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TRANSMISSION PART 1-MANUAL TRANSMISSION

1. 55 45 Main Drive Pinion Bearing Retainer 5 15 20 Transmission to Clutch Housing 50 Crossmember Attaching 50 Shift Mechanism Pivot 55 Shift Lever 30 Companion Flange 175 Gearshift Housing 5 144 Gearshift Operating Lever Ae m 216 Transmission Drain 300 TRANSMISSION 4 SPEED MANUAL 21 15 1B 4 FORWARD SPEED MANUAL TRANSMISSION The four forward speed synchromesh trans mission shown in Figure 1 consists of a series of helical gears designed for high torque capacity and with teeth so proportioned as to operate at high speeds without excessive friction loss or heat genera tion The shafts bearings synchronizers and other precision parts are held to close tolerances to provide durability during extended heavy operation The main drive pinion is supported by a heavy duty ball bearing at the rear and an Oilite bushing pressed into the end of the crankshaft The main sh
2. 150 A TRANSMISSION TORQUEFLITE 21 29 KD SERVO n M ci o o TORQUE CONVERTER OIL PRESSURES a 8 L I nem Ce 9090904 TTre B S T CONTROL SYSTEM IN NEUTRAL i FRONT PUMP REAR PUMP ENGINE RUNNING 62x230B OiL FILTER Fig 1 Neutral Hydraulic Circuits 21 30 TRANSMISSION TORQUEFLITE TORQUE CONVERTER FRONT CLUTCH LUB em CONTROL VA Nu 5 OIL PRESSURES 75 psi ES PUMP SUCTION THROTTLE 40 psi GOVERNOR 0 75 psi CONVERTER 30 75 psi LUBRICATION 5 30 psi TO CONTROL SYSTEM IN BREAKAWAY HALF THROTTLE 62x231B f N E W OIL FILTER Fig 2 Drive Breakaway Hydraulic Circuits TRANSMISSION TORQUEFLITE 21 31 REAR CLUTCH TORQUE CONVERTER OIL PRESSURES PUMP SUCTION THROTTLE 40 psi HI GOVERNOR 6 75 psi CONVERTER 3075 5 20 psi T LUB ab T uama CONTROL SYSTEM IN gt 4 DRIVE SECOND HALF THROTTLE 52x232B Olt FILTER Fig 3 Drive Second Hydraulic Circuits 21 32 TRANSMISSION TORQUEFLITE REAR CLUTCH 6000000043g
3. 361 383 413 Gear Ratio eR RR ERE 2 66 Second Sah Ne eer hot c E er aan 1 91 penes eunte NUES UE PERI Ea n 1 39 Fourth correre Ue em 1 00 ReV rt 7_ as RD e V vos e ER Rd Ea EA e dign 2 58 Rear Axle Ratios Standard 3 23 3 23 Nodes Mowe euet ede a atas is 3 23 Lubricant Capacdty 7 Type Susan SEU ER Edu Saige E epa ala d E Automatic Transmission Fluid Type Suffix Gear Gears except Tolerances Clutch Housing Face 006 Clutch Housing Bore 008 Countershaft Gear cluster End 0045 to 028 Gear Sets available through MoPar 2 93 3 55 3 91 4 1 4 3 4 56 4 89 SPECIAL TOOLS 452 Flange Holder 748 Oil Seal Remover 3837 Seal Installer C 3487 Fixture Engine Support 3938 Countershaft Arbor C 3789 Seal Installer 3951 Lever Aligning Tool TORQUE REFERENCE Foot Pounds Inch Pounds Extension Housing to Cose 5
4. 361 383 RATIO EE Way 2 55 to 1 cos ec eae See Gi Tale Sie EU eae 1 49 to 1 Direct e o q eR idet de te 1 00 to 1 oF wise d y En 3 34 to 1 LUBRICANT Capacity 3354 6 exe E ee ethos Sa E RN arene da Approximately 5 Pints us shes pe e m ed ns hace EE prd ed oe kas wey se Automatic Transmission Fluid Type A Suffix A ade adr und d e Helical TOLERANCES Clutch bebe Di eee RT T CE 006 inch Maximum Clutch Housing Bore 008 inch Maximum Countershaft End Play ricco e eR ua RR REN Rau 0045 to 028 inch Second Speed Gear End 002 to 014 inch C 3281 Brake Drum Wrench 3789 Pinion Seal Retainer Driver 3834 Cluster Gear Arbor 464 Reverse Idler Arbor 3765 Detent Ball Holding Tool 3650 Shifter Shaft Seal Driver 3806 Engine Support Fixture 3767 Shifter Shaft Protector 3837 Mainshaft Seal Driver 3638 Shifter Shaft Seal Puller 748 Mainshaft Seal Puller 3301 Snap Ring Pliers 452
5. Fig 22 Bottom View of Transmission Pan Removed adjusting screw in this position and tighten the lock nut to 29 foot pounds torque Low and Reverse Band 1 Raise the vehicle drain the transmission fluid and remove the oil pan 2 Loosen the adjusting screw lock nut and back off the nut approximately five turns Fig 22 Inspect the adjusting screw for free turning in the lever 3 Using wrench Tool C 3380 with adapter C 3705 tighten the band adjusting screw to 47 to 50 inch pounds torque If adapter 3705 is not used tighten the adjusting screw to 72 inch pounds which is the true torque 4 Back off the adjusting screw 3 turns Hold the adjusting screw in this position and tighten the lock nut to 35 foot pounds torque 5 Reinstall the oil pan using a new gasket Tight en the oil pan bolts to 150 inch pounds torque 6 Fill the transmission with Automatic Transmis sion Fluid Type Suffix Refer to Paragraph 4 13 THROTTLE LINKAGE ADJUSTMENT 1 With the engine at normal operating temper ature carburetor off the fast idle cam and choke valves open adjust the idle speed to 500 rpm for Chrysler and Imperial 900 rpm for 300 with en gine use tachometer 2 Chrysler and Imperial Adjust the throttle link age as outlined and illustrated in Figure 23 and 24 3 Model 300 with K engine Refer to Figure 25 Loosen the locking nuts and
6. TORQUE CONVERTER OIL PRESSURES 55 90 psi PUMP SUCTION THROTTLE 0 90 psi GOVERNOR 6 90 psi CONVERTER 30 75 psi LUBRICATION 5 30 psi TO LUB UN m E I CONTROL SYSTEM IN i DRIVE DIRECT OIL FILTER Fig 4 Drive Direct Hydraulic Circuits 62x233B TRANSMISSION TORQUEFLITE 21 33 KD 9 SERVO LOW amp REV SERVO E KO REAR CLUTCH TORQUE CONVERTER 2 Cate FRONT CLUTCH 2 LUB 3h CONTROL VA Cr coour LINE 90 psi PUMP SUCTION 4 THROTTLE 90 psi o o o o q Mr Ir Ul REGULATOR VA GOVERNOR 60 65 psi od i i TEB CONVERTER 30 75 psi Ld gt LUBRICATION 5 30 psi N TO CONTROL SYSTEM IN I DRIVE KICKDOWN i 50 62x234B FILTER Fig 5 Drive Kickdown Hydraulic Circuits 21 34 TRANSMISSION TORQUEFLITE TORQUE CONVERTER FRONT CLUTCH 5 LUB dH E A u UNE 55 PUMP SUCTION GOVERNOR 6 55 psi Ei CONVERTE 30 75 psi LUBRICATION 5 30 psi O CONTROL SYSTEM IN MANUAL SECOND CLOSED THROTTLE REAR 62x235B 2 1 OIL FILTER Fig 6 M
7. accelerator shaft to throttle shaft lever rod a Insert a piece of 944 inch drill rod 10 inches long into the accelerator shaft bracket and through the hole in the lever b Move the transmission throttle control lever forward against its stop then tighten the locknut securely This positions the accelerator shaft c Unsnap the accelerator pedal to shaft rod Turn the threaded end of the rod either in or out until an angle measurement of 114 degrees is obtained be tween the floor of vehicle and the flat face of the accelerator pedal Use a protractor to obtain the angle Reconnect the rod and remove the locating drill rod d Inspect each carburetor to be sure the choke valves are open that the fast idle cams are released and the throttle valves are closed Loosen the locking nuts and D left and right bank carburetor rods WITH MANUAL TRANSHISSION 1 ASSEMBLE ACCELERATOR SHAFT ASSEMBLY AND PEDAL ASSEMBLY TO BODY WITH 3 16 DIAMETER 5 APPROXIMATELY 10 LONG IN THE HOLES PROVIDED IN THE ACCELERATOR SHAFT BRACKET AND LEVER ADJUST THE PEDAL ROD 6 JLENGTH TO PROVIDE A PEDAL ANGLE OF 113 TO 115 INSTALL PEDAL ROD APPLY A THIN FILM OF 5 3608 LUBRICANT TO THE ACCELERATOR 1 WHERE TURNS IN THE FIREWALL BRACKET ASSEMBLE CARBURETOR ROD PARTS BUT DO NOT TIGHTEN ADJUSTMENT LOCK NUT 4 DISCONNECT 2 CARBURETOR OR BLOCK
8. 28 Neutral Starting 59 Torque 28 Valve Body Assembly and Accumulator Piston 60 Clutch Engagement and Band Application Chart 38 Transmission and Converter Removal and Installation 60 Hydraulic Control 39 Recondition Transmission Unit out of Vehicle 63 Gearshift and Parking Lock 40 Flushing the Torque 63 Operating 40 Aluminum Thread 63 2B Service Maintenance Adjustments and Tests 41 Front Pump Oil 63 Lubrication 2 5 hws 41 Removal of 5 64 Push Button Control 43 Recondition 5 66 Console Gearshift 44 Valve Body 67 Back up Lamp Switch Replacement 45 Accumulator Piston and 70 Push Button and Console Shift Lamp Replacement 45 Extension Housing Bearing and Oil Seal 70 Gearshift Control Cable Transmission 45 Parking Sprag and 70 Parking Lock Cable Transmission End 46 Governor and 5 71 Neutra
9. 4 D DRIVE 2 SECOND 1 FIRST PARKING LOCK HANDLE SCREW PARKING LOCK ARM GEARSHIFT CONTROL CABLE NUT AND WASHER 2 63x36 Fig 12 Removing or Installing Gearshift Control Unit Chrysier INSULATOR GEARSHIFT CONTROL HOUSING ASSEMBLY GEARSHIFT CONTROL CABLE PARKING LOCK CABLE 64x 471 Fig 13 Removing or Installing Gearshift Control Unit Imperial CAUTION To prevent dirt from entering the transmission make certain that the dip stick cap is fully seated onto the filler tube Periodic Adjustments The following adjustments should be performed at 32 000 mile intervals or more frequent under se vere operating conditions 1 Adjust the kickdown band Refer to Paragraph 12 2 Adjust the gearshift control cable Refer to Par agraph 9 3 Adjust the engine idle in neutral Refer to the Fuel System Group 14 4 Adjust the transmission and carburetor throt tle linkage to obtain the proper shift pattern Refer to Paragraph 13 5 PUSH BUTTON CONTROL UNIT Removal 1 Disconnect the negative ground cable from the battery 2 Disconnect the back up lamp switch wire con nector from the switch if so equipped 3 Chrysler Models Remove the parking lock han dle from the arm Fig 12 Remove the retaining Screws and remove the plate beneath the instrument cluster hood the chrome moulding from the left side of the instrument panel and the push button bezel and l
10. 528 74 1227 16 NOTE Some thread drag may occur screwing into the installed Heli Coil insert Therefore a torque reading should be taken of the thread drag with an inch pound torque wrench and added to the specified bolt torque so that all bolts securing a particular will be tightened fo the same torque 21 64 TRANSMISSION TORQUEFLITE Fig 49 Removing Front Pump Oil Seal removing the front pump and reaction shaft support assembly from the transmission case 1 Screw seal remover Tool C 3861 into the seal Fig 49 Tighten the screw portion of tool to with draw the seal 2 To install a new seal place the seal in the open ing of the pump housing lip side facing inward Us ing Tool C 3860 drive the seal into the housing until the tool bottoms Fig 50 29 REMOVAL OF SUB ASSEMBLIES Prior to removing any of the transmission sub assemblies plug all openings and thoroughly clean bs m Fig 50 Installing Front Pump Oil Seal the exterior of the unit preferably by steam Clean liness through the entire disassembly and assembly cannot be over emphasized When disassembling each part should be washed in a suitable solvent then dried by compressed air Do not wipe parts with shop towels All of the mating surfaces in the transmission are accurately machined therefore careful handling of the parts must be exercised to avoid nicks or burrs Oil Pan
11. Parking Brake Drum Puller 484 Snap Ring Pliers TORQUE REFERENCE Heavy Duty Three Speed Manual Transmission Foot Pounds Inch Pounds Front Bearing Retainer 360 Extension Housing 5 50 hae 50 Gearshift Operating Lever 216 Mainshaft Flange 175 Transmission to Clutch Housing 5 50 Transmission Cover Retaining 144 Transmission Drain 300 COVER BOLT STOP RING COVER GEAR FIRST AND REVERSE LOW REV FORK ROLLER BEARINGS GEAR SECOND N SYNCHRONIZER UNIT CLUTCH GEAR SLEEVE SPRING CLUTCH GEAR STOP RING SNAP RING BY THRUST ING No C THRUST PLATE GEAR HOUSING SEAL 8 M SPACER e WASHER 2ND DIR IDLER GEAR ius d Bs THRUST BEARING 2 WASHER 2 4 ROLLER BEARINGS 89 SE MAINSHAFT THRUST THRUST lt LEVER 2 WASHER WASHER Md x 25 LEVER Qa J SLEEVE DETENT BALL ay WASHER e
12. SHIFT LEVER STOP ADJUSTING SCREW AND LOCK NUT SHIFT HOUSING d 1ST AND 2ND SHIFT OPERATING LEVER REVERSE SHIFT ROD DRAIN PLUG 64 x 734 Fig 1 Forward Speed Transmission Assembly 21 16 TRANSMISSION 4 SPEED MANUAL SERVICE PROCEDURES 1 ADJUSTING THE SHIFT LINKAGE 1 Remove the shift boot attaching screws and slide the boot up on the shift lever Fig 3 Check to be sure the pivot bolt is tightened securely 55 foot pounds Check to be sure shift lever bolts are tightened securely 80 foot pounds 2 Disconnect all the shift rods from the levers at the adjusting swivels by removing the spring clip retainers and flat washers 3 Slide Tool C 3951 over the levers inserting center pin through the first two levers Tighten set screw securely This aligns the 3 levers in the gear shift control assembly and holds them in the neutral position as shown in Figure 3 4 Adjust the length of the three shift rods by 64x735 Fig 2 Four Forward Speed Transmission Sectional View 1ST AND 2ND ADJUSTING SWIVEL AT LEVER WASHER 1ST AND 2ND ROD 3RD AND 4TH ROD ALL SHIFT OPERATING LEVERS MUST BE IN NEUTRAL LEVER STOP ADJUSTING REVERSE ROD REVERSE ADJUSTING SWIVEL SCREW FRONT PIVOT BOLT 55 FT LBS SPRING CLIP 3RD AND 4TH ADJUSTING SWIVEL 64x736 Fig 3 Gearshift Linkage Adjustments turning swivels either or out u
13. 24 Lower the transmission jack and remove the transmission and converter assembly 25 To remove the converter assembly remove the C elamp from the edge of the housing then carefully slide the assembly out of the transmission Converter Installation 1 Rotate the front pump rotors with Tool C 3881 until the two small holes in the handle of Tool are vertical Fig 46 2 Carefully slide the converter assembly over the input shaft and reaction shaft Make sure the converter impeller shaft slots are also vertical and fully engage the front pump inner rotor lugs Inspect for full engagement by placing a straight edge on the face of the case Fig 47 The surface of the converter front cover lug should be at least inch to the re r of the straightedge when the convert er is pushed all the way into the transmission ALIGNMENT HOLES VERTICAL 62 169 X Fig 46 Aligning Front Pump Rotors 21 62 TRANSMISSION TORQUEFLITE 62 X 6 Fig 47 Measuring Converter for Full Engagement in Transmission 3 Attach a small C clamp to the edge of the converter housing to hold the converter in place during transmission installation Installation 1 Inspect the converter drive plate for distortion or cracks and replace if necessary 2 Coat the converter hub hole in the crankshaft with wheel bearing lubricant Place the transmission and converter assembly on a service jack and position th
14. 3204 Driver Output Shaft Bearing C 3837 Driver Output Shaft Oil Seal 3229 Pliers Snap Ring 3860 Driver Front Pump Seal 3275 Remover Output Shaft Bearing 3861 Remover Front Pump Seal C 3281 Wrench Companion Flange Holding 3863 Compressor Front Clutch Piston Spring C 3288 Studs Pilot Installer Overrunning Clutch Cam C 3292 Gauge Low Pressure C 3864 Aligning Sleeve Rear Oil Pump Cover 3293 Gauge High Pressure 3881 Aligning Tool Front Pump Rotor 3335 Straight Edge 3882 Adapter Kit Use with 3750 C 3339 Dial Indicator Transmission Stand 3422 Compressor Engine Valve Spring 3887 Kit Service Bushing Removing and 3487 Fixture Engine Support Installing 3705 Adapter Transmission Band Adjuster Use with C 3380 Torque Wrench TORQUE REFERENCE TORQUEFLITE TRANSMISSION Foot Pounds Inch Pounds Kickdown Band Adjusting Screw Lock 29 Kickdown Lever Shaft 150 Reverse Band Adjusting Screw Lock 35 Cooler Line 75 Control Cable Adjusting Wheel 40 Converter Drain 14 Converter
15. Install the shuttle valve spring shuttle valve throttle plug Install the governor plug end plate and tighten the five re taining screws to 28 inch bounds torque 4 Install E clip on the end of the shuttle valve Fig 60 Install the shuttle valve cover plate and tighten the four retaining screws to 28 inch pounds torque 5 Install the 1 2 and 2 3 shift valves and springs Fig 61 Install the shift valve end plate and tighten the three retaining screws to 28 inch pounds torque 6 Install the regulator valve throttle pressure plug sleeve and the line pressure plug Fig 61 Install the regulator valve end plate and tighten the two retain ing screws to 28 inch pounds torque 7 Install the throttle valve and spring Fig 60 Slide the kickdown detent on the kickdown valve counterbore side of detent toward valve then install the assembly in the valve body 8 Install the throttle lever stop screw Fig 60 and tighten lock nut finger tight 9 Install the manual valve in the valve body Fig 60 NOTE The insert in Figure 60 shows the manual valve used in the transmissions with the console shift 10 Install the throttle lever and shaft on the valve body Fig 62 Insert the detent spring and ball in its bore in the valve body Depress the ball and spring with Tool C 3765 or similar tool and slide the manual lever over the throttle shaft so that it engages the manual valve and detent ball Install th
16. nia has BEARING DETENT BALL SPRING NUT SNAP RINGS LOCKWASHER BOLT AND WASHER kz WASHER J IDLER SHAFT ROLLER BEARINGS PLUG ROLLER BEARINGS WASHER 2 RETAINER COUNTERSHAFT TAPERED PIN 2 4 LEVER NUT OIL SLINGER CASE gt 1 LEVER SNAP RING BEARING DRIVE PINION ov m ROLLER BEARINGS 2 SNAP RING ORG TAPERED PIN WASHER BOLT WASHER 1 GROMMET LOCKWASHER GROMMET 61 x 325C Fig 1 Duty Transmission Disassembled View TWANVW G33dS E NOISSIWSNVAL 21 4 TRANSMISSION 3 SPEED MANUAL PART 1A THREE SPEED HEAVY DUTY MANUAL TRANSMISSION The heavy duty three speed manual transmission Figs 1 and 2 is of the synchromesh type with helical cut gears to provide silent operation The countershaft gear is in constant mesh and is sup ported by two rows of needle type bearings at each end The mainshaft is supported by ball bearings at each end of the extension housing The speedometer drive gear is integral with the mainshaft SERVICE PROCEDURES 1 REMOVING THE TRANSMISSION From the Vehicle 1 Drain the lubricant from the transmission 2 Disconnect tlie propeller shaft speedometer cable and housing and the gearshift control rods CAUTION Remove the speedometer cable pin ion comes out with the cable with hand so that housing is nof crushed
17. 37 Inspection Inspect the interlocking seal rings Fig 64 on the reaction shaft support for wear or broken locks make sure they turn freely in the grooves Do not remove rings unless conditions warrant Inspect the pump body and reaction shaft support bushings for wear or Scores Inspect machined surfaces on the oil pump body and reaction shaft support for nicks and burrs Inspect the oil pump rotors for scoring or pitting With the rotors cleaned and installed in the pump body place a straightedge across the face of the rotors and 21 72 TRANSMISSION TORQUEFLITE GASKET SEAL RING OIL PUMP BODY 62x22 pump body Using a feeler gauge measure the clear ance between the straight edge and face of the rotors Clearance limits are from 001 to 0025 inch Also with a feeler gauge measure the rotor tip clearance between the inner and outer rotor teeth Clearance limits are from 007 to 012 inch Front Pump Bushing Replacement 1 Place the front pump housing on a clean smooth surface with the rotor cavity down 2 Place the removing head Tool SP 3550 in the bushing and install the handle Tol SP 3549 in the removing head Fig 65 3 Drive the bushing straight down and out of the bore Be careful not to cock the tool in the bore 4 Position a new bushing on the installing head SP 3625 5 With the pump housing on a smooth clean sur face hub end down start the bushing a
18. float to 090 inch or less Install the shim on the shoulder of the second speed gear before the spreader spring is installed as shown in Figure 10 If the synchronizer float is below 050 inch ma terial should be removed from the ends of all six synchronizer pins an equal amount until the synchron izer float is above the 050 inch dimension 3 Install the synchronizer clutch gear on the mainshaft with the shoulder to the front 4 Install the synchronizer clutch gear snap ring in the mainshaft Make certain the snap ring is bot tomed all the way around in the groove 5 Measure the clearance between the clutch gear and the 2nd speed gear The clearance should be 004 to 014 inch End play in excess of 014 inch may cause the 2nd speed gear to jump out of gear 6 Hold the synchronizer clutch gear sleeve and Fig 9 Installing Detent Balls 2ND SPEED GEAR SPREADER SPRING INSERT SHIM AGAINST THIS FACE 64 498 Fig 10 Sychronizer Shim Location two outer rings together with pins properly entered in the holes in the clutch gear sleeve and with the clutch gear sleeve engaged in the groove of the 2nd and 8rd speed shift fork position the fork in the 2nd and 3rd speed lever shaft 7 While holding the synchronizer parts and fork in position slide the mainshaft forward entering the synchronizer clutch gear into the clutch gear sleeve and at the same time entering th
19. lever 7 Again using an Allen wrench remove the re maining screw and star washer that holds the shifter fork to the divider Slide the gearshift lever fork from the divider shaft and the shift levers 8 Remove the lock ring from each end of the divider shaft and push the divider shaft out of the gearshift support 9 Pull the levers dividers and bushing assembly from the gearshift support NOTE The flat washers between the outer bush ings and gearshift support will drop out at this time 10 Separate the levers from the divider and re move the nylon bushings Inspect all the parts for wear or damage and in stall new parts if required At reassembly apply Lubriplate on the cross over pin and all moving parts that pivot Assembly Fig 11 1 Slide each lever on the divider with the nar row shoulder and nylon bushing bearing surface down against the shoulder 2 Slide the outer bushings into position against the outer shoulders then place the lever assembly in position in the gearshift support bracket 3 Slide the spacer washers spring washer on 151 reverse side between the support bracket and the nylon bushing shoulders then align the divider 4 Slide the divider shaft into the support through the shaft lever assembly and out of the support of the other side far enough to install the retaining lock rings Install the retaining rings 5 Position the shift fork screw holes in the di vider paral
20. of power when the engine starts Turn the ignition on then push the 1 low button in or move the selector lever to the low position and depress the accelerator pedal slightly After the vehicle has been pushed to a speed of 15 to 25 mph approximately the transmission will drive the en gine Towing Vehicle Transmission Inoperative Tow the vehicle with a rear end pickup or remove the propeller shaft Transmission Operating Properly The vehicle may be towed safely in N neutral at moderate speeds For long distance towing over 100 miles pro shaft should be removed SHIFT PATTERN SUMMARY CHART Condition Vehicle Speed to Axle Ratios NEWPORT 300 300 NEW YORKER With K Engine IMPERIAL 2 76 1 3 23 1 2 93 1 Closed Throttie 1 2 oce m views 8 15 7 13 8 15 Closed Throttle 2 3 Upshift P 14 20 12 17 14 20 Wide Open Throttle 1 2 35 49 40 53 35 49 Wide Throttle 2 3 75 87 74 84 74 86 3 2 Kickdown 64 80 65 78 64 79 3 1 Kickdown Limit uya S wy eect 32 41 28 47 32 41 Closed Throttle ues 6 14 5 12 6 14 e S S c d TRANSMISSION TORQUEFLITE 21 41 2B SERVICE MAINTENANCE ADJUSTMENTS AND TESTS SERVICE PROCEDURES While in the process of making adjustments and tests do not stall te
21. 1 and 2 Drive Pinion and Bearing Assembly 1 Place the oil slinger on the main drive pinion with the offset outer portion next to the drive pinion teeth Fig 5 2 Place the main drive pinion bearing on the pinion shaft with the outer snap ring away from the pinion gear 3 Press the bearing into position so it is seated firmly against the oil slinger and pinion gear 4 Install the bearing retaining snap ring on the pinion shaft using snap ring pliers Tool C 3301 Be sure the snap ring is seated in its groove The snap ring should be selected to eliminated end play 5 Coat the 15 pilot roller bearings with heavy lubricant and install them in the cavity at the rear of the main drive pinion Countershaft 1 Place the bearing spacer in the center of the bore in the cluster gear and use arbor Tool 3834 to assist in assembling the roller bearings 2 Install a row of 22 roller bearings next to one end of the spacer using heavy lubricant to help hold them in position TRANSMISSION 3 SPEED MANUAL 21 7 3 Place one of the 4 bearing washers next to the row of rollers and install another row of 22 roller bearings next to the washer 4 Install another washer at the other end of the second row of roller bearing 5 At the opposite end of the cluster gear install the remaining washers and roller bearings in the same sequence as listed in steps 2 3 and 4 6 With a small amount of lubrica
22. 3 Remove the back up light switch leads if so equipped 4 Install the engine support fixture Tool C 3806 mounting hooks firmly into the holes in the side frame members with the support ends up against the underside of the oil pan flange 5 Adjust the fixture to support the weight of the engine then raise the engine slightly and remove the rear support crossmember attaching bolts 6 Support the transmission using a suitable jack remove the bolts that attach the transmission to the clutch housing 7 Slide the transmission rearward until the pin ion shaft clears the clutch disc before lowering the transmission This precaution will avoid damaging the clutch disc 8 Lower the transmission and remove from un der the vehicle 9 Mount the transmission in repair stand DD 1014 2 DISASSEMBLY OF THE TRANSMISSION COMPONENTS PARTS Fig 1 1 Using flange holding Tool C 3281 remove the flange retaining nut and washer 2 If necessary attach puller Tool C 452 and move the flange assembly 3 Remove the bolts that attach the cover to the case Remove the cover and discard the gasket 4 Using a pair of feeler gauges measure the syn chronizer float The measurement of the float should be taken before any further disassembly of the transmission is attempted 5 The synchronizer float should be between 050 and 090 inch which measured between the syn chronizer outer ring p
23. BAND CLUTCH NEUTRAL DISENGAGED DISENGAGED RELEASED RELEASED NO MOVEMENT D DRIVE DIRECT ENGAGED ENGAGED RELEASED RELEASED OVER RUNS 1 00 to 1 D DRIVE BREAKAWAY DISENGAGED ENGAGED RELEASED RELEASED HOLDS 2 45 to 1 D DRIVE KICKDOWN SECOND DISENGAGED ENGAGED APPLIED RELEASED OVER RUNS 1 45 to 1 2 5 DISENGAGED ENGAGED APPLIED RELEASED OVER RUNS 1 45 to 1 2 SECOND KICKDOWN LOW DISENGAGED ENGAGED RELEASED RELEASED HOLDS 2 45 to 1 1 LOW DISENGAGED ENGAGED RELEASED APPLIED PARTIAL HOLD 2 45 to 1 1 LOW RETARDING DISENGAGED ENGAGED RELEASED APPLIED NO MOVEMENT 2 45 to 1 R REVERSE ENGAGED DISENGAGED RELEASED APPLIED NO MOVEMENT 2 20 to 1 Dacron filter attached to lower side of valve body assembly Engine torque is transmitted to the torque con verter then through the input shaft to the multiple disc clutches in the transmission The power flow depends on the application of the clutches and bands Refer to Clutch Engagement and Band Application Chart The TorqueFlite Transmission servicing procedures are the same for all Chrysler and Imperial Models However when a 383 or 413 cubic inch Hi Perform ance engine is used in a Chrysler Police car the gov ernor spring is lighter to provide higher shift speeds When a 413 cubic inch engine with ram manifold and two four barrel carburetors is used in a 300K model there are several parts that are different
24. BLOCKING FIXTURE 63x367 Fig 23 Throttle Linkage Adjustment Chrysler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
25. CHOKE VALVE IN FULL OPEN POSITION OPEN THROTTLE SLIGHTLY TO RELEASE FAST IDLE CAM THEN RETURN CARBURETOR CURS IDLE WITH THE 3 16 DIAMETER BY YO LONG ROD 5 PLACE IN THE ACCELERATOR SHAFT BRACKET AND LEVER ASSEMBLY TIGHTEN CARBU RETOR ROD ADJUSTMENT LOCK NUT CONNECT CHOKE ROD 2 OR REMOVE BLOCKING FIXTURE 113 TO 115 WITH AUTOMATIC TRANSMISSION 1 ASSEMBLE ACCELERATOR SHAFT ASSEMBLY AND PEDAL ASSEMBLY TO BODY WITH A 3 16 DIAMETER ROD 5 APPROXIMATELY 10 LONG IN THE HOLES PROVIDED IN THE ACCELERATOR SHAFT BRACKET AND LEVER ADJUST THE PEDAL OD TO PROVIDE A PEDAL ANGLE OF 113 TO 115 INSTALL PEDAL ROD 2 APPLY A THIN FILM OF MS 3608 LUBRICANT TO THE ACCELERATOR SHAFT T WHERE TURNS IN THE FIREWALL BRACKET 3 ASSEMBLE CARBURETOR ROD PARTS BUT DO NOT TIGHTEN ADJUSTMENT LOCK NUT 4 DISCONNECT CHOKE 2 AT CARBURETOR OR BLOCK CHOKE VALVE IN FULL OP EN POSITION OPEN THROTTLE SLIGHTLY TO RELEASE FAST 6 MOVE REAR PORTION OF CARBURETOR ROD ASSEMBLY 3 REARWARD IDLE CAM THEN RETURN CARBURETOR TO CURB IDLE UNTIL TRANSMISSION THROTTLE LEVER 7 STOP 15 CONTACTED 5 WITH THE TRANSMISSION ROD ASSEMBLY AND TRANSMISSION THROTTLE TIGHTEN CARBURETOR ROD ADJUSTAENT LOCK MUT LEVER IN PLACE HOVE THE TRANSMISSION THROTTLE LEVER 7 FOR WARD AGAINST THE STOP AND TIGHTEN TRANSMISSION ROD ADJUSTMENT LOCK NUT 8 REMOVE 3 16 DIAMETER 5 FROM ACCELERATOR SHAFT BRACKET 7 CONNECT CHOKE ROD 2 0R REMOVE
26. DRIVE condition might exist even with correct fluid pressure because of inoperative clutches or bands The inoperative units clutches bands and servos can be located through a series of tests by substituting air pressure for the fluid pressure Fig 31 The front and rear clutches kickdown servo and low reverse servo may tested by applying air pres sure to their respective passage after the valve body assembly had been removed Refer to Paragraph 24 To make the air pressure tests proceed as follows CAUTION Compressed air supply must be free of all dirt or moisture Use a pressure of 30 to 100 psi Front Clutch Apply air pressure to the front clutch apply pas sage and listen for a dull thud which indicates that the front clutch is operating Hold the air pressure on for a few seconds and inspect the system for ex cessive oil leaks Rear Clutch Apply air pressure to the rear clutch apply pas sage and listen for a dull thud which indicates LINE PRESSURE TO ACCUMULATORE FRONT SERVO APPLY FRONT PUMP SUCTION pm PRESSURE gt DA C FRONT CLUTCH APPLY REAR CLUTCH T REAR PUMP SUCTION C GOVERNOR PRESSURE TO TORQUE J CONVERTER J FROM TORQUE REAR PUMP PRESSUR CONVERTER ECT a 4 TO COOLER Fig 31 Air Pressure Tests that the rear clutch is operating Also check for ex cessive oil leaks NOTE If a
27. Drive Clip 91 1st and 2d Lever 45 Speedometer Drive Pinion Seal 92 3rd and 4th Speed Fork 46 Mainshaft Output 93 154 and 2nd Speed Fork 47 Shift Plates 3 94 Drain Plug 95 Gasket Shift Control Housing 64x740 4B Woodruff Key Fig 6 Transmission Assembly Diassembled View TRANSMISSION 4 SPEED MANUAL 21 19 64 x 740 Fig 6 Transmission Assembly Disassembled View 21 20 TRANSMISSION 4 SPEED MANUAL EXTENSION HOUSING 64x74 DOS Fig 7 Removing or Installing the Extension Housing and Mainshaft Assy 11 Slide the third and fourth synchronizer sleeve slightly forward then using a soft hammer tap on the extension housing in a rearward direc tion Slide the housing and mainshaft assembly out and away from the case as shown in Figure 7 12 Refer to Figure 8 for location of the various gears synchronizer sleeves and clutches before dis assembling the mainshaft Disassembling the Mainshaft Fig 9 1 Using a pair of snap ring pliers remove the snap ring that retains the 3rd and 4th synchronizer clutch gear and sleeve slide 3rd and 4th synchronizer assembly off the end of the mainshaft 2 Slide the 3rd speed gear and stop ring off the mainshaft Do not separate the 3rd and 4th speed synchronizer clutch gear sleeve shift plates or springs unless inspection reveals a replacement part is required 3 Using a suitable pair of long nose pliers com press the snap ri
28. Drive Plate to Crankshaft 55 Converter Drive Plate to Torque Converter 270 Extension Housing to Transmission Case 24 Extension Housing to Insulator Mounting 35 Extension Housing Crossmember to Frame 75 Front Oil Pump Housing to Transmission Case 150 Governor Body to Support 100 Neutral Starter Switch tnitial Contact to Ys 60 Max Neutral Starter Switch Console Shift 25 35 Oil Filler Tube Bracket 150 Oil Pan Bolt edsr lae m BEE ig k EM ees 150 Overrunning Clutch Cam Set 5 40 Output Shaft Flange 175 Parking Lock Cable Locking 10 Parking Lock Cover 150 Pressure Test Take off 75 Reaction Shaft Support to Front Oil Pump 150 Rear Pump Cover 140 Transmission to Engine 25 30 Valve Body Screw osse eol bx rn hr e 28 Valve Body to Transmission Case 100 Speedometer Cable Clamp 5
29. PISTON RETAINER PISTON SEAL RING SPRINGS 10 ASSEMBLY SNAP RING DRIVING DISCS PRESSURE PLATE 62x13 Fig 68 Front Clutch Assembly Disassembled check in the clutch retainer make sure the ball moves seal grooves for nicks and burrs Inspect the neo freely Inspect the seal surfaces in the clutch retainer prene seals for deterioration wear and hardness and for nicks or deep scratches light scratches will not the piston springs retainer and snap ring for distor interfere with sealing of neoprene rings Inspect the tion clutch retainer bushing for wear or scores Inspect inside bore of the piston for score marks if light remove with crocus cloth Inspect the TOOL HANDLE SP 3549 REMOVER HEAD SP 3629 FRONT CLUTCH RETAINER H BUSHING TOOL HANDLE 3549 INSTALLING HEAD 5 3628 INSTALLATION 26255 Fig 69 Removing or Installing Front Clutch Spring Retainer Snap Ring Fig 70 Replacing Front Clutch Retainer Bushing Front Clutch Retainer Bushing Replacement 1 Lay the clutch retainer open end down on a clean smooth surface and place the removing head Tool SP 3629 in the bushing Install the handle Tool SP 3549 in the removing head Fig 70 2 Drive the bushing straight down and out of the clutch retainer bore Be careful not to cock the tool in the bore 3 Lay the clutch retainer open end up on a clean sm
30. PLATE 60x3598 Fig 61 Valve Body Shift Valve Side Disassembled the regulator valve throttle pressure plug out of valve body Cleaning and Inspection Allow all parts to soak a few minutes in a suitable clean solvent Wash thoroughly and blow dry with compressed air Make sure all passages are clean and free from obstructions Inspect the manual and throttle valve operating levers and shafts for being bent worn or loose If a lever is loose on its shaft it may be silver soldered only or the lever and shaft assembly should be re placed CAUTION Do not attempt straighten bent levers Inspect all mating surfaces for burrs nicks and scratches Minor blemishes may be removed with crocus cloth using only a very light pressure Using straightetige Tool C 3335 inspect all mating surfaces for warpage or distortion Slight distortion may be corrected using a surface plate Make sure all meter ing holes in the steel plate are open Using a pen light inspect bores in the valve body for scores scratches pits and irregularities Inspect all valve springs for distortion and lapsed coils Inspect all valves and plugs for burrs nicks and scores Small nicks and scores may be re moved with crocus cloth providing extreme care is taken not to round off sharp edges The sharpness of these edges is vitally important because it prevents foreign matter from lodging between the valve and the valve body thus re
31. Remove the adjusting wheel from the gearshift ca ble 2 Remove the set screw from the gearshift lever knob and remove the knob 3 Remove four screws from inside the ash tray and lift out the ash tray assembly 4 Remove the two side mouldings from the top of the console are retained by clips at the top and two screws under the console lid 5 Lift off the finish plate bezel and rubber light seal assembly 6 Remove the four inner bolts securing the gear shift unit to the mounting plate 7 Remove the five screws from the outer edge of the mounting plate and remove the plate 8 Attach a piece of soft wire about four feet long to the lower end of each cable Lift the gear shift unit out of the console then carefully pull the cables through the floor openings under the floor mat and out through the console Disconnect and leave the wires in the floor to route the cables during reinstallation Installation 1 Attach the wires securely to the end of the cables Guide the cables and gearshift unit into the console while an assistant pulls on the wires thread ing the cables under the mat and through the floor openings 2 Position the mounting plate over the shift lever install and tighten the four mounting plate to gear shift unit screws 3 Align the mounting plate in the console in stall and tighten the five screws at the outer edge of the plate 4 Place the finish plate bezel and rubb
32. Springs 57 Thrustwasher Gear 1 12 Clutch Gear 58 Backup Light Switch 13 Shift Plates 3 59 Backup Light Switch Gasket 14 Shift Plate Spring 60 Plug 15 Snap Ring 61 Retainer Reverse Detent Ball 16 Ist and 2nd Clutch Sleeve Spring Gearing 62 Gasket 17 Stop Ring 63 Spring Reverse Detent 18 Ist Speed Gear 64 Ball Reverse Detent 19 Bearing Retaining Ring 65 Woodruff Key 20 Center Bearing 66 Reverse Slider Gear Shaft 21 Snap Ring 67 Bushing Reverse Slider Gear 22 Gasket Case to Extension 68 Gear Reverse Slider Housing 69 Fork Reverse Shifter 23 Lockwasher 70 Reverse Lever 24 Bolt 71 Oil Seal Reverse Lever Shaft 25 Extension Housing 72 Reverse Operating Lever 26 Mainshaft Rear Bearing 73 Flatwasher 27 Rear Bearing Oil Seal 74 Lockwasher 28 Companion Flange 75 Nut 29 Washer 76 Gearshift Control Housing 30 Nut 77 1st and 2nd Operating Lever 31 Main Drive Pinion 78 Flatwasher 32 Slinger 79 Lockwasher Lever 33 Needle Bearing Rollers 80 Nut lever 34 Snap Ring 81 Lockwasher Lever 35 Stop Ring 82 Fiatwasher Lever 36 Snap Ring 83 3rd and 4th Operating Lever 37 Shift Plate Spring 84 Detent 38 Clutch Gear 85 Detent Ball Spring 39 Shift Plate Spring 86 Detent Ball Sleeve 40 Clutch Sleeve 87 Detent Ball Spring 41 Stop Ring 88 Detent Sail 42 3rd Speed Gear 89 Seal 2 43 Speedometer Drive Pinion 90 3rd and 4th Lever 44 Speedometer
33. THE CARBURETOR LEVER BACK OFF FERRULE 3 1 2 THIS PROVIDES 1 2 FREE PLAY BETWEEN THE REAR SURFACE OF THE ACCELERATOR BRKT AND THE FRONT EDGE OF ACCELERATOR SHAFT LEVER TIGHTEN CLAMP NUT ROUTE CABLE SO THAT IT DOE8 NOT INTERFERE WITH THE TRANSMISSION ROD THROUGHOUT ITS FULL TRAVEL CONNECT CHOKE ROD REMOVE BLOCKING FIXTURE 64 x 422 Fig 24 Throttle Linkage Adjustment Imperial TRANSMISSION TORQUEFLITE 21 51 f Pivot bellcrank until a piece of inch drill rod 14 HYDRAULIC CONTROL PRESSURE TESTS inches long can be inserted through the bell i crank hole and locating hole in the manifold Tighten Line Pressure and Front Servo locking nuts and D securely and remove the Release Pressure locating drill rod from the bellcrank Line pressure and front servo release pressure tests Push rearward on the accelerator shaft to throt must be made in D drive position with the rear tle 1 lever rod adjusting link until the transmis Wheels free to turn The transmission fluid must be sion stop is reached then tighten locking nut operating temperature 150 to 200 securely 1 Install an engine tachometer raise the vehicle h Make sure the idle speed is adjusted to 700 rpm a hoist and position the tachometer so it can be with the engine at normal operating temperature read under the vehicle D LOCKING BOLT AND NUT CLIP PEL CRANK ACCELERATOR SHAFT TO T
34. This measurement should not exceed 0045 to 028 If measurement is greater than that specified new thrust washers must be installed at reassembly REVERSE SHIFTER SHAFT AND DETENT PLATE BACKUP LIGHT SWITCH REVERSE LEVER DETENT SPRING RETAINER REVERSE GEAR SHIFTER SHAFT 64 x 749 REVERSE SPEED GEARSHIFT FORK Fig 15 Gear Shaft and Lever Identification CLUSTER GEAR 64 x 750 Fig 16 Meesuring the Cluster Countershaft Gear End Play 21 22 TRANSMISSION 4 SPEED MANUAL REVERSE SLIDER REVERSE SLIDER GEAR SHAFT KEY SLOT 64 x 751 Fig 17 Removing or Installing the Reverse Stider Gear 9 Using a suitable drift drive the reverse slider gear shaft from front to rear far enough out of the case to remove the reverse slider gear as shown in Figure 17 Remove the woodruff key from the shaft Remove the shaft from the case 10 Remove the reverse gearshift lever detent spring retainer gasket plug and detent ball spring from the rear of the case Fig 15 The following step need only be done if leak age is visible around the reverse gearshift lever shaft 11 Carefully push the reverse gearshift lever shaft into the case and remove from the case as shown in Figure 18 Lift out the detent ball from the Bottom of the case Remove the shift fork from the shaft and detent plate 12 Using countershaft arbor C 3938 and a plastic hammer
35. With the front clutch completely assembled insert a feeler gauge between the pressure plate and snap ring Fig 72 The clearance should be 024 to 123 inch If not install a snap ring of proper thick ness to obtain the specified clearance NOTE Snap rings are the same as that used in the rear clutch and are available in 060 062 074 076 and 088 090 inch thickness 39 REAR CLUTCH Disassembly Figure 73 shows a disassembled view of the rear clutch assembly 1 Using a screw driver remove the large snap ring that secures the pressure plate in the clutch retainer Lift the pressure plate clutch plates and inner pressure plate out of the retainer 2 Remove the piston spring snap ring and remove the spring 3 Invert the clutch piston retainer assembly and bump on a wood block to remove the piston Re move seals from the piston 21 76 TRANSMISSION TORQUEFLITE CLUTCH RETAINER PISTON RETAINER INPUT SHAFT SEAL RINGS 2 THRUST WASHER SNAP RING PISTON SEAL INNER DRIVING SNAP RING SELECTIVE DISCS PRESSURE SPRING PLATE PRESSURE PLATE PISTON SNAP RING PISTON SEAL OUTER 62x165 Fig 73 Rear Clutch Assembly Disassembled 4 If necessary remove the snap ring and press the input shaft from the clutch piston retainer Inspection Inspect the facing material on all driving discs Re place discs that are charred glazed or heavily pitted Disc
36. ball bearings are clean then lubricate them with light grade engine oil Inspect the bearings for roughness This can best be determined by slowly turning the outer race by hand Measure the fit of the bearings on their respective shafts Needle Type Bearing Rollers and Spacers Inspect the main drive pinion and countershaft gear bearing rollers for flat spots or brinelling In spect the countershaft bearing roller spacers for signs of wear or galling Install new parts as required Gears Inspect the gear teeth on the synchronizer clutch gears and stop rings If there is evidence of chipping or excessively worn teeth install new parts at reas sembly Be sure the clutch sleeve slides easily on the clutch gear Inspect the teeth on the second and third speed gears and the first speed gear for chipped or broken teeth or showing signs of excessive wear Small nicks or burrs must be stoned off Inspect the teeth on the main drive pinion If ex cessively worn broken or chipped a new pinion OIL SEAL a 64 752 Fig 18 Removing or Installing the Reverse Shift Fork and Lever should be installed Test the interlock sleeve and pin for free move ment in the bore of the shift housing Examine the detent balls for signs of brinelling If the lever detents show signs of excessive wear to the extent of not locking in gear install a new part Inspect the shift forks for wear on the shanks and pads Synchronizer Stop R
37. by using the engine valve spring compressor n Fig 83 O0verrunning Clutch Low Reverse Band Link TRANSMISSION TORQUEFLITE 21 81 ADJUSTING SCREW AND LOCKNUT LEVER SHORT BAND LINK AND ANCHOR 62x21 Fig 84 Low Reverse Band and Linkage Tool C 3422 then install the snap ring 3 Position the rear band in the case install the short strut then connect the Jong lever and strut to the band Fig 84 Screw in the band adjuster just enough to hold the struts in place Be sure the long lever and strut assembly is installed as shown in Figure 83 to provide a running clearance for the low and reverse drum Install the low reverse drum Kickdown Servo 1 Carefully push the servo piston into the case bore Install the piston rod the two springs and the guide Fig 79 NOTE The 300 with K engine uses only one small inner spring in the kickdown servo 2 Compress the kickdown servo springs by using eninge valve spring compressor Tool C 3422 then install the snap ring Planezary Gear Assemblies Sun Gear Driving Shell 1 While supporting the assembly in the case in sert the output shaft through the rear pump housing Carefully work the assembly rearward engaging the rear planetary carrier lugs into the low reverse drum slots CAUTION Be very careful not to damage the ground surfaces on the output shaft during installa tion 2 Apply a coat of lubricant on the input to output Sh
38. drive the countershaft forward in the case until the key is bottomed in the recess Reverse Idler Gear 1 Position an arbor Tool C 464 in the reverse idler gear and using heavy lubricant install the 22 roller bearings in the gear 2 Place the front and rear thrust washers at each end of the reverse idler gear and position the assembly in the transmission case with the cham fered end of the gear teeth toward the front 3 Insert the reverse idler shaft into the bore 21 8 TRANSMISSION 3 SPEED MANUAL at the rear of the case with keyway to the rear pushing the arbor toward the front of the transmis sion 4 With the keyway aligned with the recess in the case drive the shaft forward inserting the key before the keyway is obscured Continue driving the shaft forward until the key seats in the recess Gearshift Mechanism Fig 8 1 Install two new lever shaft seals in the trans mission case using seal driver Tool C 3650 2 Install the 2nd and 3rd speed lever shaft in the bore provided in the transmission case 3 Install the 2nd and 3rd speed lever shaft lock pin in the hole in the case boss after coating with a suitable sealer starting the pin at the top of the hole and driving it downward While the lever shaft lock pins must be driven in firmly to prevent leakage or loss of the pin some caution must be exercised to avoid driving the pin in too tightly causing dis tortion or mushrooming of the pin Thi
39. dull thud cannot be heard in the clutches place the finger tips on the clutch housing and again apply air pressure Movement of the piston can be felt as the clutch is applied Kickdown Servo Direct air pressure into the front servo apply passage Operation of the servo is indicated by a tightening of the front band Spring tension on the servo piston should release the band Low and Reverse Servo Direct air pressure into the rear servo apply pas sage Operation of the servo is indicated by a tight ening of the rear band Spring tension on the servo piston should release the band If the clutches and servos operate properly no upshift or erratic shift conditions indicate that the malfunction exists in the control valve body assem bly Governor Governor operating failures can generally be diagnosed by a road test or hydraulic pressure tests Refer to Paragraph 14 TRANSMISSION TORQUEFLITE 21 55 SERVICING OPERATIONS WITH TRANSMISSION IN VEHICLE Various transmission components can be removed for repairs without removing the transmission from the vehicle The removal reconditioning and instal lation procedures for these components are covered here except valve body reconditioning which is de scribed in Paragraph 31 Heli Coil inserts are recommended for repairing damaged stripped or worn threads in aluminum parts Refer to Paragraph 27 17 SPEEDOMETER PINION Removal and Installation 1
40. holes in handle of the tool are vertical Fig 46 This will locate the inner rotor so the con verter impeller shaft will engage the inner rotor lugs during installation 5 74 PILOT STUDS TOOL Fig 86 Installing Front Pump and Reaction Shaft Support Assembly 1 Place the outer rotor in pump body 2 Turn the output shaft so the inner rotor driv ing ball pocket is up Install the ball and slide the inner rotor on the output shaft in alignment with the ball Fig 41 3 Install the oil pump cover with the retaining bolts threaded in a few turns Slide aligning sleeve Tool C 3864 all the way in until it bottoms against the rotors Fig 42 then tighten the cover bolts evenly to 150 inch pounds torque Governor and Support 1 Position the support and governor body assem bly on the output shaft Align the assembly so the governor valve shaft hole in the governor body aligns with the hole in the output shaft then slide the assem bly into place Install the snap ring behind the gov ernor body Tighten the housing to the support bolts to 100 inch pounds torque Bend ends of the lock straps against the bolt heads 2 Place the governor valve on the valve shaft in sert the assembly into the body and through the gov ernor weights Install the valve shaft retaining snap ring Extension Housing 1 Using a new gasket carefully slide the exten Sion housing into place Install the r
41. position by the control unit Some vehicles are equipped with a lever type con sole gearshift control The transmission and parking lock control cables are the same type as used with the push button control parking lock is applied by moving the selector lever past a gate to the PARK position CAUTION Never apply the parking lock until the vehicle has stopped otherwise a severe ratcheting noise will occur 3 OPERATING INSTRUCTIONS The transmission will automatically upshift and downshift at approximately the miles per hour given in the Shift Pattern Summary Chart NOTE shift speeds given in the Shift Pattern Summary Chart may vary somewhat due to produc tion tolerances and rear axle ratios This is not too important however the quality of the shifts is very important All shifts should be smooth responsive and with no noticeable engine runaway Mountain Driving When driving in the mountains with either heavy loads or when pulling trailers the 2 second or 1 low position should be selected on upgrades which requires heavy throttle for 1 2 mile or more Lower ratios reduces the possibility of overheating the trans mission and converter under these conditions 1 low position is for severe operation or to obtain better control Push Starting If the engine fails to start in the normal manner it may be started by pushing Towing the vehicle to start is recommended due to the sudden surge
42. retaining screw and lock washer tighten both screws securely 9 Slide the lower boot up over the shift levers being sure the screw holes are aligned 10 Slide the tool wedge between the second and high lever and the gearshift fork as described in Paragraph Gearshift Linkage Adjustments then in stall gearshift assembly in the vehicle 11 Install the attaching bolts and tighten to 150 inch pounds torque 12 Adjust the linkage as outlined in Paragraph 6 After readjustment has been made reinstall boot and retainer and secure with screws 6 GEARSHIFT LINKAGE ADJUSTMENTS 1 Remove the screws that hold the upper boot and retaining ring to the floor pan 2 Remove the retaining ring and slide the boot up on the gearshift lever far enough to expose the shift mechanism 3 Disconnect the first and reverse shift rod by removing the spring clip flat washer and the wave washer Disengage rod from lever 4 Disconnect the second and high shift rod by removing the spring clip flatwasher and the wave washer Disengage the rod from the lever CROSSOVER PIN TOOL CROSSOVER PIN 1 2ND 3RD LEVER view TRANSMISSION NEUTRAL SWIVEL NUT 2ND 3RD REAR SHIFT ROD SWIVEL IST REV SHIFT 62x244 Fig 14 Gearshift Linkage Adjustment 5 Place the transmission shift levers in neut ral position and refer to Figure 14 for the linkage ad justment 7 TRANSMISSION REAR OIL SEA
43. stall the two retaining nuts and tighten securely 3 Install the other push buttons in proper order on the control actuator slides 4 Chrysler Models Install the push button light seal and bezel Install and tighten the retaining screws Make sure the push buttons do not bind in the bezel Install the chrome moulding on the left side of the instrument panel and then the plate beneath the instrument cluster hood Install and tighten the re taining screws Install the parking lock control handle Imperial Models Place the felt seal push button lens and bezel over the push buttons Instal and tighten the four retaining screws at the outer cor ners of the bezel Make sure the push buttons do not bind in the lens or plate Install the foam rubber light seal and left switch panel secure the panel with the two retaining nuts Install the wiper control and light switch knobs Carefully install the instrument cluster chrome trim plate and secure with the seven screws Install the heater temperature and parking lock control han dles 5 Connect the back up lamp switch wire connector if so equipped Connect the battery ground ca ble 6 CONSOLE GEARSHIFT UNIT Fig 16 Removal 1 Remove the gearshift and parking lock cables from the transmission Refer to Paragraphs 9 and 10 LEVER BACK UP LAMP SWITCH MOUNTING LEGS 4 PARKING LOCK CABLE GEAR SHIFT CONTROL CABLE Fig 16 Console Gearshift Unit
44. weight assembly in the governor body and install the snap ring 36 REAR OIL PUMP Inspection Inspect the oil pump body and cover machined sur faces for nicks and burrs Inspect the rotors for scoring or pitting With the rotors cleaned and in stalled in the pump body place a straight edge across the face of the rotors and pump body Using a feeler gauge measure the clearance between the straight edge and face of the rotors The clearance limits are from 0015 to 003 inch Rear Oil Pump Body Replacement If replacement of the rear oil pump body is re quired drive it rearward out of the case with a wood block and hammer The following procedures must be followed when installing a new rear oil pump body or reinstalling the original pump body to pre vent pump body distortion 1 Screw two pilot studs Tool C 3288 into the case to guide the pump body during installation 2 Chill the pump body in cold water or with ice Quickly position the body over the pilot studs and drive it firmly into the case with a wood block and hammer Remove the pilot studs FRONT OIL PUMP AND REACTION SHAFT SUPPORT Disassembly Figure 64 shows the front oil pump and reaction shaft support disassembled 1 Remove bolts from the rear side of the reaction shaft support remove the vent baffle and lift the support off the oil pump 2 Remove the rubber seal ring from the front pump body flange 3 Drive out the oil seal with a blunt punch
45. 0 1 Remove the overcenter spring and back off the lever stop screw Fig 14 Make sure no binding exists in the neutral slide neutral slide pin and bush ing cam pivot and that they are adequately lubri cated 2 Hold the neutral slide in against the rocker bar with about 5 to 10 pound load 3 Loosen the lock nut and rotate the cam so the lever nose just touches the neutral slide pin as it passes over the pin when moving the parking lock lever from the OFF to ON position Only light contact should occur so the lever does not hang up on the pin Hold the cam in this position and tighten the lock nut to 95 inch pounds torque Install overcenter spring 4 Adjust the lever stop screw to obtain 010 inch clearance between the neutral slide pin and the lever heel Fig 15 Tighten the lever stop screw lock nut securely Installation 1 Connect the gearshift and parking lock cables to the control unit Secure the cable housings by clamping them in the control brackets NEUTRAL SLIDE PIN Te LEVER NOSE 62x193 Fig 14 Adjusting Lever Nose Contact at Slide Pin 21 44 TRANSMISSION TORQUEFLITE LEVER STOP SCREW NEUTRAL SLIDE LATCH NEUTRAL SLIDE PIN 62x192A Fig 15 Adjusting Lever Heel to Neutral Slide Pin Clearance 2 Install the neutral push button on the neutral actuator slide Carefully guide the control unit into position from the rear of the instrument cluster In
46. 1 Place the transmission assembly in repair stand Tool C 3750 with adapter C 3882 Fig 51 2 Unscrew the oil pan bolts and remove the oil pan and gasket Valve Body Assembly 1 Unscrew the retaining nut and remove the trol cable adapter from the valve body manual lever Fig 22 2 Remove the ten hex head valve body assembly to transmission case bolts Fig 22 Hold the valve body in position while removing the bolts 3 Lift the valve body assembly out of the trans mission case being careful not to cock the throttle lever shaft Accumulator Piston and Spring 1 Lift the spring off the accumulator piston and withdraw the piston from the case Measuring Drive Train End Play Measure the drive train end play before removal of ADAPTER TOOL REPAIR STAND 62x174 Fig 51 Transmission Installed in Repair Stand 3 TRANSMISSION VENT SHIELD DIAL INDICATOR TOOL Ei BP Fig 52 Measuring Drive Train End the output shaft universal joint flange This will usually indicate when a change in the thrust washer between the reaction shaft support and front clutch retainer is required to properly adjust end play during assembly except when major parts are replaced 1 Attach a dial indicator to the transmission bell housing with its plunger seated against the end of input shaft Fig 52 2 Chuck the input shaft in and out to obtain the end play reading 3 Reco
47. 5 Console Lever Type Have an assistant hold the seleetor lever firmly in the 1 low position Hold the control cable centered in the hole of the transmission ease and pull the cable outward approximately two pounds to bottom the assembly in the low detent While holding the cable outward rotate the adjust ment wheel clockwise until it just contacts the case squarely Turn the wheel counter clockwise just enough to make the next adjustment hole in the wheel line up with the screw hole in the case Counting this hole as number one continue turning the wheel counter clockwise until the fifth hole lines up with the screw hole in the case 6 Push the cable and adjusting wheel tight against the case then install the lock screw and tighten to 75 inch pounds torque 7 Refill the transmission with Automatic Trans mission Fluid Type Suffix A to proper level Refer to Paragraph 4 PARKING LOCK CABLE Es A 60 2298 Fig 18 Removing Parking Lock Cable 10 PARKING LOCK CABLE Transmission End Removal 1 Loosen the parking lock cable clamp bolt where the cable enters the housing cover Fig 18 Tap the end of the clamp bolt tightly to release its hold on the cable Remove the housing cover lower plug 2 With a screw driver inserted through the plug opening push gently against projecting portion of the cable lock spring then withdraw the lock cable Do not use pliers or similar tool to with
48. AND Inspection Figure 81 shows a disassembled view of the kick down servo assembly 21 80 TRANSMISSION TORQUEFLITE SEAL RING SPRING SNAP RING PISTON ROD GUIDE SPRING SEAL RINGS 2 PISTON ROD PISTON 92 168 Fig 81 Kickdown Servo Disassembled NOTE The large outer spring shown in Figure 81 is not used in the 300 with K engine Inspect the piston and guide seal rings for wear and make sure they turn freely in the grooves It is not necessary to remove the seal rings unless condi tions warrant Inspect the piston for nicks burrs Scores and wear and the piston bore in the case for scores or other damage Inspect the fit of the guide on the piston rod and the piston spring for distortion Inspect the band lining for wear and bond of lining to the band and the lining for black burn marks glazing non uniform wear pattern and flaking If the lining is worn so grooves are not visible at the ends or any portion of the band replace the band Inspect the band for distortion or cracked ends 43 LOW AND REVERSE SERVO AND BAND Disassembly 1 Remove the snap ring from the piston and re move the piston plug and spring Fig 82 Inspection Inspect the seal for deterioration wear and hard ness and the piston and piston plug for nicks burrs scores and wear piston plug must operate freely in the piston Inspect the piston bore in the case for scores or other damage and the spring
49. ANSMISSION TORQUEFLITE 21 47 SEAL ASSEMBLY SWITCH 64 4 Fig 21 Neutral Starting Switch transmission case and inspect to see that the switch operating lever finger is aligned in the center of the switch opening in the case 4 Place the cupper washer and ring over the threads of the switch Fig 20 then screw the switch into the transmission case a few turns 5 Connect one lead of a test lamp to the battery current and the other lead to the switch terminal Screw the switch into the transmission case until the lamp lights then tighten switch an additional to 98 turn NOTE The switch must be tight enough to pre vent oil leakage If nof add a thin washer and re adjust the switch Do not tighten over 60 foot pounds torque 6 Remove the test lamp and connect the wire to the switch 7 Add fluid to the transmission to bring up to the proper level Refer to Paragraph 4 Adjusment and Test Console Shift Only The neutral starting switch Fig 21 should operate in both the PARK and NEUTRAL selector lever posi tions 1 To test the switch disconnect the wire from the switch 2 Connect one lead of a test lamp to the battery current and the other lead to the switch terminal If the test lamp does not light the switch may be faulty out of adjustment or the gearshift control cable may be improperly adjusted 3 Unscrew the switch from the transmission case allowing the fluid to drain in
50. FRONT CLUTCH Disassembly Figure 68 shows a disassembled view of the front clutch assembly 1 Using a screw driver remove the large snap ring that secures the pressure plate in the clutch pis ton retainer Lift the pressure plate and clutch plates out of the retainer 2 Install compressor Tool C 3863 over the piston Spring retainer as shown in Figure 69 Compress the springs and remove the snap ring then slowly re lease the tool until the spring retainer is free of the hub Remove the tool retainer and springs 3 Invert the clutch retainer assembly and bump on a wood block to remove the piston Remove the seals from the piston and clutch retainer hub Inspection Inspect the facing material on all driving discs Replace discs that are charred glazed or heavily pitted Discs should also be replaced if they show evidence of material flaking off or if the facing material can be scraped off easily Inspect the driving disc splines for wear or other damage Inspect the steel plate and pressure plate surfaces for burning scoring or dam aged driving lugs Replace if necessary Inspect the steel plate lug grooves in the clutch retainer for smooth surfaces plates must travel freely in the grooves Inspect the band contacting sur face the clutch retainer for scores Note the ball 21 74 TRANSMISSION TORQUEFLITE PISTON SEAL RING INNER PISTON CLUTCH PLATES SNAP RING SPRING RETAINER SELECTIVE
51. HROTTLE SHAFT LEVER ROD RIGHT BANK CARBURETOR ROD CHOKE CABLE r ADJUSTING LINK ey ADJUSTING LINK jj SANL LOCKING NUT TOP VIEW LOCKING BOLT AND NUT SS ACCELERATOR SHAFT AND BRACKET ADJUSTING LINK Iw BELLCRANK TO TRANSMISSION ROD ed cur Iz TRANSMISSION THROTTLE CONTROL LEVER ig LEFT BANK ACCELERATOR NC KICK DOWN POSITION ETAS WIDE OPEN THROTTLE POSITION ADJUSTIN LINK 2 lt 519 15 SPRING 2 IDLE POSITION CHOKE CABLE A LOCKING NUT ACCELERATOR PEDAL TO SHAFT ROD cur a 4 GROMMET INSTRUMENT PANEL _ BELLCRANK LOCKING NUT ACCELERATOR SHAFT TO THROTTLE INSTRUMENT SHAFT LEVER ROD CHOKE CABLE PANEL ADJUSTING LINK ACCELERATOR SHAFT BRACKET ACCELERATOR PEDAL TO SHAFT ROD ACCELERATOR PEDAL ACCELERATOR SHAFT TO BELLCRANK ROD A LockinG NUT SIDE VIEW ADJUSTING LINK 63x569 Fig 25 Throttle Linkage Adjustment C 300K 21 52 TRANSMISSION TORQUEFLITE Fig 26 Pressure Test Locations Right Side of Case 2 Connect two 0 100 psi pressure gauges Tool C 3292 to pressure take off points at the side of the accumulator and at the front servo release Fig 26 3 With the control in D drive position speed up the engine slightly until the transmission shifts into direct Front servo release will be pressurized in direct Reduce engine speed slowly to 1 000 rpm Line pressure at this time 1 000 rpm
52. L Removal and Assembly 1 Disconnect the propeller shaft at the transmis sion flange Secure the shaft 2 Use wrench Tool C 3281 to hold the main shaft while removing the mainshaft flange nut Re move the mainshaft nut and washer 3 Install puller Tool C 452 on the mainshaft and the flange Pull the flange from the mainshaft CAUTION Never use a hammer to drive the TRANSMISSION 3 SPEED MANUAL 21 13 flange from the mainshaft as the splines may be damaged 4 Drive the seal from the extension using a suitable chisel NOTE Do not use puller Tool C 748 The main shaft must not be forced forward 5 When installing a new oil seal be sure to use special drift Tool C 3105 which automatically 10 cates the seal in its proper position 7 Reinstall the flange 8 Install washer convex side towards nut Tighten nut to 175 foot pounds torque 9 Reconnect the propeller shaft and tighten stud nuts to 30 foot pounds torque SPEEDOMETER PINION USAGE CHART 3 Speed Heavy Duty Manual Transmission Output Shaft Pinion Tire Size Axle Ratio Teeth Teeth Color 8 00 14 3 23 1 19 Red 8 50x14 3 23 1 19 Red 21 14 TRANSMISSION 4 SPEED MANUAL 1B 4 FORWARD SPEED MANUAL TRANSMISSION SPECIFICATIONS Transmission EH eo Chrysier Model VC 1 VC 2 Engine Displacement Cu
53. MP REPLACEMENT The Chrysler push button lamp is located approxi mately in the center of the push button cluster To re place the bulb refer to Paragraph 5 and perform steps 1 through 4 Slide a short piece of tight fitting rubber hose over the bulb to remove it from the socket The Imperial push button lamp is located in the back inner side of the control unit mounting bracket The bulb can be replaced by removing the bulb sock et from the bracket TRANSMISSION TORQUEFLITE 21 45 KICKDOWN BAND JUSTING SCREW CONTROL CABLES ADJUSTING WHEEL 9 63 578 17 Gearshift Controi Cable The console selector lever dial lamp is located in the left side of the console To replace the bulb un snap and remove the left side trim panel and remove the socket and bulb 9 GEARSHIFT CONTROL CABLE Transmission End Removal 1 Raise the vehicle on a hoist 2 Remove the gearshift control cable to trans mission adjusting wheel lock screw Pull the cable outward just enough to allow the fluid to drain into a container 3 Pull the cable out of the transmission case as far as possible back off the adjusting wheel a few turns if necessary 4 Insert a small screw driver above and slightly to the right of the cable Fig 17 Disengage the ca ble adapter lock spring by pushing the screw driver handle to the right while pulling outward on the cable Installation 1 Push B
54. Remove screw and retainer securing the speed ometer cable to the extension housing Carefully work the pinion and sleeve assembly out of the housing Fig 32 2 To replace the pinion and or oil seal pry the clip off the pinion and slide the pinion assembly off the cable Install a new seal on the cable housing 3 transmission fluid is found the cable hous ing replace the seal inside the pinion bore Fig 33 Pry the old seal out of the pinion bore Place a new seal on the end of the cable with its lip toward the cable then slide the pinion over the seal and cable Secure with the spring clip 4 To install push the pinion and sleeve assem bly into the extension housing so the sleeve flange is tight against the housing then install the retainer and screw Tighten the screw to 150 inch pounds torque 60 x 186 Fig 32 Removing or Installing Speedometer Pinion INNER SEAL OUTER SEAL CABLE Poe v Cr RETAINER BOLT 61X359 Fig 33 Speedometer Pinion Disassembled 18 OUTPUT SHAFT OIL SEAL Replacement 1 Disconnect the propeller shaft at the transmis sion flange 2 Hold the transmission flange with Tool C 3281 and remove the retaining nut and washer Fig 34 Slide the flange off the output shaft Use puller Tool C 452 if necessary 3 Screw the taper threaded end of Tool C 748 into the seal Fig 35 then tighten the screw of the tool to r
55. TH SPEED GEAR SHIFTER SHAFT AND DETENT PLATE DETENT BALL 3RD AND 1ST AND 2ND 4TH SPEED INTERLOCK GEARSHIFT FORK GEARSHIFT FORK SLEEVE DETENT 64 739 Fig 5 Transmission Shift Housing Assembly oil leakage is visible around the gearshift lever shafts 6 Remove the nuts lockwashers and flatwash ers that attach the first and second third and 4th Speed shift operating levers to the shafts Disengage the shift levers from the flats on the shafts and re move 7 Carefully push the gearshift lever shafts out of the housing allowing the detent balls to fall free Remove the seals and discard 8 Slide the gearshift interlock sleeve interlock pin and spring out of the housing Fig 5 9 Remove the main drive pinion bearing re tainer attaching bolts then slide the retainer and gasket from the main drive pinion shaft Remove the pinion seal 10 Remove the bolts that attach the extension housing to the transmission case T Bearing Retainer 49 Countershaft 2 Bearing Retoiner Gasket 50 Thrustwasher Geor 1 3 Bearing Relainer Oil Seal 51 Thrustwasher Needle Roller 4 Snap Ring Bearing Inner Bearing 5 Snap Ring Bearing Outer 52 Needle Bearing Rollers 6 Pinion Bearing 53 Bearing Spacer 7 Transmission Case 54 Countershaft Gear Cluster 8 Filler Plug 55 Meedle Bearing Rollers 9 Gear 2nd Speed 56 Thrustwasher Needle Roller 10 Stop Ring Bearing 2 11 Shift Plate
56. TMENT SCREW LEVER 62x32A STOP SCREW GOVERNOR PLUG THROTTLE LEVER END PLATE Fig 59 Valve Body Controls Assembled View ps e RETAINER REGULATOR VALVE 1 MANUAL VACVE TORQUE CONVERTER CONSOLE SHIFT ONLY CONTROL VALVE T gt 4 1 SD 2 Q W KICKOOWN VALVE LINE PRESSURE E THROTTLE VALVE ADJUSTING SCREW VW ASSEMBLY qe KICKDOWN DETENT THROTTLE LEVER STOP SCREW N M SHUTTLE VALVE A GOVERNOR PLUG END PLATE 5 Tne ae 1 2 SHIFT VALVE SHUTTLE VALVE GOVERNOR PLUG B SE es 2 3 SHIFT VALVE SHUTTLE VALVE GOVERNOR PLUG 603508 THROTTLE PLUG Fig 60 Valve Body Lever Side Disassembled 15 Remove the governor plug end plate Fig 60 Tip up tbe valve body to allow the shuttle valve throttle plug spring shuttle valve and the shift valve governor plugs to slide out into your hand Note the longer stem on the 1 2 shift valve plug as a means for identification 16 Remove the shift valve end plate Fig 61 and slide out the two springs and valves 17 Remove the regulator valve end plate Slide the regulator valve line pressure plug sleeve and REGULATOR VALVE THROTTLE a VALVE PRESSURE PLUG SLEEVE 1 2 SHIFT VALVE a REGULATOR VALVE LINE PRESSURE PLUG REGULATOR VALVE END PLATE SHIFT VALVE END
57. TRANSMISSION TORQUEFLITE DIAGNOSIS SERVICE DIAGNOSIS Continued Possible Cause 21 87 Correction Shifts Erratic Slips in Forward Drive Positions a b d e f g h i 0 k a b 9 f g h i 0 k Low fluid level Aerated fluid Incorrect throttle linkage adjustment Incorrect control cable adjustment Hydraulic pressures too high or low Governor sticking Oil filter clogged Valve body malfunction or leakage Clutches or servos sticking or not operating Faulty rear and or front oil pump Worn or broken input shaft and or reaction shaft support seal rings Low fluid level Aerated fluid Incorrect throttle linkage adjustment Incorrect control cable adjustment Hydraulic pressures too low Valve body malfunction or leakage Accumulator sticking broken rings or spring Clutches or servos sticking or not operating Worn or faulty front and or rear clutch Overrunning clutch not holding Worn or broken input shaft and or reaction shaft support seal rings 2 b d e f g h i 0 d e f g h i j k Refill to the correct level with Automatic Transmission Fluid Type A Suffix A Inspect for air leakage into the front pump suction passages Adjust the throttle linkage Adjust the control cable Perform the hydraulic
58. TRANSMISSION __ 21 1 21 TRANSMISSION PART 1 MANUAL TRANSMISSION CONTENTS 1 A 3 SPEED HEAVY DUTY MANUAL TRANSMISSION Page Page 2 7 Special Tools 2 Transmission lnstallation in the Vehicle 9 Torque 2 Gearshift 11 Transmission Removal from the Vehicle 4 Gearshift Linkage 12 Transmission Disassembly 4 Rear 5 13 1 4 FORWARD SPEED MANUAL TRANSMISSION Specifications 22 ose hei eens 14 18 Special Tools eor 14 23 Shift Linkage 16 Transmission Installation in the Vehicle 25 Transmission Removal from the Vehicle 17 Rear Oil Seal aS 25 1 5 DIAGNOSIS Manual Transmission 26 PART 2 TORQUEFLITE TRANSMISSION TORQUE CONVERTER 2 27 Parking Lock 59 Special
59. Tool C 3837 drive the seal into housing until the tool bottoms Fig 36 Installation 1 Using a new gasket carefully slide the exten sion housing into place install the retaining bolts and washers tighten bolts to 24 foot pounds torque 2 Install the crossmember insulator and spring assembly Tighten the crossmember attaching bolts to 75 foot pounds torque Lower the transmission so the extension housing rests on and is aligned with the insulator Install insulator to extension housing bolts and tighten to 35 foot pounds torque 3 Install and adjust the parking lock cable Re fer to Paragraph 10 4 Install the transmission flange and connect the propeller shaft Refer to Paragraph 18 step 5 21 57 TRANSMISSION TORQUEFLITE LOCK STRAPS 2 SNAP RING SNAP RING GOVERNOR BODY GOVERNOR SUPPORT AND PARKING GEAR 4 Fig 39 Governor Shaft and Weight Snap Rings 5 Install the speedometer drive pinion and sleeve 6 Add fluid to the transmission to bring up to the proper level Refer to Paragraph 4 20 GOVERNOR Removal 1 Remove the extension housing See Paragraph 19 2 Using a screw driver carefully pry the snap ring from the weight end of governor valve shaft Fig 39 Slide the valve and shaft assembly out of the governor body 3 Remove the large snap ring from the weight end of the governor body lift out the governor weight assembly 4 Remove the s
60. UL 46 1 21 38 TRANSMISSION TORQUEFLITE PART 2 TORQUEFLITE TRANSMISSION TORQUE CONVERTER The TorqueFlite Transmisssion combines a torque converter with a fully automatic 3 speed gear system Fig 9 The torque converter housing and transmis Sion case are an integral aluminum casting The transmission consists of two multiple disc clutches an overrunning clutch two servos and bands and two planetary gear sets to provide three forward ratios and a reverse ratio The common sun gear of the planetary gear sets is connected to the front clutch by a driving shell which is splined to the sun gear and to the front clutch retainer The hydraulic System consists of a front and rear pump and a single valve body which contains all of the valves except the governor valve Venting of the transmission is accomplished by a drilled passage through the upper part of the front oil pump housing The torque converter is attached to crankshaft through a flexible driving plate Cooling of the con verter is accomplished by circulating the transmission fluid through an oil to water type cooler located in the radiator lower tank The torque converter as sembly is a sealed unit which cannot be disassembled The transmission fluid is filtered by an internal CLUTCH ENGAGEMENT AND BAND APPLICATION CHART BUTTON POSITION FRONT REAR AND DRIVE FRONT REAR KICKDOWN LOW REV OVERRUNNING CONDITION CLUTCH CLUTCH BAND
61. a b 4 f No Drive in Any a Position b 4 f Low fluid level Aerated fluid Incorrect control cable adjustment Hydraulic pressures too high or Jow Low reverse band out of adjustment Valve body malfunction or leakage Front clutch or rear servo sticking or not operating Low reverse servo band or linkage malfunction Faulty front oil pump Low fluid level Hydraulie pressures too low Valve body malfunction or leakage Faulty front oil pump Clutches or servos sticking or not operating Worn or broken input shaft and or reaction shaft support seal rings Low fluid level Hydraulie pressures too low Oil filter clogged Valve body malfunction or leakage Faulty front oil pump Clutches or servos sticking or not operating b 4 4 g h x i a b b 4 Refill to correct level with Automatic Transmission Fluid Type A Suffix A Inspect for air leakage into front pump suction passages Adjust the control cable Perform the hydraulic pressure tests and adjust to specifications Adjust the low reverse band Perform pressure tests to deter mine cause and correct as required Remove the valve body assembly and perform air pressure tests Repair as required Inspect the servo for damaged seals binding linkage or faulty band l
62. a inch diameter welding rod and a weld ing current of 80 to 125 amps d Direct the arc at the intersection of the gear and front cover from an angle of 45 degrees from the rear face of the gear 4 Inspect the gear teeth and remove all nicks where metal is raised weld metal splatter etc in order to ensure quiet starter operation 2 DIAGNOSIS NOTE The transmission should not be removed nor disassembled until a careful diagnosis is made the definite cause determined and all possible externa corrections performed In diagnosing any abnormal shift condition always make the hydraulic pressure tests before disassembly or replacement of parts Oe I T Da Condition Possible Cause Correction Engine idle speed too high Adjust the engine idle speed to 500 rpm Readjust throttle linkage Harsh Engagement a in D 1 2 and R b Hydraulic pressures too high or low b Inspect the fluid level then perform hydraulic pressure tests and adjust to specifications c Low reverse band out of adjustment c Adjust the low reverse band d Valve body malfunction or leakage d Perform pressure tests to deter mine cause and correct as required e Accumulator sticking broken rings or e Inspect the accumulator for spring sticking broken rings or spring Repair as required f Low reverse servo band or linkage f Inspect the servo for damaged malfunction seals binding lin
63. aft front end is piloted in 16 needle type roller bearings located in a cavity in the end of the main drive pinion Fig 2 and is supported by a heavy duty ball bearing in the center of the case The rear end of the mainshaft is supported by a ball bearing pressed on the end of the mainshaft and a snug fit in the end of the extension housing as shown in Fig ure 2 The countershaft gear cluster is supported by a double row of needle type roller bearings 38 at each end and the thrust is taken on thrustwashers between the ends of the gear and transmission case The alignment of the needle type roller bearings within the gear are maintained by 4 thrust washers one being used between the rows of roller bearings and one at each end Fig 2 The reverse idler gear is supported on a bronze bushing pressed into the gear The gearshifting is manually operated through shift control rods to the transmission Fig 1 Any for ward gear may be engaged while the vehicle is in motion through the use of synchronizing clutches Fig 2 The transmission may be used as an aid to decel eration by downshifting in sequence without double clutching or gear clashing due to the fact that all forward speeds are synchronized The reverse speed gear is not synchronized 2 4 BREATHER D TST AND 2ND SHIFT ROD 3RD AND 4TH SHIFT ROD 3RD AND 4TH SHIFT OPERATING LEVER REVERSE SHIFT OPERATING LEVER 57 adi uie
64. aft thrust washer Fig 78 and install washer on the front end of the output shaft 21 82 TRANSMISSION TORQUEFLITE A STRUT ANCHOR LEVER LEVER SHAFT ADJUSTING SCREW AND LOCKNUT BAND 62x17 Fig 85 Kickdown Band and Linkage Disassembled Input Shaft and Rear Clutch 1 Invert the transmission and support in an up right position with the output shaft downward 2 Align the rear clutch plate inner splines lower the input shaft and clutch assembly into position in the case 3 Carefully work the clutch assembly in a circular motion to engage the clutch splines over splines of the front annulus gear 4 Coat one side of the fiber thrust washer with heavy grease then position the washer in the recess on the front face of the rear clutch piston retainer Front Clutch 1 Align the front clutch plate inner splines lower the clutch assembly into position in the case 2 Carefully work the clutch assembly in a cir cular motion to engage the clutch splines over splines of the rear clutch piston retainer Make sure the front clutch driving lugs are fully engaged in the slots in the driving shell Front Band Figure 85 shows a disassembled view of the kick down band assembly 1 Slide the band over the front clutch assembly 2 Install the band strut screw in adjuster just enough to hold the strut and anchor in place Froni Pump and Reaction Shaft Support If difficulty was encountere
65. alve body to transmission case bolts Hold the valve body in position while re moving the bolts 6 Lower the valve body assembly down out of the transmission being careful not to cock the throttle lever shaft in the case hole or lose the accumulator spring 7 Withdraw the accumulator piston from the transmission case Inspect the piston for scoring and the rings for wear or breakage Replace as re quired NOTE Servicing the valve body assembly i out lined in Paragraph 31 Installation 1 Clean mating surfaces and inspect for burrs on both the transmission case and the valve body Steel plate 2 Install the accumulator piston in the transmis sion case 3 Position the accumulator spring on the valve body 4 Carefully position the valve body assembly in the transmission case install the retaining bolts and tighten finger tight With the neutral starting switch installed place the manual valve in the neutral posi tion Shift the valve body if necessary to center the neutral finger over the neutral switch plunger Snug the bolts down evenly then tighten to 100 inch pounds torque 5 Connect the control cable adapter to the valve body manual lever and install the retaining nut Con nect the gearshift control cable Refer to Paragraph 6 6 Install the seal flat washer and throttle lever on throttle shaft Tighten the clamping bolt Test the throttle lever for looseness by forcing it in both direc
66. ansmission Fluid Type Suffix an COOLING METHOD Ge eee ee ed Water Heat Exchanger LUBRICATION Feat ee ot Pump Rotor Type CLUTCHES Number of Front Clutch 4 Number of Front Clutch 4 Number of Rear Clutch 3 Number of Rear Clutch PO TP 4 GEAR RATIOS iod icai Den Lc 2 45 to 1 2 568c nd PEE yy e vimm d parte 1 45 to 1 D Dive eei eue VERS p rip ave Pol Por tend 1 to 1 p HReverse ensis eed ate Cere RR RUE E 2 20 to 1 ES E Ud A ette e eae tis FRONT REAR PUMPS Gear Rotary Clearance Le Bae Awa WE ar CE 001 to 0025 inch DRIVE TRAIN END 2 252522 25 4 eee 030 to 069 inch CLUTCH PLATE CLEARANCE Front retin Me ee aere a 024 to 123 inch Rear Clutch icici l eee dy 026 to 054 inch SNAP RINGS Front and Rear Clutches Rea
67. anual Second Hydraulic Circuits TRANSMISSION TORQUEFLITE 21 35 OIL PRESSURES GOVERNOR 9 30 psi CONVERTER 30 75 psi en LUBRICATION 5 30 psi TO LUB CONTROL SYSTEM IN MANUAL LOW CLOSED THROTTLE 62x 236B REAR PUMP Fig 7 Manual Low Hydraulic Circuits 21 36 TRANSMISSION TORQUEFLITE 56660 FRONT CLUTCH TORQUE CONVERTER DE LUB 5 E CONTROL 5 OIL PRESSURES COOLER J eere 2305260 psi q LINE 230 260 psi PUMP SUCTION CONVERTER 30 75 psi 5 5 BE WERICATION 5 30 CONTROL SYSTEM IN Ge REVERSE REAR PUMP 62 2378 BEE SH FRONT PUMP OIL FILTER Fig 8 Hydraulic Circuits ONE PIECE ALUMINUM CASE TURBINE REAR CLUTCH STATOR FRONT PLANETARY GEAR SET IMPELLER REAR PLANETARY GEAR SET FRONT OIL PUMP LOW amp REVERSE BAND FRONT CLUTCH PLANETARY OVERRUNNING CLUTCH GOVERNOR eee 1 3 REAR OIL PUMP OIL FILTER CONTROL VALVE BODY IMPUT SHAFT SUN GEAR DR VING SHELL FLEXIBLE DRIVE PLATE FRONT CLUTCH BAND ENGINE CRANKSHAFT Kickdown Fig 9 TorqueFlite Transmission and Torque Converter SPEEDOMETER PINION PARKING LOCK ASSEMBLY OUTPUT SHAFT 62 1858 EXTENSION HOUSING 3LiT33010301 NOISSIWSNV
68. asket Line up the shift fork ends with the shaft in the housing 6 Install the attaching bolts and tighten evenly to avoid distortion of the housing center bolt on each side are pilot bolts and should be installed first 7 Using Tool C 3789 install a new oil seal in the retainer bore Install the main drive pinion bear ing retainer and gasket Install the attaching bolts and tighten from 30 to 35 foot pounds torque 8 Install the gearshift control assembly and the shift rods Fig 3 in correct position and secure with washers and clips 9 Install the propeller shaft companion flange on end of mainshaft Install washer and nut and tighten to 175 foot pounds torque 5 INSTALLING THE TRANSMISSION Before installing the transmission a test of the clutch housing bore and face alignment should be made Refer to the Clutch Group 6 for the ser vice procedure Place a small amount of short fibre wheel bearing lubricant around the inner end of the main drive pinion shaft pilot bushing in the flywheel and on the pinion bearing retainer release bearing sleeve area TRANSMISSION 4 SPEED MANUAL 21 25 NOTE Do not lubricate the end of the pinion shaft the clutch disc splines or the clutch release levers 1 Remove the transmission from the repair stand and install the rear crossmember and support then roll under the vehicle using a suitable transmission jack 2 Raise the transmission until the main dri
69. be suspected if the part throttle shift speeds are either very delayed or occur too early in relation to vehicle speeds In which case the throttle linkage should be adjusted before throttle pressure setting is adjust ed Refer to Paragraphs 13 and 15 15 HYDRAULIC CONTROL PRESSURE ADJUSTMENTS Line Pressure An incorrect throttle pressure setting will cause incorrect line pressure readings even though the line pressure adjustment is correct Always inspect and correct the throttle pressure adjustment before ad justing the line pressure Fig 28 Measuring Spring Retainer Location 21 53 TRANSMISSION TORQUEFLITE NUT ADJUSTING SCREW 460 3790 Fig 29 Line Pressure Adjustment NOTE Before adjusting the line pressure meas ure the distance between manual valve valve in position and line pressure adjusting screw Fig 28 This measurement must be 17 inches cor rect by foosening the spring retainer screws and positioning the spring retainer The regulator valve may cock and hang up in its bore if the spring re tainer is out of position If the line pressure is not correct it will be neces sary to remove the valve body assembly to perform the adjustment Refer to Paragraph 24 The approximate adjustment is 15 inches meas ured from the valve body to the inner edge of the adjusting nut Fig 29 However due to manufactur ing tolerances the adjustment can be varied t
70. ce Adjustments and Tests Para graphs 9 11 and 13 RECONDITION TRANSMISSION UNIT OUT OF VEHICLE The following reconditioning paragraphs cover the removal disassembly inspection repair assembly and installation procedures for each sub assembly in detail In the event that any part has failed in the trans mission the torque converter should be flushed to insure that fine metal particles are not later trans ferred back into the reconditioned transmission SERVICE PROCEDURES 26 FLUSHING THE TORQUE CONVERTER The torque converter must be removed from the vehicle for flushing as the converter should never be rotated by the starter with the transmission removed 1 Place the torque converter in an upright posi tion and pour two quarts of new clean solvent or kerosene into the converter through the impeller hub 2 Turn and shake the converter so as to swirl the solvent through the internal parts Turning the tur bine and stator with transmission input and reaction shafts will aid in dislodging foreign material 3 Position the converter in its normal operating position with drain plug at the lowest point Remove the drain plug and drain the solvent Rotate the tur bine and stator and shake the converter while drain ing to prevent dirt particles from settling 4 Repeat the flushing operation at least once or as many times as required until the solvent or kero sene drained out is clear 5 After flushing sha
71. ckness outer snap rings Snap rings are available in 060 062 074 076 and 088 090 inch thickness 40 PLANETARY GEAR ASSEMBLIES SUN GEAR DRIVING SHELL Measure the end play of the planetary gear assem blies sun gear and driving shell before removing these parts from the output shaft With the assembly in an upright position push the rear annulus gear sup port downward on the output shaft Insert a feeler 21 78 TRANSMISSION TORQUEFLITE te REAR ANNULUS REAR PLANETARY GEAR_ASSEMBLY DRIVING SHELL 62x172 Fig 77 Measuring End Play of Planetary Gear Assembly Sun Gear and Driving Shell gauge between the rear annulus gear support hub and the shoulder on the output shaft Fig 77 The clear ance should be 010 to 039 inch Disassembly 1 Remove the thrust washer from the forward end of the output shaft Fig 78 2 Remove the snap ring from the forward end of the output shaft then slide the front planetary assembly off the shaft 8 Slide the front annulus gear off the planetary gear set Fig 78 Remove the thrust washer from the rear side of the planetary gear set 4 Slide the sun gear driving shell and rear plane tary assembly off the output shaft 5 Lift the sun gear and driving shell off the rear planetary gear assembly Remove the thrust washer from inside the driving shell Remove snap ring and steel washer from the sun gear rear side of driving shell and sli
72. d in removing the front oil pump assembly due to an exceptionally tight fit in the case it may be necessary to expand the case with heat during the pump installation Using a suit able heat lamp heat the case in the area of the front pump for a few minutes prior to installing the front pump and reaction shaft support assembly NOTE If the drive train end play was not within specifications 030 069 inch when measured graph 29 replace the thrust washer on the reaction shaft support hub with one of the proper thickness The following selective thrust washers are avail able Thickness Color 043 045 inch Natural 061 063 inch Green 084 086 inch Red 102 014 inch Yellow 1 Screw two pilot studs Tool C 3288 in the front oil pump opening in the case Fig 86 Install a new gasket over the pilot studs 2 Place a new rubber seal ring in the groove on the outer flange of the oil pump housing Make sure the seal ring is not twisted Coat the seal ring with grease for easy installation 3 Insert aligning Tool C 3881 through the pump body and engage with the inner rotor 4 Install the assembly in the case tap lightly with a soft mallet if necessary Place the deflector over the vent opening and install four pump body bolts re move pilot studs and install the remaining bolts Snug bolts down evenly then tighten to 150 inch pounds torque 5 Rotate the pump rotors with Tool C 3881 until the two small
73. de the sun gear out of the shell Remove the front snap ring from the sun gear if necessary Note that the front end of the sun gear is longer than the rear 6 Remove the thrust washer from the forward side of the rear planetary gear assembly remove the planetary gear set from the rear annulus gear Inspection Inspect the bearing surfaces on the output shaft for nicks burrs scores or other damage Light scratches small nicks or burrs can be removed with crocus cloth or a fine stone Inspect the speedometer drive gear for any nicks or burrs and remove with a sharp edged stone Make sure all oil passages in the shaft are open and clean Inspect the bushings in the sun gear for wear or scores replace the sun gear assembly if bushings are damaged Inspect all thrust washers for wear and scores replace if damaged or worn below specifica tions Inspect the thrust faces of the planetary gear carriers for wear scores or other damage replace as required Inspect the planetary gear carrier for cracks and pinions for broken or worn gear teeth and for FRONT ANNULUS GEAR DRIVING SHELL SNAP RING ASSEMBLY THRUST REAR PLANETARY GEAR THRUST WASHER ASSEMBLY FRONT PLANETARY GEAR ASSEMBLY THRUST WASHER 62x15 OUTPUT SHAFT STEEL REAR ANNULUS THRUST GEAR ASSEMBLY LOW AND REVERSE DRUM Fig 78 Planetary Gear Assemblies Sun Gear Driving Shell Low and Reverse Drum and Output Shaft Disassembled broken pinion s
74. draw cable from adapter cover as the cable cover might be damaged causing an oil leak Installation 1 Place the push button parking lock lever in the OFF position or place the console selector lever in the NEUTRAL position 2 Insert a screw driver through the plug opening and position it behind the cable adapter stop washer Fig 19 Hold the adapter outward while pushing the cable in as far as possible making sure the lock spring engages the cable 3 Gently pull outward on the cable housing to its limit of travel release and then tighten the clamp bolt to 10 inch pounds torque Reinstall the plug in the cover and tighten to 75 inch pounds torque Adjustment Parking Lock Lever Push Button Control Only 1 Operate the parking lock lever from one end of the slot in the instrument panel to the other The lever should have clearance at both ends One hole in the parking lock arm is slotted to permit parking lock lever adjustment Fig 12 13 If adjustment of the lever is required first loosen the cable clamp bolt on the transmission making sure the cable hous ing is free to move in the parking sprag cover hole 2 To adjust move the lever to the fully OFF po CUSPARKING 3 LOCK S 62x90A Fig 19 Installing Parking Lock Cable sition Loosen two nuts attaching the lock arm to the pushbutton housing Loosen the nuts just enough to free up the lock arm 3 Block the locking lever 4 inch fr
75. drive the countershaft out of the case allowing the countershaft gear to be lowered to the bottom of the case This will permit the removal of the main drive pinion 13 Using a pair of snap ring pliers remove the main drive pinion bearing outer snap ring using a plastic hammer drive the main drive pinion into the case and remove 14 Using snap ring pliers remove the main drive pinion bearing inner snap ring Using an arbor press remove the bearing from the main drive pin ion 15 Remove the countershaft gear cluster from the bottom of the case as shown in Figure 19 16 Remove the arbor and the 76 needle type bearings thrust washers and spacer from the center of the countershaft gear Cleaning and Inspection Transmission Case Clean the transmission case thoroughly using a suitable solvent dry with compressed air Inspect the case for cracks stripped threads in the various holt holes and the machined mating surfaces for burrs nicks or any condition that would render the case unfit for further service The front mating surface should be smooth if any burrs are present dress them off with a fine mill file threads are stripped install Helicoil inserts Ball Bearings Wash the ball bearing using a clean solvent and blow dry with compressed air CAUTION Do not spin the bearings with air pressure turn slowly by hand Spinning unlubricated bearings may cause damage to the races and the balls Be sure the
76. ducing the possibility of stick ing Inspect all valves and plugs for freedom of operation in the valve body bores When bores valves and plugs are clean and dry the valve and plugs should fall freely in the bores NOTE The valve body bores do not change dimen sionally with use Therefore a valve body that was functioning properly when the vehicle was new will operate correctly if it is properly and thoroughly cleaned There is no need to replace the valve body unless it is damaged in handling Assembly 1 Place the rear pump check valve and spring in the transfer plate Fig 57 Position the steel plate on the transfer plate hold the rear pump check valve in its bore with a thin steel scale and install four steel plate to transfer plate retaining screws Make sure bolt holes in the steel plate and transfer plate are aligned then tighten the screws evenly to 28 inch pounds torque Inspect the rear pump check valve for free movement in the transfer plate Install the stif TRANSMISSION TORQUEFLITE 21 69 fener plate and tighten retaining screws to 28 inch pounds torque 2 Turn transfer plate over and install the reverse blocker valve spring and valve Fig 57 Rotate the valve until it seats through the steel plate Hold the valve down and install blocker valve cover plate Tighten the two retaining screws to 28 inch pounds torque 3 Place the 1 2 and 2 3 shift valve governor plugs in their respective bores Fig 60
77. due to the high performance of this vehicle The main differences are as follows 1 Governor Spring lighter spring 2 Governor Inner Weight lighter weight 3 Kickdown Servo Spring only one spring used 4 Kickdown Band heavy duty friction material 5 Kickdown Lever higher lever ratio 6 Front Clutch Disc heavy duty friction mate rial These special parts are listed in the 1964 Parts Catalog therefore be sure they are used when re placement is necessary 1 HYDRAULIC CONTROL SYSTEM Figures 1 through 8 shows the position of the vari ous valves with color coded passages to indicate those under hydraulic pressure for all operations of the transmission The hydraulic control system makes the transmis sion fully automatic and has four important func tions to perform In a general way the components of any automatic control system may be grouped into the following basic groups The pressure supply system the clutches and band servos the pressure regulating valves and the flow control valves Taking each of these basic groups or systems in turn the control system may be described as follows Pressure Supply System The pressure supply system consists of a front pump driven by the engine through the torque con verter and a rear pump driven by the transmission output shaft Pressure Regulating Valves The pressure regulating valves consist of a regu lator valve which controls line pressure at a val
78. dy Using a feeler gauge measure the clearance between the straight edge and the face of the rotors The clearance limits are from 0015 to 003 inch Installation 1 Place the outer rotor in the pump body 2 Turn the output shaft so the inner rotor driving ball pocket is up Install the ball and slide the inner Olt PUMP COVER 64x18 Fig 42 Aligning Rear Oil Pump Cover rotor on output shaft in alignment with the ball and outer rotor Fig 41 8 Install the oil pump cover with the retaining bolts threaded in a few turns Slide the aligning fix ture Tool C 3864 all the way in until it bottoms against the rotors Fig 42 then retighten the cover bolts evenly to 140 inch pounds torque 4 Install the governor and support See Para graph 20 5 Install the extension housing flange and connect the propeller shaft 6 Connect the parking lock cable transmission 22 PARKING LOCK COMPONENTS Removal 1 Remove the extension housing See Paragraph 19 2 To replace the governor support refer to Para graph 20 3 Remove the parking lock cable adapter cover from the bottom of the extension housing 4 Remove the plug from the extension housing slide out the shaft to remove the parking lock lever spacer and cable adapter Fig 43 Replace the adap ter spring if it is distorted 5 Slide the bushing sleeve out of the housing to remove the parking sprag and spring Fig 44 Installa
79. e Replace the parts as required Remove and recondition the valve body assembly Inspect and repair the clutch as required Drain the fluid to the correct level Inspect and clean breather vent opening in front pump housing Replace the oil filter Inspect for air leakage into front pump suction passages Refill to the correct level with Automatic Transmission Fluid Type A Suffix A Adjust the kickdown band Adjust the low reverse band Inspect the transmission cooling system clean and repair as required Inspect the oil pump for incorrect clearance repair as required Measure the clutch plate clearance and correct with the proper size snap ring Condition TRANSMISSION TORQUEFLITE DIAGNOSIS SERVICE DIAGNOSIS Continued Possible Cause 21 91 Correction impossible to Push Start Starter Will Not Energize in Neutral a Low fluid level b Low reverse band slipping e Valve body malfunction or leakage d Rear oil pump faulty e Low reverse servo band or linkage malfunction Worn or faulty rear clutch g Worn or broken input shaft and or reaction shaft support seal rings Incorrect control cable adjustment b Faulty or incorrectly adjusted neutral starting switch Broken lead to neutral switch a b 9 f g a b e Refill to the correct level with Automatic Transmission Fluid Type A Suffix A Adjust the lo
80. e assembly under the vehicle for installation Raise DRAIN PLUG Fig 48 Converter and Drive Plate Markings or tilt as necessary until the transmission is aligned with the engine 3 Rotate the converter so mark on converter made during removal will align with mark on drive plate The offset holes in the plate are located next to the inch hole in the inner circle of the plate stamped V mark identifies the offset hole in the con verter front cover Fig 48 Carefully work the trans mission assembly forward over the engine block dowels with the converter hub entering the crank shaft opening 4 After the transmission is in position install the converter housing bolts and tighten 25 to 30 foot pounds torque 5 Install and tighten the two lower drive plate to converter bolts and tighten to 270 inch pounds torque 6 Install the starting motor and connect the bat tery ground cable 7 Rotate the engine with the Remote Control Switch and install the other two drive plate to conver ter bolts Tighten bolts to 270 inch pounds torque 8 Install the crossmember and tighten attaching bolts securely Lower the transmission so the exten sion housing is aligned and rests on the insulator Install bolts and tighten to 35 foot pounds torque 9 Insert a screw driver through parking lock cover plug opening and position it behind the cable adapter Stop washer Fig 19 Hold the adapter outward whi
81. e band from the case Overrunning Clutch 1 Note the position of the overrunning clutch rollers and springs before disassembly to assist in reassembly 2 Carefully slide out the clutch hub and remove the rollers and springs NOTE If the overrunning clutch cam and or roller spring retainer are found damaged or worn refer to Paragraph 41 for replacement procedures Kickdown Servo 1 Compress the kickdown servo spring by using engine valve spring compressor Tool C 3422 then remove the snap ring Fig 54 62 173 Compressing Kickdown Servo Spring 2 Remove the rod guide springs and piston rod from the case Be careful not to damage the piston rod or guide during removal 3 Insert Tool C 484 inside piston and withdraw the piston from the transmission case Low and Reverse Servo 1 Compress the low and reverse servo piston spring by using engine valve spring compressor Tool C 3422 then remove the snap ring 2 Remove the spring retainer spring and servo piston and plug assembly from the case 30 RECONDITION SUB ASSEMBLIES The following procedures cover the disassembly in spection repair and assembly of each sub assembly as removed from the transmission Pre sized service bushings are available for replace ment for most all bushings in the TorqueFlite trans mission The two bushings in the sun gear are not serviced because of the low cost of the sun gear as sembly If the bushings are found wor
82. e mainshaft rear oearing in the case bore NOTE If the synchronizer parts are not posi tioned as described in steps 6 and 7 it will not be possible to place them in position after mainshaft is fully in position due to interference with counter shaft drive gear 8 While continuing to hold the synchronizer parts in position tap the mainshaft forward until the rear bearing bottoms in the case bore 8 Install the mainshaft rear bearing snap ring into place in the groove in the case bore Drive Pinion 1 Install the new seal in the retainer using Tool C 3789 until it bottoms on the seat of the counter bore Synchronizer front inner ring must be posi tioned as outlined in steps 2 and 3 while installing the drive pinion since it will not clear the counter shaft drive gear teeth when attempting to install the drive pinion with the inner ring installed on the drive pinion splines 2 Place the synchronizer front inner ring in position in the front outer ring and enter the main drive pinion through the case bore 3 Engage the splines on the rear of the pinion with the inner stop ring and tap the drive pinion into the transmission case until the outer snap ring TRANSMISSION 3 SPEED MANUAL 21 9 on the pinion bearing is against the transmission case 4 Place the drive pinion bearing retainer with out a gasket over the pinion shaft and against the transmission case While holding the retainer with hand pr
83. e retaining E clip on the throttle shaft NOTE The insert in Figure 59 shows the manual lever used in the transmissions with the console shift 11 Position the valve body assembly on the re pair stand 12 Place the six steel balls in the valve body chambers with the large ball in the large chamber Fig 58 Place the front pump check valve and spring in the valve body 13 Position the transfer plate assembly on the valve body Hold the front pump check valve in its 21 70 TRANSMISSION TORQUEFLITE bore with a thin steel scale Install the 14 retaining screws starting at the center and working outward tighten the screws to 28 inch pounds torque 14 Install the torque converter valve and the regulator valve Fig 60 15 Position the torque converter valve spring and regulator valve spring over the ends of their respec tive valves Place the line pressure adjusting screw assembly on the end of the regulator valve spring with long dimension of nut at right angles to the valve body 16 Install the spring retainer bracket making sure the converter valve spring is engaged on the tang and position squarely in the bracket Tighten the three bracket retaining screws to 28 inch pounds torque NOTE Measure and if necessary align the spring retainer bracket as described in Paragraph 15 17 Install the oil filter and gasket and tighten the three retaining screws to 28 inch pounds torque NOTE After the valve b
84. e shift housing 2 Drain the lubricant from the transmission 3 Disconnect the propeller shaft speedometer cable and pinion When removing the speedometer cable care should be used so as not to crush the housing Remove by hand 4 Disconnect the left hand exhaust pipe dual exhaust from the exhaust manifold 5 Disconnect the parking brake control cable 6 Disconnect the back up light switch leads at the connector If so equipped 7 Install the engine support fixture C 3487 or a suitable jack engaging the hooks in the holes in the frame side members Be sure the support ends are up against the underside of the oil pan flange 8 Adjust the fixture or jack to support the weight of the engine then raise the engine slightly and remove the rear crossmember attaching bolts Remove the crossmember 9 Support the transmission then remove the transmission attaching bolts 10 Rotate the transmission until the shift hous ing and stub lever clear then slide the transmission toward the rear until the main drive pinion shaft clears the clutch disc before lowering the transmis GEARSHIFT HOUSING GASKET BREATHER COMPANION FLANGE BACK UP LIGHT SWITCH REVERSE OPERATING LEVER 64 x 738 Fig 4 Four Forward Speed Transmission in Repair Stand 21 18 TRANSMISSION 4 SPEED MANUAL sion This will avoid damaging the clutch disc 11 Lower the transmission and remove from under t
85. eaction Shaft Support 1 Remove the front oil pump housing retaining bolts 2 Tighten the front band adjusting screw until the band is tight on the front clutch retainer This prevents the clutch retainer from coming out with the pump which might cause unnecessary damage to the clutches 3 Attach Tool C 3752 to the pump housing flange as shown in Figure 53 thread the screws of the tool into the flange holes at 9 and 3 o clock locations 4 Bump outward evenly on the two knocker weights to withdraw the oil pump and reaction shaft support assembly from the case Front Band and Front Clutch 1 Loosen the front band adjuster remove the band strut and slide the band out of the case 2 Slide the front clutch assembly out of the case Input Shaft and Rear Clutch 1 Grasp the input shaft and slide thc and rear clutch assembly out of the case 3haft 21 66 TRANSMISSION TORQUEFLITE CAUTION Be careful not to lose the thrust washer located between the rear end of input shaft and for ward end of output shaft Planetary Gear Assemblies Sun Gear Driving Shell 1 While supporting the output shaft and driving shell carefully slide the assembly forward and out through the case CAUTION Be very careful not to damage the ground surfaces on the output shaft during removal Rear Band and Low Reverse Drum 1 Remove the low reverse drum then loosen the rear band adjuster remove the band strut and remove th
86. eller shaft at the trans mission flange and secure the shaft to the frame mem ber for working clearance 2 Hold the mainshaft with Tool C 3281 then remove the flange nut and washer 3 Remove the transmission flange using Tool C 452 if necessary 4 Remove the oil seal using Tool C 748 21 26 TRANSMISSION MANUAL DIAGNOSIS 5 Drive a new seal into the extension housing nut Tighten nut to 175 foot pounds torque using Tool C 3837 7 Reconnect the propeller shaft and tighten the 6 Install the transmission flange washer and flange nuts to 30 foot pounds torque SPEEDOMETER PINION USAGE CHART 4 Forward Speed Manual Transmission Output Shaft Pinion Tire Size Axle Ratio Teeth Teeth Color 8 00x14 2 93 8 17 Orange 3 23 8 19 Dark Blue 8 50x14 2 93 8 17 Orange 3 23 8 19 Dark Blue IC SERVICE DIAGNOSIS Condition Possible Cause Correction Hard Shifting a Incorrect clutch adjustment a Refer to the Clutch Group 6 for corrections b Improper cross over adjustment b Perform the cross over adjustment as outlined in Paragraph 2 Gearshift Linkage Adjustments Synchronizer clutch sleeve e d e Causes noted can only be corrected damaged by disassembling the transmission and d Synehronizer spring improperly replacing damaged or worn parts installed e Broken or worn synchronizer stop rings Transmission Slips a Linkage interference Inspect and remove all linkage Out of Gear i
87. emove the seal 4 To install a new seal position seal in the open ing of the extension housing with lip of seal facing in ward Drive the seal into the housing with Tool C 383 Fig 36 S 60 x 182 Fig 34 Removing or Installing Output Shaft Flange Nut 21 56 TRANSMISSION TORQUEFLITE SPEEDOMETER PINION USAGE CHART Tire Axle Output Pinion Size Ratio Shaft No Teeth Color 8 00 14 2 76 1 8 Teeth 16 Brown 3 23 1 8 Teeth 19 Dark Blue 8 50 14 2 76 1 8 Teeth 16 Brown 3 2341 8 19 9 00 14 2 76 1 8 Teeth 16 Brown 3 23 1 8 Teeth 18 Dark Purple 7 10 15 3 23 1 8 Teeth 19 Dark Blue 7 60 15 3 23 1 8 Teeth 18 Dark Purple 8 20 15 2 93 1 8 Teeth 16 Brown 5 Install the transmission output shaft flange In stall washer with its three projections toward the flange and the nut with its convoluted surface con tacting the washer Hold the flange with Tool C 3281 and tighten the nut to 175 foot pounds torque 6 Connect the propeller shaft to the transmission flange 19 EXTENSION HOUSING Removal 1 Remove the speedometer drive pinion and sleeve assembly See Paragraph 17 2 Remove the transmission flange See Paragraph 18 3 Drain approximately two quarts of fluid from the transmission 4 Loosen the parking lock cable clamp bolt where cable enters the housing cover Refer to Figure 18 Tap the end of clamp bolt lightly to release its hold on the cable Remove the h
88. er light seal assembly in proper position over the shift lever 5 Install the two side mouldings on top of the console be sure to install the two screws under the console lid 6 Install the ash tray and secure with the four screws inside the tray 7 Install the shift lever knob and secure with the set screw 8 Inspect the cables for proper routing Make sure there are no sharp kinks or interference with the other parts 9 Install the adjusting wheel on the gearshift ca ble Install the cables in the transmission and adjust as outlined in Paragraphs 9 and 10 7 BACK UP LAMP SWTICH REPLACEMENT 1 Push Button Type Remove the push button gearshift and parking lock control unit Straighten the four tabs that hold the switch to the switch bracket and separate the switch from the bracket To install place the switch in position on the switch bracket and bend over the four tabs Reinstall the push button gearshift and parking lock control unit 2 Console Lever Type Refer to Paragraph 6 and perform steps 2 through 7 under Removal Discorinect the switch wires and remove the screw attaching the switch to the side of the gearshift unit To install attach the switch to the side of the gear shift unit and tighten the retaining screw Connect the wires and test the back up light for proper op eration Refer to Paragraph 6 and perform steps 2 through 7 under Installation 8 PUSH BUTTON AND CONSOLE SHIFT LA
89. es and install the attaching bolts Tighten to 50 foot pounds torque Remove the engine support fixture and disen gage the hooks from the holes in the frame side rails 7 Install the back up light switch wires if so equipped 8 Reconnect the speedometer cable the gearshift control rods and the propeller shaft 9 Fill the transmission with 5 pints of lubri cant 10 Road test the vehicle making sure the trans mission shifts smoothly and operates quietly 11 the shaft linkage requires adjustment refer to the procedure outlined in Paragraph Gearshift Linkage Adjustments 5 GEARSHIFT ASSEMBLY Removal 1 Disconnect the first and reverse second and TRANSMISSION 3 SPEED MANUAL 21 11 third shift rods from the shift levers Note position of the wave washers 2 Remove the screws that attach the upper boot retainer to the floor pan Remove the retainer and slide the boot up on the hand lever to expose the gearshift mounting bolts 3 Remove the bolts that attach the gearshift as sembly to the floor pan 4 Remove the gearshift assembly and lower boot from the vehicle Slide the lower boot off the shift levers 5 Using a 44 inch Allen wrench remove the tor sion spring retaining screw Slide the star washer out from under the spring 6 Using a screwdriver pry the lower end of the spring out of its hole in the divider shaft then disengage the upper loop of the spring from the shift
90. essure against the transmission case measure the clearance between the retainer and case using a feeler gauge 5 Select a gasket 008 to 005 inch thicker than the clearance found This eliminates end play of the front bearing in the transmission case and also elim inates the distortion of the bearing outer race due to excess pressure 6 Install and tighten the front bearing retainer attaching bolts to 360 inch pounds torque Extension Housing 1 Install new seal in the extension housing using Tool C 3837 2 Install the extension housing Tighten the mounting bolts and nuts to 50 foot pounds torque 3 Install the mainshaft flange Install the washer and nut and tighten to 175 foot pounds torque using the flange holding Tool C 3281 4 Install the drain plug in the transmission case 5 Install the gearshift operating levers with a flat washer and lockwasher under each nut and tight en to 144 inch pounds torque 6 Install the plug with gasket or back up light Switch if so equipped tightening securely 7 Install the speedometer cable and drive gear pinion 4 INSTALLATION OF THE TRANSMISSION the Vehicle measurement of the clutch housing bore and the face alignment should be made before installation Refer to Clutch Group 6 for procedure An old transmission drive pinion shaft may be used to meas ure the clutch disc alignment Place a small amount of short fibre wheel bearing lubr
91. etaining bolts and washers tighten bolts to 24 foot pounds torque 2 Install the transmission flange install washer with its three projections toward the flange and the nut with its convoluted surface contacting the washer Hold flange with Tool C 3281 and tighten the nut to 175 foot pounds torque IMPORTANT Measure the drive train end play as described in Paragraph 29 Correct if necessary Valve Body Assembly and Accumulator Piston 1 Clean the mating surfaces and inspect for burrs on both the transmission case and valve body steel plate 2 Install the accumulator piston in the transmis sion case and place the piston spring on the accumu lator piston 3 Carefully position the valve body assembly in the transmission case install the retaining bolts and tighten finger tight With the neutral starting switch installed place the manual valve in the neutral posi tion Shift the valve body if necessary to center the neutral finger over the neutral switch plunger Snug the bolts down evenly then tighten to 100 inch pounds torque TRANSMISSION TORQUEFLITE 21 83 4 Connect the control cable adapter to the man ual lever and install the retaining nut 5 Install the seal flat washer and throttle lever on the throttle shaft Tighten the clamp bolt 6 Adjust the kickdown and low reverse bands as described in Paragraph 12 7 Install the oil pan using a new gasket Tighten the pan bolts to 150 inch pounds tor
92. ew the remover into the bushing 3 to 4 additional turns to firmly engage the threads in the bushing 4 Turn the hex nut down against the cup to pull the bushing from the reaction shaft Thoroughly clean the reaction shaft to remove the chips made by the remover threads 5 Lightly grip the bushing in a vise or with pliers and back the tool out of the bushing Be careful not to damage the threads on the bushing remover HEX NUT SP 1191 TOOL HANDIE 5 3549 INSTALLING HEAD SP 3634 REACTION SHAFT SUPPORT REMOVAL Fig 67 Replacing Reaction Shaft Bushing TRANSMISSION TORQUEFLITE 21 73 6 Slide a new bushing chamfered end first on the installing head Tool SP 3634 and start them in the bore of the reaction shaft 7 Support the reaction shaft upright on a clean smooth surface and install handle Tool SP 3549 in the installing head Fig 67 Drive the bushing into the shaft until the tool bottoms 8 Thoroughly clean the reaction shaft support assembly before installation Assembly 1 Assemble the pump rotors in the pump housing Fig 64 2 Install the reaction shaft support and position the vent baffle over the vent opening Install the retaining bolts and tighten to 150 inch pounds torque 8 Place a new oil seal in the opening of the front oil pump housing lip of seal facing inward using Tool C 3860 drive the seal into housing until the tool bottoms 38
93. f g h i 0 Refill to correct level with Automatie Transmission Fluid Type A Suffix A Adjust the control cable Replace the oil filter Perform the hydraulic pressure tests and adjust to specifications Perform pressure tests to deter mine cause and correct as required Inspect the accumulator for sticking broken rings or spring Repair as required Remove the valve body assembly and perform air pressure tests Repair as required Perform the hydraulic pressure tests Adjust or repair as required Disassemble and inspect clutch Repair or replace as required Inspect and replace seal rings as required also inspect respective bores for wear Replace the parts as required Inspect for air leakage into the front pump suction passages Refill to correct level with Automatic Transmission Fluid Type A Suffix A Adjust the throttle linkage Perform the hydraulic pressure tests and adjust to specifications Adjust the kiekdown band Perform pressure tests to deter mine cause and correct as required Inspect the governor and repair as required Inspect the aceumulator for sticking broken rings or spring Repair as required Remove the valve body assembly and perform the air pressure tests Repair as required Inspect the servo for sticking broken seal rings binding linkage or faulty band lining Repair as required Disassemble and inspect the clutch Repair or replace as required In
94. ft into the bore in the case and position Fig 18 Install the reverse fork in the lever 2 Install the reverse shift detent ball and spring Install the reverse detent ball spring retainer gasket and retainer Tighten securely 3 Position the reverse slider gearshaft in posi tion in the end of the case and drive in far enough to position the reverse slider gear on the protruding end of the shaft with the shift slot toward the rear Fig 17 At the same time engage the slot with the reverse shift fork 4 With the reverse slider gear correctly posi tioned drive the reverse gear shift into the case far enough to be able to install the woodruff key Drive the shaft into position flush with the end of the case Fig 15 5 Install the back up light switch and gasket if so equipped and tighten securely Installing the Extension Housing and Mainshaft Assembly 1 Coat new extension housing to case gasket with grease both sides then place in position on the case 2 Center the reverse slider gear on its shaft then carefully insert the mainshaft assembly into the case Fig 7 Be sure the third and fourth speed Stop ring is indexed with the shifter plates 3 Move the third and fourth speed clutch sleeve slightly toward the front and at the same time align the end of the mainshaft with the main drive pinion Push in on the extension housing and bottom against the case and gasket 4 Install the attaching bolt
95. g and valve 8 Note location of the six steel balls in the valve body one of them is larger than the other five and is in the larger chamber Fig 58 Remove the steel balls front pump check valve and spring 9 Invert the valve body and lay it on a clean cloth or paper Remove E clip from the throttle lever STIFFENER PLATE 60x368 4 Fig 57 Transfer and Steel Separator Plate Assembly 21 68 TRANSMISSION TORQUEFLITE ONE LARGE STEEL BALL RONT PUMP FIVE SMALL STEEL BALLS W CHECK VALVE 60x370 A Fig 58 Front Pump Check Valve and Steel Ball Location shaft Fig 59 Remove any burrs from the shaft then while holding the manual lever detent ball and spring in their bore with Tool C 3765 or similar tool slide the manual lever off the throttle shaft Remove the detent bail and spring 10 Remove the manual valve carefully slide it out of the valve body with a rotating motion 11 Remove the throttle lever and shaft from the valve body 12 Remove the shuttle valve cover plate Fig 59 Remove the E clip from the exposed end of the shuttle valve 13 Remove the throttle lever stop screw assembly Fig 60 being careful not to disturb setting any more than is necessary 14 Remove the kickdown detent kickdown valve ihrottle valve spring and the throttle valve Fig 60 DETENT SHUTTLE VALVE BALL COVER PLATE MANUAL REVERSE BLOCKER VALVE MANUAL VALVE LINE PRESSURE ADJUS
96. haft lock pins Inspect annulus gear and driving gear teeth for damage Replace dis torted lock rings Assembly Refer to Figure 78 for parts reference 1 Position the rear planetary gear assembly in the rear annulus gear Place the thrust washer on front side of the planetary gear assembly 2 Insert the output shaft in rear opening of the rear annulus gear Carefully work the shaft through the annulus gear and planetary gear assembly Make sure the shaft splines are fully engaged in splines of the annulus gear 3 Install the snap ring in the front groove of the sun gear long end of gear Insert the sun gear through the front side of the driving shell install the rear steel washer and snap ring 4 Carefully slide the driving shell and sun gear assembly on the output shaft engaging sun gear teeth with the rear planetary pinion teeth Place thrust washer inside the front of the driving shell 5 Place thrust washer on the rear hub of the front planetary gear set then slide the assembly into the front annulus gear 6 Carefully work the front planetary and annulus gear assembly on the output shaft meshing planetary pinions with the sun gear teeth 7 With all components properly positioned in stall retaining snap ring on the front end of the output shaft Re measure the end play of the assembly 41 OVERRUNNING CLUTCH Inspection Inspect the clutch rollers for smooth round sur faces they must be free of fla
97. he vehicle Clean the outside of the case be fore disassembling 3 DISASSEMBLING THE TRANSMISSION To disassemble the transmission for repair or over haul refer to Figures 1 3 4 5 and 6 1 Mount the transmission in repair stand DD 1014 then disconnect the gearshift control rods from the shift control levers and the transmission operating levers by removing the spring retainer clips and the flatwashers 2 Remove the two gearshift control housing mounting bolts then remove the gearshift control housing from the transmission extension housing or mounting bracket if so equipped Remove the gear shift control housing mounting bracket bolts and re move bracket If so equipped 3 Remove the back up light switch equipped 4 Using a suitable holding tool remove the companion flange attaching nut and washer then slide the flange from the end of the mainshaft out put 5 Remove the bolts that attach the gearshift housing to the transmission case With all the lever s in the neutral detent position pull the housing out and away from the case first and second third and fourth shift fork may remain in engagement with the synchronizer sleeves Work the forks out of the sleeves and remove from the case Discard the hous ing gasket The following three steps need only be done if If so 1ST AND 2ND SPEED GEAR SHIFTER SHAFT AND DETENT PLATE LEVERS NEUTRAL POSITION 3RD AND 4
98. he water has come to a boil Steam Place the ring gear on a flat surface and direct a steam flow around the gear for approximately two minutes Flame Place the ring gear squarely on a flat sur face Using a medium size tip direct a slow flame evenly around the inner rim of the gear Do not apply flame to the gear teeth Place a few drops of water on the face of gear at intervals during the heating process When the gear is hot enough to just boil the water installation of the gear on the torque converter can be made 1 After the ring gear is expanded by heating place the gear in position on the converter front cover Tap the gear on the cover evenly with a plastic or rawhide mallet until the front face of the gear is even with the scribed line made during removal on TRANSMISSION TORQUEFLITE DIAGNOSIS the front cover Make sure the gear is even with a cover 2 Reweld the ring gear to the torque converter front cover being careful to place as nearly as pos sible the same amount of weld material in exactly the same location as was used in the original weld This is necessary in order to maintain proper balance of the unit Place the welds alternately on opposite sides of the converter to minimize distortion 3 The following suggestions are offered as an aid in making the weld a Do not gas weld b Use a D C welder that is set at straight polarity or welder if proper electrode is available c Use
99. hen remove the oil pan 3 Remove the access plate from in front of the converter remove the drain plug allowing the fluid to drain Fig 10 Install and tighten the converter drain plug to 14 inch pounds torque and install the access plate 4 If necessary adjust the reverse band Refer to Paragraph 12 5 Install a new oil filter on the bottom on the valve body Be sure to use a new gasket and tighten the retaining screws to 28 inch pounds torque 6 Clean the oil pan and reinstall using a new gasket Tighten the oil pan bolts to 150 inch pounds torque 7 Pour eight quarts of Automatic Transmission Fluid Type Suffix into the transmission 8 Start the engine and allow to idle for at least two minutes With the parking brake on depress each push button momentarily ending with the N Neutral button pushed in or move the selector lever to each position ending in the neutral position 9 Add sufficient fluid to bring fluid level to the ADD ONE PINT mark Approximately 2 quarts 10 Recheck the fluid level after the transmission is at normal operating temperature The level should be between the FULL mark and the ADD ONE PINT mark Fig 11 Fig 11 Dip Stick Markings 21 42 TRANSMISSION TORQUEFLITE SCREW 3 FELT SEAL INSTRUMENT PANEL GROMMET 4 WASHER 4 NUT 4 GEARSHIFT CONTROL 2 A HOUSING ASSEMBLY su Kol d N NEUTRAL
100. icant around the inner end of the drive pinion shaft pilot bushing sufficient amount will be left at this location after pressing the excess out of the crankshaft cavity Do not lubricate the bushing or the end of the transmission pinion shaft the clutch disc splines or clutch release levers 1 Remove the transmission from the repair stand and install the rear crossmember and support then roll transmission under the vehicle using a suitable jack 2 Raise the transmission until the main drive pinion is centered in the clutch housing bore LEVER FLAT WASHER LOCK WASHER SCREW BUSHING FLAT WASHER SPRING WASHER ROD 1ST AND REVERSE FLAT WASHER CLIP NS SPRING WASHER Fig 11 Gearshift Assembly Disassembled View ROD 2ND AND 3RD 61 108 01 15 Q334S E NOISSIWSNVUL GEARSHIFT LEVER UPPER BOOT LOW AND REVERSE LEVER SECOND AND 60x1339A LOWER Fig 12 the Crossover Pin 3 Move the transmission slowly forward until the pinion shaft enters the clutch disc Turn the pinion shaft until the splines are aligned then push the transmission forward until seated against the clutch housing NOTE Do not allow the transmission to affer the pinion has entered the clutch disc 4 Install the transmission attaching bolts and tighten to 50 foot pounds torque 5 Using a pointed drift align the crossmember bolt hol
101. ides freely on the clutch gear 7 Inspect the pins of the outer synchronizer stop ring assembly for straightness and tightness Replace Stop ring if pins are bent or loose 8 Replace the countershaft cluster gear if any of its gear teeth are broken chipped or excessively worn Small nicks or burrs can be stoned off 9 Inspect the roller bearing and countershaft for pits and scoring 10 Inspect the condition of the thrust washers and replace if wear is excessive 11 Inspect the clutch teeth of the drive pinion If excessively worn broken or chipped install a new pinion 12 Inspect the mainshaft pilot roller bearings in drive pinion for pitting or scoring If either of these conditions exist replace all roller bearings 13 Inspect the case at the gearshift bosses and operating levers Replace rubber lip seals if worn or torn 14 Inspect the interlock sleeve for free move ment in its bore Examine interlock balls for corro sion If operating lever shaft detents show signs of wear replace shaft Inspect shift fork for free move ment 15 Inspect the general condition of the transmis sion case extension housing and the front bearing retainer 16 Inspect all the threaded holes and plugs for stripped or pulled threads 17 Inspect the case for small cracks and sand holes 18 Inspect all mating and gasket surfaces for roughness and scratches 3 ASSEMBLY OF THE TRANSMISSION Refer to Figs
102. ight seal Imperial Models Remove the heater temperature and parking lock control handles Fig 13 Remove seven screws from the face of the instrument cluster chrome trim plate carefully remove the plate Depress the spring lock on the light switch and pull out the switch knob and shaft Loosen the set screw and remove the wiper control knob From the back remove the two nuts securing the left switch panel and name plate carefully remove the switch panel and foam rubber light seal Remove the four screws from the outer corners of the push button bezel carefully slide the lens and bezel assembly off the push buttons 4 Remove all the push buttons except neutral button by pulling them off the control actuator slides 5 Using a socket and long extension through the push button opening remove the two nuts secur ing the control assembly to the mounting bracket Carefully work the assembly rearward out of the clus ter 6 Remove the neutral push button and discon nect the gearshift and parking lock cables from the control unit TRANSMISSION TORQUEFLITE 21 43 Control Unit Adjustment The following procedures describe the gearshift control unit adjustments If the transmission fails to shift into NEUTRAL when the parking lock is ap plied inspect the parking lock lever travel in the in strument panel slot and the parking lock cable ad justment at the transmission before adjusting the control unit Refer to Paragraph 1
103. in and the opposite synchroni zer outer ring The measurement must be made on two pins 180 degrees apart with equal gap on both pin ends for float determination as shown in Fig ure 3 6 There should be a snug fit between the pins and the outer ring similar to that obtained when measur ing with a micrometer IXIGOA Fig 2 Heavy Duty Transmission Sectional View Fig 3 Measuring the Synchronizer Float Extension Housing 1 Remove the bolts and one stud nut that at taches the extension housing to the transmission case Slide the extension off the main shaft Discard the gasket Remove the oil seal using Tool C 748 2 Remove the extension housing and the main shaft bearing Drive Pinion 1 Remove the bolts that attach the main drive pinion bearing retainer then slide the retainer the pinion Discard the gasket and drive the seal out of the retainer using a suitable drift 2 When removing the drive pinion and the bear ing assembly from the transmission case slide the synchronizer front inner stop ring from the short splines on the pinion as the assembly is being re moved from the case as shown in Figure 4 3 Remove the snap ring which locks the main drive pinion bearing on the pinion shaft using a 61 12 Fig 4 Removing the Drive Pinion Assembly TRANSMISSION 3 SPEED MANUAL 21 5 BEARING OIL SLINGER DRIVE PINION 57 172 Fig 5 Drive Pinion Asse
104. ing lock cable adapter cover from the bottom of the extension housing 2 Remove the plug and slide the shaft out of the extension housing to remove the parking lock lever adapter and spacer Fig 43 3 Slide the bushing sleeve out of the housing to remove the sprag and spring Fig 44 Inspection Figure 63 shows the parking sprag and lever disas sembled Inspect the bushing sleeve and shaft for scores and free movement in the housing and in the sprag and LAT 63x579 SPRING Fig 63 Parking Lock Lever Sprag and Cable Adapter Disassembled lever Inspect roller for nicks burrs and free turning Inspect the square lug on the parking sprag for broken edges or other damage Replace as re quired Assembly 1 Position the parking sprag and spring in the housing and insert the bushing sleeve Fig 44 Make sure the square lug on the sprag is toward the support gear and the spring is positioned so as to lift the sprag away from the gear 2 Position the lock lever adapter and spacer in the housing and install the lever shaft Fig 43 The lever roller must be on top of the sprag so as to push it into engagement with the gear 3 Place a new adapter cover gasket on the exten sion housing then insert a small punch through the cable opening in the adapter cover and into the end of the adapter Carefully lower the cover into position feeding the adapter into the cable opening in the cover Install the c
105. ings Inspect the stop rings for cracks at the corners of the shift plate indexing slots If the rings are cracked or show signs of extreme wear on the threaded bore install new rings at reassembly Mainshaft Output Refer to Figure 14 and inspect the mainshaft gear and bearing mating surfaces If the gear contact sur faces show signs of galling or excessively worn a new mainshaft should be installed Inspect the snap ring grooves for burred edges rough or burred remoge the condition using a fine file or crocus cloth Inspect the synchronizer clutch gear teeth on the shaft for burrs 4 ASSEMBLING THE TRANSMISSION To reassemble the transmission refer to Figures 1 4 and 6 Countershaft Gear Cluster Fig 6 1 Using heavy grease coat the inside of the bore of the gear at each end then install the roller bearing spacer centered Insert arbor Tool C 3938 into the gear and through the spacer Center the arbor 2 Coat the needle type roller bearings with heavy grease then at each end of the gear install 19 rollers followed by a spacer ring and 19 more roller bearings and 1 spacer ring Refer to Fig 2 3 Coat the thrustwasher with heavy grease and install them over the arbor with the tang side toward the case boss as shown in Figure 20 4 Install the countershaft gear assembly into the case as shown in Figure 19 Allow the gear assembly to rest on the bottom of the case Be sure the thrust washers s
106. ining Repair as required Perform the hydraulic pressure tests adjust or repair as required Refill to the correct level with Automatie Transmission Fluid A Suffix A Perform the hydraulie pressure tests and adjust to specifications Perform pressure tests to deter mine cause and correct as required Perform the hydraulic pressure tests adjust or repair as required Remove the valve body assembly and perform air pressure tests Repair as required Inspect and replace the seal rings as required also inspect respeetive bores for wear Replace the parts as required Refill to the correct level with Automatie Transmission Fluid Type A Suffix A Perform the hydraulic pressure tests and adjust to specifications Replace the oil filter Perform pressure tests to deter mine cause and correct as required Perform the hydraulie pressure tests adjust or repair as required Remove the valve body assembly and perform air pressure tests Repair as required TRANSMISSION TORQUEFLITE DIAGNOSIS 21 89 SERVICE DIAGNOSIS Continued Condition Possible Cause Correction No Drive in Forward a Drive Positions b d e f g No Drive in Reverse a b e d e f g Drives in Neutral a b e Drags or Locks a b e e f Hydraulic pressures too low Valve body malfunetion or leakage Accumulator sticking broken rings or sp
107. into the groove to retain the bearing Be sure the snap ring is seated 3 Install the main drive pinion and bearing in the case and into position in the front bore Tap light 1 into place using a plastic hammer Install the outer snap ring in the bearing groove 4 Start the countershaft in its bore at the rear of the case Raise the countershaft gear until the teeth mesh with the main drive pinion gear Be sure the thrust washers remain in position on the ends of the arbor and the tangs aligned with the slots in the case BEARING SNAP RING OUTER TOWARD THE FRONT MAIN DRIVE PINION SNAP RING R BEARINGS 16 ROLLE 16 64 x 755 Fig 21 Drive Pinion and Bearing Assembly 5 Align the countershaft arbor with the bores in the case then drive or press the countershaft into the gear Install the woodruff key Continue to press the shaft into the case until the end of the shaft is flush with the rear face of the case Remove arbor Tool C 3938 Testing the Countershaft Gear End Play Using a shim stock feeler gauge measure the end play of the countershaft by inserting the feeler gauge between the thrust washer and the gear Fig 16 This measurement should not exceed 0045 to 028 inch The following step need only be done if the reverse shaft was removed because of oi leak 1 Install a new oil seal on the reverse gearshift lever shaft and coat with Lubriplate Carefully install the lever sha
108. isting motion seat the piston in bottom of the retainer 4 Position the clutch retainer over the piston re tainer splines and support the assembly so the clutch retainer remains in place 5 Place spring over the piston with outer edge of SPRING SNAP RING 2 62X1 Fig 75 Installing Rear Clutch Spring and Snap Ring TRANSMISSION TORQUEFLITE 21 77 SELECTIVE SNAP RING FEELER GAUGE Ass 62X3 Fig 76 Measuring Rear Clutch Plate Clearance spring positioned below the snap ring groove Start one end of snap ring in the groove make sure the spring is exactly centered on the piston then pro gressively tap the snap ring into the groove Fig 75 Be sure the snap ring is fully seated in the groove 6 Install the inner pressure plate in the clutch re tainer with raised portion of plate resting on the spring 7 Lubricate all clutch plates install one lined plate followed by a steel plate until all plates are in stalled Install the outer pressure plate and snap ring 8 With the rear clutch completely assembled in sert a feeler gauge between the pressure plate and snap ring Fig 76 The clearance should be 026 054 inch not install a snap ring of proper thickness to obtain the specified clearance Low limit clearances are desirable NOTE Rear clutch plate clearance is very impor tant in obtaining proper clutch operation The clear ance can be adjusted by the use of various thi
109. ix Adjust the throttle linkage Adjust the kickdown band Perform the hydraulic pressure tests and adjust to specifications Remove and clean the governor Replace parts if necessary Perform pressure tests to deter mine cause and correct as required Inspect accumulator for sticking broken rings or spring Repair as required Remove the valve body assembly and perform the air pressure tests Repair as required Perform the hydraulic pressure tests adjust or repair as required Inspect the servo for sticking broken seal rings binding linkage or faulty band lining Repair as required Disassemble and inspect clutch Repair or replace as required Inspect and replace the seal rings as required also inspect the respective bores for wear Replace parts as required Adjust the throttle linkage Adjust the control cable Adjust the kickdown band Perform the hydraulic pressure tests and adjust to specifications Remove and clean the governor Replace parts if necessary Perform pressure tests to deter mine cause and correct as required Inspect the accumulator for sticking broken rings or spring Repair as required Remove the valve body assembly and perform the air pressure tests Repair as required I Inspect the servo for sticking broken seal rings binding linkage or faulty band lining Repair as required Disassemble the transmission and repair the overrunning clutch as required Condition
110. kage or faulty band lining Repair as required Disassemble and inspect clutch Repair or replace as required g Worn faulty front and or rear clutch g Condition TRANSMISSION TORQUEFLITE DIAGNOSIS SERVICE DIAGNOSIS Continued Possible Cause 21 85 Correction Delayed Engagement in D 1 2 and R Runaway or Harsh Upshift and 3 2 Kickdown a b 4 f g h G 0 b e d e f h i 0 Low fluid level Incorrect control cable adjustment Oil filter clogged Hydraulic pressures too high or low Valve body malfunction or leakage Accumulator sticking broken rings or spring Clutches or servos sticking or not operating Faulty front pump Worn or faulty front and or rear clutch Worn or broken input shaft and or reaction shaft support seal rings Aerated fluid Low fluid level Incorrect throttle linkage adjustment Hydraulic pressures too high or low Kickdown band out of adjustment Valve body malfunction or leakage Governor malfunction Accumulator sticking broken rings or spring Clutches or servos sticking or not operating Kiekdown servo band linkage malfunction Worn or faulty front clutch Worn or broken input shaft and or reaction shaft support seal rings a b 4 g h 0 a b 4
111. ke and rotate the converter several times with the drain plug out to remove any residual solvent and dirt Flush any remaining sol vent from the converter with two quarts of new trans mission fluid This will prevent any adverse effect the solvent may have on the transmission seals Reinstall the drain plug and tighten to 14 foot pounds torque 27 ALUMINUM THREAD REPAIR Damaged or worn threads in the aluminum trans mission case and valve body can be repaired by the use of Heli Coils Essentially this repair consists of drilling out the worn or damaged threads tapping the hole with a special Heli Coil Tap and installing a Heli Coil insert into the tapped hole This brings the hole back to its original thread size chart lists the threaded hole sizes which are used in the aluminum case and valve body and the necessary tools and inserts for the repair of damaged or worn threads Heli Coil tools and inserts are readily available from most automotive parts jobbers 28 FRONT PUMP OIL SEAL Replacement The front pump oil seal can be replaced without INSERTING EXTRACT HELI COIL INSERT DRILL TAP TOOL ING TOOL Thread Part Insert Part Part Part Size No Length Size No No No 10 24 1185 3 285 203 528 3 1227 6 4 20 1185 4 3 174 265 4 528 1227 6 56 18 1185 5 1 Q 332 5 528 5 1227 6 16 1185 6 Ae X 397 6 CPB 528 6N 1227 6 7 14 1185 7 2 2952 4537 7
112. l Starting 47 Rear Oil 71 Band 48 Front Oil Pump and Reaction Shaft Support 71 Throttle Linkage 48 Front 73 Hydraulic Control Pressure 51 Rear 75 Hydraulic Control Pressure Adjustments 53 Planetary Gear Assemblies Sun Gear and Air Pressure 5 54 Driving Shell 0 0 02 eee cee eee 77 Servicing Operations with Transmission in 55 Overrunning 79 Speedometer 55 Kickdown Servo and 79 Output Shaft 5 55 Low Reverse Servo and 80 Extension 56 Installation of Sub Assemblies poc 81 57 Starter Ring Gear 83 Rear Oil 58 2C Service 84 21 2 TRANSMISSION 3 SPEED MANUAL 3 SPEED HEAVY DUTY MANUAL TRANSMISSION SPECIFICATIONS THREE SPEED HEAVY DUTY MANUAL TRANSMISSION Model Application VC 1 2 Engine Displacement Cu
113. le pushing the cable in as far as possible making sure lockspring engages cable Gently pull outward on the cable housing to its limit of travel then tighten the clamp bolt to 10 inch pounds torque Remove the screw driver and reinstall the plug in the cover 10 Connect the propeller shaft to the front flange Tighten the flange nuts to 35 foot pounds torque Imperial Models Place the propeller shaft center bearing housing shims under the housing install the retaining bolts and tighten to 35 foot pounds torque 11 Install the speedometer drive pinion and sleeve 12 Connect the oil cooler lines to the transmis sion Install the oil filler tube 13 Connect the throttle rod to the relay lever at the left side of the transmission 14 Have an assistant engage and hold in firmly the R reverse button or place the console selector lever in the park position Insert the control cable in the transmission case push inward on the cable making sure the lock spring engages the cable In stall the control cable adjusting wheel lock screw 15 Connect the wire to the neutral starting switch TRANSMISSION TORQUEFLITE TORQUE CONVERTER 16 Install the cover plate in front of the converter assembly 17 Refill the transmission with Automatic Trans mission Fluid Type Suffix 21 63 NOTE To completely adjust the throttle linkage gearshift control cable and neutral starting switch refer to Maintenan
114. lel with the center line of the divider 21 12 TRANSMISSION 3 SPEED MANUAL SPECIAL SCREW FLATWASHER Fig 13 Lever Torsion Spring Installed shaft Slide the gearshift fork and shaft down into position on the divider shaft with the gearshift knob facing to the rear and the three holes in the support plate Fig 12 6 Install the shift fork retaining screw and lock washer front Do not tighten at this time 7 Engage the loop of the torsion spring with the gearshift fork shaft and slide the other end into the hole at the bottom of the divider as shown in Fig ure 13 GEARSHIFT amp BRACKET ASSY REV LEVER WITH CROSSOVER PIN ENGAGED THE 2ND 3RD LEVER THE GAP FROM CROSSOVER PIN TO IST REV LEVER SHOULD NOT EXCEED 055 INCHES SEE VIEW A WITH BOTH GEARSHIFT amp BRACKET ASSEMBLY AND LOWER INSTALLED CLIP THE CROSSOVER PIN TOOL OVER 2ND 3RD END OF CROSSOVER PIN SO THAT PIN ENGAGES BOTH LEVERS SEE FIG 1 PRESET THE LENGTH OF THE 15 SHIFT ROD BY ADJUST ING THE SWIVEL AND INSTALL IT SO THAT THE TRANS MISSION WILL BE IN NEUTRAL AND THE SHIFT LEVERS VERTICAL SEE FIG 2 INSTALL 2ND 3RD FRONT SHIFT ROD BELLCRANK AND 2ND 3RD REAR SHIFT ROD IN THAT ORDER AS SHOWN IN FIG 2 WITH TRANSMISSI N NEUTRAL SWIVEL NUT TO 20 LBS PER INCH TORQUE REMOVE CROSSOVER PIN TOOL N CROSSOVER PIN TOOL 8 Install the spring
115. mately doubled as the throttle is opened to the maximum line pressure Rear Servo Apply Pressure 1 Connect a 0 300 psi pressure gauge Tool C 3293 to the apply pressure take off point at the rear servo Fig 27 2 With the transmission control R reverse position and the engine speed set at 1600 rpm the reverse servo apply pressure should be 240 280 psi Governor Pressure 1 Connect a 0 100 psi pressure gauge Tool C 3292 to the governor pressure take off point located at lower left side of the extension near the mounting flange Fig 27 2 Governor pressures should fall within the limits given in the Goverrior Pressure Chart If governor pressures are in orrect at the given vehicle speeds the governor valve and or weights are probably sticking GOVERNOR PRESSURE CHART VEHICLE SPEED TO AXLE RATIOS PRESSURE VC 1 2 3 300 with Engine VY 1 LIMITS 2 76 1 3 23 1 2 76 1 3 23 1 2 93 1 PSI 20 22 17 19 20 23 17 20 20 23 15 44 53 37 45 45 54 50 56 44 53 50 73 80 62 69 75 82 73 80 74 81 75 governor pressure should respond smoothly to changes in m p h and should return to 0 to 1 2 psi when the vehicle is stopped High pressure at standstill above 2 psi will prevent the transmission from downshifting Fig 27 Pressure Test Locations Rear End of Case Throttle Pressure No provisions are made to test the throttle pres sure Incorrect throttle pressure should only
116. mbly snap ring pliers Carefully press the pinion shaft out of the bearing using an arbor press Remove the oil slinger Fig 5 4 Remove the 15 rollers from the cavity in the end of the drive pinion gear using a hook Mainshaft 1 Remove the mainshaft rear bearing snap ring from the groove in the mainshaft rear bearing bore in the 2 Slide the mainshaft and rear bearing assembly to the rear until the rear bearing is out of the case 3 Remove the synchronizer assembly Fig 8 from the mainshaft and out of the case 4 Remove the second and third speed shift fork 5 Remove the synchronizer clutch gear snap ring using Tool C 484 6 Remove the synchronizer clutch gear second speed gear and first and reverse sliding gear from the mainshaft NOTE f the synchronizer clutch gear cannot be removed easily from the mainshaft position the low and reverse fork and sliding gear to the rear of the SYNCHRONIZER STOP INNER RING CLUTCH GEAR SLEEVE SYNCHRONIZER STOP INNER RING SPREADER RING SYNCHRONIZER STOP OUTER RING ASSY S 61x120A Fig 6 Synchronizer Assembly 21 6 TRANSMISSION 3 SPEED MANUAL case and using a plastic hammer gently the mainshaft back out of the synchronizer clutch gear 7 Remove the mainshaft and bearing out through the rear of the case Fig 7 8 Remove the low and reverse shift fork from the case Countershaft CAUTION Do not drive the co
117. ment Output shaft bearing damaged Governor support binding or broken seal rings Front and or rear oil pump seored or binding Front and or rear clutch faulty Planetary gear sets broken or seized Overrunning clutch worn broken or seized Low fluid level Pumps sucking air Valve body malfunction Overrunning clutch inner race damaged High fluid level Breather clogged Oil filter clogged Aerated fluid Low fluid level Kickdown band adjustment too tight Low reverse band adjustment too tight Faulty cooling system Faulty rear and or front pump Insufficient clutch plate clearance in front and or rear clutches b 4 h a b x a b e d a b e d e Correction Adjust the kickdown band Adjust the low reverse band Remove the extension housing and replace the bearing Inspect the condition of the governor support and repair as required Inspect the condition of the pump and repair as required Disassemble and inspect clutch Repair or replace as required Inspect the condition of the planetary gear sets and replace as required Inspect the condition of overrunning clutch and replace parts as required Refill to the correct level with Automatic Transmission Fluid Type A Suffix A Inspect the pumps for nicks or burrs on mating surfaces porous casting and or excessive rotor clearanc
118. must be 54 60 psi and the front servo release pressure must not be more than 3 psi below line pressure 4 Disconnect the throttle linkage from the trans mission throttle lever and move the throttle lever gradually to full throttle position Line pressure must rise to a maximum of 90 96 psi just before or at kitkdowit into low gear Front servo release pressure must follow line pressure up to the kickdown point and should not be more than 3 psi below line pressure If line pressure is not 54 60 psi at 1 000 rpm ad j st the pressure as outlined in Paragraph 15 If front servo release pressures are less than pres sure specified and line pressures are within limits there excessive leakage in the front clutch and or front servo circuits CAUTION Always inspect the external transmis sion throttle lever for looseness on the valve body shaft when making the pressure tests Lubrication Pressures The lubrication pressure test should be made at the same time that line pressure and front servo release pressures are tested 1 Install a tee fitting between the cooler re turn line fitting and fitting hole in the transmission case at rear of the left side of the transmission case Fig 27 Connect a 0 100 psi pressure gauge Tool C 3292 to the tee fitting 2 At 1 000 engine rpm with the throttle closed and the transmission in direct the lubrication pres sure should be 5 15 psi Lubrication pressure will be approxi
119. n or scored they should be replaced as outlined in the following reconditioning procedures The bushing replacement tools listed by SP num bers are part of Tool Kit C 3887 The use of crocus cloth is permissible where neces sary providing it is used carefully When used on valves use extreme care to avoid rounding off the sharp edges The sharp edge is vitally important to this type valve Sharp edges prevent dirt and foreign matter from getting between the valve and body thus reducing the possibilities of sticking When it becomes necessary to recondition the transmission and ve hicle has accumulated considerable mileage install new seal rings on parts requiring their usage FILTER 64x19 TOOL REPAIR STAND Fig 55 Removing or Installing Oil Filter NOTE Coat each part with Automatic Transmis sion Fluid Type Suffix A during assembly 31 VALVE BODY ASSEMBLY Disassembly NOTE Never clamp any portion of the valve body or transfer plate in a vise Any slight distortion of the aluminum body or the transfer plate will result in sticking valves excessive leakage or both When re moving or installing valves or plugs slide them in or out carefully Do not use force 1 Place the valve body assembly on a repair stand Tool C 3749 Fig 55 Remove three screws from the oil filter and lift off the filter and gasket 2 While holding the spring retainer bracket firmly against the
120. nap ring from inside the governor weight remove the inner weight and spring from the outer weight Figure 40 shows a disassembled view of the governor assembly SPRING BODY VALVE SHAFT SNAP RINGS A VALVE OUTER 7 WEIGHT Sep INNER WEIGHT SNAP RING 641 358 Fig 40 Governor Assembly Disassembled 21 58 TRANSMISSION TORQUEFLITE 5 Remove the snap ring from behind the gover nor body then slide the body and support assembly off the output shaft If necessary remove four bolts and separate the governor from the support Cleaning and Inspection The primary cause of governor operating failure is due to a sticking governor valve or weights Rough surfaces may be removed with crocus cloth Thor oughly clean all parts in clean solvent and inspect for free movement before assembly Installation l 1 Assemble the governor body to the support if disassembled and tighten the bolts finger tight Make sure oil passage of governor body aligns with pas sage in the supporrt 2 Position the support and governor assembly on output shaft Align the assembly 50 the governor valve shaft hole in the governor body aligns with the hole in the output shaft then slide the assembly into place Install snap ring behind the governor body Fig 39 Tighten body to support bolts to 100 inch pounds torque Bend ends of lock straps over the bolt heads 3 Assemble the governor weights and spring and secure with sna
121. nd installing head in the bushing bore Install the handle Tool Sp 3549 in the installing head Fig 65 6 Drive the bushing into the housing until the tool bottoms in the pump cavity Be careful not to cock the tool during installation 7 Stake the bushing in place by using a blunt punch or similar tool Fig 66 A gentle tap at each stake slot location will suffice 8 Using a narrow bladed knife or similar tool remove the high points or burrs around the staked OUTER ROTOR VENT BAFFLE SEAL RINGS REACTION SHAFT SUPPORT INNER ROTOR THRUST WASHER SELECTIVE Fig 64 Front Pump and Reaction Shaft Support Diassembled BOLTS 6 area Fig 66 Do not use a file or similar tool that will remove more metal than is necessary 9 Thoroughly clean the pump housing before in stallation TOOL HANDLE SP 3549 REMOVING HEAD 5 3550 HOUSING BUSHING TOOL HANDLE SP 3549 INSTALLATION 62X 347 Fig 65 Replacing Front Pump Bushing Reaction Shaft Bushing Replacement 1 Assemble the remover Tool SP 3632 the cup Tool SP 3633 and the hex nut Tool SP 1191 CAUTION Do not clamp any part of the reaction shaft or support in a vise 2 With the cup held firmly against the reaction shaft thread the remover into the bushing as far as possible by hand Fig 67 3 Using a wrench scr
122. ng that retains the mainshaft center IST SPEED GEAR 35 TEETH EXTENSION HOUSING 1ST AND 2ND CLUTCH SLEEVE GEAR 34 TEETH SECOND SPEED GEAR 34 TEETH MAINSHAFT STOP RING 3RD AND 4TH CLUTCH SLEEVE 3RD SPEED GEAR 29 TEETH 64 742 Fig 8 Mainshaft Gear Identification 3RD AND 4TH SPEED SYNCHRONIZER CLUTCH GEAR 3RD SPEED GEAR CLUTCH GEAR SHOULDER SNAP RING SLEEVE STOP RING 64x743 Fig 9 Disassembling the Transmission Mainshaft bearing in the extension houisng as shown in Figure 10 4 Holding the snap ring compressed pull the mainshaft assembly and bearing out of the extension housing as shown in Figure 11 Remove the rear oil seal from the extension housing Discard the seal CLUTCH GEAR SHIFT PLATES 3 1ST SPEED GEAR 1ST AND 2ND CLUTCH STOP RING SLEEVE GEAR 1ST AND 2ND SYNCHRONIZER CLUTCH GEAR EXTENSION HOUSING PLIERS 64x744 Fig 10 Removing or Installing Center Bearing Snap Ring SNAP RING GROOVE BEARING SNAP RING EXTENSION HOUSING Fig 11 8Removing or Installing the Mainshaft E PLIERS BEARING SNAP RING BEARING Y RETAINING RING AR 7722 64x746 12 Removing or Installing the Center Bearing Snap Ring 5 Remove the rear bearing from the mainshaft by inserting steel plates on the front side of the 1st speed gear then using an arbor or hammer press or d
123. nt to hold it in place install the front thrust washer on the arbor at the front end of the cluster gear with the tabs out ward 7 Install the tabbed rear thrust washer the arbor against the rear of the cluster gear with the tabs positioned in the grooves provided in the cluster gear 8 Install the remaining rear thrust washer plate on the rear of the gear and arbor with the step in the washer facing upward as viewed from the rear NOTE The rear thrust washer must be insfalled with step O D of washer engaged on the ledge inside the rear of the case thus preventing rotation of the thrust washer plate 9 Align the tabs of the front thrust washer vertically to index with the notches in the transmis sion case and with the step in the rear thrust washer positioned upward Position the cluster gear and arbor assembly in the transmission case Make sure the thrust washers are not dislodged from the arbor and engage the thrust washer tabs in the case grooves while sliding the assembly into position 10 Measure the end play of the countershaft gear End play should be from 0045 to 028 inch 11 Using the countershaft and a soft hammer drive the arbor forward out of the cluster gear and through the bore in the front of the case Before driving the countershaft all the way into the case be sure keyway is positioned in line with the key recess provided in the rear of the case Insert the shaft key and continue to
124. nterferences b Gearshift rods out of b Adjust the gearshift rods as outlined in adjustment Paragraph 2 Gearshift Linkage Adjustments c Second or direct speed gear c Disassemble the transmission and replace synehronizer cluteh teeth worn parts as necessary d Clutch housing out d Refer to the Clutch Group 6 for of alignment eorrection procedures Transmission Noises a Excessive end play in the cluster a Replace the worn gear Backlash Noise gear b Loose synchronizer hub spline b Inspect the mainshaft and synchronizer fit on mainshaft hub and replace parts as necessary Loose spline fit on low speed Inspect the low idle speed sliding gear and sliding gear to mainshaft spline mainshaft Replace parts as necessary d Loose spline fit of rear d Inspect the mainshaft and flange splines mainshaft flange Replace parts as necessary e Damaged broken or excessively e Replace the worn gears worn gear teeth f Drive pinion bearing worn f Replace the worn bearing TRANSMISSION TORQUEFLITE 21 27 PART 2 TORQUEFLITE TRANSMISSION TORQUE CONVERTER 2A SPECIFICATIONS TORQUEFLITE TRANSMISSION TYPE ebd ae ROC USE DRY S Automatic Three Speed with Torque Converter TORQUE CONVERTER Diamelet oor ELE bd dhe Lip etus 1134 inches OIL CAPACITY TRANSMISSION AND TORQUE 20 Automatic Tr
125. ntil the swivel stub shafts match the control rod lever holes Trans mission shift operating levers must be in the neutral detent position during this Adjustment Install the swivel stub shafts and secure the flat washers and spring clip retainers 5 Remove the lever aligning tool 6 With the transmission hand shift lever in the third or fourth speed detent position adjust the lever stop screw front and rear to provide from 020 to 040 inch clearance between the lever and the stops When this adjustment has been made tighten the adjusting screw locknuts securely 7 Inspect the linkage for ease of shifting into all gears and for smoothness of crossover and handshift lever clearances CAUTION Because there is no reverse gear in terlock it is very important that the transmission linkage adjustments are correctly performed in order to prevent the possibility of engagement into two gears at the same time 8 Slide the boot down the shift lever shaft to the floor pan and secure with attaching screws 2 TRANSMISSION Removal from the Vehicle 1 Remove the shift lever boot attaching screws and slide the boot up on the shift lever Remove the DRIVE PINION PINION BEARING RETAINER 3RD AND 4TH OPERATING LEVER REPAIR STAND CASE 157 AND 2ND OPERATING LEVER TRANSMISSION 4 SPEED MANUAL 21 17 lever attaching bolts and remove the shift lever and boot from the stub lever of th
126. o ob tain the sp cified line pressure The adjusting screw be turned with an Allen wrench One complete turn of the adjusting screw changes closed throttle line pressure approximately 1 psi Turning the adjusting screw counterclockwise increases pressure and clockwise decreases the pres sure THROTTLE LEVER STOP SCREW 60x376 Fig 30 Throtile Pressure Adjustment 21 4 TRANSMISSION TORQUEFLITE Throttle Pressure Throttle pressure cannot tested accurately therefore the adjustment should be inspected if a malfunction is evident 1 Remove the valve body assembly from the trans mission to perform the adjustment Refer to Para graph 24 2 Loosen the throttle lever stop screw lock nut and back off approximately five turns Fig 30 3 Insert the gauge pin of Tool C 3763 between the throttle lever cam and the kickdown valve 4 By pushing in on the tool compress the kick down valve against its spring so the throttle valve is completely bottomed inside the valve body 5 As force is being exerted to compress the spring tighten the throttle lever stop screw finger tight against the throttle lever tang with the throttle lever cam touching the tool and the throttle valve bottomed Be sure the adjustment is made with the spring fully compressed and the valve bottomed the valve body 6 Remove the tool and tighten the stop screw lock nut securely 16 AIR PRESSURE TESTS A NO
127. o the bushing as far as possible by hand Fig 74 4 Using a wrench screw the remover into the bushing 3 to 4 additional turns to firmly engage the threads in the bushing 5 Turn the hex nut down against the cup to pull the bushing from the input shaft 6 Thoroughly clean the input shaft to remove the chips made by the remover threads Make certain TOOL HANDLE 5 3549 SP 1191 CUP SP 3633 INSTALLING REAR CLUTCH Spec RETAINER INSTALLATION 62 35 Fig 74 Replacing Input Shaft Bushing the small lubrication hole next to the ball in end of the shaft is not plugged with chips Be sure no chips are lodged next to the steel ball 7 Slide a new bushing on the installing head Tool SP 3630 and start them in the bore of the input shaft 8 Stand the input shaft upright on a clean smooth surface and install handle Tool SP 3549 in the install ing head Fig 74 Drive the bushing into the shaft until the tool bottoms 9 Thoroughly clean the input shaft and clutch piston retainer before assembly and installation Assembly 1 If removed press the input shaft into the clutch piston retainer and install the snap ring 2 Lubricate and install the inner and outer seal rings on the clutch piston Make sure lip of seals face toward head of the clutch retainer and are properly seated in the piston grooves 3 Place the piston assembly in the retainer and with a tw
128. ody has been serviced and completely assembled adjust the throttle and line pressures as outlined in Paragraph 15 However if pressures were satisfactory prior to disassembly use original settings 32 ACCUMULATOR PISTON AND SPRING Inspection Inspect the two seal rings for wear and make sure they turn freely in the piston grooves It is not neces sary to remove rings unless condition warrants In the piston for nicks burrs scores and wear Inspect the piston bore in the case for scores or other damage and tbe piston spring for distortion Re place parts as required 33 EXTENSION HOUSING BEARING AND OIL SEAL Replacement 1 Pry or drive the oil seal out of the extension housing with a long blunt drift Be sure not to mar the oil seal surface in the extension housing 2 Remove the bearing snap ring from the exten sion housing 3 Drive the bearing rearward out of the exten sion housing with Tool C 3275 Fig 37 4 Place a new bearing in opening of the extension housing Using Tool C 3204 drive the bearing into the housing Fig 38 Install the bearing retaining snap ring 5 Place a new oil seal in the opening of the exten 1 MANUAL LEVER Fig 62 Installing Detent Ball Spring and Manual Lever sion housing lip of seal facing inward Using Tool C 3837 drive the seal into the housing until the tool bottoms Fig 36 34 PARKING SPRAG AND LEVER Disassembly 1 Remove the park
129. of the transmission case 3 Remove the second and third gear lever shafts in the same manner 4 Remove the lever shafts from the transmission case taking care not to lose the spring loaded detent balls 5 Remove the interlock sleeve spring pin and detent balls Cleaning and Inspection 1 Before inspecting wash each part thoroughly in a suitable solvent then dry Clean mainshaft drive pinion shaft end bearings Dry by applying com pressed air directly through the bearing Never spin bearings with compressed air Apply a little oil and turn the bearing several times by hand 2 Inspect the bearings for looseness or noise by comparing with a new bearing Be sure to wash the lubricant from the new bearing then apply a little oil before making the comparison test 3 Inspect the fit of the bearings on their respec tive shafts and in the bores 4 Inspect the bearings shaft and case for wear If installation of a new bearing does not correct conditions install a new shaft or repair case as re quired 5 Inspect the mainshaft splines for galling or scoring Inspect bearing mounting surfaces and snap ring groove Slight nicks or burrs can be stoned off Replace the damaged parts 6 Inspect the gear teeth and threads on the inner synchronizer rings and synchronizer clutch gear sleeve If there is evidence of chipped or excessively worn teeth replace the part Make sure the syn chronizer clutch sleeve sl
130. om the OFF end of the lever slot then tighten the two nuts on the pushbutton housing Inspect the lever travel to be cer tain that clearance exists at both ends of the lever travel 4 Place the parking lock lever on instrument panel in the OFF position Adjustment tTransmission Cable End Push Button and Console Shift 5 IF not performed in step 1 loosen the clamp bolt securing the cable housing in the parking lever cover on bottom on the transmission extension hous ing Tap the end of clamp bolt lightly to release its hold on the cable 6 Gently pull outward on the cable housing to its limit of travel release and then tighten the clamp bolt to 10 inch pounds torque Do not use pliers or similar tool to pull outward on the cable as the cable cover might be damaged causing an oil leak 7 Inspect the adjustments by allowing the vehicle to roll slowly on a slight incline The parking sprag should fully engage the parking gear with the lever in ON position and there should be no ratcheting noise with the lever in the OFF position 11 NEUTRA STARTING SWITCH Adjustment and Test Push Button Control Only 1 With the proper control cable adjustment as sured depress the N neutral push button 2 Raise the vehicle on a hoist loosen the neutral starting switch allowing the fluid to drain into a con tainer 3 Unscrew the neutral starting switch from the 56x228 Fig 20 Neutral Starting Switch TR
131. ooth surface Slide new bushing on the installing head Tool SP 3628 and start them in the clutch re tainer bore 4 Install handle Tool SP 3549 in the installer Fig 70 Drive the bushing into the clutch retainer until the tool bottoms 5 Thoroughly clean the clutch retainer before assembly and installation Assembly 1 Lubricate and install the inner seal on hub of the clutch retainer Make sure lip of the seal faces down and is properly seated in the groove 2 Install the outer seal on the clutch piston with lip of seal toward bottom of the clutch retainer Ap ply a coating of Door Ease to the outer edge of the seal for easier installation of the piston assembly Place the piston assembly in retainer and carefully seat the piston in the bottom of the retainer 8 Place the 10 springs on the piston hub exactly as shown in Figure 71 Position the spring retainer Fig 71 9Front Clutch Piston Return Spring Location 21 75 TRANSMISSION TORQUEFLITE _ FEELER lt GAUGE SELECTIVE SNAP RING a 62 X 2 Fig 72 Measuring Front Clutch Plate Clearance and snap ring on the springs Compress springs with Tool C 3863 Fig 69 and seat snap ring in the hub groove Remove the compressor tool 4 Lubricate all clutch plates install one steel plate followed by a lined plate until ali plates are installed Install the pressure plate and snap ring Make sure the snap ring is properly seated 5
132. ousing cover lower plug Insert a screw driver through the hole then while exerting pressure against projecting portion of the cable lock spring withdraw the lock cable 62x178 35 Output Shaft Seal 62x177 Fig 36 Installing Output Shaft Oil Seal 5 Remove two bolts securing the extension hous ing to the crossmember insulator 6 Raise the transmission slightly to clear the crossmember with a service jack Tool 3203A Re move crossmember attaching bolts and remove the crossmember insulator and spring assembly 7 Remove the extension housing to transmission bolts tap the housing lightly with a soft mallet to TOOL 62x180 Fig 37 Removing Output Shaft Bearing TOOL EXTENSION HOUSING 62 179 38 Installing Output Shaft Bearing break it loose from the transmission then remove the housing Bearing Replacement 1 Pry or drive the oil seal out of the extension housing with a long blunt drift Be sure not to mar the oil seal surface in the housing 2 Remove the bearing snap ring from the exten sion housing Drive the bearing rearward out of the housing with Tool C 3275 Fig 37 3 Place a new bearing in the opening of the ex tension housing Using Tool C 3204 drive the bear ing into the housing Fig 38 Install the bearing retaining snap ring 4 Place new seal in the opening of the exten sion housing lip of seal facing inward Using
133. over retaining screws and tighten to 150 inch pounds torque 35 GOVERNOR AND SUPPORT Disassembly 1 Remove the large snap ring from the weight end of the governor body and lift out the weight assembly 2 Remove the snap ring from inside the governor weight remove the inner weight and spring from the outer weight 3 the lugs on the parking gear are damaged remove the four bolts and separate the support from the governor body Cleaning and Inspection Figure 40 shows a disassembled view of the gover nor assembly Inspect all parts for burrs and wear Inspect the inner weight for free movement in the outer weight and outer weight for free movement in the governor body Inspect the valve for free movement in the governor body The weights and valve should fall freely in the bores when clean and dry Rough sur faces may be removed with crocus cloth Inspect the governor weight spring for distortion Inspect the lugs on the parking gear for broken edges or other damage Thoroughly clean all governor parts in clean solvent and inspect for free movement be fore assembly Assembly 1 the support was separated from the governor body assemble and tighten the bolts finger tight Make sure the oil passage of the governor body aligns with the passage in the support TRANSMISSION TORQUEFLITE 21 71 2 Assemble governor weights and spring and secure with snap ring inside of the large governor weight Place the
134. p ring inside of the large governor weight Place the weight assembly in the governor body and install the snap ring 4 Place the governor valve on the valve shaft in sert the assembly into the body and through the governor weights Install the valve shaft retaining snap ring Inspect the valve and weight assembly for free movement after installation 5 Install the extension housing flange and connect the propeller shaft transmission Fig 41 Removing or Installing Rear Pump Inner Rotor 6 Connect and adjust the parking lock cable Re fer to Paragraph 10 21 REAR OIL PUMP Removal 1 Remove the extension housing See Paragraph 19 2 Remove the governor and support See Para graph 20 3 Unscrew the rear oil pump cover retaining bolts and remove the cover 4 The oil pump inner rofor is keyed to the output shaft by a small ball therefore use care in sliding out the inner rotor so as not to lose the ball Fig 41 Remove the outer rotor from the pump body NOTE If the rear oil pump body requires replace ment it will be necessary to disassemble the trans mission as the pump body must be driven rearward out of the case with a wood block Inspection Inspect the oil pump body and cover machine sur faces for nicks and burrs Inspect the rotors for scor ing or pitting With the gears cleaned and installed in the pump body place a straight edge across the face of the rotors and the pump bo
135. pressure tests and adjust to specifications Remove and clean the governor Replace parts if necessary Replace the oil filter Perform pressure tests to deter mine cause and correct as required Remove the valve body assembly and perform air pressure tests Repair as required Perform the hydraulic pressure tests adjust or repair as required Inspect and replace the seal rings as required also inspect respective bores for wear Replace the parts as required Refill to the correct level with Automatic Transmission Fluid Type A Suffix A Inspect for air leakage into the front pump suction passages Adjust the throttle linkage Adjust the control cable Perform the hydraulic pressure tests and adjust to specifications Perform pressure tests to deter mine cause and correct as required Inspect the accumulator for sticking broken rings or spring Repair as required Remove the valve body assembly perform air pressure tests Repair as required Disassemble and inspect clutch Repair or replace as required Disassemble the transmission and repair the overrunning clutch as required Inspect and replace the seal rings as required also inspect the respective bores for wear Replace parts as required 21 88 TRANSMISSION TORQUEFLITE DIAGNOSIS SERVICE DIAGNOSIS Continued Condition Possible Cause Correction Slips in Reverse Only b 4 g h i Slips in All Positions
136. que 45 STARTER RING GEAR REPLACEMENT The starter ring gear is mounted directly on the outer diameter of the torque converter front cover With the torque converter removed from the vehicle replacement of the gear is as follows Removing Ring Gear 1 Cut through the weld material at the rear side of ring gear with a hack saw or grinding wheel Fig 87 Be careful not to cut or grind into the front cover stamping 2 Scribe a heavy line on the front cover next to the front face of the ring gear to aid in locating the new gear 3 Support the converter with the four lug faces resting on blocks of wood The converter must not rest the front cover hub during this operation Using a blunt chisel or drift and hammer tap down ward on the ring gear near the welded areas to break any remaining weld material Fig 87 Tap around the ring gear until it comes off the converter 4 Smooth off weld areas on the cover with a file Installing Ring Gear Any of the following methods may be used to heat and expand the starter ring gear for installation on the converter BRASS DRIFT WOOD BLOCKS 60x 1607 Fig 87 Removing Starter Ring Gear 21 84 Oven Place ring gear in Oven C 794 and set temperature at 200 degrees F Allow the ring gear to remain in the oven for 15 to 20 minutes Boiling Water Place the ring gear in a shallow con tainer add water and heat for approximately eight minutes after t
137. r Snap Ring 060 to 062 inch 074 to 076 inch 088 to 090 inch Output Shaft 086 to 088 inch THRUST WASHERS Reaction Shaft Support to Front Clutch Retainer Selective 043 to 045 inch Natural 061 to 063 inch Green 084 to 086 inch Red Output Shaft to Input 062 to 064 inch Sun Gear Driving Shell Thrust Plate 034 to 036 inch Rear Planetary Gear to Driving 5 062 to 064 inch Front Planetary Gear to Annulus Gear 062 to 064 inch Front Annulus Gear Support to Driving 062 to 064 inch Front Clutch Retainer to Rear Clutch Piston 8 061 to 063 inch Green 21 28 TRANSMISSION TORQUEFLITE SPECIAL TOOLS 452 Puller Companion Flange 3749 Stand Valve Body 484 Pliers Snap Ring 3752 Remover Front Pump and Reaction 748 Remover Output Shaft Seal Shaft Support C 763 Switch Remote Control Starter 3763 Gauge Throtile Pressure Setting C 3203A Jack Transmission 3765 Installer Shifter Shaft Detent Ball
138. rd the indicator reading for reference when reassembling the transmission The end play specifi cations are 030 069 inch TRANSMISSION VENT 62x19 Fig 53 Removing Front Oil Pump and Reaction Shaft Support Assembly TRANSMISSION TORQUEFLITE 21 65 Extension Housing 1 Hold the transmission flange with Tool C 3281 and remove the retaining nut and washer Fig 34 Slide the flange off the output shaft Use puller Tool C 452 if necessary 2 Remove the extension housing to transmission bolts tap the housing lightly with a soft mallet to break it loose from the transmission then carefully remove the housing Governor and Support 1 Using a screw driver carefully pry the snap ring from weight end of the governor valve shaft Fig 39 Slide the valve and shaft assembly out of the governor body 2 Remove the snap ring from behind the gover nor body then slide the governor body and support assembly off the output shaft Rear Oil Pump 1 Unscrew the rear pump cover retaining bolts and remove the cover 2 The oil pump inner rotor is keyed to the output shaft by a small ball Therefore use care in sliding out the inner rotor so as not to lose the ball Fig 41 Remove the outer rotor from the pump body NOTE If replacement of the rear oil pump body is required drive if rearward out of the case with a wood block after the transmission has been disas sembled Front Pump and R
139. ring Clutches or servos sticking or not operating Worn or faulty rear clutch Overrunning clutch not holding Worn or broken input shaft and or reaction shaft support seal rings Incorrect control cable adjustment Hydraulic pressures too low Low reverse band out of adjustment Valve body malfunction or leakage Front clutch or rear servo sticking or not operating Low reverse servo band or linkage malfunction Worn or faulty front clutch Incorrect control cable adjustment Valve body malfunction or leakage Rear clutch inoperative Kickdown band out of adjustment Low reverse band out of adjustment Kickdown and or low reverse servo band linkage malfunction Front and or rear clutch faulty Planetary gear sets broken or seized Overrunning clutch worn broken or seized a Perform the hydraulic pressure tests and adjust to specifications b Perform pressure tests to deter mine cause and correct as required Inspect the accumulator for sticking broken rings or spring Repair as required 4 Remove the valve body assembly perform air pressure tests Repair as required Disassemble and inspect clutch Repair or replace as required f Disassemble the transmission and repair overrunning clutch as required 2 Inspect and replace the seal rings as required also inspect the respective bores for wear Replace parts as required a Adjust the control cable b Perform
140. rive the rear bearing off the mainshaft Be careful not to damage the gear teeth 6 Using snap ring pliers remove the snap ring that retains the mainshaft bearing on the shaft as shown in Figure 12 Remove the bearing bearing retainer ring 1st speed gear and first speed stop ring 7 Again using snap ring pliers remove the snap ring that retains the 1st 2nd clutch sleeve gear and clutch to the mainshaft as shown in Figure 13 Slide the 1st and 2nd clutch sleeve gear and clutch from the mainshaft Do not separate the clutch sleeve gear and the clutch unless inspection reveals a replacement part is required Figure 14 shows the various mainshaft bearing surfaces of the gears Inspect these surfaces for signs of wear scoring or any condition that would not allow the shaft to be used at reassembly See Clean ing and Inspection Figure 15 shows the reverse gear shift fork the reverse sliding gear the reverse sliding gear shaft and the cluster gear STOP RING 1ST SPEED GEAR CLUTCH 8 IST AND 2ND CLUTCH SLEEVE GEAR 64x747 Fig 13 Removing or Installing Clutch Gear Snap Ring TRANSMISSION 4 SPEED MANUAL 21 21 SNAP RING SNAP RING GROOVE GROOVE SNAP RING GROOVE 64 x 748 Fig 14 Mainshaft Bearing Surfaces 8 Using a shim stock feeler gauge measure the end play of the countershaft gear by inserting the gauge between the thrust washer and the gear as shown in Figure 16
141. s and tighten securely 5 Move the reverse slider gear ahead to the neutral position Transmission Gearshift Housing The following 4 steps need only be done if the gearshift housing was disassembled previously be cause of leaking seals 1 Slide the interlock sleeve into position in the housing Coat a new seal with Lubriplate then slide over a shift shaft and down into its groove 2 Install the gearshift lever shaft in position in the housing then install the gearshift operating lever on the flats of the shaft lever pointing upward refer to Figure 1 Install a flat washer lock washer and nut Tighten securely 3 Place a detent ball in the sleeve followed by the poppet spring and interlock pin Start the remain ing lever shaft into the housing after installing the shaft seal as mentioned previously Install the operat ing lever on the flats of the shaft lever pointing upward and secure with flatwasher lockwasher and nut Tighten the nut securely 4 Place the remaining detent ball on the poppet spring then compress the ball and the spring using a small screwdriver Push the shafts in until seated Turn the shafts until the balis drop into the neutral position detent See Fig 5 5 Place the transmission assembly on its side with the gearshift housing cover opening up Install a shift fork in each synchronizer sleeve collar and with both sleeves in the neutral position install the shift housing and a new g
142. s could result in much difficulty if it is necessary to remove the pin at a later date 4 Place the interlock parts in position in the case in the following order ball sleeve spring pin and ball 5 While using the detent ball installer Tool C 3765 as shown in Figure 9 to depress the detent ball against the spring tension push the low and reverse lever shaft firmly into position so it engages the detent ball SECOND AND DIRECT SECOND AND DIRECT FORK LEVER LOW AND REVERSE zd FORK LOW AND REVERSE LEVER Fig 8 Gearshift Forks and Shafts SLEEVE SPRING BALL 61x3 6 Remove the detent installing tool 7 Install the low and reverse lever shaft lock pin in the case driving it down firmly from the top using the caution as stated above 8 Place the low and reverse fork in the lever shaft with the offset toward the rear of transmission Fig 8 Mainshaft 1 While holding the low and reverse sliding gear in position in the fork with the hub extension to the rear insert the mainshaft with the rear bearing through the rear of the case and into the sliding gear 2 Place the synchronizer stop ring spring and then the rear stop ring on the synchronizer splines of the 2nd speed gear Install the 2nd speed gear on the mainshaft In cases where the synchronizer float measure ment was above 090 inch synchronizer shims Part No 2464724 should be installed to reduce
143. s for distortion Inspect the band lining for wear and bond of lining to the band If the lining is worn so grooves are not visible at the ends or any portion of the band PISTON SPRING SEAL RING PISTON PLUG SNAP RING SPRING RETAINER 60 x 175 Fig 82 Low and Reverse Servo Disassembled replace band Inspect the band for distortion or cracked ends Assembly 1 Lubricate and insert the piston plug and spring in the piston and secure with the snap ring 44 INSTALLATION OF SUB ASSEMBLIES The assembly procedures given here include the installation of sub assemblies in the transmission case and adjusting drive train end play Do not use force to assemble mating parts If the parts do not assemble freely investigate the cause and correct the trouble before proceeding with the assembly procedures Always use new gaskets during the assembly opera tions IMPORTANT Use only Automatic Transmission Fluid Type A Suffix A to lubricate transmission parts during assembly Overrunning Clutch 1 With the transmission case in an upright posi tion insert the clutch race inside the cam Install the overrunning clutch rollers and springs exactly as shown in Figure 83 Low and Reverse Servo and Band 1 Carefully work the servo piston assembly into the case with a twisting motion Place the spring retainer and snap ring over the piston Fig 82 2 Compress the low and reverse servo piston spring
144. s should also be replaced if they show evidence of material flaking off or if the facing material can be scraped off easily Inspect the driving disc splines for wear or other damage Inspect the steel plate and pressure plate surfaces for burning scoring or dam aged driving lugs Replace if necessary Inspect the steel plate lug grooves in the clutch retainer for smooth surfaces plates must travel freely in grooves Note the ball check in the piston make sure the ball moves freely Inspect the seal surfaces in the clutch retainer for nicks or deep scratches light scratches will not interfere with sealing of neoprene seals Inspect the neoprene seals for deteri oration wear and hardness and the piston spring and snap rings for distortion Inspect the interlocking seal rings Fig 73 on the input shaft for wear or broken locks make sure they turn freely in the grooves Do not remove the rings uriless conditious warrant Inspect the bushing in the input shaft for wear or scores Inspect the rear clutch to front clutch thrust washer for wear Washer thick ness should be 061 to 063 inch replace if necessary Input Shaft Bushing Replacement 1 Clamp the input shaft in a vise with soft jaws being careful not to clamp on the seal ring lands or journals 2 Assemble the remover Tool SP 3630 the cup Tool SP 3633 and the hex nut Tool SP 1191 3 With the cup held firmly against the clutch piston retainer thread the remover int
145. s slot 8 Slide the third speed gear over the mainshaft with the synchronizer cone toward the front fol lowed by the third gear stop ring 9 Install the third and fourth speed synchronizer clutch gear assembly including sleeve shift plates and springs on the mainshaft shift fork slot toward the rear down against the third speed gear Be sure and index the rear stop ring with the clutch gear shift plates Refer to Figure 9 10 Install the retaining snap ring as shown in Figure 9 then using heavy grease position the front stop ring over the clutch gear again indexing the ring slots with the shift plates Refer to Fig 8 CAUTION it is very important that the index COUNTER SHAFT CLUSTER GEAR 64 x 753 Fig 19 8Removing or Installing the Cluster Gear and Arbor 21 24 TRANSMISSION 4 SPEED MANUAL WASHER COUNTER SHAFT TERE ANG GEAR THRUST WASHER TANG Fig 20 Cluster Gear and Arbor Assembly 64 x 754 ing of all stop rings and the positioning of the gears and clutches on the mainshaft be correct or the mat ing of the extension housing to the case will not be possible without damage Main Drive Pinion Fig 21 1 Slide the bearing oil slinger over the main drive pinion shaft then press the main drive pinion bearing on the pinion shaft Be sure the outer snap ring groove is toward the front Seat the bearing fully against the shoulder on the gear 2 Install a new inner snap ring
146. shift from direct to second second to breakaway or direct to breakaway depending on vehicle speed by depressing the accelerator pedal past the detent feel near wide open throttle The shuttle valve has two separate functions and performs each independently of each other The first is that of providing fast release of the kickdown band and smooth front clutch engagement when the driver makes a lift foot upshift from second to direct The second function of the shuttle valve is to regulate the application of the kickdown servo and band when making direct to second kickdowns Clutches Band Servos and Accumulator The front and rear clutch pistons and both servo pistons are moved hydraulically to engage the clutches and apply the bands The pistons are re leased by spring tension when hydraulic pressure is released On the 2 3 upshift the kickdown servo pis ton is released by spring tension and hydraulic pres sure The accumulator controls the hydraulic pressure 21 40 TRANSMISSION TORQUEFLITE on the apply side of the kickdown servo during the 1 2 shift thereby cushioning the kickdown band ap plication at any throttle position 2 GEARSHIFT AND PARKING LOCK CONTROLS push button gearshift control unit is essen tially the same on all vehicles The parking lock lever is attached to the left side of the push button unit When the parking lock is applied the transmission is automatically shifted to the neutral
147. sition This maintains the balance of the engine and converter 7 Rotate the engine with the Remote Control Switch to locate two converter to drive plate bolts at 5 and 7 o clock positions Remove the two bolts rotate the engine with the switch and remove the other two bolts Do not rotate the converter or drive plate by prying with a screw driver or similar tool as the drive plate might become distorted Also the starter should never be engaged if the drive plate is not attached to the converter with at least one bolt or if the transmission case to engine block bolts been loosened 8 Disconnect the negative ground cable from the battery 9 Remove the starting motor assembly 10 Disconnect the wire from the neutral starting switch 11 Remove the gearshift contro cable to trans mission adjusting wheel lock screw Pull the gearshift cable out of the transmission case as far as possible back off the adjusting wheel a few turns if necessary 12 Insert a small screwdriver above and slightly to the right of the gearshift cable Fig 17 Disengage the cable adapter lock spring by pushing the screw driver handle to the right while pulling outward on the cable 13 Disconnect the throttle rod from the relay lever at the left side of the transmission 14 Disconnect the oil cooler lines at the trans mission and remove the oil filler tube 15 Remove the speedometer pinion and sleeve assembly from
148. smission case a few turns Refer to Paragraph 11 for complete Adjust ment and Test 3 Console Shift Place the seal assembly over the threads of the switch Fig 21 then install and tighten the switch 25 to 35 foot pounds torque Refer to Para graph 11 for complete Adjustment and Test 4 Add fluid to the transmission to bring up to the proper level Refer to Paragraph 4 NOTE Test the starter for operating in all push button or selector lever positions If it should operate in any position other than push button neutral or selector lever park and neutral readjust the gearshift 21 60 TRANSMISSION TORQUEFLITE control cable Refer to Paragraph 9 In some cases it may be necessary to align the valve body neutral and or park fingers with the switch plunger Refer to Para graph 24 24 VALVE BODY ASSEMBLY AND ACCUMULATOR PISTON Removal 1 Raise the vehicle on a hoist 2 Loosen the oil pan bolts tap the pan to break it loose allowing the fluid to drain then remove the oil pan 3 Loosen clamp bolt and lift the throttle lever and washer off the transmission throttle lever shaft 4 Disconnect the gearshift control cable Refer to Paragraph 9 Shift the valve body manual lever to the 1 low position to expose the nut securing the cable adapter to the lever Fig 22 Remove the nut and disengage the cable adapter from the manual lever 5 Place a drain pan under the transmission then remove the ten hex head v
149. spect and replace seal rings as required also inspect the respective bores for wear Replace parts as required 21 86 Condition No Upshift No Kickdown or Normal Downshift a b e d e f g h 1 4 b 9 f g h i Q TRANSMISSION TORQUEFLITE DIAGNOSIS SERVICE DIAGNOSIS Continued Possible Cause Low fluid level Incorrect throttle linkage adjustment Kickdown band out of adjustment Hydraulic pressures too high or low Governor sticking Valve body malfunction or leakage Accumulator sticking broken rings or spring Clutches or servos sticking or not operating Faulty rear oil pump Kickdown servo band or linkage malfunction Worn or faulty front clutch Worn or broken input shaft and or reaction shaft support seal rings Incorrect throttle linkage adjustment Incorrect control cable adjustment Kickdown band out of adjustment Hydraulic pressures too high or low Governor sticking Valve body malfunction or leakage Accumulator sticking broken rings or spring Clutches or servos sticking or not operating Kickdown servo band or linkage malfunction Overrunning clutch not holding b c d e h i 0 k 0 a b e d e f g h i Q Correction Refill to correct level with Automatic Transmission Fluid Suff
150. spring force remove the three bracket retaining screws Fig 56 3 Remove the spring bracket torque converter control valve spring and the regulator valve spring with line pressure adjusting screw assembly NOTE Do not alter the setting of the line pressure adjusting screw and nut The nut has an interference thread and does not turn easily on the screw 4 Slide the regulator valve out of the valve body Slide the torque converter control valve out of the valve body 5 Remove the 14 transfer plate retaining screws Carefully lift the transfer plate and steel plate as sembly off the valve body SCREWS 4 REVERSE BLOCKER TRANSFER PLATE VALVE AND COVER REAR PUMP CHECK VALVE 21 67 TRANSMISSION TORQUEFLITE sS REVERS VALVE COVER PLAT C CONTROL ALVE SPRING REGULATOR SPRING RETAINER BRACKET kickoown ROD 8 7 MANUAL VALVE THROTTLE LEVER STOP SCREW ASSY THROTTLE LEVER MANUAL LEVER 4 UN PRESSURE ADJUSTING SCREW ASSEMBLY CABLE ADAPTER STUD HOLE THROTTLE LEVER SHAFT Fig 56 Regulator and Converter Contro Valves Assembled View 6 Invert the transfer plate assembly and remove the stiffener plate Remove remaining screws secur ing the steel plate to the transfer plate and carefully lift off the steel plate Fig 57 Remove the rear pump check valve and spring 7 Remove the reverse blocker valve cover and lift out the sprin
151. st the torque converter For safety reasons and because damage to the transmis sion may occur wide open throttle stall operation should be avoided 4 LUBRICATION The transmission fluid and the oil filter should pro vide satisfactory lubrication and protection to the automatic transmisssion and no change is recom mended in vehicles used in normal service Regular ly scheduled oil and filter changes therefore will not be required in these vehicles except when the op eration of the vehicle is classified as severe If the regular operation of the vehicle is classified as severe the transmission should be adjusted and the fluid and the oil filter changed approximately every 32 000 miles according to any of the following Police or taxicab operation Frequent towing of trailers Continuous operation at higher than normal loading and or temperature The transmission should not be idled in gear for long periods Fluid Level Inspect the fluid level every 6 months more often if conditions warrant with the engine and transmis sion at normal operating temperature Refer to Lu brication and Maintenance Group Drain and Refill 1 Raise the vehicle on a hoist Place a drain con tainer with a large opening under the transmission oil pan 2 Loosen the pan bolts tap the pan to break it DRAIN PLUG Me C M R Fig 10 Converter Drain Plug loose allowing the fluid to drain t
152. t spots and chipped 62x18 Fig 79 Removing Overrunning Clutch Cam 21 79 TRANSMISSION TORQUEFLITE Fig 80 Installing Overrunning Clutch Cam edges Inspect the roller contacting surfaces in the cam and race for brinelling Inspect the roller springs for distortion wear or other damage Inspect the cam set screw for tightness If loose tighten and restake the case around the screw Overrunning Clutch Cam Replacement If the overrunning clutch cam and or the roller spring retainer are found damaged replace the cam and spring retainer in the following manner 1 Remove set screw from the case below the clutch eam 2 Insert punch through the pump body bolt holes and drive the cam from the case Fig 79 Alternate the punch from one bolt hole to another so the cam will be driven evenly from the case 3 Clean all burrs and chips from the cam area in the case 4 Place the spring retainer on the cam making sure the retainer lugs snap firmly into the notches on the cam 5 Position the cam in the case with the cam serra tions aligned with those in the case Tap the cam evenly into the case as far as possible with a soft mallet 6 Install Tool C 3863 as shown in Figure 80 tighten nut on the tool to seat the cam into the case Make sure the cam is firmly bottomed then install the cam retaining set screw Stake the case around the set screw to prevent it from coming loose 42 KICKDOWN SERVO AND B
153. tay in position Mainshaft 1 Slide the second speed gear over the mainshaft synchronizer cone toward the rear and down into position against the shoulder on the shaft See Figure 13 2 Slide the first and second clutch sleeve gear assembly including 2nd gear stop ring over the mainshaft with the shift fork slot toward the front and down into position against the second speed gear Be sure the stop ring is indexed with the shift plates Install a new snap ring to secure Fig 13 TRANSMISSION 4 SPEED MANUAL 21 23 3 Slide the low gear stop ring over the shaft and down into position and index with the shift plates 4 Slide the first speed gear synchronizer cone toward the clutch sleeve gear just installed over the mainshaft and down into position against the clutch sleeve gear 5 Install the mainshaft bearing retaining ring followed by the mainshaft center bearing Using an arbor and a suitable tool drive or press the bearing down into position Install a new snap ring to secure refer to Figure 12 6 Slide the rear bearing over the mainshaft and drive or press into position 7 Install the partially assembled mainshaft into the extension housing far enough to engage the re taining ring in the slot in the extension housing See Figure 11 Compress the retaining ring and at the same time seat the mainshaft in the extension hous ing Refer to Figure 10 Be sure retaining ring is seated all around it
154. the hydraulic pressure tests and adjust to specifications Adjust the low reverse band d Perform pressure tests to deter mine cause and correct as required e Remove the valve body assembly and perform air pressure tests Repair as required f Inspect the servo for damaged seals binding linkage or faulty band lining Repair as required g Disassemble and inspect clutch Repair or replace as required a Adjust the control cable b Perform pressure tests to deter mine cause and correct as required c Inspect the clutch and repair as required a Adjust the kickdown band b Adjust the low reverse band c Inspect the servo for sticking broken seal rings binding linkage or faulty band lining Repair as required Disassemble and inspect clutch Repair or replace as required e Inspect the condition of the planetary gear sets and replace as required f Inspect the condition of the overrunning clutch and replace parts as required gt 21 90 Condition Grating Scraping or Growling Noise Buzzing Noise Hard to Fill Oil Flows out Filler Tube Transmission Overheats a b 4 f g b e d b 4 b 4 TRANSMISSION TORQUEFLITE DIAGNOSIS SERVICE DIAGNOSIS Continued Possible Cause Kickdown band out of adjustment Low reverse band out of adjust
155. the transmission Fig 32 16 Loosen the transmission parking lock cable clamp bolt where the cable enters the cover Fig 18 Tap the end of clamp bolt lightly to release its hold on the cable Remove the housing cover lower plug Insert a screw driver through the hole then gently exert pressure against the projecting portion of the cable lock spring and withdraw the lock cable 17 Disconnect the front universal joint and sup port the propeller shaft out of the way Imperial Models Remove the propeller shaft cen ter bearing housing bolts Slide the front propeller shaft rearward to disengage the front universal joint from the front flange 18 Remove the engine rear mount insulator to ex tension housing bolts 19 Install engine support fixture Tool C 3487 and raise the engine slightly 20 Remove the crossmember attaching bolts and remove the crossmemher 21 Place a transmission service jack under the transmission to support the assembly 22 Attach a small clamp to the edge of the converter housing to hold the converter in place dur ing the removal of the transmission 23 Remove the converter housing retaining bolts Carefully work the transmission rearward off the en gine block dowels and disengage the converter hub from the end of the crankshaft Fig 45 TRANSMISSION TORQUEFLITE m omm H 21 6T Fig 45 Removing or Installing Transmission and Converter Assembly
156. tion 1 Position the sprag and spring in the housing and insert the bushing sleeve Fig 44 Make sure the square lug on the sprag is toward the gear and the spring is positioned so as to lift the sprag away from the parking gear 2 Position the lock lever spacer and cable adapter 4 LEVER Pv ADAPTER i f Fig 43 Removing or Installing Parking Lock Lever and Cable Adapter TRANSMISSION TORQUEFLITE 21 59 SPRING BUSHING SLEEVE Fig 44 Removing or Installing Parking Sprag assembly in the extension housing and install the lever shaft Fig 43 The lever roller must be on top of the sprag so as to push it into engagement with the parking gear Install and tighten the plug to 150 inch pounds torque 3 Insert a small punch through the cable opening in the adapter cover and into the end of the adapter Carefully lower the cover into position feeding the adapter into the cable opening in the cover Install the cover retaining screws and tighten to 150 inch pounds torque 4 Install the extension housing flange and connect the propeller shaft 5 Connect the parking lock cable See Paragraph 10 transmission 23 NEUTRAL STARTING SWITCH Replacement 1 Disconnect the wire from the switch unscrew the switch allowing the fluid to drain into a container 2 Push Button Control Place the cupped washer and O ring over the threads of the switch Fig 20 then screw the switch into the tran
157. tions 7 Install the oil pan using a new gasket 8 Add fluid to the transmission to bring it up to proper level Refer to Paragraph 4 25 TRANSMISSION AND CONVERTER The transmission and converter must be removed and installed as an assembly otherwise the converter drive plate front pump bushing and oil seal will be damaged The drive plate will not support a load therefore none of the weight of the transmission should be allowed to rest on the plate during removal or installation Removal 1 Connect a Remote Control Starter Switch Tool C 763 to the starter solenoid and position the switch so the engine can be rotated from under the vehicle 2 Disconnect the secondary high tension cable from the ignition coil 3 Place the parking lock lever if so equipped in the OFF position then raise the vehicle on a hoist or support with stands 4 Remove the cover plat from in front of the con verter assembly io provide access to tlie converter drain plug and mounting bolts 5 Rotate the engine with the femote Control Switch to bring the drain plug to the 6 o clock posi tion Drain the torque converter and transmission 6 Mark the converter and drive plate to aid in reassembly The crankshaft flange bolt circle the inner and outer circle of holes in the drive plate and the four tapped holes in the front face of the con verter all have one hole offset so these parts will be installed in the original po
158. to a container Move the selector lever to the PARK and then to TRAL positions and inspect to see that the switch 21 48 TRANSMISSION TORQUEFLITE operating lever fingers are centered in the switch opening in the case 4 Screw the switch into the transmission case and tighten 25 to 35 foot pounds torque Retest the switch with the test lamp 5 Add fluid to the transmission to bring up to the proper level Refer to Paragraph 4 NOTE Test the starter for operating in all push button or selector lever positions If it should operate in any position other than push button neutral or selector lever park and neutral readjust the gearshift control cable Refer to Paragraph 9 In some case may be necessary to align the valve body neutral and or park fingers with the switch plunger Refer to Paragraph 24 12 BAND ADJUSTMENTS Kickdown Band The kickdown band adjusting screw is located on the left side of the transmission case near the throt tle lever shaft Fig 17 1 Loosen the lock nut and back off approximately five turns Inspect the adjusting screw for free turn ing in the transmission case 2 Using wrench Tool C 3380 with adapter 3705 tighten the band adjusting screw 47 to 50 inch pounds torque If adapter C 3705 is not used tighten the adjusting screw to 72 inch pounds which is the true torque 3 Back off the adjusting screw 2 turns Hold the LOW AND REVERSE BAND ADIUSTING SCREW
159. ue TRANSMISSION TORQUEFLITE 21 39 dependent on throttle opening The torque converter control valve maintains torque converter operating pressure and transmission lubricating pressure The governor valve transmits regulated pressure to the transmission in conjunction with throttle pres sure to control upshift and downshift speeds The throttle valve transmits regulated pressure to the transmission in conjunction with governor pres sure to control upshift and downshift speeds Flow Control Valves The rear pump check valve prevents loss of front pump pressure through the rear pump circuit during reverse operation The front pump check valve pre vents loss of rear pump pressure through the front pump circuit when the front pump flow is recircu lating A check valve is incorporated in the rear oil pump cover to prevent air from entering the system during reverse operation The manual valve obtains the different transmis sion drive ranges as selected by the vehicle operator The reverse blocker valve mechanically blocks the manual valve from moving into reverse position above approximately 20 mph The 1 2 shift valve automatically shifts the trans mission from low to second or from second to low depending on the vehicle operation The 2 3 shift valve automatically shifts the trans mission from second to direct or from direct to sec ond depending on the vehicle operation The kickdown valve makes possible a forced down
160. untershaft toward the front of the transmission case 1 Using a feeler gauge measure the countershaft end play The measurement should be from 0045 to 028 inch This will determine if new thrust washers are to be installed at reassembly 2 Using the countershaft bearing arbor Tool C 3834 drive the countershaft toward the rear of the case until the small key can be removed from the countershaft 8 Drive the countershaft the remaining way out of the case keeping arbor tight against the end of the countershaft to prevent loss of the roller bearings 4 Remove the cluster gear thrust washers and the thrust plate from the case 5 Remove the 88 roller bearings 4 washers and the center spacer from the cluster gear Reverse Idler Gear 1 Using a blunt drift drive the reverse idler shaft toward the rear of the case far enough to re move the key from the shaft 2 Drive the shaft the remaining way out of the case and remove the idler gear and the bearing assembly using reverse idler assembly arbor Tool C 464 3 Remove the thrust washers and the 22 roller bearings Fig 7 Removing or Installing the Mainshaft Assembly Gearshift Mechanism NOTE This operation need only be done if the seals are leaking 1 necessary remove both of the lever shaft seals using Tool C 3638 2 Using a small punch remove the low and re verse gear lever shaft tapered lock pin by driving it toward the top
161. utton Type With the parking lock lever in the OFF position have an assistant engage the button and hold it firmly engaged until the cable attachment operation is completed Console Lever Type Place the selector lever in the PARK position 2 Back the adjustment wheel off on the cable housing counter clockwise until two or three threads are showing on the guide behind the wheel 3 Lubricate the cable housing with transmission fluid insert the cable in the transmission case push inward on the cable making sure the lock spring en gages the cable ll 21 46 TRANSMISSION TORQUEFLITE Adjustment NOTE Inspect the wheel for free turning on the guide remove any dirt or burrs in the threads of the cable guide that may interfere Lubricate the cable guide threads with a few drops of transmission fluid 4 Push Button Type Have an assistant hold the R button firmly depressed Hold the control cable guide centered in the hole of the transmission case and apply only enough inward force approximately two pounds to bottom the assembly in the reverse detent While holding the cable bottomed rotate the adjustment wheel clockwise until it just contacts the case squarely Turn the wheel clockwise just enough to make the adjustment hole in the wheel line up with the screw hole in the case Counting this hole as number one continue turning the wheel clockwise until the fifth hole lines up with the screw hole in the case
162. ve pinion is centered in the clutch housing bore 3 Roll the transmission slowly forward until the pinion shaft enters the clutch disc then drop the jack Turn the pinion shaft until the splines are aligned then work the transmission forward until seated against the clutch housing NOTE Do not allow the transmission to hang after the pinion shaft has entered the clutch disc 4 Install the transmission attaching bolts and tighten to 50 foot pounds torque 5 Using a pointed drift align the crossmember bolt holes and then install the attaching bolts Tight en to 50 foot pounds torque 6 Remove the engine support fixture and dis engage the hooks from the holes in the frame side Tails 7 Install the speedometer drive pinion and cable Connect the back up light switch wires if so equip ped 8 Reconnect the parking brake cable and pro peller shaft 9 Reconnect the exhaust pipes if removed Tighten bolts securely 10 Fill the transmission with 714 pints of Type A Suffix lubricant or until the oil just dribbles out of the filler hole 11 Install the gearshift lever and boot to the stub lever on the shift housing and secure with bolts Tighten securely 12 Slide the boot down the shift lever to the floor pan and secure with screws 13 Road test the vehicle to make sure the trans mission shifts smoothly and operates quietly 6 SERVICING THE REAR OIL SEAL 1 Disconnect the prop
163. w reverse band Remove and recondition the valve body assembly Inspect and repair the rear oil pump as required Inspect the servo for damaged seals binding linkage or faulty band lining Repair as required Disassemble and inspect clutch Repair or replace as required Inspect and replace the seal rings as required also inspect respective bores for wear Replace the parts as required Adjust the control cable Test the operation of the switch with a test lamp Adjust or replace as required Inspect the lead and test with a test lamp Repair the broken lead

TRANSMISSION PART 1-MANUAL TRANSMISSION

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