER FRONT

FLAT ANNULUS

ALI GN S THRUST

W IT H F LA T WASHER

O N P L AN E TA R Y

HUB " IREAR

TAB ANNULUS

FACES GEAR

FRONT

FRONT

PLANETARY

GEAR

I

SELECTIVE

SNAP

RING

i ~ Q T S G ]



U P P E R

HOUSING

LI M IT

VAL VE

? S I N G

VA L VE B ODY R E A S S E MB L YUPPER HOUSI NG VALVE I NSTALLATI ON

1. Posi t i on upper val ve body housi ng wi t ht k i d f i d t h hi f t

10. Turn upper - val ve body housi n~ ov er andi t i h i Fi 89

~QTSG)



BOO ST

VA LVE

COVER

D

/UPPER

HOUSING

BOOS T

VALVE

COVERSP RING

AND

VALVE

SHUT T LE

~VA LVE

~ COV ER

( ~ ~ T 5 G ] Technical S e r vi -ce-I n-f -e-f m at ion~)¥~.,'



T H R O T T l E

PL U G

R E G U L A TO R

VA LVE

S PR I N G

SHVffiE

VAL VE

PRI/v\ AR Y

SPR I N G

2-3

G O V E R N O R

PLUG

G O VE R N O R ~

P L UG ~

C O V E R

3- 4 ACCUMULATOR ASSEMBLY

1. I nst al l new seal s on 3- 4 accumul at orpi st on, a s s hown i n F i gur e 92.

2. Lubr i cat e 3- 4 accumul at or bor e i n t he3- 4 accumul at or housi ng wi t h Tr ans- J e l ,l ubr i c at e pi s t o n s e al s , and i ns t a l l t hepi st on i nt o t he housi ng ( See Fi gure 92)

3 I t l l t h 3 4 l t i i

3-4

AC C U M U L AT O R

H O U SI N G

AC C U M U L AT O R

PI ST O N

[ ~ Q T S G )



TIMINGVALVE _

COVER

CONVERTER

CLUTCH.

VALVE AND

SPRING

CONVERTER CLUTCH

TIMING VALVE

AND SPRING

CONVERTER

CLUTCH

SOlENOID

SOLENOID

GASKET

CASE

CONNECTOR OVERDRIVE

SEPARATOR PLATE

Fi gur e 93

LOWER HOUSt N~ VALVE I NSTALLATI ON

1. Posi t i o n l o wer val ve body housi ng a sh i F i 93

3-4 SH IFT

VALVE AN

SPRING

SPRING

RETAINER

3- 4 QUI CK FI LL VALVE OPERA TI ON

The 3- 4 s hut t l e va l ve i s r epl ac ed by a3 4 Q i k F i l l V l i t h 42RE l



~QT5G)



1/4" D IAMETER

CHECKBALLS ( 6)

11 / 32" DIAMETER

CHECKBALL ( 1)

( ~ Q T 5 G l



TRANSFER

PLATE

LOWER

HOUSING

(OVERDRIVE)

SEPARATOR

PLATE

F i gur e 99

"~LOWER

12.

HOUSING

13.

14.

15.

Fi gur e 100

16.

LOWER

Now ver y car ef ul l y gr asp bo t h hal v es atonce and t urn t he ent i r e assembl y overand l ay i t as s hown i n F i gur e 99.Posi t i on t he l ower housi ng spacer pl at eo n t r ansf er pl at e and al i gn, as s hown

i n Fi gur e 99.I nst al l l ower val v e body housi ng on t opof s pacer pl at e ( See Fi gur e 100) .I nst a l l and st ar t by hand t he 13 val vebody s cr ews, maki ng s ur e t hat t he t ubebr ace i s i nst a l l ed i n pr o per po si t i o n,as shown i n F i gur e 101.

Tor que val v e body s c r e ws t o 35 i n. l bs,st ar t i ng at t he cent er and wor ki ng out

~QT5G)



~6. Posi t i on pl ug on end of t he conver t ercl ut ch val ve spr i ng ( See Fi gur e 103) .

~7. Swi ng accumul at or housi ng upwar d overt he val ve spr i ngs and pl ug, whi l e you

are hol di ng t he spr i ngs and pl ug comp-r essed.

28. Hol d accumul at or housi ng f i r ml y i npl ace, and i nst al l t he t wo r emai ni ngat t achi ng scr ews ( See Fi gur e 105) .

29. Be s ur e t hat s pr i ngs and t he c onv er t er

c l ut c h v al v e pl ug ar e s eat ed pr oper l y.

( See Fi gure 105) .30. Tor que t he 3 accumul at or housi ng scr ews

t o 35 i n. l bs . ( See F i gur e 105) .

CONVERTER

CLUTCH

VALVE

S P RI NG A N D

PLUG

3-.(

SHIFT

VALVE

SPR I NG

SPECIAL

TOOL 6583

POSITIONED



PRESSURE

REGULATOR

VAL VE SPR IN G

AD JUS TIN G

SCREW

BRACKET

THROTILE

PRESSURE

ADJ US TIN G

SCREW

125

T O R X

B IT

O N D ET EN T

HOUSING

Fi gur e 109

I nst al l t he manual val ve i nt o t he bor e

i n t he upper housi ng ( See Fi gur e 91) .

I nst al l t he t hr ot t l e val ve and spr i ng,

ki ckdown val ve, and ki ckdown det ent as


I ns t al l t he pr essur e r egul at or val ve

i n t he bor e i n upper housi ng as shown

i n Fi gur e 91.

I nst al l t he s wi t c h val ve i nt o t he bor ei n t he upper housi ng ( See Fi gur e 91) .

Posi t i on l i ne pr e ss ur e ad j us t i ng s cr e~

i n t he adj ust i ng scr ew br acket .

I ns t al l pr es s ur e r e gul at or s pr i ng on

t h e end of pr essur e r egul at or val ve, a5


I nst al l swi t ch val ve spr i ng on t ang at

end of ad j ust i ng s cr e w br acket ( See

Fi gur e 106) .

( ~ Q T S G )



45. P r e s s do wn o n ma nua l l e ve r unt i l i t i sf u l l y se at e d, wh i l e h ol d i n g u p o n t h et hr ot t l e l ever .

46. Re mo ve t he d et e nt b al l r e t a i ne r t o ol

a f t e r l e ve r i s f ul l y s e at e d.47. T he n i ns t al l t hr o t t l e l e ve r s e al o ve r

t he s h af t , a nd i ns t al l t he wa s he r a nd" E " c l i p a s s h own i n F i gur e 112.

48 . Lub r i c a t e t h e ma nua l l e ve r wi t h l i g htc o at o f Tr a ns- J e l .

49 . Ve r i f y a ga i n t h at t h e t hr o t t l e l e ve ri s a l i gn ed wi t h e nd o f k i c k do wn val v est e m, a nd t ha t ma nu al l e ve r a r m i s e n-

g ag ed i n ma nu al val ve ( S ee Fi g ur e I l l ) .

MANUAL

LEVER

ASSEMBLY

< -MANUAL

L EVE R

\ VALVE

( r : ; ; iI l" 1 nil J

SOLENOIDHARNESS CASE



GO VERNORSEN SOR

WIRE

OVERDRIVE /CONVERTERCLUTCH SOLENOID

ASSEMBLY

HARNESS CASE

CONNECTOR

~3-4

CCUMULATOR

HOUSING \

Fi gur e 116

I nst al l Over dr i ve/ Conver t ergasket o n upper ho usi ng and

Tr ans - J el ( See Fi gur e 113) .I nst a l l t he so l eno i d and wi r i ng har neas s embl y , and t or que t he 3 r et ai ni ng

s c r ews t o 72 i n. l bs ( See Fi gur e 114) .Rout e t he wi r e har ness , as shown i n I

F i gur e 115, and hoo k i nt o t he 3- 4 ac e- I 'umul at or cover pl at e. 1

At t a ch t he s ol e noi d c as e connect or t o 1

3- 4 accumul at or hous i ng wi t h s houl der It ype s cr ew ( See Fi gur e 116) .

Cas e connec t or has s mal l l oc at i ng t angt hat f i t s i nt o di mpl e at t he t op of 3-

,

sol enoi d Ir et ai n wi t t



I ~ Q T 5 G )RETAINER 61 Al i gn t he s c r ew hol e s i n t he governor



RETAINERPLATE

64.

65.

66.

SC REW (2 )./

Fi gur e 122

GOVERNOR IPRESSURESENSOR AND

WIRES

I I I

~GOVERNORPRESSURESOLENOID

VALVE ANDWIRES

61. Al i gn t he s c r ew hol e s i n t he governorbody, gasket , and t r ansf er pl at e, and

i ns t a l l t he t wo r et a i ni ng s cr ews , as

s hown i n Fi gur e 122.

62. Tor que t he t wo gover no r bo dy s cr ews t35 i n. l bs . ( See Fi gur e 122) .63. Connect t he wi r e har n es s t o gover nor

pr es s ur e s ol enoi d, us i ng c ar e s o asnot t o bend t he t er mi na l s . Ref er t o

F i gur e 123.Connect t he wi r e harn es s t o gov er norpr es s ur e s ens or , usi ng car e s o as nott o be nd t he t er mi nal s ( Fi gur e 123) .

The Ohms r eadi ngs f or al l el ect r i c al

component s i s f ound on Page 13. The val v e body i s now r eady f or t hef i nal l i ne pr es s ur e a nd t hr ot t l e pr es

sur e adj ust ment checks , and can t henbe s e t as i de f or f i nal as s embl y .

~QT5G)

T R A NS MI S S I ON R E AS S E MB L Y



T R A NS MI S S I ON R E AS S E MB L Y1. Ens ur e t hat r ol l e r c l ut c h as s embl y has

been i nst al l ed i nt o t he r ol l er cl ut chcam, as shown i n Fi gur e 127.

2. I ns t a l l r ea r band r eac t i on pi n i n c as eas s hown i n F i gur e 126, and e ns u re i ti s f ul l y seat ed.

3. I ns t al l r e ar band i n c as e, as s hown i nF i gur e 127, and e ns ur e t he t wi n l ugson band are s e at e d agai ns t t he r eac t i on

pi n.

Ther e ar e t wo cont r ol pr es s ur e adj us t ment so n t he v al v e bo dy whi c h a r e , l i ne pr es s ur e

and t hr ot t l e pr e s s ur e.L i ne and t hr ot t l e pr e s s ur e work t oge t he r,

as each af f ect s shi f t qual i t y and t i mi ng.Bot h adj ust ment s must be per f or med pr oper l ya nd i n t he c or r ec t s equenc e. L i ne pr es s ur e

i s a dj us t ed f i r s t a nd t hr o t t l e pr es s ur e i s

adj ust ed l ast .

LI NE PRESSURE ADJ USTMENT

1. Measure di st ance f r om t he val ve body t o

t he i nne r e dge of t he adj us t i ng s c r e wwi t h a n a cc ur a t e s t eel s c al e, a s s howni n F i gur e 124.

2. Di s t anc e s houl d be 1 and 5/ 16 i nc he s ., 3. I f adj us t me nt i s r e qui r e d, t ur n adj us t -

i ng s c r e w i n, o r out , t o o bt a i n t hedesi r ed set t i ng.

4. The ( 1- 5/ 16 i nc h) s e t t i ng i s appr oxi -mat e. Because of manuf act uri ng t ol er-

anc es , i t may be ne ce s s ar y t o var y f r o m

t hi s demensi on t o obt ai n desi r ed pr es-sures .

. . 5. One compl et e t urn of t he adj ust i ng sc-r e w c hange s l i ne pr es s u re appr oxi mat el y

2 P SI . T ur ni ng t he a dj us t i ng s c r e w i ncount ercl ockwi se di r ect i on i ncr eases

pr e s s ur e, and c l ockwi s e wi l l de cr eas epressure. '

THROTTLE PRESSURE ADJ USTMENT

REAR

BAND

REACTION

PIN

( ~ Q T 5 G JR EA R

B D O J ""



~ B ~ D = O =c := := :J =" "> 0

f l -~-r: l -TS-G)



IN TER M ED IA TES H A F T H U B

( ~ Q T 5 G )



FRONT

BAND

LEVER

PI VO T 22.SHAFT

" '- . ~

\ ~FRO NTBAND

LE V E R

SHA FT

ACCESS

PLUG

\

Fi gur e 139 1

From t hi s poi nt , i t wi l l be best i f we jhave t he t r ansmi s si on st andi ng upr i ght ,

We r ecommend usi ng an ol d 904 " Baby 8lt j '

case wi t h bel l hous i ng f aci ng f l oor .

Your t r ansmi ssi on can now be st ood up Ion t he ol d case wi t h i nt er medi at e shaf (

goi ng t hr ough t he ol d c ase. i

I nst al l t he pr eassembl ed f r ont and r e~

cl ut ch housi ng assembl y i nt o t he case.

as shown i n Fi gur e 136. j

Car ef ul l y t wi st assembl ed cl ut ches ba~

and f ort h t o e ngage and s eat t he r e ar j

cl ut ches on f r o nt r i ng gear hub. Al so

be s ur e f r ont cl ut ch housi ng dr i ve l u~

ar e f ul l y engaged i n t he sl ot s of t he Idr i vi ng shel l af t er i nst al l at i on. j

Sl i de t he f r ont band over f r ont cl ut e

housi ng as s hown i n Fi gur e 137.

( ~ Q T 5 G l Tee h n i c a-l -S e r vie e I n f or mat ion- -- - - - - -- -



SEAL

RINGS

( ~ Q T S G )

------"

J



ACCUMULATOR

P ISTON

OU TERSPR I NG

VALVE

BODY

ACCUMUL ATOR

PISTON

Fi gur e 146

( ~ Q T S G )



F IL T E R

SCR EWS

(3)



PISTON

LOCATINLUGS

Fi gur e 152

I ns t a l l a ne w manua l s ha f t s e al i n t hec as e us i ng a 15/ 16" s oc ke t , as s howni n Fi gur e 155

THRUST

BEARING

WAVESPRING



SPRING

REACTION

RING

O V E RD R I V E S E C T I O N D I S A S S E MB L Y1. Remove t he s peci al t ool f or al i gni ng

t he over r unni ng cl ut ch and pl anet ar y

gear s pl i nes , i f i t was pr evi ousl y

i ns t a l l ed ( See F i gur e 1) .

TORX



SCREWDRIVER (T25)

ACCESSCOVER

SCREWS

EXPAND BEARINGLOCATING

RINGWITH SNA PRING PUERS

- - -PUSH OUTPUT SHAFT

FORWARD TO FREEBEARING FROM RING

REARBEARING



WARNING: THE NEXT STEP IN DISASSEMBLY IN-

VOLVES COMPRESSING THE DIRECT CLUTCH

SPRING. IT I S EXTREMELY I MPORTANT THAT

PROPER EQUIPMENT BE USED TO COMPRESSTHE SPRING AS SPRING FORCE IS APPROXI·

MATELY 830 POUNDS. USE SPRING COMPRESSOR

TOOL 6227-1 AND A HYDRAULIC SHOP PRESS

WI TH A MI NIMUM RAM TRAVEL OF 5-6 INCHES.

THE PRESS MUST ALSO HAVE A BED THAT CAN

BE ADJUSTED UP OR DOWN AS REQUIRED. RE-

LEASE CLUTCH SPRING TENSION SLOWLY AND

COMPLETELY TO AVOID PERSONAL INJURY.

PRESSRAM

SPECIALTO OL

C-3995- A

(O R SIMI LARTO OL)

SPECIAL TOOL6m·l

DIRECTCLUTCHPACK

S NAPRING

CLUTCH

D R UM

SPECIAL

TOOL



6227-1

DIRECT

CLUTCH

PACK

DIRECT

CLUTCH

HU B

DIRECTCLUTCH

SPRING

DIRECTCLUTCH

HU B

Fi gur e 17

20. Af t er t he pr es s i s f ul l y r el eased, r e-

move t he Speci al T ool 6227- 1,

i n Fi gur e 14.

21. Remove t he di r ect cl ut ch pack

( See Fi gur e 14) .

22. Remove t he di r ect cl ut ch

as shown i n Fi gur e 15.23. Remove sun gear , pl anet ar y t h r us t bea

i ng, and over dr l ve car r i er , as shown

Fi gur e 16.

24. Remove t he over r unni ng

wi t h snap r i ng pl i er s,

17. Remove cl utc h wi t h count ercl ockwi

t wi st i ng mot i on ( See F i gur e 17) .

25. Remove over r unni ng cl ut ch f r om cl ut ch

OVERRUNNING

C U T C HINNER

RETAINING



CLUTCHH U B

THRUS T

BEARING

RETAINING

RING

( ~ Q T S G )

Cl ean t he gear t r ai n and al l component s igo od cl ean so l v ent ( See Fi gur e 25) Dr y a



ANNULUS

GEAR

go od cl ean so l v ent ( See Fi gur e 25) . Dr y apar t s, except t he bear i ngs, wi t h compr essai r . Al l ow t he bear i ngs t o ai r dr y .

Do not use shop t owel s f or wi pi ng par t sdr y unl ess t he t owel s are made f r om l i ntf r ee mat er i al .

I nspect t he geart r ai n and al l component sf or any wear and/ or damage, and r epl acenecessar y.



l>C

~o

~l>~n

~:IJ

l>Z

en >Tj

(Xl ~ ;;-

>-' en cen ~

oz

en

m:IJ

<

nmG):IJ

oC

Ll

C D OVERDRIVE PISTON THRUST PLATE

ill OVERDRIVE PISTON THRUST BEARING

C D OVERDRIVE CLUTCH PACK RETAINING RING

@ OVERDRIVE CLUTCH PACK

C D OVERDRIVE CLUTCH REACTION RING

® OVERDRIVE CLUTCH SNAP RING

C D DIRECT CLUTCH PACK SNAP RING

' C D DIRECT ClUTCH PACK

® CLUTCH HUB RETAINING RING

@ DIRECT ClUTCH HUB

@ DIRECT CLUTCH SPRING

@ SUN GEAR AND SPRING PlATE ASSEMBLY

@ PLANETARY THRUST BEARING

® PLANETARY GEAR

@ OVERRUNNING CLUTCH HUB

@ OVERRUNNING CLUTCH

® OVERRUNNING CLUTCH THRUST BEARING

@ RETAINING RING (CLUTCH DRUM INNER)

@ DIRECT CLUTCH DRUM

@ RETAINING RING (CLUTCH DRUM OUTER)

® ANNULUS GEAR. OUTPUT SHAFT.

AND SNAP RING ASSEMBLY

@ REAR BEARING

@ REAR BEARING SNAP RING

( ~ Q T 5 G ]OUTPUT·

SHAFT



SHAFT

H U B

~~T5G)

CLUTC H

HU B

OVERRUNNING

CLUTCH

AS SE MB LY



OVERRUNNING

CLUTC H

BE SURE

THRUST BEARING

IS SEATED SQUARELY

AG AIN ST CL UT CH HU B

~

CLUTCH

HU B

AS SE MB LY

EXP AN DING- TYP

SN AP RINGPL IER S

OVERRUNNING

LU TCH ASS EM BL YSE ATE D I N

O U T P UT S H A F T

AN NULUSGE AR

PL ANE T ARY

GEAR



14. I nst al l di r e ct cl ut c h s pr i ng pl at e ont he s un gear , wi t h t he shoul der si deof t he pl at e f aci ng out , as s hown i nFi gur e 10, and secur e pl at e t o t he s ungear wi t h t he s nap r i ng.

15. I ns t al l t he be ar i ng ont o t he s p ri ngpl at e usi ng a l i ber al amount Trans- J elt o r et ai n. Be s ur e be ar i ng s i t s s quar eagai ns t pl at e as i t onl y f i t s one way( See Fi gure 11) .

SPR I NG

P L A T E

DIRECT

C LU T C HSPR I NG

SPECIALTOOL

(-6227-2

( ~ Q T 5 G )

DI REC T

C LU T C H D I S CS ( 6)



ROLLER S ANDSPRI NGS

PRESSURE

--- PL ATE

( ~ Q T S G l '

21. I ns t al l t he f i r s t l i ned di r e ct cl ut c hpl at e over t he hub and aga i ns t r e ac t i

l t f l l d b t l l t t i l



pl at e, f ol l owed by a st eel pl at e unt i l6 l i ne d pl a t es and 5 s t ee l pl a t es havebeen i nst al l ed ( See F i gur e 16) .

22. I nst al l t he di r ect cl ut ch pr es s ur e pl -at e on t op of t he l as t l i ned pl at e wi

t he s houl der s i de o f pr e ss ur e pl a t e up

as s hown i n Fi gur e 16.23. I ns t al l c l ut c h hub and di r ect cl ut c h

pa ck a s s embl y on t he di r ect cl ut c h s p-r i ng, and be s ur e hub i s s t a rt e d on ts un gear s pl i ne s ( See F i gur e 17) .

WARNING: THE N EXT STEP IN G EA RTRA IN A SSE

BL Y INVOLVES COMPRESSING THE DIRECT CLUTC

HUB AND SPRING. IT IS EXTREMELY IMPORTA

THAT PROPER EQUIPMENT B E USED TO COMPRESS

THE SPRING AS SPRING FORCE IS APPROXIMATEL

830 POUNDS. USE SPRING COMPRESSOR TO

C·6227·1 A ND A HYDRA UL IC-TYPE SHOP PRE

WITH A M IN IMU M RA M TR AV EL OF 5-6 IN CH ES. T

PRESS MUST A LSO HA VE A B ED THA T CA N B E A

JUSTED UP OR DOWN A S REQUIRED. REL EA S

CLUTCH SPRING TENSION SLOWLY AND COf ll .

PLETELY TO AVOID PERSONAL INJURY.

24. Pos i t i on Compr ess or Too l 6227- 1 on the

cl ut ch hub, as shown i n Fi gur e 18.25. Pos i t i o n s peci al t ool or s i mi l a r t ype

t ool on t o p o f Tool 6227 1 as s hown

'SPEC IAL TOOL

SPECIAL

TOOL

C·6m·2

DIRECT

CLUTCH

PACK

SNAP



'SPEC IAL TOOL

, MB9908Q1

SPECIAL

TOOL

6m·2

SPECIAL

TOOL

6227·1

CLUTCH

DRUM

DIRECT

lUTCH

PACK

LUTCHH U B

/

RING

SPECIAL

TOOL

C·6227·2

( ~ Q T 5 G lREACTION

P L U G S N A P .

R IN G (DO --c:



R IN G (DO c:NO T OVERCOMPRESS .•. .

TO INSTA L L )

P A RKLOCK

REACTIONPL UG

[ ~ Q T 5 G ]EXPAND BEARING

LOCA TINGRING

WITH SNA PRING PLIER S

, TORXSCREWDRIVER (T25)

AC CESS



RING PLIER S

~~.,.. -

PUSH OUTPUT SHAFTFORWARD TO FREE

BEARING FROM RING,,.. _' _""'ll4 I ,

38. Ver i f y t ha t t he t a b e nds o f r ea r bea r -i ng l ocat i ng r i ng ext end i nt o accesshol e i n over dr i ve housi ng, as s h own i nFi gur e 25.

39. I nst a l l t he over dr i v e housi ng ont o t hegear t r ai n, and st ar t on r ear bear i ng,as s ho wn i n F i gur e 26.

40. Expand t he r ear bear i ng snap r i ng wi t hs na p r i ng pl i er s , a s s ho wn F i gur e 27,and sl i de housi ng downwar d unt i l t hel ocat i ng r i ng s na ps i nt o gr o ov e i n t heb

. ~ear 1ng.

41. I ns t a l l ne w l o cat i ng r i ng a cc es s c ov er

gasket , and i nst al l acces s cover , asshown i n Fi gur e 28.

42 At t hi s po i nt you s houl d hav e t hr ee

COVERSCREWS

WAVESPRING

REACTIONRING

RETAINING RING(W IRE -TYPE)

RE ACTIONRING

( ~ Q T 5 G ]



OD CLUTCH F L A T S NAP R I NG.

OD C L U T CH ~ S NAP RI NG.

OD CLt r r CH REA C T I ON P L AT E ( THI N) .

OD CLt r r CH PRE S SURE P L AT E ( T HI CK) .

OD CLt r r CH ROUND S NA P R I NG.

DI R E CT C L U T CH S NAP RI NG.

DI R E CT C L U T CH R EACTI ON P L AT E.

DI R E CT C L U T CH P LAT E S ( S EE CHART BELOW) .

DI R E CT C L U T CH P RE S S UR E P L A T E ( LI P DOWN) .

DI REC T C L UT CH HOUSI NG.

-( ------.,-,----",I I

I

- T • • . - - - - - - - - - - - . ; ",-

: I

( ~ ~ T 5 G )OVERDRIVE

C L U TC H D I SC S (3)R E A C TIO N

PL A TE

\



\

C L UT CH P L A TES (2)

F i gur e 33

46. I ns t al l t he o ve r d r i v e c l ut c h r e ac t i o npl at e i nt o o v er dri v e hous i ng o n t o p of t he s nap r i ngs as s hown i n F i gur e 33.No t e t hat r eact i on pl at e i s t hi nnert han t he pr e ss ur e pl a t e ( F i gur e 33) .

47. I ns t a l l t he f i r s t l i ne d c l ut c h pl at e,f ol l owed by a s t eel pl a t e, al t er nat i ngunt i l t he overdr i ve cl ut ches have al lbeen i ns t al l ed ( See F i gur e 33) .

48 CAUTI ON: Some model s r equi r e 3 l i ned

[~ Q T 5 G ]

SELECTIVESPACER1

SPACER

GROOVE



Fi gur e 36

SPECI AL

TOOL C-4962 -

SPECIA L

TOOL 6311 52.

SPECI AL 53.TOOL 6312

54.

55.J9221-47

F i gure 37

End PlayMeasurement Spacer Thi ckness

The s pac er on t he i nt er medi at e s haf t i ssel ect i ve, and s et s t he e nd pl ay on t he.i nt er medi at e s haf t ( See F i gure 36) .I nser t Speci a l Tool 6312 t hrough t hes un gear and i nt o pi l o t bus hi ng i n t heout put s haf t ( See Fi gur e 37) .

Pos i t i o n Gauge Tool 6311 a c r os s f ace of t he ov er dr i ve hous i ng, a s s ho wn i n F i g-ur e 37. Then pos i t i on di a l cal i per over gauget ool , as s hown i n F i gur e 37. Ext end t hes l i di ng s cal e of di al cal i per downwar dt hr o ugh ga uge t oo l s l o t unt i l t he s cal econt act s t he end of Gauge Tool 6312.L oc k t he s c al e i n pl a ce, r emove di al

l i d t di t d

[~ ~ T 5 G )End Play

Measurement Spacer Thickness

(Inches) (Inches)



SPECIAL

TOOL 6311

63. Rot at e t he t r ansmi ssi on and sta nd i t

up on t he bel l housi ng, as s hown i n

Fi gur e 43, i n pr epar at i on t o i nst al l

t he over dr i ve sect i on.

64. I nst al l t hr ust bear i ng on t o p of t he

sel ect i ve t hr ust pl at e wi t h t he bl ack

si de f aci ng t he pi s t on, and r et ai n wi t ha l i ber al amount of Tr ans- J el , as s hown

i n Fi gur e 43.

1.7500 . 1.7649 .108 - .110

1.7650 . 1.7799 .123 - .125

1.7800 - 1.7949 .138 .. 1401.7950 - 1.8099 .153 .. 155

1.8100·1.8249 .168 - .170

1.8250 . 1.8399 .183 .. 185

1.8400· 1.8549 .198 .. 200

1.85 50 . 1.8699 .213 .. 215

1.8700 . 1.8849 .228 .. 230

1.8850· 1.8999 .243 .. 245

[ ~ ~ T 5G )



( ~ Q T 5 G )

11m m

SOCKET



65. Rai se over dr i ve uni t , car ef ul l y sl i dei t s t r ai ght ont o i nt er medi at e shaf t as


66. Al i gn and car ef ul l y i ns er t par k r od

i nt o par ki ng pawl . Rod wi l l make cl i ck

noi s e as i t ent er s par k pawl . Move t he

r od r ear war d sl i ght l y.

67. Wor k overdr i ve uni t down on i nt er med-

i at e s haf t unt i l f ul l y s eat ed on t he

68. I f uni t i s not f ul l y seat ed, t i ght en

over dr i ve bol t s t o dr a w t he uni t up t o

case.

69. Appl y Lock- Ti t e 242 t o t he t hr eads of

over d r i ve bol t s, i nst al l and t or que t o

25 f t . l bs ( See Fi gur e 45) .70. Lay t r ansmi ssi on assembl y down on t he

bot t om pan as shown i n Fi gure 46.

CAU TI ON: I t i s poss i bl e f or t he par k

r od t o di s pl ace i nt o a cavi t y j ust over

t he pawl spr ag when. i ns t al l o. D. uni t .

Make sur e t he r od i s act ual l y engaged

i n t he pawl and has not di s pl aced i nt o

t hi s cavi ty.

( ~ Q T S G ]



SPEED

SENSOR

78. I nt er medi at e s haf t t hr u st washer t ha ti s i n hub of r ear c l ut c h dr um c ont r ol s

endpl ay. T hr ust wa she r i s se l e ct i v e

and ca n be changed t o ad j us t endpl ay.79. I f endpl ay t ur ns out t o be i ncor r ect ,

r emove oi l pump, cl ut ch dr ums, i ns t al lt hi nner / t hi cker was her as nec essar y.

80. I ns t al l out put s haf t s peed s ens or i nt ot he over dr i v e housi ng, as s hown F i gur e48, wi t h new "a" r i ng, a nd t o r que t hes ens or t o 20 f t . l bs.

81. I nst a l l t he t o r que conv er t e r a s shown

l~ Q J 5 ~ L-. . . . .~"'.,.

ITEM TORQUE

A 2·3 N-m (15·27 in. Ibs.l

B 10-12 N-m (90-110 in.lbs.)



VEHICLE

SPEED

~SENSOR~~~,.

jf; .',: t i : \ l ; •...::••.- " 1 : . ; :l~''; ",.~1"t}

{. '~

1~~ t ; l : ; ;~ 4 ~E E D 0 M E T E R1. Thor oughl y cl ean adapt er f l ange and t he

adapt er mount i ng s ur f ace i n t he hous i ng.Sur f aces mus t be c l ean f or pr oper adap-t er al i gnment and speedometer operat i on.

2. I ns t al l new " 0 " r i ngs o n v ehi c l e s peedsensor and speedometer adapt er, showni n Fi gur e 50.

SPEEDOMETER

PINION

( ~ ~ T 5G )SPECI FICA TIONS

42RE GENERAL SPECIFICA TIONS 42RE THRUST WASHER/SPACER/SN AP RING

DIMENSIONS



TRANSMISSION·MODel· 42 RE

Oil Pump Clear ances (all) 0.089-0.190 mm(0.0035-0.0075 in)

Planetar y End Ploy 0.127-1.22 mm(0.005-0.048 in)

Input Shaft End Ploy 0.56-2.31 mm

(0.022-0.091 in)

Clutch Pock Clearance:Front Clutch (4 Disc) 1.70-3.40mm

(0.067-0.134 in)

Rear Clutch (4 Disc) 0.81-1.40 mm

(0.032-0.055 in)

Clutch Disc Usage:

Fr ont Clutch 4

Rear Clutch 4

Overdrive Clutch 3

Dir ect Clutch 6

Bond Adjustments:(backed of f form 72 in. Ibs.)

Front Bond 3-5/8 TurnsRear ' Bond 4 Turns

Recommended (and prefer r ed) Fluid MOPAR ATF.Plus,

Type 717 6 Automatic Trammission

Fluid

TRANSMISSION MODEL 42 RE

Front Clutch Thrust Washer 0.061 in.

(on r eaction shaft suppor t hub)

Rear Clutch Thr ust Washer 0.061 in.

(on dutch r etainer)

Intermediate' Shaft Thr ust Plate 0.060-0.063 in.

(on shaf t pilot hub)

Intermedioie Shaft Thrust. Select f it io set.

Washer (in rear clutch hub) overall end ploy

.

Rear Clutch Pock Snap Ring 0.060 in.

0.076 in.. '

0.098 in.

Planetar y Gear train Snap Ring Select f it

(3 thicknesses(at front end of intermediateshaft)

available)

Overdrive PistonThrust Plate Thrust plate and spacer

are selectfit components..

Inter mediate Shaft Spacer Ref er to size charts and

selection pr;;edur es in

"Overdr ive Unit. Assembly

and Adjustment.· .' .

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atsg rebuild manual transmission service overhaul manual pdf

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