Installation Instructions - B and M Racing and Performance
Contents
1. Installation Instructions Shift Improver Kit for 1981 90 THM200 4R Transmission Part No 35265 B amp M Racing amp Performance Products 1999 Congratulations You have just pur chased the most complete and versa tile recalibration kit available forthe TH 200 4R transmission We have endeav ored to make the installation instruc tions on the following pages as clear and complete as possible Installation of your Shift Improver Kitcan be accom plished by anyone with minimum me chanical experience It is important however to closely follow the instruc tions Read through the instructions completely before beginning the installation Read each step carefully before proceeding if you do not under stand go back and read the step again NOTE This Shift Improver Kit is not a cure all for an ailing transmission If your transmission is slipping or in poor general shape the installation of this Shift Improver Kit may worsen the con dition However on aproperly operating transmission in average condition the Shift Improver Kit will provide the kind of transmission performance your looking for Check the tool list at the end of these instructions for the tools re quired to install your Shift Improver Kit INTRODUCTION This kit can be installed in a few hours by carefully following the instruc Printed in U S A tions Read all instructions first to familiarize yourself with the parts and procedures Trans2. Small flat screwdriver Internal retaining ring pliers Funnel cable is extended except in D2 amp D1 where pressure should remain con stant then look atthe pressure regula tor assembly for sticking valves or in correct order of assembly PARTS LIST Pressure Regulator Spring Blue Ring Retaining Spring Line Bias Red Gasket Valve body upper Gasket Valve body lower Gasket Accumulator Gasket Oil pan Spacer 3 8 Red Spacer 3 4 Blue Drill 3 32 094 Drill 5 64 078 PARK amp NEUTRAL 1000 RPM REVERSE 1000 RPM DRIVE D4 amp TH200 4R TRANSMISSION OIL PRESSURE OIL PRESSURE AT MINIMUM T V kPa 517 634 517 MANUAL THIRD D3 1000 RPM MANUAL SECOND D2 amp LOW D1 1000 RPM PSI kPa 75 758 92 1380 75 758 OIL PRESSURE AT FULL T V PSI 110 DUE TO THE LARGE VARIETY OF PRESSURE REGULATOR COMPONENTS USED IN DIFFERENT PRODUCTION MODELS OF THE TH200 4R TRANSMISSION THE OIL PRESSURES LISTED ABOVE ARE MINIMUM VALUES IN MOST CASES THE PRESSURE READING WHICH YOU OBTAIN WILL BE SUBSTANTIALLY HIGHER FOR A MORE ACCURATE ESTIMATE CONSULT THE APPROPRIATE FACTORY SERVICE MANUAL FOR YOUR MODEL AND YEAR OVERHEATING FOAMING OIL AT DIP STICK OR BREATHER ERRATIC SHIFTING LATE HARD SHIFTS WILL NOT SHIFT Valve body bolts loose Low fluid level 1 2 and or 3 4 accumulator seals missing or damaged 1 2 accumulator housing bolts loose Pressure
3. regulator valve assembly improperly installed Throttle valve linkage incorrectly installed TV cable improperly set Throttle valve sticking Misaligned or interchanged valve body gasket Filter O rings damaged or missing Oil cooler has insufficient capacity Oil cooler plugged High fluid level Shifter not properly adjusted Manual valve not properly engaged Low fluid level Valve body gaskets damaged or incorrectly installed TV cable binding or improperly set Valve body gaskets incorrectly installed TV cable binding or improperly set Check balls missing or mislocated Governor failure TV cable not properly set TV exhaust checkball 5 lifter binding missing or unhooked PUMP BUZZ OR WHINE SOFT 2 3 SHIFTS WILL NOT MOVE NO CONVERTER CLUTCH APPLY NO CONVERTER CLUTCH RELEASE NO PART THROTTLE DOWN SHIFT NO REVERSE AND SLIPS IN FORWARD RANGES Low oil level Filter tube O ring cut or missing Filter clogged Pressure regulator valve assembly incorrectly installed TV cable not set properly Check balls missing or mislocated Manual valve not properly engaged Accumulator piston s left out or seals damaged Pressure regulator retaining ring did not seat in groove Voltage not reaching solenoid Harness plug not fully engaged Connectors not on correct switches Wires pinched and grounded out Converter clutch valve stuck Converter clutch app
4. Youmustresetthe TV cable See Fig 11 for the correct procedure Failure to reset the TV cable will result in poor shift quality and or transmis sion failure STEP 23 Inspect the transmission for leaks with engine running Lower ve hicle and check fluid level again adjust ing level as required Test drive vehicle and recheck for leaks while transmis sion is hot TROUBLE SHOOTING Most problems can be traced to Automatic cable adjuster Carburetor lever Valve body 4 assembly TM link incorrectly installed components Ifthe transmission makes unusual noise or feels as if it is binding up turn off the engine immediately Go back and re check the entire installation If the problem is shift quality slip ping hard early late then do the following 1 Check transmission oil level 2 Check and adjust T V Cable 3 Check outside manual shift linkage If the above does not remedy the problem then perform the following di agnostic oil pressure check 1 CHECK ENGINE TUNE 2 INSTALL A 0 2 080 kPa 0 300 PSI OILPRESSURE GAGE THELINE PRESSURE TAP IS LOCATED JUST ABOVE THE OUTSIDE MANUAL LINK AGE ON THE LEFT HAND SIDE OF THE CASE Check oil pressures as follows Minimum T V Line Pressure Check Setthe T V cable See Fig 11 Withthe brakes applied take the line pressure readings at the selector lever position and engine R P M specified inthe chart Maximum T V Line Pressure Check With the b
5. ation and safety MAKE SURE THE VEHICLE IS RIGIDLY AND SECURELY SUPPORTED JACK STANDS WHEEL RAMPSOR AHOIST WORK BEST DO NOT USE JACKS ALONE Have an oil drain pan ready to catch oil and atray on which to put small parts so they won t ge lost STEP 1 Position your drain pan be neath the transmission to catch the oil Toremove the oil pan first remove all but three bolts on the right hand side of the pan Nextloosen but do notremove the three remaining bolts If the pan sticks to the gasket insert a flat screwdriver between the pan and case and pry down gently to break pan loose Slowly remove the remaining three bolts allow ing the pan to tilt down and drain Remove all gasket material from the pan and case flange STEP 2 Remove the oilfilter by gen tly pulling it straight down The pickup tube has an O ring or seal around the Make sure manual link is installed as shown Pressure regulator bore Make sure retaining ring is fully seated in groove Fig 3 Pressure Regulator Bore Pressure regulator valve Pressure regulator m spring Reverse boost SA Reverse boost valve sleeve T V boost valve T V boost valve sleeve Pressure regulator assembly retaining ring Fig 4 Pressure Regulator Assembly end that fits into the pump housing Sometimes the pickup tube O ring or seal remains in the pump bore if so remove O ring or seal from pump STEP 3 See Fig 1 There are a variety of differen
6. d sepa rator plate with clean solvent and air dry ASSEMBLY STEP 9 Heavy Duty and Street Check ball placement See Figs 6 amp 7 Place check balls inthe valve body and case in the positions shown Use a dab of grease or petroleum jelly to hold check balls in position There are 3 check balls located in the valve body and 8 in the case STEP 10 Place the new separator plate gaskets on the separator plate See Fig 8 Use a dab of grease or petroleum jelly to help hold the gas kets to the plate The gasket with the C cut in it goes next to the case and the gasket with the V or VB cut in it goes next to the valve body Make sure no holes inthe separator plate are covered by the gasket If your gaskets become damaged anytime during the installation of the kit replace them Purchase OEM gaskets for your specific year and model vehicle STEP 11 Heavy Duty Level Only In Sert the 3 4 accumulator pin inthe case Overthe pin place the spring andthenthe accumulator piston Use adab of grease or petroleum jelly to hold Components in place See Fig 9 STEP 12 Street Level Only Insert the 3 4 accumulator pin inthe case Over the pin place the Red 3 8 spacer spring and accumulator piston Use a dab of grease or petroleum jelly to hold components in place See Fig 10 STEP 13 With the 3 4 accumulator components and case check balls in place place the separator plate gas ket assembly up to the case follo
7. eburr the holes after drilling STEP 8 Street Level Only Line bias valve Rinse off valve body with clean solventto remove any dirt or grit Move to aclean working area The valve body consists of precision fit compo nents which will not tolerate dirt or burrs Remove the roll pin retaining the line bias valve See Fig 6 Remove the aluminum plug valve and spring from bore The stock spring will not be re used Insertthe RED spring from the kit gt C poi 3 32 094 O H S l U L ele ER l A ri L564 078 f A N o K Z z C C K So m 0 lt Heavy duty co Drill 5 64 078 i 3 cy Streetonly Se 5 lt Drill 3 32 094 4 G 8 o R 0 LU L i C L L O C J LT 5 2 oof E Q 0 L 7 S O LU L a a O C Pa K T L Noa 5 64 078 ome S D D LC C T l C CO S a OO ae mm S a a a _ L P 7 Pe So a Fig 5 Drill Seperator Plate lets ee F Recess on plug o i RERE KZ faces out SE See Street level only Replace line bias spring with red spring from kit Install checkball in 3 places marked Fig 6 Valve Body Checkball Placement 4 Fig 8 Valve Body Gaskets Valve body into the bore then install the valve aluminum plug and roll pin in reverse order of removal Important Do Not dry or wipe parts with cloth rags be cause the lint and loose threads can contaminate the transmission fluid and resultin jambed pressure regulator and shiftvalves Clean valve body an
8. f the 1 2 and 3 4 accumulator springs for correct reassembly Remove all old gasket material from these parts MODIFICATIONS STEP 6 All Performance Levels Pressure regulator Remove the snap ring at the end of the pressure regulator bore in the oil pump assembly See Fig 3 Use a screwdriver to hold the pressure regulator assembly while re moving the retaining ring Ifthe sleeves stick in the bore lightly tap the sleeve with a small rod and a mallet piece of 2X4 Remove two sleeves with valves the pressure regulator spring and valve Reassemble the pressure regulator assembly using the BLUE spring sup plied with the kit See Fig 4 Use the new retaining ring from the kit Impor tant Make sure the retaining ring is firmly seated in its groove when as sembled CAUTION The pressure regulator boost valve train MUST be installed in the proper order with the sleeves and valves oriented as shown There are several ways the sleeves and valves can be installed however only the orientation shown will work properly Improper in Stallation will cause low line pressure resulting in slipping clutches and burnt friction elements STEP 7 Heavy Duty and Street Separator Plate Using the supplied drills enlarge the holes in your separa tor plate as indicated see Fig 5 for the performance level desired Pay close attention to the diagram when locating the holes to be enlarged so as not to enlarge the wrong hole Carefuly d
9. ft pin is properly installed 4 Wiring properly connected 5 Regulator valve retaining ring fully seated in groove Place O ring or sealonthe end ofthe filter tube Coat the O ring or seal with clean ATF and push the tube into the pump bore until it is fully seated The filter retainer clip should be located at the small depression in filter housing STEP 20 Remove all old pan gasket material from pan and case pan rail Clean inside of pan with solvent You may wantto installa B amp M Drain plug kit 80250 at this time Install the new pan gasket on the pan and align the holes Use grease or petroleum jelly to help hold the gasket in place during installa tion of pan Do not use any gasket sealer or silicone compounds To prevent premature band failure make sure the servo exhaust hole shown in 6 3 4 Accumulator Piston Note Some transmissions come with the 3 4 accumulator springs installed above the piston You should rein stall the spring as shown here Red 3 8 spacer Fig 10 Street Level Accumulator Assembly Order Fig 1 is not obstructed Place pan up to case align holes and install all bolts finger tight Tighten bolts to 14 NM 10 Ft Lb Do not over tighten bolts If the bolts are over tightened the gasket will deform excessively and result in oil leaks STEP 21 Fill transmission with fresh automatic transmission fluid to the full mark on the dip stick You will need about 6 quarts STEP 22
10. ly valve stuck open TV cable not set properly Throttle valve binding Pressure regulator valve assembly incorrectly installed Pressure regulator retaining ring did not seat in groove
11. mission com ponents are precision fit work slowly and do not force any parts Burrs and dirt are the number one enemies of an automatic transmission Cleanliness is very important so a clean work surface from which oil can easily be removed Is necessary This kit contains all parts neces sary to obtain two different levels of performance depending on intended use 1 Heavy Duty For passenger vehicles towing police taxi or any other heavy duty use Firm shift feel perfect for every day street use 2 Street For full performance street use Streetlevel produces firm positive shifts and maximum transmission torque capacity It is important to install either the heavy duty or street levels Do not mix modifications from different levels When installing your Shift Improver Kit there are several other B amp M prod ucts you may wish to consider DRAIN PLUG KIT 80250 TH 200 4R transmissions are notfactory equipped with a drain plug The B amp M Drain plug kit is inexpensive and easy to install and it helps eliminate the mess during fluid change or pan removal TRANSMISSION OIL COOLER We feel that it is very important that every vehicle used in a heavy duty application Towing RV Commercial Police etc should have an oil cooler Heat is the major causes of transmission failures and an oil cooler is an inexpensive safeguard against overheating and fail ure B amp M offers a wide range of trans mission coolers to sui
12. rakes applied hold or tie the T V cable in it s fully extended position then take the line pressure readings again at the selector lever positions and engine R P M specified in the chart IMPORTANT Only pull out T V cable for this test DO NOT open throttle to Ww Throttle lever amp C bracket assembly 4 Throttle lever Reset tab Fitting Reset direction _ mmn ee r eee TM cable Slider housing T V Cable Resetting Procedure 1 Turn off engine 2 Depress and hold reset tab then pull TMV cable housing in reset direction Release reset tab Gently depress throttle pedal to the floor board TV cable will automatically reset Fig 11 T V Cable Adjustment Procedure wide open position Basic line pressure is controlled by the pumps output volume and the pressure regulator valve The T V system whichis controlled by the T V cable causes line pressure to increase with increased throttle opening Because of system requirements line pressure is boosted by the reverse boost valve and sleeve as sembly when the selector is in the Re verse D2 or D1 position If the oil pressure readings are low high or do not change when the T V TOOL LIST Hydraulic jack Gasket Scraper Jack stands or Wheel ramps 3 8 Drill motor Oil drain pan Fine cut flat file 3 8 drive ratchet wrench 10mm 13 mm Sockets Wet or Dry sand paper Grease or petroleum jelly Small punch or scribe Torque wrench
13. t every need which are available at your B amp M dealer TEMPERATURE GAGE KIT 80212 Most transmission and converter fail ures can be traced directly to exces sive heat The B amp M transmission tem perature gage can save you a costly repair bill by warning you ahead of time ofanoverheatedtransmission The B amp M temperature gage is extremely accu rate and dependable it comes with all necessary hardware and is easy to install DISASSEMBLY Automatic transmissions normally operate at temperatures between 150 and 250 degrees Fahrenheit We sug gest the vehicle be allowed to cool for several hours before disassembly to avoid burns from hot oil and parts The vehicle should be raised so there is at least two feet ground clearance for 9500536 01 Pressure regulator bore Manual link Oil filter ae ww bore hicat a converter solenoid T V lever amp bracket Do not block hole servo exhaust Fig 1 Valve body and accumulator installed T V exhaust check ball lifter rod T V lever and bracket assembly A V Cable link GH t wn rea me T pr Fig 2 T V Lever and Bracket Electrical connector Signal pipe 1 2 accumulator C NN Ns a ee ee s TAMANE EE lt Fha Ma d lt lt gt wed BL Governor GEE cover 1 2 accumulator housing Bolt Lengths A 1 15 5 mm 0 61 B 3 30 0 mm 1 17 C 11 45 0 mm 1 76 D 5 60 0 mm 2 34 ease of install
14. t wiring harnesses used on the TH 200 4R Before pro ceeding further make a sketch and some notes describing your particular unit recording which connectors go to which switch Disconnectthe T V cable connector from the throttle lever on carburetor or throttle body Remove connectors from switches Unplug the wiring harness from case electrical con nector by prying the lock tab away from the plug and pulling down onthe plug do not pull on the wires Removing sole noid is not required just tie the wires up out of the way Remove signal oil pipe detentspring andthe throttle valve lever and bracket assembly Be careful notto lose the T V exhaust checkballlifter rod when removing throttle valve lever and bracket assembly see Fig 2 STEP 4 Remove allvalve body bolts except the center one See Fig 1 Hold the valve body up firmly with one hand and remove the remaining bolt slowly Lower the valve body and disen gage the manual valve link There are several check balls in the valve body along with several pints of oil Have your drain pan ready to catch the oil and check balls should they fall out Save all 12 check balls in a safe place where they won t get lost STEP 5 Remove the 1 2 accumula 3 tor housing and plate while holding the separator plate up to the case Then slowly lower the separator plate and retrieve the 8 check balls located above the plate IMPORTANT Make note of the color size and location o
15. ully engaged before attempting to draw the accumulator up to the case STEP 16 Valve body installation Make sure check balls are in proper locations Position the manual valve so the link rod can be engaged See Fig 1 Do not force the manual valve at any time When the link and manual valve are fully engaged align the valve body and case holes then install one bolt finger tight to hold valve body in place Important Make sure the manual valve link is located as shown STEP 17 Install the throttle valve TV linkage onto the valve body as shown make sure the T V exhaust checkball lifter rod is correctly assembled See Fig 2 IMPORTANT NOTE The T V cable MUST be reset before operating vehicle refer to step 22 STEP 18 Carefully insert ends of the signal oil pipe in their respective bores and push them in evenly until fully engaged Engage all of the remaining bolts to finish lining up the separator plate and gaskets See Fig 1 Tighten all the valve body and accumulator bolts to 11 NM 8 Ft Lb Avoid stripped threads Do not over tighten bolts Reconnect wiring harness connec tors to the terminals from which they were removed Refer to sketch or notes made at Step 3 Reconnect the har ness to the case connector making sure it is firmly seated and locked STEP 19 Double check installation 1 make sure all bolts are installed and torqued 2 Throttle valve linkage oper ates freely 3 TV exhaust checkball 5 li
16. wed by the 1 2 accumulator plate Carefully line up the gaskets and install the short accumulator plate bolt Tighten bolt finger tight Note When installing valve body and accumulator housing install all bolts finger tight first to allow the separator plate and gaskets to properly line up before attempting to torque them STEP 14 Heavy Duty Level Only 3 4 Accumulator Piston Note Some transmissions come with the 3 4 accumulator springs installed above the piston You should rein stall the spring as shown here Fig 9 Heavy Duty Level Accumula tor Assembly Order Install gasket piston spring and 1 2 accumulator housing in reverse order of removal Tighten bolts finger tight See Fig 9 STEP 15 Street Level Only Remove the spring and piston from the 1 2 accumulator housing See Fig 10 and install the Blue 3 4 spacer over the guide pin Install piston and spring into 1 2 accumulator housing in reverse order of removal With the spacer in Stalled it willbe necessary to compress the accumulator spring when installing the accumulator assembly To help keep the separator plate and gaskets aligned thread 5 or 6 bolts into the case at various positions Place gasket on accumulator housing then hold the 1 2 accumulator assembly up to the case As an assembly aid use two of the long valve body bolts as guides while com pressing the accumulator spring To avoid stripped threads make sure bolts are f
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