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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
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( ~ 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
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(~ 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
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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
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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.
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[~ ~ 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) .
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[~ ~ 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
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( ~ Q T S G )
VI EW LOOKI NG I NTO THE
GOVERNOR PRES SURE
SENSOR CONNECTOR
VI EW LOOKI NG I NTO THE
GOVERNOR PRES SURE
SENSOR HARNESS
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VI EW LOOKI NG I N TO THE TRANSMI S SI ON CASE CONNEC TOR
r--------- ---------- -- - -- ------ -- ---.,I I
I I
I II
I I
I 0.0. Tee II
I
I
II.
I
I
I
I
I
II
I
I
I
I
I
J
f
II
I
I
~ I. . . J I
e l l I
GOVERNOR
PRESSURESENSOR
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( ~ 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
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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
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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 ]
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( ~ 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 )
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[ ~ 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)
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(~QT51i)
Condition Possible Cause Correction
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
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Condition Possible Cause Correction
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
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1 ~ ~ T 5 G I
Condition Possible Cause Correction
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
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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
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( 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
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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 )
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( ~ ~ T 5 G )
Condition Possible Cause Correction
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
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(~ QTSG] Technical Service Information
TRANSMISSION DIAGNOSIS
Condition Possible Cause Correction
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 )
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[ Q T 5 G )
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[ ~ 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)
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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
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llmm
SOCKET
I ~ Q T 5 G )
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)
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 )
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( ~ 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 ]
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( ~ Q T 5 G ]
OIL PUMP AND REACTION
SHAFT SUPPORT ~SSEMBLY
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__ \' 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 )
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[ )
ETA IN ER
B O lT S
I ~ Q T 5 G ]
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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 ]
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( ~ 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.
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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 )
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( 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
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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
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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
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( ~ Q T 5 G l
o-RING
SEAl
SPEC IAL
TOOL
(-4171
RE ACTION SHA FT
SUP POR T
THRUSTWASHER
~QT5G)
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)
PREVIOUS
DESIGN
NEW
DESIGN
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( ~ Q T S G )27 L b i t l i t i h f t
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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
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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
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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 )
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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 ) .
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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
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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
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REAR ANNULUSAND PLANETARY G EAR
ASSEMBLY
FRONTTAB8ED
THRUST
WASHER
REAR
HRUST
P L AT E
( ~ Q T S G ]
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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 )
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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 ]
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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)
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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~)¥~.,'
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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 )
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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
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~QT5G)
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1/4" D IAMETER
CHECKBALLS ( 6)
11 / 32" DIAMETER
CHECKBALL ( 1)
( ~ Q T 5 G l
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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)
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~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
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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
shown i n Fi gur e 91.
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
shown i n Fi gur e 106.
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 )
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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
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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
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I ~ Q T 5 G )RETAINER 61 Al i gn t he s c r ew hol e s i n t he governor
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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
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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 ""
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~ B ~ D = O =c := := :J =" "> 0
f l -~-r: l -TS-G)
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IN TER M ED IA TES H A F T H U B
( ~ Q T 5 G )
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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- -- - - - - -- -
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SEAL
RINGS
( ~ Q T S G )
------"
J
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ACCUMULATOR
P ISTON
OU TERSPR I NG
VALVE
BODY
ACCUMUL ATOR
PISTON
Fi gur e 146
( ~ Q T S G )
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F IL T E R
SCR EWS
(3)
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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
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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
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SCREWDRIVER (T25)
ACCESSCOVER
SCREWS
EXPAND BEARINGLOCATING
RINGWITH SNA PRING PUERS
- - -PUSH OUTPUT SHAFT
FORWARD TO FREEBEARING FROM RING
REARBEARING
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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
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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
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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
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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.
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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
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SHAFT
H U B
~~T5G)
CLUTC H
HU B
OVERRUNNING
CLUTCH
AS SE MB LY
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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
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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)
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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
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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
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'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:
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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
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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 ]
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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
\
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\
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
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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)
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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 )
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( ~ Q T 5 G )
11m m
SOCKET
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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
shown i n Fi gur e 44.
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 ]
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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
end- pl 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 end- pl ay.79. I f end- pl 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.)
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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
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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.· .' .
-U N E P R E S S U R E
(160- 270 psi)
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